FARGO ND – Moorhead Flood Risk Management Project
Red River Levees Phase I 2nd Street Downtown Reach
CONTRACT AWARD DOCUMENTS
October 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
PROJECT TABLE OF CONTENTS
October 9, 2014
DIVISION 02 - EXISTING CONDITIONS
02 41 00 DEMOLITION
DIVISION 03 – CONCRETE
03 11 13.00 10 STRUCTURAL CAST-IN-PLACE CONCRETE FORMING 03 15 00.00 10 STRUCTURAL CAST-IN-PLACE CONCRETE FORMING 03 20 00.00 10 CONCRETE REINFORCING 03 30 00.00 10 CAST-IN-PLACE CONCRETE 03 35 00.00 10 CONCRETE FINISHING 03 39 00.00 10 CONCRETE CURING 03 45 33 PRECAST AND PRESTRESSED STRUCTURAL CONCRETE
DIVISION 04 - MASONRY
04 20 00 MASONRY
DIVISION 05 – METALS
05 12 00 STRUCTURAL STEEL 05 50 13 MISCELLANEOUS METAL FABRICATIONS 05 50 14 STRUCTURAL METAL FABRICATIONS 05 51 33 METAL LADDERS 05 72 00 DECORATIVE METAL SPECIALTIES
DIVISION 06 - WOOD, PLASTICS, AND COMPOSITES
06 10 00 ROUGH CARPENTRY
DIVISION 07 - THERMAL AND MOISTURE PROTECTION
07 11 13 BITUMINOUS DAMPPROOFING 07 14 00 FLUID-APPLIED WATERPROOFING 07 19 00 WATER REPELLENTS 07 21 13 BOARD AND BLOCK INSULATION 07 22 00 ROOF AND DECK INSULATION 07 53 23 ETHYLENE-PROPYLENE-DIENE-MONOMER ROOFING 07 60 00 FLASHING AND SHEET METAL 07 92 00 JOINT SEALANTS
DIVISION 08 – OPENINGS
08 11 16 ALUMINUM DOORS AND FRAMES 08 60 45 SKYLIGHTS 08 71 00 DOOR HARDWARE 08 81 00 GLAZING 08 91 00 METAL WALL LOUVERS
DIVISION 09 – FINISHES
09 06 90 COLOR SCHEDULE 09 90 00 PAINTS AND COATINGS
TABLE OF CONTENTS Page 1 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
DIVISION 10 - SPECIALTIES
10 14 00.20 INTERIOR SIGNAGE 10 44 16 FIRE EXTINGUISHERS
DIVISION 22 – PLUMBING
22 00 00 PLUMBING, GENERAL PURPOSE 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER- TYPE 22 10 00.00 10A SYSTEM CURVE 22 12 00 WET WELL PHYSICAL MODEL STUDY 22 13 29 SUBMERSIBLE NON-CLOG PUMP
DIVISION 23 - HEATING, VENTILATING, AND AIR CONDITIONING
23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS 23 08 00.00 10 COMMISSIONING OF HVAC SYSTEMS 23 09 33.00 40 ELECTRIC AND ELECTRONIC CONTROL SYSTEM FOR HVAC 23 23 00 REFRIGERANT PIPING 23 31 13.00 40 METAL DUCTS 23 82 46.00 40 ELECTRIC UNIT HEATERS
DIVISION 26 – ELECTRICAL
26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS 26 20 00 INTERIOR DISTRIBUTION SYSTEM 26 23 00.00 40 SWITCHBOARDS 26 29 01.00 10 ELECTRIC MOTORS, 3-PHASE VERTICAL INDUCTION TYPE 26 36 00.00 10 AUTOMATIC TRANSFER SWITCH 26 41 00 LIGHTNING PROTECTION SYSTEM 26 51 00 INTERIOR LIGHTING 26 56 00 EXTERIOR LIGHTING
DIVISION 31 – EARTHWORK
31 00 00.00 14 EARTHWORK FOR PUMP STATION AND FLOODWALL
DIVISION 33 – UTILITIES
33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION
DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION
35 05 40.17 SELF-LUBRICATED MATERIALS, FABRICATION, HANDLING, AND ASSEMBLY 35 20 14 STOPLOGS 35 20 16.53 VERTICAL LIFT GATES
TABLE OF CONTENTS Page 2 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
DIVISION 40 - PROCESS INTEGRATION
40 05 13 PIPELINES, LIQUID PROCESS PIPING 40 95 00 PROCESS CONTROL 40 95 00A PROCESS CONTROL - PLC POINTS LIST 40 95 00B PROCESS CONTROL - CONTROL LOOP DESCRIPTIONS
DIVISION 46 - WATER AND WASTEWATER EQUIPMENT
46 20 20 MANUALLY CLEANED TRASH RACK AND RAKE
END OF TABLE OF CONTENT
TABLE OF CONTENTS Page 3 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 2 EXISTING CONDITIONS
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 02 41 00
DEMOLITION 05/10 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN SOCIETY OF SAFETY ENGINEERS (ASSE/SAFE)
ASSE/SAFE A10.6 (2006) Safety Requirements for Demolition Operations
U.S. ARMY CORPS OF ENGINEERS (USACE)
EM 385-1-1 (2008; Errata 1-2010; Changes 1-3 2010; Changes 4-6 2011; Change 7 2012) Safety and Health Requirements Manual
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
40 CFR 61 National Emission Standards for Hazardous Air Pollutants
1.2 PROJECT DESCRIPTION
1.2.1 Demolition/Deconstruction Plan
Prepare a Demolition Plan and submit proposed demolition, and removal procedures for approval before work is started. Include in the plan procedures for careful removal and disposition of materials specified to be salvaged, coordination with other work in progress, a disconnection schedule of utility services, a detailed description of methods and equipment to be used for each operation and of the sequence of operations. Coordinate with Waste Management Plan. Provide procedures for safe conduct of the work in accordance with EM 385-1-1. Plan shall be approved by Owner's Representative prior to work beginning.
1.2.2 General Requirements
Do not begin demolition until authorization is received from the Owner's Representative. Remove rubbish and debris from the project site daily; do not allow accumulations inside or outside the buildings. The work includes demolition, salvage of identified items and materials, and removal of resulting rubbish and debris. Remove rubbish and debris from Owner's property daily, unless otherwise directed. Store materials that cannot be removed daily in areas specified by the Owner's Representative. In the interest of occupational safety and health, perform the work in accordance with EM 385-1-1, Section 23, Demolition, and other applicable Sections.
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1.3 ITEMS TO REMAIN IN PLACE
1.3.1 Existing Construction Limits and Protection
Do not disturb existing construction beyond the extent indicated or necessary for installation of new construction. Provide temporary shoring and bracing for support of building components to prevent settlement or other movement. Provide protective measures to control accumulation and migration of dust and dirt in all work areas. Remove dust, dirt, and debris from work areas daily.
1.3.2 Trees
Protect trees within the project site which might be damaged during demolition or deconstruction, and which are indicated to be left in place, by a 6 foot high fence. Erect and secure fence a minimum of 5 feet from the trunk of individual trees or follow the outer perimeter of branches or clumps of trees. Replace any tree designated to remain that is damaged during the work under this contract with like-kind or as approved by the Owner's Representative.
1.3.3 Utility Service
Maintain existing utilities indicated to stay in service and protect against damage during demolition operations. Prior to start of work, Owner's Representative will coordinate shutoff of utilities serving each area of alteration or removal. Disconnect and seal utilities in accordance with Utility Owner requirement.
1.3.4 Facilities
Protect electrical and mechanical services and utilities. Where removal of existing utilities and pavement is specified or indicated, provide approved barricades, temporary covering of exposed areas, and temporary services or connections for electrical and mechanical utilities. Floors, roofs, walls, columns, pilasters, and other structural components that are designed and constructed to stand without lateral support or shoring, and are determined to be in stable condition, must remain standing without additional bracing, shoring, or lateral support until demolished or deconstructed, unless directed otherwise by the Owner's Representative. Ensure that no elements determined to be unstable are left unsupported and place and secure bracing, shoring, or lateral supports as may be required as a result of any cutting, removal, deconstruction, or demolition work performed under this contract.
1.4 BURNING
The use of burning at the project site for the disposal of refuse and debris will not be permitted.
1.5 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-01 Preconstruction Submittals
Existing Conditions; G
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SD-07 Certificates
Demolition Plan; G Deconstruction Plan; G Notification
SD-11 Closeout Submittals
Receipts
1.6 QUALITY ASSURANCE
Submit timely notification of demolition projects to Federal, State, regional, and local authorities in accordance with 40 CFR 61, Subpart M. Notify the local air pollution control district/agency and the Owner's Representative in writing 10 working days prior to the commencement of work in accordance with 40 CFR 61, Subpart M. Comply with federal, state, and local hauling and disposal regulations. In addition to the requirements of the "Contract Clauses," conform to the safety requirements contained in ASSE/SAFE A10.6. Comply with the Environmental Protection Agency requirements specified.
1.6.1 Dust and Debris Control
Prevent the spread of dust and debris and avoid the creation of a nuisance or hazard in the surrounding area. Do not use water if it results in hazardous or objectionable conditions such as, but not limited to, ice, flooding, or pollution.
1.7 PROTECTION
1.7.1 Traffic Control Signs
a. Where pedestrian and driver safety is endangered in the area of removal work, use traffic barricades with flashing lights. Anchor barricades in a manner to prevent displacement by wind. Notify the Owner's Representative prior to beginning such work.
1.7.2 Protection of Personnel
Before, during and after the demolition work continuously evaluate the condition of the structure being demolished and take immediate action to protect all personnel working in and around the project site. No area, section, or component of floors, roofs, walls, columns, pilasters, or other structural element will be allowed to be left standing without sufficient bracing, shoring, or lateral support to prevent collapse or failure while workmen remove debris or perform other work in the immediate area.
1.8 EXISTING CONDITIONS
Before beginning any demolition work, survey the site and examine the drawings and specifications to determine the extent of the work. Record existing conditions in the presence of the Owner's Representative showing the condition of structures and other facilities adjacent to areas of alteration or removal. It is the Contractor's responsibility to verify and document all required outages which will be required during the course of work, and to note these outages on the record document. Submit survey results.
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1.9 USE OF EXPLOSIVES
Use of explosives will not be permitted.
PART 2 PRODUCTS
2.1 FILL MATERIAL
a. Comply with excavating, backfilling, and compacting procedures for soils used as backfill material to fill basements, voids, depressions or excavations resulting from demolitionof structures.
b. Fill material shall conform to the definition of satisfactory soil material as defined in ASTM D2487, Standard Practice for Classification of Soils for Engineering Purposes and approved by the Owner's Representative. In addition, fill material shall be free from roots and other organic matter, trash, debris, frozen materials, and stones larger than 2 inches in any dimension.
PART 3 EXECUTION
3.1 EXISTING FACILITIES TO BE REMOVED
3.1.1 Structures
a. Remove,in their entirety, any existing structures encountered with approval by the Owner's Representative.
3.1.2 Utilities and Related Equipment
3.1.2.1 General Requirements
Do not interrupt existing utilities serving occupied or used facilities, except when authorized in writing by the Owner's Representative. Do not interrupt existing utilities serving facilities occupied and used by the Owner except when approved in writing and then only after temporary utility services have been approved and provided. Do not begin demolition work until all utility disconnections have been made. Shut off and cap utilities for future use, as indicated.
3.1.2.2 Disconnecting Existing Utilities
Remove existing utilities , as indicated and uncovered by work and terminate in a manner conforming to the nationally recognized code covering the specific utility and approved by the Owner's Representative. When utility lines are encountered but are not indicated on the drawings, notify the Owner's Representative prior to further work in that area. Remove meters and related equipment and deliver to a location in accordance with instructions of the Owner's Representative.
3.1.3 Paving and Slabs
Remove concrete and asphaltic concrete paving and slabs including aggregate base to a depth of Six (6) inches below existing adjacent grade. Provide neat sawcuts at limits of pavement removal as indicated.
3.2 CONCURRENT EARTH-MOVING OPERATIONS
Do not begin excavation, filling, and other earth-moving operations that
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are sequential to demolition work in areas occupied by structures to be demolished until all demolition in the area has been completed and debris removed. Fill holes, open basements and other hazardous openings.
3.3 DISPOSITION OF MATERIAL
3.3.1 Title to Materials
All materials and equipment removed shall become the property of the Contractor and shall be removed from Owner's property unless noted otherwise. Title to materials resulting from demolition, and materials and equipment to be removed, is vested in the Contractor upon approval by the Owner's Representative of the Contractor's demolition, deconstruction, and removal procedures, and authorization by the Owner's Representative to begin demolition and deconstruction. The Owner's Representative will not be responsible for the condition or loss of, or damage to, such property after contract award. Showing for sale or selling materials and equipment on site is prohibited.
3.4 DISPOSAL OF REMOVED MATERIALS
3.4.1 Regulation of Removed Materials
Dispose of debris, rubbish, scrap, and other nonsalvageable materials resulting from removal operations with all applicable federal, state and local regulations as contractually specified in the Waste Management Plan.
3.4.2 Burning on Owner's Property
Burning of materials removed from demolished structures will not be permitted on Owner's property.
3.4.3 Removal from Owner's Property
Transport waste materials removed from demolished structures, except waste soil, from Owner's property for legal disposal.
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SECTION 02 41 00 Page 5 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 3 CONCRETE
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 03 11 13.00 10
STRUCTURAL CAST-IN-PLACE CONCRETE FORMING 08/10 08/22/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)
ACI 347 (2004; Errata 2008; Errata 2012) Guide to Formwork for Concrete
AMERICAN HARDBOARD ASSOCIATION (AHA)
AHA A135.4 (1995; R 2004) Basic Hardboard
APA - THE ENGINEERED WOOD ASSOCIATION (APA)
APA L870 (2010) Voluntary Product Standard, PS 1-09, Structural Plywood
ASTM INTERNATIONAL (ASTM)
ASTM C1077 (2013b) Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation
ASTM C31/C31M (2012) Standard Practice for Making and Curing Concrete Test Specimens in the Field
ASTM C39/C39M (2012) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens
1.2 SYSTEM DESCRIPTION
The design, engineering, and construction of the formwork is the responsibility of the Contractor. Formwork and shoring to be designed by a Professional Structural Engineer currently registered in the state of North Dakota and having a minimum of three (3) years experience in this type of design work. Design formwork in accordance with methodology of ACI 347 for anticipated loads, lateral pressures, and stresses, and capable of withstanding the pressures resulting from placement and vibration of concrete. Comply with the tolerances specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE, paragraph CONSTRUCTION TOLERANCES. However, for surfaces with an ACI Class A surface designation, limit the allowable deflection for facing material between studs, for studs between walers and walers between bracing to 0.0025 times the span. Design the formwork as a
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complete system with consideration given to the effects of cementitious materials and mixture additives such as fly ash, cement type, plasticizers, accelerators, retarders, air entrainment, and others. Monitor the adequacy of formwork design and construction prior to and during concrete placement as part of the Contractor's approved Quality Control Plan. Submit design analysis and calculations for form design and methodology used in the design.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
Acknowledgement that products submitted meet requirements of standards referenced. Manufacturer's installation instructions. Manufacturer and type of proposed form materials. Manufacturer and type of proposed form ties. Manufacturer and type of proposed form coating material. Manufacturer and type of Void Forms including compressive strength. Formwork designer qualifications required for the following: Walls and columns with vertical pour heights exceeding 15 FT. Elevated floor slabs and beams. Simulated stone finishes. If requested, submit structural analysis and concrete strength data used in planning and implementing for removal and shoring.
PART 2 PRODUCTS
2.1 FORM MATERIALS
Submit manufacturer's data, including literature describing form materials, accessories, and form releasing agents.
2.1.1 Forms For Class B Finish
This class of finish shall apply to all surfaces except those specified to receive Class C. Forms for Class B finished surfaces shall be plywood panels conforming to APA L870, Grade B-B concrete form panels, Class I or II. Other form materials or liners may be used provided the smoothness and appearance of concrete produced will be equivalent to that produced by the plywood concrete form panels. Forms for round wall surfaces shall be the prefabricated seamless type. Steel lining on wood sheathing will not be permitted. Do not use aluminum forms.
2.1.2 Forms For Class C Finish
Forms for Class C finished surfaces shall be shiplap lumber; plywood conforming to APA L870, Grade B-B concrete form panels, Class I or II; tempered concrete form hardboard conforming to AHA A135.4; other approved concrete form material; or steel, except that steel lining on wood sheathing shall not be used. Forms for round wall surfaces may have one vertical seam. Do not use aluminum forms.
2.1.3 Forms for Floodwall, Building, and Screen walls
Refer to Sheet A-103 of drawings and attachment 03 11 13.00 10A.
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2.1.4 Form Ties
1. Commercially fabricated for use in form construction.
a. Do not use wire ties.
2. Constructed so that ends or end fasteners can be removed without causing spalling at surfaces of the concrete.
3. 3/4 inch minimum diameter cones on both ends.
4. Embedded portion of ties to be not less than 2 inches from face of concrete after ends have been removed.
5. Provide ties with built-in waterstops in all below grade level walls, and all walls that will be in contact with process liquid during pump station operation.
6. Through-wall ties that are designed to be entirely removed are not allowed in all walls that will be in contact with process liquid during pump station operation.
2.1.5 Form Releasing Agents
Form releasing agents shall be commercial formulations that will not bond with, stain or adversely affect concrete surfaces. Agents shall not impair subsequent treatment of concrete surfaces depending upon bond or adhesion nor impede the wetting of surfaces to be cured with water or curing compounds. If special form liners are to be used, follow the recommendation of the form coating manufacturer. Submit manufacturer's recommendation on method and rate of application of form releasing agents.
2.1.6 Void Forms
A. Acceptable Manufacturer's:
1. SureVoid Products, Inc.
2. Deslauriers, Inc.
B. Accessories:
1. Continuous void forms.
2. Specially designed and manufactured for the purpose of creating a void area directly under concrete members which will allow a space for soil vertical upward movement.
3. Able to support the weight of concrete and construction loads to be placed thereon with no decrease in required void form depth.
4. Constructed from double faced corrugated cardboard or fiberboard which is wax impregnated and laminated with moisture-resistant adhesive.
5. Capable of resisting moisture with no loss of load carrying strength or change in depth or configuration.
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PART 3 EXECUTION
3.1 INSTALLATION
3.1.1 Formwork
Forms shall be constructed true to the structural design and required alignment. Forms shall be mortar tight, properly aligned and adequately supported to produce concrete surfaces meeting the surface requirements specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE and conforming to construction tolerance given in TABLE 1. Continuously monitor the alignment and stability of the forms during all phases to assure the finished product will meet the required surface class or classes specified. Failure of any supporting surface either due to surface texture, deflection or form collapse shall be the responsibility of the Contractor as will the replacement or correction of unsatisfactory surfaces. Where concrete surfaces are to have a Class B finish, joints in form panels shall be arranged as approved. When forms for continuous surfaces are placed in successive units, care shall be taken to fit the forms over the completed surface to obtain accurate alignment of the surface and to prevent leakage of mortar. Forms shall not be re-used if there is any evidence of defects which would impair the quality of the resulting concrete surface. All surfaces of used forms shall be cleaned of mortar and any other foreign material before reuse.
3.1.2 Void Forms
1. After void forms are in place and before concrete is placed thereon, cover joints between abutting form sections and cover ends of forms to prevent intrusion of soil, concrete or any other materials.
2. Install void forms in accordance with manufacturer's instructions.
3.2 CHAMFERING
All exposed joints, edges and external corners shall be chamfered by 3/4 inch molding placed in the forms unless the drawings specifically state that chamfering is to be omitted or as otherwise specified. Chamfered joints shall not be permitted where earth or rockfill is placed in contact with concrete surfaces. Chamfered joints shall be terminated twelve inches outside the limit of the earth or rockfill so that the end of the chamfers will be clearly visible.
3.3 COATING
Forms for Class B and Class C finished surfaces shall be coated with a form releasing agent before the form or reinforcement is placed in final position. The coating shall be used as recommended in the manufacturer's printed or written instructions. Surplus coating on form surfaces and coating on reinforcing steel and construction joints shall be removed before placing concrete.
3.4 FORM REMOVAL
Forms shall not be removed without approval. The minimal time required for concrete to reach a strength adequate for removal of formwork without risking the safety of workers or the quality of the concrete depends on a number of factors including, but not limited to, ambient temperature, concrete lift heights, type and amount of concrete admixture, and type and
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amount of cementitious material in the concrete. It is the responsibility of the Contractor to consider all applicable factors and leave the forms in place until it is safe to remove them. In any case forms shall not be removed unless the minimum time, minimum ambient temperature, and minimum compressive strength requirements below are met, except as otherwise directed or specifically authorized. When conditions are such as to justify the requirement, forms will be required to remain in place for a longer period. All removal shall be accomplished in a manner which will prevent damage to the concrete and ensure the complete safety of the structure. Where forms support more than one element, the forms shall not be removed until the form removal criteria are met by all supported elements. Form removal shall be scheduled so that all necessary repairs can be performed. Evidence that concrete has gained sufficient strength to permit removal of forms shall be determined by tests on control cylinders. All control cylinders shall be stored in the structure or as near the structure as possible so they receive the same curing conditions and protection methods as given those portions of the structure they represent. Control cylinders shall be removed from the molds at an age of no more than 24 hours. All control cylinders shall be prepared and tested in accordance with ASTM C31/C31M and ASTM C39/C39M at the expense of the Contractor by an independent laboratory that complies with ASTM C1077 and shall be tested within 4 hours after removal from the site.
3.4.1 Formwork Not Supporting Weight of Concrete
Formwork for walls, columns, sides of beams, gravity structures, and other vertical type formwork not supporting the weight of concrete shall not be removed in less than 24 hours after concrete placement is completed and may be removed as soon as concrete has hardened sufficiently to resist damage from removal. Leave forms and shoring used to support weight of concrete in place until concrete has attained its specified 28 day comprehensive strength.
3.4.2 Formwork Supporting Weight of Concrete
Formwork supporting weight of concrete and shoring shall not be removed until structural members have acquired their specified 28 day compressive strength.
3.5 INSPECTION
Forms and embedded items shall be inspected in sufficient time prior to each concrete placement in order to certify to the Owner's Representative that they are ready to receive concrete. The results of each inspection shall be reported in writing. Submit field inspection reports for concrete forms and embedded items.
TABLE 1 TOLERANCES FOR FORMED SURFACES
1. Variations from the plumb: a. In the lines and surfaces of 1/4 inch in any 10 feet of length piers, walls and in arises Maximum for entire length -- 1 inch
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TABLE 1 TOLERANCES FOR FORMED SURFACES b. For exposed corner, 1/4 inch in any 20 feet of length control-joint grooves, and other Maximum for entire length -- 1/2 conspicuous lines inch
2. Variation from the level or from the grades indicated on the drawings: a. In slab soffits, ceilings beam 1/4 inch in any 10 feet of length soffits, and in arises,measured 3/8 inch in any bay or in any 20 before removal of supporting shores feet of length Maximum for entire length -- 3/4 inch b. In exposed lintels, sills, 1/4 inch in any bay or in any 20 parapets, horizontal grooves, and feet of length other conspicuous lines Maximum for entire length -- 1/2 inch 3. Variation of the linear 1/2 inch in any 10 feet building lines from established 1 inch maximum position in plan
4. Variation of distance between 1/4 inch per 10 feet of distance, walls. but not more than 1/2 inch in any one bay, and not more than 1 inch total variation
5. Variation in the sizes and Minus 1/4 inch, Plus 1/2 inch locations of sleeves, floor openings, and wall openings.
6. Variation in cross-sectional Minus 1/4 inch, Plus 1/2 inch dimensions of beams and in the thickness of slabs and walls
7. Footings: a. Variation of dimensions in plan Minus 1/2 inch, plus 2 inches when formed or plus 3 inches when placed against unformed excavation b. Misplacement of eccentricity 2 percent of the footing width in the direction of misplacement but not more than 2 inches c. Reduction in thickness Minus 5 percent of the specified thickness
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SECTION 03 15 00.00 10
CONCRETE ACCESSORIES 08/10 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN HARDBOARD ASSOCIATION (AHA)
AHA A135.4 (1995; R 2004) Basic Hardboard
ASTM INTERNATIONAL (ASTM)
ASTM C919 (2012) Use of Sealants in Acoustical Applications
ASTM C920 (2011) Standard Specification for Elastomeric Joint Sealants
ASTM D1751 (2004; E 2013; R 2013) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)
ASTM D1752 (2004a; R 2008) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion
ASTM D2628 (1991; R 2011) Standard Specification for Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements
ASTM D2835 (1989; R 2012) Lubricant for Installation of Preformed Compression Seals in Concrete Pavements
ASTM D412 (2006a; R 2013) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension
ASTM D5249 (2010) Backer Material for Use with Cold-and Hot-Applied Joint Sealants in Portland-Cement Concrete and Asphalt Joints
ASTM D7116 (2005) Standard Specification for Joint Sealants, Hot Applied, Jet Fuel Resistant Types, for Portland Cement Concrete Pavement
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U.S. ARMY CORPS OF ENGINEERS (USACE)
COE CRD-C 513 (1974) Corps of Engineers Specifications for Rubber Waterstops
COE CRD-C 572 (1974) Corps of Engineers Specifications for Polyvinylchloride Waterstops
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Waterstops; G
SD-03 Product Data
Preformed Expansion Joint Filler Sealant Waterstops
SD-04 Samples
Lubricant for Preformed Compression Seals Field-Molded Type Non-metallic Materials Waterstops Splicing Waterstops; G
SD-07 Certificates
Preformed Expansion Joint Filler Sealant Waterstops
1.3 DELIVERY, STORAGE, AND HANDLING
Protect material delivered and placed in storage off the ground from moisture, dirt, and other contaminants. Deliver sealants in the manufacturer's original unopened containers. Remove sealants from the site whose shelf life has expired.
PART 2 PRODUCTS
2.1 CONTRACTION JOINT STRIPS
Contraction joint strips shall be 1/8 inch thick tempered hardboard conforming to AHA A135.4, Class 1. In lieu of hardboard strips, rigid polyvinylchloride (PVC) or high impact polystyrene (HIPS) insert strips specifically designed to induce controlled cracking in slabs on grade may be used. Such insert strips shall have removable top section.
2.2 PREFORMED EXPANSION JOINT FILLER
Expansion joint filler shall be preformed material conforming to ASTM D1751 or ASTM D1752, Type I, or resin impregnated fiberboard conforming to the
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physical requirements of ASTM D1752. Submit certified manufacturer's test reports for premolded expansion joint filler strips, compression seals and lubricant, and metallic waterstops to verify compliance with applicable specification. Unless otherwise indicated, filler material shall be 3/8 inch thick and of a width applicable for the joint formed. Backer material, when required, shall conform to ASTM D5249.
2.3 SEALANT
Joint sealant shall conform to the following:
2.3.1 Preformed Polychloroprene Elastomeric Type
ASTM D2628.
2.3.2 Lubricant for Preformed Compression Seals
ASTM D2835. Submit a piece not less than 9 ft of 1 inch nominal width or wider seal or a piece not less than 12 ft of compression seal less than 1 inch nominal width. Provide one quart of lubricant.
2.3.3 Field-Molded Type
ASTM C920. Sealant shall be Type M, Grade P or NS, Class 25, Use NT for horizontal joints. Type M, Grade NS, Class 25, Use NT for vertical joints. Except, the joint sealant that will be submerged underwater for part or all of its service life shall meet the requirements of USE I. Bond breaker material shall be polyethylene tape, coated paper, metal foil or similar type materials. The back-up material shall be compressible, non-shrink, nonreactive with sealant, and non-absorptive material type such as extruded butyl or polychloroprene rubber. Submit One gallon of field-molded sealant and one quart of primer (when primer is recommended by the sealant manufacturer) identified to indicate manufacturer, type of material, quantity, and shipment or lot represented.
2.3.4 Hot-Applied Jet-Fuel Resistant Type
ASTM D7116, Type I
2.4 WATERSTOPS
Shop fabricate intersection and change of direction waterstops. Submit a sample of each material consisting of a piece not less than 12 inches long cut from each 200 feet of finished waterstop furnished, but not less than a total of 4 linear feet of each type and size furnished. For spliced segments of waterstops to be installed in the work, furnish one spliced sample of each size and type for every 50 splices made in the factory and every 10 splices made at the job site for inspection and testing. Make the spliced samples using straight run pieces with the splice located at the mid-length of the sample and finished as required for the installed waterstop. The total length of each spliced sample shall be not less than 12 inches long. Submit waterstop materials and splice samples for inspection and testing identified to indicate manufacturer, type of material, size and quantity of material and shipment represented.
2.4.1 Non-Metallic Materials`
D. Waterstops, PVC Type: 1. Acceptable manufacturers:
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a. Greenstreak Plastic Products. b. Vinylex Corporation. 2. Materials: a. Virgin polyvinyl chloride compound not containing any scrap or reclaimed materials or pigment. b. Standard: COE CRD-C572. 3. In expansion joints: a. 9 IN wide by 3/8 IN thick tear web type waterstop. b. 2 IN minimum horizontal movement without rupturing. c. Greenstreak Plastic Products Style #700. 4. In joints as indicated on Drawings: a. 4 inches wide by 3/16 inch thick bulb type waterstop. b. Greenstreak Plastic Products Style #701. 5. In control joints: a. 6 IN wide by 3/8 IN thick with ribs and center bulb. b. Greenstreak Plastic Products Style #705. 6. In all other joints: a. 6 IN wide by 3/8 IN thick with ribs and center bulb. b. Greenstreak Plastic Products Style #705 or equal. 7. Provide hog rings or grommets at maximum 12 IN OC along the length of the waterstop. 8. Provide factory-made waterstop fabrications at all changes in direction, intersections and transitions, leaving only straight butt splices for the field.
Submit a piece not less than 12 inch long cut from each 200 ft of finished waterstop furnished, but not less than a total of 4 ft of each type, size, and lot furnished. One splice sample of each size and type for every 50 splices made in the factory and every 10 splices made at the job site. Make the splice samples using straight run pieces with the splice located at the mid-length of the sample and finished as required for the installed waterstop. The total length of each splice shall be not less than 12 inches long.
2.4.2 Non-Metallic Hydrophilic
Swellable strip type compound of polymer modified chloroprene rubber that swells upon contact with water shall conform to ASTM D412 as follows: Tensile strength 420 psi minimum; ultimate elongation 600 percent minimum. Hardness shall be 50 minimum on the type A durometer and the volumetric expansion ratio in distilled water at 70 degrees F shall be 3 to 1 minimum.
E. Waterstops, Preformed Strip Type: 1. Acceptable manufacturers: a. Hydrotite CJ by Greenstreak Plastics, Inc. b. Adeka Ultra Seal USA. c. Synko Flex. d. Volclay Waterstop Rx. e. Swellstop by Greenstreaks Plastics, Inc. 2. Materials: a. Hydrophilic type waterstop manufactured solely for the purpose of preventing water from traveling through construction joints. b. Hydrotite type CJ-0725-3K.
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2.5 TESTS, INSPECTIONS, AND VERIFICATIONS
2.5.1 Materials Tests
2.5.1.1 Non-Metallic Waterstops
Samples of materials and splices will be visually inspected and tested by and at the expense of the Owner's Representative for compliance with COE CRD-C 513 or COE CRD-C 572 as applicable. If a sample fails to meet the specification requirements, provide new samples and the cost of retesting will be deducted from payments due the Contractor.
2.5.2 Splicing Waterstops
2.5.2.1 Procedure and Performance Qualifications
Demonstrate procedure and performance qualifications for splicing waterstops in the presence of the Owner's Representative. Submit procedures for splicing waterstops for approval.
2.5.2.2 Non-Metallic Waterstops
Demonstrate procedure and performance qualifications for splicing non-metallic waterstops by the manufacturer at the factory and the Contractor at the job site by each making three spliced samples of each size and type of finished waterstop.
PART 3 EXECUTION
3.1 INSTALLATION
Joint locations and details, including materials and methods of installation of joint fillers and waterstops, shall be as specified and indicated. In no case shall any fixed metal be continuous through an expansion or contraction joint.
3.1.1 Contraction Joints
Contraction joints may be constructed by inserting tempered hardboard strips or rigid PVC or HIPS insert strips into the plastic concrete using a steel parting bar, when necessary, or by cutting the concrete with a saw after concrete has set. Make joints 1/8 inch to 3/16 inch wide and extend into the slab one-fourth the slab thickness, minimum, but not less than 1 inch.
3.1.1.1 Joint Strips
Provide strips of the required dimensions and as long as practicable. After the first floating, groove the concrete with a tool at the joint locations. Insert the strips in the groove and depress them until the top edge of the vertical surface is flush with the surface of the slab. Float and finish the slab as specified. Working of the concrete adjacent to the joint shall be the minimum necessary to fill voids and consolidate the concrete. Where indicated, saw out the top portion of the strip after the curing period to form a recess for sealer. Discard the removable section of PVC or HIPS strips and leave the insert in place. Maintain true alignment of the strips during insertion.
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3.1.1.2 Sawed Joints
Saw joints early enough to prevent uncontrolled cracking in the slab, but late enough that this can be accomplished without appreciable spalling. Cutting shall be started as soon as the concrete has hardened sufficiently to prevent raveling of the edges of the saw cut. Cutting shall be completed before shrinkage stresses become sufficient to produce cracking. Use concrete sawing machines that are adequate in number and power, and with sufficient replacement blades to complete the sawing at the required rate. Cut joints to true alignment and in sequence of concrete placement. Remove sludge and cutting debris. Form reservoir for joint sealant.
3.1.1.3 Bond Breaker
Coat joints requiring a bond breaker with curing compound or with bituminous paint. Protect waterstops during application of bond breaking material to prevent them from being coated.
3.1.2 Expansion Joints
Use preformed expansion joint filler in expansion and isolation joints in slabs around columns and between slabs on grade and vertical surfaces where indicated. Extend the filler to the full slab depth, unless otherwise indicated. neatly finish the edges of the joint with an edging tool of 1/8 inch radius, except where a resilient floor surface will be applied. Where the joint is to receive a sealant, the filler strips shall be installed at the proper level below the finished floor with a slightly tapered, dressed and oiled wood strip temporarily secured to the top to form a recess to the size shown on the drawings. Remove the wood strip after the concrete has set. Contractor may opt to use a removable expansion filler cap designed and fabricated for this purpose in lieu of the wood strip. Thoroughly clean the groove of laitance, curing compound, foreign materials, protrusions of hardened concrete, and any dust. If blowing out the groove use oil-free compressed air.
3.1.3 Joint Sealant
Fill sawed contraction joints and expansion joints in slabs with joint sealant, unless otherwise shown. Joint surfaces shall be clean, dry, and free of oil or other foreign material which would adversely affect the bond between sealant and concrete. Apply joint sealant as recommended by the manufacturer of the sealant.
3.1.3.1 Joints With Preformed Compression Seals
Install compression seals with equipment capable of installing joint seals to the prescribed depth without cutting, nicking, twisting, or otherwise distorting or damaging the seal or concrete and with no more than 5 percent stretching of the seal. Cover the sides of the joint and, if necessary, the sides of the compression seal with a coating of lubricant. Coat butt joints with liberal applications of lubricant.
3.1.3.2 Joints With Field-Molded Sealant
Do not seal joints when the sealant material, ambient air, or concrete temperature is less than 40 degrees F. When the sealants are meant to reduce the sound transmission characteristics of interior walls, ceilings, and floors the guidance provided in ASTM C919 shall be followed. Coat joints requiring a bond breaker with curing compound or with bituminous
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paint. Install bond breaker and back-up material where required. Joints shall be primed and filled flush with joint sealant in accordance with the manufacturer's recommendations.
3.2 WATERSTOPS, INSTALLATION AND SPLICES
Install waterstops at the locations shown to form a continuous water-tight diaphragm. Make adequate provision to support and completely protect the waterstops during the progress of the work. Repair or replace any waterstop punctured or damaged. Protect exposed waterstops during application of form release agents to avoid being coated. Provide suitable guards to protect exposed projecting edges and ends of partially embedded waterstops from damage when concrete placement has been discontinued. Accomplish splices with certified trained personnel using approved equipment and procedures.
3.2.1 Non-Metallic
Fittings shall be shop made using a machine specifically designed to mechanically weld the waterstop. A miter guide, proper fixturing (profile dependant), and portable power saw shall be used to miter cut the ends to be joined to ensure good alignment and contact between joined surfaces. The splicing of straight lengths shall be done by squaring the ends to be joined. Maintain continuity of the characteristic features of the cross section of the waterstop (ribs, tabular center axis, protrusions, etc.) across the splice.
3.2.1.1 Polyvinyl Chloride Waterstop
Make splices by heat sealing the adjacent waterstop edges together using a thermoplastic splicing iron utilizing a non-stick surface specifically designed for waterstop welding. Use the correct temperature to sufficiently melt without charring the plastic. Reform waterstops at splices with a remolding iron with ribs or corrugations to match the pattern of the waterstop. The spliced area, when cooled, shall show no signs of separation, holes, or other imperfections when bent by hand in as sharp an angle as possible.
3.2.1.2 Quality Assurance
Edge welding will not be permitted. Compress or close centerbulbs when welding to non-centerbulb type. Waterstop splicing defects which are unacceptable include, but are not limited to the following: 1) Tensile strength less than 80 percent of parent section. 2) Free lap joints. 3) Misalignment of centerbulb, ribs, and end bulbs greater than 1/16 inch. 4) Misalignment which reduces waterstop cross section more than 15 percent. 5) Bond failure at joint deeper than 1/16 inch or 15 percent of material thickness. 6) Misalignment of waterstop splice resulting in misalignment of waterstop in excess of 1/2 inch in 10 feet. 7) Visible porosity in the weld area, including pin holes. 8) Charred or burnt material. 9) Bubbles or inadequate bonding. 10) Visible signs of splice separation when cooled splice is bent by hand at a sharp angle.
3.2.2 Non-Metallic Hydrophilic Waterstop Installation
Miter cut ends to be joined with sharp knife or shears. The ends shall be adhered with cyanacryiate (super glue) adhesive. When joining hydrophilic type waterstop to PVC waterstop, the hydrophilic waterstop shall be positioned as shown on the drawings. Apply a liberal amount of a single
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component hydrophilic sealant to the junction to complete the transition.
3.3 CONSTRUCTION JOINTS
Treat construction joints coinciding with expansion and contraction joints as expansion or contraction joints as applicable.
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SECTION 03 20 00.00 10
CONCRETE REINFORCING 08/10 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)
ACI 318 (2011; Errata 1 2011; Errata 2 2012; Errata 3-4 2013) Building Code Requirements for Structural Concrete and Commentary
ACI SP-66 (2004) ACI Detailing Manual
ASTM INTERNATIONAL (ASTM)
ASTM A1035/A1035M (2013b) Standard Specification for Deformed and Plain, Low-carbon, Chromium, Steel Bars for Concrete Reinforcement
ASTM A1064/A1064M (2013) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete
ASTM A184/A184M (2006; E2011) Standard Specification for Fabricated Deformed Steel Bar Mats for Concrete Reinforcement
ASTM A370 (2012a) Standard Test Methods and Definitions for Mechanical Testing of Steel Products
ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
ASTM A615/A615M (2013) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement
ASTM A675/A675M (2003; R 2009) Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality, Mechanical Properties
ASTM A706/A706M (2013) Standard Specification for Low-Alloy Steel Deformed and Plain Bars
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for Concrete Reinforcement
ASTM A884/A884M (2012) Standard Specification for Epoxy-Coated Steel Wire and Welded Wire Reinforcement
CONCRETE REINFORCING STEEL INSTITUTE (CRSI)
CRSI 10MSP (2009; 28th Ed) Manual of Standard Practice
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Reinforcement; G
SD-03 Product Data
Welding Butt-Splices; G Material; G
SD-06 Test Reports
Material; G Tests, Inspections, and Verifications; G
SD-07 Certificates
Reinforcing Steel Qualification of Steel Bar Butt-Splicers
1.3 QUALITY ASSURANCE
1.3.1 Qualification of Steel Bar Butt-Splicers
Qualification of steel bar butt-splicers shall be certified to have satisfactorily completed a course of instruction in the proposed method of butt-splicing or have satisfactorily performed such work within the preceding year. Submit certificates on the Qualifications of Steel Bar Butt-Splicers prior to commencing butt-splicing.
1.3.2 Qualification of Butt-Splicing Procedure
As a condition of approval of the butt-splicing procedure, make three test butt-splices of steel bars of each size to be spliced using the proposed butt-splicing method, in the presence of the Owner's Representative. These test butt-splices and unspliced bars of the same size shall be tension tested to destruction with stress-strain curves plotted for each test. Test results shall show that the butt-splices meet the specified strength and deformation requirements in order for the splicing procedure to be approved.
1.4 DELIVERY, STORAGE, AND HANDLING
Reinforcement and accessories shall be stored off the ground on platforms,
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skids, or other supports.
PART 2 PRODUCTS
2.1 DOWELS
Dowels shall conform to ASTM A675/A675M, Grade 80 or ASTM A1035/A1035M. Steel pipe conforming to ASTM A53/A53M, Schedule 80, may be used as dowels provided the ends are closed with metal or plastic inserts or with mortar.
2.2 FABRICATED BAR MATS
Fabricated bar mats shall conform to ASTM A184/A184M.
2.3 REINFORCING STEEL
Reinforcing steel shall be deformed bars conforming to ASTM A615/A615M, ASTM A706/A706M, or ASTM A1035/A1035M grades and sizes as indicated.
Submit certified copies of mill reports attesting that the reinforcing steel furnished contains no less than 25 percent recycled scrap steel and meets the requirements specified herein, prior to the installation of reinforcing steel.
2.4 WELDED WIRE FABRIC
Welded wire fabric shall conform to ASTM A1064/A1064M. When directed by the Owner's Representative for special applications, welded wire fabric shall conform to ASTM A884/A884M. For wire with a specified yield strength (fy) exceeding 60,000 psi, fy shall be the stress corresponding to a strain of 0.35 percent.
2.5 WIRE TIES
Wire ties shall be 16 gauge or heavier black annealed steel wire.
2.6 REBAR ADHESIVE ANCHORS
Acceptable Manufacturer's:
a. HIT-HY150 System by HILTI FASTENING SYSTEMS, INC.
b. SET XP Structural Epoxy-Tie.
c. Anchoring System by Simpson.
d. Strong -Tie Anchor Systems.
2.7 SUPPORTS
Bar supports for formed surfaces shall be designed and fabricated in accordance with CRSI 10MSP and shall be steel or precast concrete blocks. Precast concrete blocks shall have wire ties and shall be not less than 4 inches square when supporting reinforcement on ground. Precast concrete block shall have compressive strength equal to that of the surrounding concrete. Where concrete formed surfaces will be exposed to weather or where surfaces are to be painted, steel supports within 1/2 inch of concrete surface shall be galvanized, plastic protected or of stainless steel. Concrete supports used in concrete exposed to view shall have the
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same color and texture as the finish surface. For slabs on grade, supports shall be precast concrete blocks, plastic coated steel fabricated with bearing plates, or specifically designed wire-fabric supports fabricated of plastic.
Bar supports shall comply with the requirements of ACI SP-66. Supports for bars in concrete with formed surfaces exposed to view or to be painted shall be plastic-coated wire, stainless steel or precast concrete supports. Precast concrete supports shall be wedged-shaped, not larger than 3-1/2 by 3-1/2 inches, of thickness equal to that indicated for concrete cover and have an embedded hooked tie-wire for anchorage. Bar supports used in precast concrete with formed surfaces exposed to view shall be the same quality, texture and color as the finish surfaces.
2.8 TESTS, INSPECTIONS, AND VERIFICATIONS
Perform material tests, specified and required by applicable standards, by an approved laboratory and certified to demonstrate that the materials are in conformance with the specifications. Tests, inspections, and verifications shall be performed and certified at the Contractor's expense. Submit certified tests reports of reinforcement steel showing that the steel complies with the applicable specifications for each steel shipment and identified with specific lots prior to placement. Submit three copies of the heat analyses for each lot of steel furnished certifying that the steel conforms to the heat analyses.
2.8.1 Reinforcement Steel Tests
Mechanical testing of steel shall be in accordance with ASTM A370 except as otherwise specified or required by the material specifications. Tension tests shall be performed on full cross-section specimens using a gage length that spans the extremities of specimens with welds or sleeves included. Chemical analyses of steel heats shall show the percentages of carbon, phosphorous, manganese, sulphur and silicon present in the steel.
PART 3 EXECUTION
3.1 REINFORCEMENT
Reinforcement steel and accessories shall be fabricated and placed as specified and shown and approved shop drawings. Fabrication and placement details of steel and accessories not specified or shown shall be in accordance with ACI SP-66 and ACI 318. Reinforcement shall be cold bent unless otherwise authorized. Bending may be accomplished in the field or at the mill. Bars shall not be bent after embedment in concrete. Safety caps shall be placed on all exposed ends of vertical concrete reinforcement bars that pose a danger to life safety. Wire tie ends shall face away from the forms. Submit detail drawings showing reinforcing steel placement, schedules, sizes, grades, and splicing and bending details. Drawings shall show support details including types, sizes and spacing.
3.1.1 Placement
Reinforcement shall be free from loose rust and scale, dirt, oil, or other deleterious coating that could reduce bond with the concrete. Reinforcement shall be placed in accordance with ACI 318 at locations shown plus or minus one bar diameter. Reinforcement shall not be continuous through expansion joints and shall be as indicated through construction or contraction joints. Concrete coverage shall be as indicated or as required
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by ACI 318. If bars are moved more than one bar diameter to avoid interference with other reinforcement, conduits or embedded items, the resulting arrangement of bars, including additional bars required to meet structural requirements, shall be approved before concrete is placed.
3.1.2 Splicing
Splices of reinforcement shall conform to ACI 318 and shall be made only as required or indicated. Splicing shall be by lapping or by mechanical connection; except that lap splices shall not be used for bars larger than No. 11 unless otherwise indicated. Lapped bars shall be placed in contact and securely tied or spaced transversely apart to permit the embedment of the entire surface of each bar in concrete. Lapped bars shall not be spaced farther apart than one-fifth the required length of lap or 6 inches. Mechanical butt splices shall be in accordance with the recommendation of the manufacturer of the mechanical splicing device. Butt splices shall develop 125 percent of the specified minimum yield tensile strength of the spliced bars or of the smaller bar in transition splices. Bars shall be flame dried before butt splicing. Adequate jigs and clamps or other devices shall be provided to support, align, and hold the longitudinal centerline of the bars to be butt spliced in a straight line.
Rebar Mechancal Splicing - Acceptable Manufacturers:
a. Lenton Rebar Splicing by Erico, Inc.
b. Richmond dowel bar splicer system by Richmond Screw and Anchor Co., Inc.
c. Bar-Grip Systems by Barsplice Products, Inc.
3.1.3 Placing Tolerances
3.1.3.1 Spacing
The spacing between adjacent bars and the distance between layers of bars may not vary from the indicated position by more than one bar diameter nor more than 1 inch.
3.1.3.2 Concrete Cover
The minimum concrete cover of main reinforcement steel bars shall be as shown. The allowable variation for minimum cover shall be as follows:
MINIMUM COVER (inch) VARIATION (inch)
6 plus 1/2
4 plus 3/8
3 plus 3/8
2 plus 1/4
1-1/2 plus 1/4
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3.1.4 Splicing
Splices in steel bars shall be made only as required. Bars may be spliced at alternate or additional locations at no additional cost to the Owner's Representative subject to approval.
3.1.4.1 Lap Splices
Lap splices shall be used only for bars smaller than size 14 and welded wire fabric. Lapped bars may be placed in contact and securely tied or spaced transversely apart to permit the embedment of the entire surface of each bar in concrete. Lapped bars shall not be spaced farther apart than 1/5 the required length of lap or 6 inches.
3.1.4.2 Butt-Splices
Use butt-splices only for splicing size 14 and 18 bars and for splicing #11 bars to larger bars except where otherwise shown or authorized. Make butt-splices by a method which develops splices suitable for tension, compression and stress reversal applications. Bars shall be cleaned of all oil, grease, dirt, rust, scale and other foreign substances and shall be flame dried before splicing. Adequate jigs and clamps or other devices shall be provided to support, align and hold the longitudinal centerline of the bars to be butt-spliced in a straight line. Submit proposed procedure for butt-splicing steel bars prior to making the test butt-splices for qualification of the procedure. Properties and analyses of steel bars and splicing materials shall be included in the submitted procedure. Physical properties of splicing sleeves shall include length, inside and outside diameters, and inside surface details. Butt-splices shall be as follows:
3.1.4.2.1 Mechanical Butt-Splices
Mechanical butt-splices shall be an approved exothermic, threaded coupling, swaged sleeve or other positive connecting type. Bars to be spliced by a mechanical butt-splicing process may be sawed, sheared or flame cut provided the ends of sheared bars are reshaped after shearing and all slag is removed from the ends of flame cut bars by chipping and wire brushing prior to splicing. Surfaces to be enclosed within a splice sleeve or coupling shall be cleaned by wire brushing or other approved method prior to splicing. Splices shall be made using manufacturer's standard jigs, clamps, ignition devices and other required accessories. In addition to the strength requirements specified paragraph BUTT-SPLICES the additional deformation of number 14 and smaller bars due to slippage or other movement within the splice sleeve shall not exceed 0.015 inches (unit strain 0.0015 inches/inch) beyond the elongation of an unspliced bar based upon a 10 inch gage length spanning the extremities of the sleeve at a stress of 30,000 psi. The additional deformation of number 18 bars shall not exceed 0.03 inches (unit strain 0.003 inches/inch) beyond the elongation of an unspliced bar based upon a 10 inch gage length spanning the extremities of the sleeve at a stress of 30,000 psi. The amount of the additional deformation shall be determined from the stress-strain curves of the unspliced and spliced bars tested as required paragraph QUALIFICATION OF BUTT-SPLICING PROCEDURE for qualification of the butt-splicing procedure. Tension splices of number 14 or smaller bar shall be staggered longitudinally a minimum of 5 feet or as otherwise indicated so that no more than half of the bars are spliced at any one section. Tension splices of number 18 bars shall be staggered longitudinally a minimum of 5 feet so that no more than 1/3 of the bars are spliced at any one section.
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Proprietary Rebar Mechanical Splices:
To develop in tension and compression a minimum of 125% of the yield strength of the rebars being spliced.
3.2 WELDED-WIRE FABRIC PLACEMENT
Welded-wire fabric shall be placed in slabs as indicated. Fabric placed in slabs on grade shall be continuous between expansion, construction, and contraction joints. Fabric placement at joints shall be as indicated. Lap splices shall be made in such a way that the overlapped area equals the distance between the outermost crosswires plus 2 inches. Laps shall be staggered to avoid continuous laps in either direction. Fabric shall be wired or clipped together at laps at intervals not to exceed 4 feet. Fabric shall be positioned by the use of supports.
3.3 DOWEL INSTALLATION
Dowels shall be installed in slabs on grade at locations indicated and at right angles to joint being doweled. Dowels shall be accurately positioned and aligned parallel to the finished concrete surface before concrete placement. Dowels shall be rigidly supported during concrete placement. One end of dowels shall be coated with a bond breaker.
3.4 FIELD TESTS AND INSPECTIONS
3.4.1 Identification of Splices
Establish and maintain an approved method of identification of all field mechanical butt-splices which will indicate the splicer and the number assigned each splice made by the splicer.
3.4.2 Examining, Testing, and Correcting
Perform the following during the butt-splicing operations as specified and as directed:
3.4.2.1 Visual Examination
Visually inspect all mechanical splices and verify they are done per manufacturer's recommendations.
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 03 30 00.00 10
CAST-IN-PLACE CONCRETE 11/10 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)
ACI 117 (2010; Errata 2011) Specifications for Tolerances for Concrete Construction and Materials and Commentary
ACI 211.1 (1991; R 2009) Standard Practice for Selecting Proportions for Normal, Heavyweight and Mass Concrete
ACI 214R (2011) Evaluation of Strength Test Results of Concrete
ACI 305.1 (2006) Specification for Hot Weather Concreting
ACI 318 (2011; Errata 1 2011; Errata 2 2012; Errata 3-4 2013) Building Code Requirements for Structural Concrete and Commentary
ASTM INTERNATIONAL (ASTM)
ASTM C1017/C1017M (2007) Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete
ASTM C1059/C1059M (1999; R 2008) Standard Specification for Latex Agents for Bonding Fresh to Hardened Concrete
ASTM C1064/C1064M (2011) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete
ASTM C1077 (2013b) Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation
ASTM C1107/C1107M (2013) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)
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ASTM C136 (2006) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates
ASTM C143/C143M (2012) Standard Test Method for Slump of Hydraulic-Cement Concrete
ASTM C150/C150M (2012) Standard Specification for Portland Cement
ASTM C172/C172M (2010) Standard Practice for Sampling Freshly Mixed Concrete
ASTM C192/C192M (2013a) Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory
ASTM C231/C231M (2010) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method
ASTM C260/C260M (2010a) Standard Specification for Air-Entraining Admixtures for Concrete
ASTM C31/C31M (2012) Standard Practice for Making and Curing Concrete Test Specimens in the Field
ASTM C33/C33M (2013) Standard Specification for Concrete Aggregates
ASTM C39/C39M (2012) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens
ASTM C42/C42M (2013) Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete
ASTM C494/C494M (2013) Standard Specification for Chemical Admixtures for Concrete
ASTM C552 (2013) Standard Specification for Cellular Glass Thermal Insulation
ASTM C578 (2012b) Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation
ASTM C591 (2013) Standard Specification for Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation
ASTM C618 (2012a) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete
ASTM C881/C881M (2010) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete
ASTM C937 (2010) Grout Fluidifier for
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Preplaced-Aggregate Concrete
ASTM C94/C94M (2013a) Standard Specification for Ready-Mixed Concrete
ASTM D75/D75M (2009) Standard Practice for Sampling Aggregates
ASTM E96/E96M (2012) Standard Test Methods for Water Vapor Transmission of Materials
NATIONAL READY MIXED CONCRETE ASSOCIATION (NRMCA)
NRMCA QC 3 (2011) Quality Control Manual: Section 3, Plant Certifications Checklist: Certification of Ready Mixed Concrete Production Facilities
NRMCA TMMB 100 (2001; R 2007) Truck Mixer, Agitator and Front Discharge Concrete Carrier Standards
U.S. ARMY CORPS OF ENGINEERS (USACE)
COE CRD-C 104 (1980) Method of Calculation of the Fineness Modulus of Aggregate
COE CRD-C 400 (1963) Requirements for Water for Use in Mixing or Curing Concrete
COE CRD-C 521 (1981) Standard Test Method for Frequency and Amplitude of Vibrators for Concrete
COE CRD-C 94 (1995) Corps of Engineers Specification for Surface Retarders
1.2 SYSTEM DESCRIPTION
Provide concrete composed of portland cement, other cementitious and pozzolanic materials as specified, aggregates, water and admixtures as specified.
1.2.1 Proportioning Studies-Normal Weight Conc
Trial design batches, mixture proportions studies, and testing requirements for various classes and types of concrete specified are the responsibility of the Contractor. Mixture proportions shall be based on compressive strength as determined by test specimens fabricated in accordance with ASTM C192/C192M and tested in accordance with ASTM C39/C39M.
a. Samples of all materials used in mixture proportioning studies shall be representative of those proposed for use in the project and be accompanied by the manufacturer's or producer's test reports indicating compliance with these specifications.
b. Make trial mixtures having proportions, consistencies, and air content suitable for the work based on methodology described in ACI 211.1, using at least three different water-cement ratios for each type of mixture, which will produce a range of strength encompassing those required for each class and type of concrete required on the project.
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c. The maximum water-cement ratios required in subparagraph Water-Cement Ratio below will be the equivalent water-cement ratio as determined by conversion from the weight ratio of water to cement plus pozzolan by the weight equivalency method as described in ACI 211.1. If pozzolan is used in the concrete mixture, the minimum pozzolan content shall be 15 percent by weight of the total cementitious material, and the maximum shall be 35 percent.
d. Design laboratory trial mixtures for maximum permitted slump and air content. Make separate sets of trial mixture studies for each combination of cementitious materials and each combination of admixtures proposed for use. No combination of either shall be used until proven by such studies, except that, if approved in writing and otherwise permitted by these specifications, an accelerator or a retarder may be used without separate trial mixture study. Separate trial mixture studies shall also be made for concrete for any conveying or placing method proposed which requires special properties and for concrete to be placed in unusually difficult placing locations.
e. Report the temperature of concrete in each trial batch. For each water-cement ratio, at least three test cylinders for each test age shall be made, cured in accordance with ASTM C192/C192M and tested at 7 and 28 days in accordance with ASTM C39/C39M. From these test results, plot a curve showing the relationship between water-cement ratio and strength for each set of trial mix studies. In addition, a curve shall be plotted showing the relationship between 7 day and 28 day strengths. Design each mixture to promote easy and suitable concrete placement, consolidation and finishing, and to prevent segregation and excessive bleeding.
f. Submit the results of trial mixture design studies along with a statement giving the maximum nominal coarse aggregate size and the proportions of ingredients that will be used in the manufacture of each strength or class of concrete, at least 14 days prior to commencing concrete placing operations. Aggregate weights shall be based on the saturated surface dry condition. Accompany the statement with test results from an approved independent commercial testing laboratory, showing that mixture design studies have been made with materials proposed for the project and that the proportions selected will produce concrete of the qualities indicated. No substitutions shall be made in the materials used in the mixture design studies without additional tests to show that the quality of the concrete is satisfactory.
g. Mass Concrete: a. Mass Concrete s defined as any concrete member or pour that is equal or greater than 36 IN thick in the minimum direction. b. The use of a concrete set-retarding admixture is required and the use of concrete water reducing admixture is recommended. The use of established curing and testing procedures are acceptable and may be used in establishing potential concrete strength with the purpose of detecting variations of concrete quality and judging the effectiveness of job control measures. c. Provide mass concrete in accordance with ACI 301-10, Section 8 unless otherwise indicated. d. Thermal requirements: 1) The maximum temperature in concrete after palcements shall not exceed 158 DegF; and 2) The maxium temperature difference between center and surface
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of placement shall not excee 35 DegF. e. Cement: Type II. f. Pozzolan: 1) Mass concrete: use both of the following in the mix design: a) Fly Ash: 35 percent maximum by weight of Portland cement content per cubic yard shall be replaced with fly ash at a rate of 1 LB fly ash for 1 LB cement. b) GGBFS: 20 to 30 percent by weight of Portland cement content per cubic yard shall be replaced with GGBFS at a rate of 1 LB GGBFS for 1 LB cement.
1.2.2 Average Compressive Strength
The mixture proportions selected during mixture design studies shall produce a required average compressive strength (f'cr) exceeding the specified compressive strength (f'c) by the amount indicated below. This required average compressive strength, f'cr, will not be a required acceptance criteria during concrete production. However, whenever the daily average compressive strength at 28 days drops below f'cr during concrete production, or daily average 7-day strength drops below a strength correlated with the 28-day f'cr, adjust the mixture, as approved, to bring the daily average back up to f'cr. During production, the required f'cr shall be adjusted, as appropriate, based on the standard deviation being attained on the job.
1.2.3 Computations from Test Records
Where a concrete production facility has test records, establish a standard deviation in accordance with the applicable provisions of ACI 214R. Test records from which a standard deviation is calculated shall represent materials, quality control procedures, and conditions similar to those expected; shall represent concrete produced to meet a specified strength or strengths (f'c) within 1,000 psi of that specified for proposed work; and shall consist of at least 30 consecutive tests. A strength test shall be the average of the strengths of two cylinders made from the same sample of concrete and tested at 28 days. Required average compressive strength f'cr used as the basis for selection of concrete proportions shall be the larger of the equations that follow using the standard deviation as determined above:
f'cr = f'c + 1.34S where units are in psi
f'cr = f'c + 2.33S - 500 where units are in psi
Where S = standard deviation
Where a concrete production facility does not have test records meeting the requirements above but does have a record based on 15 to 29 consecutive tests, a standard deviation shall be established as the product of the calculated standard deviation and a modification factor from the following table:
NUMBER OF TESTS MODIFICATION FACTOR FOR STANDARD DEVIATION 15 1.16
20 1.08
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NUMBER OF TESTS MODIFICATION FACTOR FOR STANDARD DEVIATION 25 1.03
30 or more 1.00
1.2.4 Computations without Previous Test Records
When a concrete production facility does not have sufficient field strength test records for calculation of the standard deviation, the required average strength f'cr shall be determined as follows:
a. If the specified compressive strength f'c is less than 3,000 psi,
f'cr = f'c + 1000 psi
b. If the specified compressive strength f'c is 3,000 to 5,000 psi,
f'cr = f'c + 1,200 psi
c. If the specified compressive strength f'c is over 5,000 psi,
f'cr = f'c + 1,400 psi
1.2.5 Tolerances
Except as otherwise specified herein, tolerances for concrete batching, mixture properties, and construction as well as definition of terms and application practices shall be in accordance with ACI 117. Take level and grade tolerance measurements of slabs as soon as possible after finishing; when forms or shoring are used, the measurements shall be made prior to removal.
1.2.6 Floor Finish
For the purpose of this Section the following terminology correlation between ACI 117 and this Section shall apply:
Floor Profile Quality This Section Classification From ACI 117 Conventional Bullfloated Same
Conventional Straightedged Same
Flat Float Finish or Trowel Finish
Levelness tolerance does not apply where design requires floors to be sloped to drains or sloped for other reasons.
1.2.6.1 Floors by the Straightedge System
The flatness of the floors shall be carefully controlled and the tolerances shall be measured by the straightedge system as specified in paragraph 4.5.7 of ACI 117, using a 10 foot straightedge, within 72 hours after floor slab installation and before shores and/or forms are removed. The listed tolerances shall be met at any and every location at which the straightedge can be placed.
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Bullfloated 5/16 inch
Straightedged 5/16 inch
Float Finish 5/16 inch
Trowel Finish 5/16 inch
1.2.7 Strength Requirements
Specified compressive strength (f'c) shall be as follows:
COMPRESSIVE STRENGTH STRUCTURE OR PORTION OF STRUCTURE
5000 psi at 28 days Precast Concrete
4500 psi at 56 days Mass Concrete
4000 psi at 28 days Concrete topping
3000 psi at 28 days Concrete Fill
4500 psi at 28 days All other concrete
Concrete made with high-early strength cement shall have a 7-day strength equal to the specified 28-day strength for concrete made with Type I or II portland cement. Compressive strength shall be determined in accordance with ASTM C39/C39M.
1.2.7.1 Evaluation of Concrete Compressive Strength
Fabricate compressive strength specimens (6 by 12 inch cylinders), laboratory cure them in accordance with ASTM C31/C31M and test them in accordance with ASTM C39/C39M. The strength of the concrete will be considered satisfactory so long as the average of all sets of three consecutive test results equals or exceeds the specified compressive strength f'c and no individual test result falls below the specified strength f'c by more than 500 psi. A "test" is defined as the average of two companion cylinders, or if only one cylinder is tested, the results of the single cylinder test. Additional analysis or testing, including taking cores and/or load tests may be required at the Contractor's expense when the strength of the concrete in the structure is considered potentially deficient.
1.2.7.2 Investigation of Low-Strength Compressive Test Results
When any strength test of standard-cured test cylinders falls below the specified strength requirement by more than 500 psi or if tests of field-cured cylinders indicate deficiencies in protection and curing, take steps to assure that the load-carrying capacity of the structure is not jeopardized. When the strength of concrete in place is considered
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potentially deficient, cores shall be obtained and tested in accordance with ASTM C42/C42M. At least three representative cores shall be taken from each member or area of concrete in place that is considered potentially deficient. The location of cores will be determined by the Owner's Representative to least impair the strength of the structure. Concrete in the area represented by the core testing will be considered adequate if the average strength of the cores is equal to at least 85 percent of the specified strength requirement and if no single core is less than 75 percent of the specified strength requirement. Non-destructive tests (tests other than test cylinders or cores) shall not be used as a basis for acceptance or rejection. Perform the coring and repair the holes; cores will be tested by the Owner's Representative.
1.2.7.3 Load Tests
If the core tests are inconclusive or impractical to obtain or if structural analysis does not confirm the safety of the structure, load tests may be directed by the Owner's Representative in accordance with the requirements of ACI 318. Concrete work evaluated by structural analysis or by results of a load test as being understrength shall be corrected in a manner satisfactory to the Owner's Representative. All investigations, testing, load tests, and correction of deficiencies shall be performed by and at the expense of the Contractor and approved by the Owner's Representative, except that if all concrete is found to be in compliance with the drawings and specifications, the cost of investigations, testing, and load tests will be at the expense of the Owner.
1.2.8 Water-Cement Ratio
Maximum water-cement ratio (w/c) for normal weight concrete shall be as follows:
WATER-CEMENT RATIO, BY WEIGHT STRUCTURE OR PORTION OF STRUCTURE
0.40 Mass Concrete
0.42 All other concrete with 4500 psi compressive strength 0.45 Concrete Topping with 4000 psi compressive srength
0.45 Concrete Topping with 3000 psi compressive srength
0.45 Precast Concrete with 5000 psi compressive srength
These w/c's may cause higher strengths than that required above for compressive strength. The maximum w/c required will be the equivalent w/c as determined by conversion from the weight ratio of water to cement plus pozzolan, by the weight equivalency method as described in ACI 211.1. In the case where silica fume or GGBF slag is used, the weight of the silica fume and GGBF slag shall be included in the equations of ACI 211.1 for the term P which is used to denote the weight of pozzolan.
1.2.9 Air Entrainment
Provide air entrainment in all concrete resulting in a total air content
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percent by volume as follows: a. 1-1/2 IN maximum aggregate size: 4-1/2 to 6-1/2 percent total air content. b. 1 IN maximum aggregate size: 5 to 7 percent total air content. c. 3/4 IN maximum aggregate size: 5 to 7 percent total air content. d. 1/2 IN maximum aggregate size: 5-1/2 to 8 percent total air content. e. Interior slabs and mats with power trowel finish: Maximum 3 percent total air content.
1.2.10 Slump
Slump of the concrete, as delivered to the point of placement into the forms, shall be within the following limits. Slump shall be determined in accordance with ASTM C143/C143M.
Structural Element Slump (inches)
Minimum Maximum
Wallsand beams, foundatin 2 4 walls, footings, slabs and toppings
Any structural concrete approved for placement by pumping:
At pump 2 6
At discharge of line 1 4
When use of a plasticizing admixture conforming to ASTM C1017/C1017M or when a Type F or G high range water reducing admixture conforming to ASTM C494/C494M is permitted to increase the slump of concrete, concrete shall have a slump of 2 to 4 inches before the admixture is added and a maximum slump of 8 inches at the point of delivery after the admixture is added.
1. Concrete of lower than minimum slump may be used provided it can be properly placed and consolidated.
2. Provide additional water or water reducing admixture at ready mix plant for concrete that is to be pumped to allow for slump loss due to pumping.
a. Provide only enough additional water so that slump of concrete at discharge end of pump hose does not exceed maximum slump specified and the maximum specified water-cement ration is not exceeded.
3. Slump may be adjusted in the field through the use of water reducers.
b. Coordinate dosage and mixing requirements with concrete supplier.
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1.2.11 Concrete Temperature
The temperature of the concrete as delivered shall not exceed 90 degrees F. When the ambient temperature during placing is 40 degrees F or less, or is expected to be at any time within 6 hours after placing, the temperature of the concrete as delivered shall be between 55 and 75 degrees F.
1.2.12 Size of Coarse Aggregate
Use the largest feasible nominal maximum size aggregate (NMSA), specified in PART 2 paragraph AGGREGATES, in each placement. However, nominal maximum size of aggregate shall not exceed any of the following: three-fourths of the minimum cover for reinforcing bars, three-fourths of the minimum clear spacing between reinforcing bars, one-fifth of the narrowest dimension between sides of forms, or one-third of the thickness of slabs or toppings.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Recycled Content Products; (LEED) Portland Cement Ready-Mixed Concrete Vapor Barrier Latex Bonding Agent Floor Finish Floor Hardener Chemical Admixtures Epoxy Resin
SD-04 Samples
Surface Retarder
SD-05 Design Data
Mixture Proportions; G
SD-06 Test Reports
Testing and Inspection for CQC; G
SD-07 Certificates
Qualifications
1.4 QUALITY ASSURANCE
Submit qualifications for Contractor Quality Control personnel assigned to concrete construction as American Concrete Institute (ACI) Certified Workmen in one of the following grades or show written evidence of having completed similar qualification programs:
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Concrete Field Testing Technician Grade I
Concrete Laboratory Testing Grade I or II Technician Concrete Construction Inspector Level II
Concrete Transportation Jointly certified by American Construction Inspector or Concrete Institute (ACI), Building Reinforced Concrete Special Official and Code Administrators Inspector International (BOCA), International Code Council (ICC), and Southern Building Code Congress International (SBCCI)
Foreman or Lead Journeyman of the Similar qualification for ACI flatwork finishing crew Concrete Flatwork Technician/Finisher or equal, with written documentation
1.4.1 Special Properties and Products
Concrete may contain admixtures other than air entraining agents, such as water reducers, superplasticizers, or set retarding agents to provide special properties to the concrete, if specified or approved. Any of these materials to be used on the project shall be used in the mix design studies.
1.4.2 Owner's Representative Assurance Inspection and Testing
Day-to day inspection and testing shall be the responsibility of the Contractor Quality Control (CQC) staff. However, representatives of the Owner's Representative can and will inspect construction as considered appropriate and will monitor operations of the Contractor's CQC staff. Owner's Representative inspection or testing will not relieve the Contractor of any CQC responsibilities.
1.4.2.1 Materials
The Owner's Representative will sample and test aggregates, cementitious materials, other materials, and concrete to determine compliance with the specifications as considered appropriate. Provide facilities and labor as may be necessary for procurement of representative test samples. Samples of aggregates will be obtained at the point of batching in accordance with ASTM D75/D75M. Other materials will be sampled from storage at the jobsite or from other locations as considered appropriate. Samples may be placed in storage for later testing when appropriate.
1.4.2.2 Fresh Concrete
Fresh concrete will be sampled as delivered in accordance with ASTM C172/C172M and tested in accordance with these specifications, as considered necessary.
1.4.2.3 Hardened Concrete
Tests on hardened concrete will be performed by the Owner's Representative when such tests are considered necessary.
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1.4.2.4 Inspection
Concrete operations may be tested and inspected by the Owner's Representative as the project progresses. Failure to detect defective work or material will not prevent rejection later when a defect is discovered nor will it obligate the Owner's Representative for final acceptance.
1.5 DELIVERY, STORAGE, AND HANDLING
Store cement and other cementitious materials in weathertight buildings, bins, or silos which will exclude moisture and contaminants and keep each material completely separated. Aggregate stockpiles shall be arranged and used in a manner to avoid excessive segregation and to prevent contamination with other materials or with other sizes of aggregates. Aggregate shall not be stored directly on ground unless a sacrificial layer is left undisturbed. Store reinforcing bars and accessories above the ground on platforms, skids or other supports. Other materials shall be stored in such a manner as to avoid contamination and deterioration. Admixtures which have been in storage at the project site for longer than 6 months or which have been subjected to freezing shall not be used unless retested and proven to meet the specified requirements. Materials shall be capable of being accurately identified after bundles or containers are opened.
PART 2 PRODUCTS
2.1 CEMENTITIOUS MATERIALS
Cementitious Materials shall be portland cement, portland-pozzolan cement, or portland cement in combination with pozzolan conforming to appropriate specifications listed below. Restrict usage of cementitious materials in concrete that will have surfaces exposed in the completed structure so there is no change in color, source, or type of cementitious material.
2.1.1 Portland Cement
ASTM C150/C150M, Type II low alkali.
2.1.2 High-Early-Strength Portland Cement
ASTM C150/C150M, Type III with tricalcium aluminate limited to 5 percent, low alkali. Use Type III cement only in isolated instances and only when approved in writing.
2.1.3 Pozzolan (Fly Ash)
Pozzolan shall conform to ASTM C618, Class F, including low alkali multiple factor, drying shrinkage, uniformity, and moderate sulfate resistance requirements in Table 3 of ASTM C618.
1. Non-staining. 2. Suited to provide hardened concrete of uniform light gray color. 3. Maximum loss on ignition: 4 percent. 4. Compatible with other concrete ingredients and having no deleterious effects on the hardened concrete. 5. Produced by source approved by the State Highway Department in the state where the Project is located for use in concrete for bridges. 6. Cement and fly ash type used shall correspond to that upon which
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selection of concrete proportions was based in the mix design.
If pozzolan is used, it shall never be less than 15 percent nor more than 35 percent by weight of the total cementitious material.
2.2 AGGREGATES
Provide aggregates approved for bridge construction by the State Highway Department in the State of North Dakota. Pozzolan and other additives shall not be used to compensate for alkali oreactivity of aggregates.
2.2.1 Fine Aggregate
Fine aggregate shall conform to the quality and gradation requirements of ASTM C33/C33M, fine aggregates to be natural, not manufactured.
2.2.2 Coarse Aggregate
Coarse aggregate shall conform to ASTM C33/C33M. Coarse aggregate sieve analysis:
a. For concrete topping: ASTM C33, size number 7 (maximum 1/2 IN).
b. For Mass Concrete: ASTM C33, size number 4 (maximum 1-1/2 IN). 1) Minimum specific gravity: 2.57,
c. For all other concrete: ASTM C33, size number 57 (maximum 1 IN) or size number 67 (maximum 3/4 IN).
2.3 CHEMICAL ADMIXTURES
Chemical admixtures, when required or permitted, shall conform to the appropriate specification listed. Admixtures shall be furnished in liquid form and of suitable concentration for easy, accurate control of dispensing. Do not use calcium chloride.
2.3.1 Air-Entraining Admixture
ASTM C260/C260M and shall consistently entrain the air content in the specified ranges under field conditions.
2.3.2 Accelerating Admixture
ASTM C494/C494M, Type C or E, except that calcium chloride or admixtures containing calcium chloride shall not be used.
2.3.3 Water-Reducing or Retarding Admixture
ASTM C494/C494M, Type A, B, or D, except that the 6-month and 1-year compressive and flexural strength tests are waived.
2.3.4 High-Range Water Reducer
ASTM C494/C494M, Type F or G, except that the 6-month and 1-year strength requirements are waived. The admixture shall be used only when approved in writing, such approval being contingent upon particular mixture control as described in the Contractor's Quality Control Plan and upon performance of separate mixture design studies.
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2.3.5 Surface Retarder
COE CRD-C 94. Submit sample of surface retarder material with manufacturer's instructions for application in conjunction with air-water cutting.
2.3.6 Expanding Admixture
Aluminum powder type expanding admixture conforming to ASTM C937.
2.3.7 Shrinking Reducing Admixture
Utilize at dosage necessary to help achieve required skrinkage value stated herein.
1. Similar to:
a. Eclipse 4500 by W.R. Grace & Co.
b. Conex by Euclid Chemical Co.
2. Admixtures to be chlorine free.
Provide admixture of same type, manufacturer and quantity as used in establishing required concrete proportions in the mix design.
2.3.8 Other Chemical Admixtures
Chemical admixtures for use in producing flowing concrete shall comply with ASTM C1017/C1017M, Type I or II. These admixtures shall be used only when approved in writing, such approval being contingent upon particular mixture control as described in the Contractor's Quality Control Plan and upon performance of separate mixture design studies.
2.4 WATER
Water for mixing shall be fresh, clean, potable, and free of injurious amounts of oil, acid, salt, or alkali, except that non-potable water may be used if it meets the requirements of COE CRD-C 400.
2.4.1 Allowable Shrinkage
1. Concrete for all water containing structures: 0.032% per ASTM C157 after 28 days.
2. All other concrete: 0.048% per ASTM C157 after 28 days.
3. Use shrinkage reducing asmixture if requried to met specified shrinkage limit.
Maximum total chloride ion content for concrete mix including all ingredients measured as a weight percent of cement:
1. Prestressed concrete: 0.06%.
2. All other concrete: 0.10%.
Sand Cement Grout:
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1. Approximately three (3) parts sand, one (1) part Portland cement, 6 +1 percent entrained air and water to produce a slump which allows grout to completely fill required areas and surround adjacent reinforcing.
a. Provide sand in accordance with requirements for fine aggregate for concrete.
2. Minimum 28 day compressive strength: 3000 psi.
2.5 NONSHRINK GROUT
Nonshrink grout shall conform to ASTM C1107/C1107M, and shall be a commercial formulation suitable for the proposed application.
1. Nonshrink, nonmetallic, noncorrosive, and nonstaining.
2. Premixed with only water to be added in accordance with manufacturer's instructions at jobsite.
3. Grout to produce a positive but controlled expansion.
a. Mass expansion shall not be created by gas liberation or by other means.
4. Minimum 28 day compressive strength: 6500 psi.
5. Acceptable manufacturers:
a. BASF Admixtures, Inc. "Masterflow, 713 Plus".
b. Euclid Chemical "NS Grout".
c. Sauereisen Cements "F-100 Level Fill Grout".
d. U.S. Grout "Five Star Grout".
e. Set Products, Inc. "Set NonShrink Grout".
f. The Upco Corp "Upcon".
g. L&M "Crystex".
h. Sika Corporation "Sika Grout 212".
6. In accordance with COE CRD-C621.
2.6 LATEX BONDING AGENT
Latex agents for bonding fresh to hardened concrete shall conform to ASTM C1059/C1059M.
2.7 EPOXY RESIN
Epoxy resins for use in repairs shall conform to ASTM C881/C881M, Type V, Grade 2. Class as appropriate to the existing ambient and surface temperatures. Submit manufacturer's product data, indicating VOC content. Manufacturer's catalog data for the items above, including printed instructions.
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1. Three-component epoxy resin system:
a. Two (2) liquid epoxy components.
b. One (1) inert aggregate filler component.
2. Adhesive acceptable manufacturers:
a. BASF "Masterflow 648 CP".
b. Exxon Chemical Company "Escoweld 2505."
c. Sika "Sikadur Hi-Mod."
d. U.S. Grout "Five Start Epoxy Grout."
e. Euclid Chemical "E3-G."
3. Aggregate acceptable manufacturers:
a. BASF "Masterflow 648 CP".
b. Exxon Chemical Company "Escoweld 2510."
c. Sika aggregate.
d. U.S. Grout aggregate.
e. Euclid Chemical "Euclid aggregate."
4. Aggregate manufacturer shall be the same as the adhesive manufacturer.
5. The aggregate shall be compatible with the adhesive.
6. Each component furnished in separate package for mixing at jobsite.
2.8 EMBEDDED ITEMS
Embedded items shall be of the size and type indicated or as needed for the application.
2.9 FLOOR HARDENER
Floor hardener shall be a colorless aqueous solution containing zinc silicofluoride, magnesium silicofluoride, or sodium silicofluoride. These silicofluorides can be used individually or in combination. Proprietary hardeners may be used if approved in writing by the Owner's Representative.
2.10 PERIMETER INSULATION
Perimeter insulation shall be polystyrene conforming to ASTM C578, Type II; polyurethane conforming to ASTM C591, Type II; or cellular glass conforming to ASTM C552, Type I or IV.
2.11 VAPOR BARRIER
Vapor barrier shall be polyethylene sheeting with a minimum thickness of 6
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mils or other equivalent material having a vapor permeance rating not exceeding 0.5 perms as determined in accordance with ASTM E96/E96M.
2.12 JOINT MATERIALS
2.12.1 Joint Fillers, Sealers, and Waterstops
Materials for expansion joint fillers and waterstops shall be in accordance with Section 03 15 00.00 10 CONCRETE ACCESSORIES. Materials for and sealing of joints shall conform to the requirements of Section 07 92 00 JOINT SEALANTS.
2.12.2 Contraction Joints in Slabs
Materials for contraction joint inserts shall be in accordance with Section 03 15 00.00 10 CONCRETE ACCESSORIES.
PART 3 EXECUTION
3.1 PREPARATION FOR PLACING
Before commencing concrete placement, perform the following: Surfaces to receive concrete shall be clean and free from frost, ice, mud, and water. Forms shall be in place, cleaned, coated, and adequately supported, in accordance with Section 03 11 13.00 10 STRUCTURAL CONCRETE FORMWORK. Reinforcing steel shall be in place, cleaned, tied, and adequately supported, in accordance with Section 03 20 00.00 10 CONCRETE REINFORCEMENT. Transporting and conveying equipment shall be in-place, ready for use, clean, and free of hardened concrete and foreign material. Equipment for consolidating concrete shall be at the placing site and in proper working order. Equipment and material for curing and for protecting concrete from weather or mechanical damage shall be at the placing site, in proper working condition and in sufficient amount for the entire placement. When hot, windy conditions during concreting appear probable, equipment and material shall be at the placing site to provide windbreaks, shading, fogging, or other action to prevent plastic shrinkage cracking or other damaging drying of the concrete.
3.1.1 Foundations
3.1.1.1 Concrete on Earth Foundations
Earth (subgrade, base, or subbase courses) surfaces upon which concrete is to be placed shall be clean, damp, and free from debris, frost, ice, and standing or running water. Prior to placement of concrete, the foundation shall be well drained and shall be satisfactorily graded and uniformly compacted, inspected, and approved by Geotechnical Engineer.
3.1.1.2 Excavated Surfaces in Lieu of Forms
Concrete for footings may be placed directly against the soil provided the earth has been carefully trimmed, is uniform and stable, and meets the compaction requirements of Section 31 00 00.00 14 EARTHWORK FOR PUMP STATION AND GATEWELL. Place the concrete without becoming contaminated by loose material, and outlined within the specified tolerances.
3.1.2 Previously Placed Concrete
Concrete surfaces to which additional concrete is to be bonded shall be
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prepared for receiving the next horizontal lift by cleaning the construction joint surface with either air-water cutting, sandblasting, high-pressure water jet, or other approved method. Prepare concrete at the side of vertical construction joints as approved by the Owner's Representative. Air-water cutting shall not be used on formed surfaces or surfaces congested with reinforcing steel. Regardless of the method used, the resulting surfaces shall be free from all laitance and inferior concrete so that clean surfaces of well bonded coarse aggregate are exposed and make up at least 10-percent of the surface area, distributed uniformly throughout the surface. The edges of the coarse aggregate shall not be undercut. Keep the surface of horizontal construction joints continuously wet for the first 12 hours during the 24-hour period prior to placing fresh concrete. The surface shall be washed completely clean as the last operation prior to placing the next lift. For heavy duty floors and two-course floors, a thin coat of neat cement grout of about the consistency of thick cream shall be thoroughly scrubbed into the existing surface immediately ahead of the topping placing. The grout shall be a 1:1 mixture of portland cement and sand passing the No. 8 sieve. The topping concrete shall be deposited before the grout coat has had time to stiffen.
3.1.2.1 Air-Water Cutting
Air-water cutting of a fresh concrete surface shall be performed at the proper time and only on horizontal construction joints. The air pressure used in the jet shall be 100 psi, plus or minus 10 psi, and the water pressure shall be just sufficient to bring the water into effective influence of the air pressure. When approved by the Owner's Representative, a surface retarder complying with the requirements of COE CRD-C 94 may be applied to the surface of the lift in order to prolong the period of time during which air-water cutting is effective. After cutting, the surface shall be washed and rinsed as long as there is any trace of cloudiness of the wash water. Where necessary to remove accumulated laitance, coatings, stains, debris, and other foreign material, high-pressure waterjet or sandblasting shall be used as the last operation before placing the next lift.
3.1.2.2 High-Pressure Water Jet
Use a stream of water under a pressure of not less than 3,000 psi for cutting and cleaning. Its use shall be delayed until the concrete is sufficiently hard so that only the surface skin or mortar is removed and there is no undercutting of coarse-aggregate particles. If the waterjet is incapable of a satisfactory cleaning, the surface shall be cleaned by sandblasting.
3.1.2.3 Wet Sandblasting
Use wet sandblasting after the concrete has reached sufficient strength to prevent undercutting of the coarse aggregate particles. After wet sandblasting, the surface of the concrete shall then be washed thoroughly to remove all loose materials.
3.1.2.4 Waste Disposal
The method used in disposing of waste water employed in cutting, washing, and rinsing of concrete surfaces shall be such that the waste water does not stain, discolor, or affect exposed surfaces of the structures, or damage the environment of the project area. The method of disposal shall be subject to approval.
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3.1.2.5 Preparation of Previously Placed Concrete
Concrete surfaces to which other concrete is to be bonded shall be abraded in an approved manner that will expose sound aggregate uniformly without damaging the concrete. Remove laitance and loose particles. Surfaces shall be thoroughly washed and shall be moist but without free water when concrete is placed.
3.1.3 Vapor Retarder
Provide vapor retarder beneath the interior on-grade concrete floor slabs. Use the greatest widths and lengths practicable to eliminate joints wherever possible. Joints shall be lapped a minimum of 12 inches. Torn, punctured, or damaged vapor retarder material shall be removed and new vapor retarder shall be provided prior to placing concrete. For minor repairs, patches may be made using laps of at least 12 inches. Lapped joints shall be sealed and edges patched with pressure-sensitive adhesive or tape not less than 2 inches wide and compatible with the membrane. Place vapor retarder directly on underlying subgrade, base course, or capillary water barrier, unless it consists of crushed material or large granular material which could puncture the vapor retarder. In this case, a thin layer of approximately 1/2 inch of fine graded material should be rolled or compacted over the fill before installation of the vapor retarder to reduce the possibility of puncture. Control concrete placement so as to prevent damage to the vapor retarder.
3.1.4 Perimeter Insulation
Install perimeter insulation at locations indicated. Adhesive shall be used where insulation is applied to the interior surface of foundation walls and may be used for exterior application.
3.1.5 Embedded Items
Before placement of concrete, determine that all embedded items are firmly and securely fastened in place as indicated on the drawings, or required. Conduit and other embedded items shall be clean and free of oil and other foreign matter such as loose coatings or rust, paint, and scale. The embedding of wood in concrete will be permitted only when specifically authorized or directed. Voids in sleeves, inserts, and anchor slots shall be filled temporarily with readily removable materials to prevent the entry of concrete into voids. Welding shall not be performed on embedded metals within 12 inches of the surface of the concrete. Tack welding shall not be performed on or to embedded items.
3.2 CONCRETE PRODUCTION
3.2.1 General Requirements
Concrete shall be furnished from a ready-mixed concrete plant. Ready-mixed concrete shall be batched, mixed, and transported in accordance with ASTM C94/C94M, except as otherwise specified. Truck mixers, agitators, and nonagitating transporting units shall comply with NRMCA TMMB 100. Ready-mix plant equipment and facilities shall be certified in accordance with NRMCA QC 3. Approved batch tickets shall be furnished for each load of ready-mixed concrete.
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3.2.2 Truck Mixers
Truck mixers, the mixing of concrete therein, and concrete uniformity shall conform to the requirements of ASTM C94/C94M. A truck mixer may be used either for complete mixing (transit-mixed) or to finish the partial mixing done in a stationary mixer (shrink-mixed). Each truck shall be equipped with two counters from which it is possible to determine the number of revolutions at mixing speed and the number of revolutions at agitating speed. Or, if approved in lieu of this, the number of revolutions shall be marked on the batch tickets. Water shall not be added at the placing site unless specifically approved; and in no case shall it exceed the specified w/c. Any such water shall be injected at the base of the mixer, not at the discharge end.
3.3 TRANSPORTING CONCRETE TO PROJECT SITE
Transport concrete to the placing site in truck mixers.
3.4 CONVEYING CONCRETE ONSITE
Convey concrete from mixer or transporting unit to forms as rapidly as possible and within the time interval specified by methods which will prevent segregation or loss of ingredients using following equipment. Conveying equipment shall be cleaned before each placement.
3.4.1 Buckets
The interior hopper slope shall be not less than 58 degrees from the horizontal, the minimum dimension of the clear gate opening shall be at least 5 times the nominal maximum-size aggregate, and the area of the gate opening shall not be less than 2 square feet. The maximum dimension of the gate opening shall not be greater than twice the minimum dimension. The bucket gates shall be essentially grout tight when closed and may be manually, pneumatically, or hydraulically operated except that buckets larger than 2 cubic yards shall not be manually operated. The design of the bucket shall provide means for positive regulation of the amount and rate of deposit of concrete in each dumping position.
3.4.2 Transfer Hoppers
Concrete may be charged into nonagitating hoppers for transfer to other conveying devices. Transfer hoppers shall be capable of receiving concrete directly from delivery vehicles and shall have conical-shaped discharge features. Equip the transfer hopper with a hydraulically operated gate and with a means of external vibration to effect complete discharge. Concrete shall not be held in nonagitating transfer hoppers more than 30 minutes.
3.4.3 Trucks
Truck mixers operating at agitating speed or truck agitators used for transporting plant-mixed concrete shall conform to the requirements of ASTM C94/C94M. Use nonagitating equipment only for transporting plant-mixed concrete over a smooth road and when the hauling time is less than 15 minutes. Bodies of nonagitating equipment shall be smooth, watertight, metal containers specifically designed to transport concrete, shaped with rounded corners to minimize segregation, and equipped with gates that will permit positive control of the discharge of the concrete.
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3.4.4 Chutes
When concrete can be placed directly from a truck mixer, agitator, or nonagitating equipment, the chutes normally attached to this equipment by the manufacturer may be used. Use a discharge deflector when required by the Owner's Representative. Separate chutes and other similar equipment will not be permitted for conveying concrete.
3.4.5 Belt Conveyors
Design and operate belt conveyors to assure a uniform flow of concrete from mixer to final place of deposit without segregation of ingredients or loss of mortar and provided with positive means, such as discharge baffle or hopper , for preventing segregation of the concrete at the transfer points and the point of placing. Construct belt conveyors such that the idler spacing does not exceed 36 inches. The belt speed shall be a minimum of 300 feet per minute and a maximum of 750 feet per minute. If concrete is to be placed through installed horizontal or sloping reinforcing bars, the conveyor shall discharge concrete into a pipe or elephant truck that is long enough to extend through the reinforcing bars.
3.4.6 Concrete Pumps
Concrete may be conveyed by positive displacement pump when approved. The pumping equipment shall be piston or squeeze pressure type; pneumatic placing equipment shall not be used. The pipeline shall be rigid steel pipe or heavy-duty flexible hose. The inside diameter of the pipe shall be at least 3 times the nominal maximum-size coarse aggregate in the concrete mixture to be pumped but not less than 4 inches. Aluminum pipe shall not be used.
3.5 PLACING CONCRETE
Discharge mixed concrete within 1.5 hours or before the mixer drum has revolved 300 revolutions, whichever comes first after the introduction of the mixing water to the cement and aggregates. When the concrete temperature exceeds 85 degrees F, reduce the time to 45 minutes. Place concrete within 15 minutes after it has been discharged from the transporting unit. Concrete shall be handled from mixer or transporting unit to forms in a continuous manner until the approved unit of operation is completed. Provide adequate scaffolding, ramps and walkways so that personnel and equipment are not supported by in-place reinforcement. Placing will not be permitted when the sun, heat, wind, or limitations of facilities prevent proper consolidation, finishing and curing. Provide sufficient placing capacity so that concrete can be kept free of cold joints.
3.5.1 Depositing Concrete
Deposit concrete as close as possible to its final position in the forms, and with no vertical drop greater than 5 feet except where suitable equipment is provided to prevent segregation and where specifically authorized. Depositing of the concrete shall be so regulated that it will be effectively consolidated in horizontal layers not more than 12 inches thick, except that all slabs shall be placed in a single lift. Concrete to receive other construction shall be screeded to the proper level. Concrete shall be deposited continuously in one layer or in layers so that fresh concrete is deposited on in-place concrete that is still plastic. Fresh concrete shall not be deposited on concrete that has hardened sufficiently
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to cause formation of seams or planes of weakness within the section. Concrete that has surface dried, partially hardened, or contains foreign material shall not be used. When temporary spreaders are used in the forms, the spreaders shall be removed as their service becomes unnecessary. Concrete shall not be placed in slabs over piers and walls until concrete in piers and walls has been in-place at least two hours or until the concrete begins to lose its plasticity. Place concrete for beams at the same time as concrete for adjoining slabs.
3.5.2 Consolidation
Immediately after placing, consolidate each layer of concrete by internal vibrators, except for slabs 4 inches thick or less. The vibrators shall at all times be adequate in effectiveness and number to properly consolidate the concrete; keep a spare vibrator at the jobsite during all concrete placing operations. The vibrators shall have a frequency of not less than 10,000 vibrations per minute, an amplitude of at least 0.025 inch, and the head diameter shall be appropriate for the structural member and the concrete mixture being placed. Insert vibrators vertically at uniform spacing over the area of placement. The distance between insertions shall be approximately 1.5 times the radius of action of the vibrator so that the area being vibrated will overlap the adjacent just-vibrated area by a reasonable amount. The vibrator shall penetrate rapidly to the bottom of the layer and at least 6 inches into the preceding layer if there is such. Vibrator shall be held stationary until the concrete is consolidated and then vertically withdrawn slowly while operating. Form vibrators shall not be used unless specifically approved and unless forms are constructed to withstand their use. Vibrators shall not be used to move concrete within the forms. Slabs 4 inches and less in thickness shall be consolidated by properly designed vibrating screeds or other approved technique. Frequency and amplitude of vibrators shall be determined in accordance with COE CRD-C 521. Do not use grate tampers (jitterbugs).
3.5.3 Cold Weather Requirements
Use special protection measures, approved by the Owner's Representative, if freezing temperatures are anticipated before the expiration of the specified curing period. The ambient temperature of the air where concrete is to be placed and the temperature of surfaces to receive concrete shall be not less than 40 degrees F. The temperature of the concrete when placed shall be not less than 50 degrees F nor more than 75 degrees F. Heating of the mixing water or aggregates will be required to regulate the concrete placing temperature. Materials entering the mixer shall be free from ice, snow, or frozen lumps. Salt, chemicals or other materials shall not be incorporated in the concrete to prevent freezing. Upon written approval, an accelerating admixture conforming to ASTM C494/C494M, Type C or E may be used, provided it contains no calcium chloride. Do not use calcium chloride.
3.5.4 Hot Weather Requirements
When job-site conditions are present or anticipated that accelerate the rate of moisture loss or rate of cement hydration of freshly mixed concrete, including an ambient temperature of 80 degrees F or higher, and an evaporation rate that exceeds 0.2 lb/ft2/h, concrete work shall conform to all requirements of ACI 305.1.
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3.5.5 Prevention of Plastic Shrinkage Cracking
During hot weather with low humidity, and particularly with appreciable wind, as well as interior placements when space heaters produce low humidity, the Contractor shall be alert to the tendency for plastic shrinkage cracks to develop and shall institute measures to prevent this. Take particular care if plastic shrinkage cracking is potentially imminent and especially if it has developed during a previous placement. Conform with the requirement of ACI 305.1. In addition the concrete placement shall be further protected by erecting shades and windbreaks and by applying fog sprays of water, sprinkling, ponding or wet covering. Plastic shrinkage cracks that occur shall be filled by injection of epoxy resin as directed, after the concrete hardens. Plastic shrinkage cracks shall never be troweled over or filled with slurry.
3.5.6 Placing Concrete in Congested Areas
Use special care to ensure complete filling of the forms, elimination of all voids, and complete consolidation of the concrete when placing concrete in areas congested with reinforcing bars, embedded items, waterstops and other tight spacing. An appropriate concrete mixture shall be used, and the nominal maximum size of aggregate (NMSA) shall meet the specified criteria when evaluated for the congested area. Vibrators with heads of a size appropriate for the clearances available shall be used, and the consolidation operation shall be closely supervised to ensure complete and thorough consolidation at all points. Where necessary, splices of reinforcing bars shall be alternated to reduce congestion. Where two mats of closely spaced reinforcing are required, the bars in each mat shall be placed in matching alignment to reduce congestion.
3.5.7 Placing Flowable Concrete
If a plasticizing admixture conforming to ASTM C1017/C1017M is used or if a Type F or G high range water reducing admixture is permitted to increase the slump, the concrete shall meet all requirements of paragraph SYSTEM DESCRIPTION. Use extreme care in conveying and placing the concrete to avoid segregation. No relaxation of requirements to accommodate flowable concrete will be permitted.
3.6 JOINTS
Locate and construct joints as indicated or approved. Joints not indicated on the drawings shall be located and constructed to minimize the impact on the strength of the structure. In general, locate such joints near the middle of the spans of supported slabs, beams, and girders unless a beam intersects a girder at this point, in which case the joint in the girder shall be offset a distance equal to twice the width of the beam. Joints in walls and piers shall be at the underside of floors, slabs, beams, or girders and at the tops of footings or floor slabs, unless otherwise approved. Joints shall be perpendicular to the main reinforcement. All reinforcement shall be continued across joints; except that reinforcement or other fixed metal items shall not be continuous through expansion joints, or through construction or contraction joints in slabs on grade. Reinforcement shall be 2 inches clear from each joint. Except where otherwise indicated, construction joints between interior slabs on grade and vertical surfaces shall consist of expansion joint filler material for the full depth of the slab. The joint filler material shall be recessed 1/2 inch and sealant applied at exposed floor locations. The perimeters of the slabs shall be free of fins, rough edges, spalling, or other unsightly
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appearance. Reservoir for sealant for construction and contraction joints in slabs shall be formed to the dimensions shown on the drawings or by sawing to widen the top portion of sawed joints. Joints to be sealed shall be cleaned and sealed as indicated and in accordance with Section 07 92 00 JOINT SEALANTS.
3.6.1 Construction Joints
For concrete other than slabs on grade, locate construction joints as directed below. Concrete shall be placed continuously so that each unit is monolithic in construction. Fresh concrete shall not be placed against adjacent hardened concrete until it is at least 48 hours old. Locate construction joints as indicated or approved. Where concrete work is interrupted by weather, end of work shift or other similar type of delay, location and type of construction joint shall be subject to approval of the Owner's Representative. Unless otherwise indicated and except for slabs on grade, extend reinforcing steel through construction joints. Construction joints in slabs on grade shall be doweled as shown. Concrete walls, or piers shall be in place at least 2 hours, or until the concrete begins to lose its plasticity, before placing concrete for beams, girders, or slabs thereon. In walls having openings, terminate lifts at the top and bottom of the opening. Other lifts shall terminate at such levels as to conform to structural requirements. Where horizontal construction joints in walls are required, a strip of 1 inch square-edge lumber, beveled and oiled to facilitate removal, shall be tacked to the inside of the forms at the construction joint. Place concrete to a point 1 inch above the underside of the strip. The strip shall be removed 1 hour after the concrete has been placed, and any irregularities in the joint line shall be leveled off with a wood float, and all laitance shall be removed. Prior to placing additional concrete, horizontal construction joints shall be prepared as specified in paragraph Previously Placed Concrete above.
A. Construction Joints - General: 1. Locate joints as indicated on Contract Drawings or as shown on approved Shop Drawings. a. Where construction joint spacing shown on Drawings exceeds the joint spacing indicated in Paragraph B. below, submit proposed construction joint location in conformance with this Specification Section. 2. Unplanned construction joints will not be allowed. a. If concrete cannot be completely placed between planned construction joints, then it must be removed. 3. In general, locate joints near middle of spans of slabs, beams and girders unless a beam intersects a girder at this point, in which case, offset joint in girder a distance equal to twice the width of the beam. 4. Locate joints in walls and columns at underside of floors, slabs, beams, or girders, and at tops of foundations or floor slabs, unless shown otherwise. a. At Contractor's option, beam pockets may be formed into concrete walls. b. Size pockets to allow beam reinforcing to be placed as detailed on Drawings. 5. Place beams and girders at same time as slabs. 6. Place corbels monolithically with walls. a. Locate wall vertical construction joints midway between corbels. b. Where only a single corbel is located place it also monolithically with wall and locate wall vertical construction joint a minimum of 3 feet from face of corbel.
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7. Make joints perpendicular to main reinforcement with all reinforcement continuous across joints. 8. Provide roughened construction joints at all construction joints unless indicated otherwise on Drawings. a. Clean the previously hardened concrete interface and remove all laitance. b. Intentionally roughen the interface to a full amplitude of 1/4 inch. c. Provide recessed flat surface as required to install strip type waterstops. 9. Provide continuous keyways only where indicated on Drawings. a. Construction joint keyways shall have the following dimensions, unless shown otherwise on Drawings or directed otherwise by Engineer. b. Construction joint keyways in walls: 1) Keyway width, not less than 1/3 and not more than 1/2 the wall thickness measured perpendicular to wall faces. 2) Keyway depth to be not less than 1-1/2 inches. 3) Place keyway in wall center unless shown otherwise on Drawings. c. Construction joint keyways in footings, foundations, base slabs, and structural or elevated slabs: 1) Keyway height not less than 1/3 and not more than 1/2 the footing or slab thickness. 2) Keyway depth not less than 1-1/2 inches. 3) Keyway in footing or slab center unless shown otherwise on Drawings. d. Construction joint keyways in beams: 1) Keyway height not less than 1/3 and not more than 1/2 the beam depth. 2) Keyway depth not less than 1-1/2 IN. 3) Keyway in beam center unless shown otherwise on Drawings. 10. Allow a minimum of 48 HRS before placement of adjoining concrete construction. B. Construction Joints - Spacing: 1. General - Structures not intended to contain liquid: a. Wall vertical construction joints: 1) 60 FT maximum centers. 2) At wall intersections, 30 FT maximum from corner. b. Wall horizontal construction joints: 20 to 25 FT centers. c. Base slab, floor, and roof slab construction joints: 1) Placements to be approximately square and not to exceed 3500 square feet. 2) Maximum side dimension of a slab pour to be less than: a) Twice the length of the short side. b) 80 foot. 2. Structures intended to contain liquids: a. Wall vertical construction joints: 1) 30 FT maximum centers. 2) At wall intersections, 15 FT maximum from corner. b. Wall horizontal construction joints: 12 to 18 FT centers. c. Walls that are thicker than 18 inches may be poured less than 30 feet tall in one (1) pour provided the following requirements are satisfied: 1) A test wall of similar size, height and thickness will be poured to demonstrate the quality of the concrete work. 2) The test wall will be located as a portion of a non-water bearing wall. a) The test wall will include a waterstop at the bottom of
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the wall. b) Alternatively, a separate test wall, not part of the final work, may be constructed. 3) The concrete placement and concrete quality of the test wall will be observed by the Engineer. a) Concrete will be judged on the following: (1) Ability to keep bottom of the pour clean and free from trash and debris. (2) Ability to protect the waterstop from folding over due to the force of falling concrete. (3) Ability to properly consolidate all concrete in the wall pour, including below formed openings. 4) Engineer will evaluate the Contractor's work and may recommend taller concrete wall pours if concrete quality is acceptable. 5) Preparation for all subsequent wall pours over 18 feet tall must be the same as the preparation of the test wall. 6) Should the quality of concrete work on subsequent wall pours be judged inadequate, the Contractor may be directed to limit wall pour heights to 18 feet as originally specified. 7) Should the quality of concrete work on the test wall be judged inadequate, additional test walls will not be observed and judged to allow pour heights greater that 18 feet unless allowed by Engineer. d. Base slab and floor slab construction joints: 1) Placements to be approximately square and not to exceed 2000 square feet. 2) Maximum side dimension of a slab pour to be less than: a) Twice the length of the short side. b) 60 feet. C. Construction Joints - Bonding: 1. Obtain bond between concrete pours at construction joints by thoroughly cleaning and removing all laitance from construction joints. a. Before new concrete is placed, all construction joints shall be coated with cement grout, or dampened. 1) General: Use cement grout or dampening for all construction joints. 2. Roughened construction joints: a. Roughen the surface of the concrete to expose the aggregate uniformly. b. Remove laitance, loosened particles of aggregate or damaged concrete at the surface, or at the Contractor's option, use an approved chemical retarder which delays but does not prevent setting of the surface of the mortar in accordance with the manufacturer's recommendations. 1) Retarded mortar shall be removed within 24 hours after placing to produce a clean exposed aggregate bonding surface. c. Cover the hardened concrete of horizontal joints with a coat of cement grout of similar proportions to the concrete, except substitute fine aggregate for coarse aggregate. d. Place 1 inch layer of grout in bottoms of wall or column lifts immediately before placing concrete. 1) Vibrate grout and first layer of concrete simultaneously. e. Place fresh concrete before the grout has attained its initial set. 3. Other keyed construction joints: a. Thoroughly clean construction joints and remove all laitance. b. Dampen the hardened concrete (but do not saturate) immediately
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prior to placing of fresh concrete.
3.6.2 Contraction Joints in Slabs on Grade
Contraction joints shall be located and detailed as shown on the drawings. Produce contraction joints by forming a weakened plane in the concrete slab using materials and procedures specified in Section 03 15 00.00 10 CONCRETE ACCESSORIES, or sawing a continuous slot with a concrete saw, as indicated on the drawings.
3.6.3 Expansion Joints
Installation of expansion joints and sealing of these joints shall conform to the requirements of Section 03 15 00.00 10 EXPANSION JOINTS, CONTRACTION JOINTS, AND WATERSTOPS and Section 07 92 00 JOINT SEALANTS.
1. Do not permit reinforcement or other embedded metal items bonded to concrete (except smooth dowels bonded on only one side of joint) to extend continuously through an expansion joint.
2. Use neoprene expansion joint fillers, unless noted otherwise on Drawings.
3. Seal expansion joints.
3.6.4 Waterstops
Install waterstops in conformance with the locations and details shown on the drawings using materials and procedures specified in Section 03 15 00.00 10 EXPANSION JOINTS, CONTRACTION JOINTS, AND WATERSTOPS.
1. Preformed strip type:
a. Install on smooth surface of hardened concrete by use of nails, adhesive or other means as recommended by manufacturer to prevent movement of waterstop during placement of concrete.
b. Waterstop to be continuous with splices in accordance with manufacturer's instructions.
c. Use in joints against existing concrete and where indicated on Drawings.
2. PVC type:
a. Position waterstop accurately in forms.
b. Secure waterstops in correct position using hog rings or grommets spaced along the length of waterstop and tie wire to adjacent reinforcing.
c. Hold horizontal waterstops in place with continuous supports.
d. Install according to manufacturer's instructions.
1) Do not displace reinforcement from required location.
e. Waterstops to be continuous.
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f. Splice ends with perpendicular butt splice using electrical splicing iron in accordance with manufacturer's instructions.
g. Unless otherwise noted, use for all construction joints in new construction for all structures indicated on Drawings.
3.6.5 Dowels and Tie Bars
Install dowels and tie bars at the locations shown on the drawings and to the details shown, using materials and procedures specified in Section 03 20 00.00 10 CONCRETE REINFORCEMENT and herein. Conventional smooth "paving" dowels shall be installed in slabs using approved methods to hold the dowel in place during concreting within a maximum alignment tolerance of 1/8 inch in 12 inches. "Structural" type deformed bar dowels, or tie bars, shall be installed to meet the specified tolerances. Care shall be taken during placing adjacent to and around dowels and tie bars to ensure there is no displacement of the dowel or tie bar and that the concrete completely embeds the dowel or tie bar and is thoroughly consolidated.
3.7 FLOOR HARDENER
Areas as indicated on the drawings shall be treated with floor hardener applied after the concrete has been cured and then air dried for 28 days. Apply three coats, each the day after the preceding coat was applied. For the first application, one pound of the silicofluoride shall be dissolved in one gallon of water. For subsequent applications, the solution shall be two pounds of silicofluoride to each gallon of water. Floor should be mopped with clear water shortly after the preceding application has dried to remove encrusted salts. Apply proprietary hardeners in accordance with the manufacturer's instructions. During application, area should be well ventilated. Take precautions when applying silicofluorides due to the toxicity of the salts. Any compound that contacts glass or aluminum should be immediately removed with clear water.
3.8 EXTERIOR SLAB AND RELATED ITEMS
3.8.1 Pits and Trenches
Construct pits and trenches as indicated on the drawings. Bottoms and walls shall be placed monolithically or waterstops and keys, shall be provided as approved.
3.9 SETTING BASE PLATES AND BEARING PLATES
After being properly positioned, column base plates, bearing plates for beams and similar structural members, and machinery and equipment base plates shall be set to the proper line and elevation with damp-pack bedding mortar, except where nonshrink grout is indicated. The thickness of the mortar or grout shall be approximately 1/24 the width of the plate, but not less than 3/4 inch unless noted otherwise on the drawings. Concrete and metal surfaces in contact with grout shall be clean and free of oil and grease, and concrete surfaces in contact with grout shall be damp and free of laitance when grout is placed. Use nonshrink grout for equipment base plates and as indicated on the drawings.
3.9.1 Damp-Pack Bedding Mortar
Damp-pack bedding mortar shall consist of 1 part cement and 2-1/2 parts fine aggregate having water content such that a mass of mortar tightly
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squeezed in the hand will retain its shape but will crumble when disturbed. The space between the top of the concrete and bottom of the bearing plate or base shall be packed with the bedding mortar by tamping or ramming with a bar or rod until it is completely filled.
3.9.2 Nonshrink Grout
Nonshrink grout shall be a ready-mixed material requiring only the addition of water. Water content shall be the minimum that will provide a flowable mixture and completely fill the space to be grouted without segregation, bleeding, or reduction of strength.
3.9.2.1 Mixing and Placing of Nonshrink Grout
Mixing and placing shall be in conformance with the material manufacturer's instructions and as specified therein. Ingredients shall be thoroughly dry-mixed before adding water. After adding water, mix the batch for 3 minutes. Batches shall be of size to allow continuous placement of freshly mixed grout. Discard grout not used within 30 minutes after mixing. The space between the top of the concrete or machinery-bearing surface and the plate shall be filled solid with the grout. Forms shall be of wood or other equally suitable material for completely retaining the grout on all sides and on top and shall be removed after the grout has set. The placed grout shall be carefully worked by rodding or other means to eliminate voids; however, overworking and breakdown of the initial set shall be avoided. Grout shall not be retempered or subjected to vibration from any source. Where clearances are unusually small, placement shall be under pressure with a grout pump. Temperature of the grout, and of surfaces receiving the grout, shall be maintained at 65 to 85 degrees F until after setting.
3.9.2.2 Treatment of Exposed Surfaces
For metal-oxidizing nonshrink grout, exposed surfaces shall be cut back 1 inch and immediately covered with a parge coat of mortar consisting of 1 part portland cement and 2-1/2 parts fine aggregate by weight, with sufficient water to make a plastic mixture. The parge coat shall have a smooth finish. For other mortars or grouts, exposed surfaces shall have a smooth-dense finish and be left untreated. Curing shall comply with Section 03 39 00.00 10 CONCRETE CURING.
3.10 TESTING AND INSPECTION FOR CQC
Perform the inspection and tests described below and, based upon the results of these inspections and tests, take the action required. Submit certified copies of laboratory test reports, including mill tests and all other test data, for portland cement, blended cement, pozzolan, ground granulated blast furnace slag, silica fume, aggregate, admixtures, and curing compound proposed for use on this project.
a. When, in the opinion of the Owner's Representative, the concreting operation is out of control, cease concrete placement and correct the operation.
b. The laboratory performing the tests shall be onsite and shall conform with ASTM C1077. Materials may be subjected to check testing by the Owner's Representative from samples obtained at the manufacturer, at transfer points, or at the project site.
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c. The Owner's Representative will inspect the laboratory, equipment, and test procedures prior to start of concreting operations and at least once per 50 cubic yards thereafter for conformance with ASTM C1077.
3.10.1 Grading and Corrective Action
3.10.1.1 Fine Aggregate
At least once during each shift when the concrete plant is operating, there shall be one sieve analysis and fineness modulus determination in accordance with ASTM C136 and COE CRD-C 104 for the fine aggregate or for each fine aggregate if it is batched in more than one size or classification. The location at which samples are taken may be selected by the Contractor as the most advantageous for control. However, the Contractor is responsible for delivering fine aggregate to the mixer within specification limits. When the amount passing on any sieve is outside the specification limits, the fine aggregate shall be immediately resampled and retested. If there is another failure on any sieve, the fact shall be immediately reported to the Owner's Representative, concreting shall be stopped, and immediate steps taken to correct the grading.
3.10.1.2 Coarse Aggregate
At least once during each shift in which the concrete plant is operating, there shall be a sieve analysis in accordance with ASTM C136 for each size of coarse aggregate. The location at which samples are taken may be selected by the Contractor as the most advantageous for production control. However, the Contractor shall be responsible for delivering the aggregate to the mixer within specification limits. A test record of samples of aggregate taken at the same locations shall show the results of the current test as well as the average results of the five most recent tests including the current test. The Contractor may adopt limits for control coarser than the specification limits for samples taken other than as delivered to the mixer to allow for degradation during handling. When the amount passing any sieve is outside the specification limits, the coarse aggregate shall be immediately resampled and retested. If the second sample fails on any sieve, that fact shall be reported to the Owner's Representative. Where two consecutive averages of 5 tests are outside specification limits, the operation shall be considered out of control and reported to the Owner's Representative. Concreting shall be stopped and immediate steps shall be taken to correct the grading.
3.10.2 Quality of Aggregates
Thirty days prior to the start of concrete placement, perform all tests for aggregate quality required by ASTM C33/C33M. In addition, after the start of concrete placement, perform tests for aggregate quality at least every three months, and when the source of aggregate or aggregate quality changes. Samples tested after the start of concrete placement shall be taken immediately prior to entering the concrete mixer.
3.10.3 Scales, Batching and Recording
Check the accuracy of the scales by test weights prior to start of concrete operations and at least once every three months. Such tests shall also be made as directed whenever there are variations in properties of the fresh concrete that could result from batching errors. Once a week the accuracy of each batching and recording device shall be checked during a weighing operation by noting and recording the required weight, recorded weight, and
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the actual weight batched. At the same time, test and ensure that the devices for dispensing admixtures are operating properly and accurately. When either the weighing accuracy or batching accuracy does not comply with specification requirements, the plant shall not be operated until necessary adjustments or repairs have been made. Discrepancies in recording accuracies shall be corrected immediately.
3.10.4 Batch-Plant Control
Continuously control the measurement of concrete materials, including cementitious materials, each size of aggregate, water, and admixtures. Adjust the aggregate weights and amount of added water as necessary to compensate for free moisture in the aggregates. The amount of air-entraining agent shall be adjusted to control air content within specified limits. Prepare a report indicating type and source of cement used, type and source of pozzolan used, amount and source of admixtures used, aggregate source, the required aggregate and water weights per cubic yard amount of water as free moisture in each size of aggregate, and the batch aggregate and water weights per cubic yard for each class of concrete batched during each day's plant operation.
3.10.5 Concrete Mixture
3.10.5.1 Air Content Testing
Perform air content tests when test specimens are fabricated. In addition, at least two tests for air content shall be made on randomly selected batches of each separate concrete mixture produced during each 8-hour period of concrete production. Perform additional tests when excessive variation in workability is reported by the placing foreman or Owner's Representative inspector. Tests shall be made in accordance with ASTM C231/C231M for normal weight concrete. Plot test results on control charts which shall at all times be readily available to the Owner's Representative and submitted weekly. Keep copies of the current control charts in the field by testing crews and results plotted as tests are made. When a single test result reaches either the upper or lower action limit, perform a second test immediately. The results of the two tests shall be averaged and this average used as the air content of the batch to plot on both the air content and the control chart for range, and for determining need for any remedial action. The result of each test, or average as noted in the previous sentence, shall be plotted on a separate control chart for each mixture on which an "average line" is set at the midpoint of the specified air content range from paragraph Air Entrainment in PART 1. Set an upper warning limit and a lower warning limit line 1.0 percentage point above and below the average line, respectively. An upper action limit and a lower action limit line shall be set 1.5 percentage points above and below the average line, respectively. The range between each two consecutive tests shall be plotted on a secondary control chart for range where an upper warning limit is set at 2.0 percentage points and an upper action limit is set at 3.0 percentage points. Samples for air content may be taken at the mixer, however, the Contractor is responsible for delivering the concrete to the placement site at the stipulated air content. If the Contractor's materials or transportation methods cause air content loss between the mixer and the placement, correlation samples shall be taken at the placement site as required by the Owner's Representative, and the air content at the mixer controlled as directed.
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3.10.5.2 Air Content Corrective Action
Whenever points on the control chart for percent air reach either warning limit, an adjustment shall immediately be made in the amount of air-entraining admixture batched. As soon as practical after each adjustment, another test shall be made to verify the result of the adjustment. Whenever a point on the secondary control chart for range reaches the warning limit, the admixture dispenser shall be recalibrated to ensure that it is operating accurately and with good reproducibility. Whenever a point on either control chart reaches an action limit line, the air content shall be considered out of control and the concreting operation shall immediately be halted until the air content is under control. Additional air content tests shall be made when concreting is restarted.
3.10.5.3 Slump Testing
In addition to slump tests which are made when test specimens are fabricated, at least four slump tests shall be made on randomly selected batches in accordance with ASTM C143/C143M for each separate concrete mixture produced during each 8-hour or less period of concrete production each day. Also, additional tests shall be made when excessive variation in workability is reported by the placing foreman or Owner's Representative inspector. Plot test results on control charts which shall at all times be readily available to the Owner's Representative and submitted weekly. Keep copies of the current control charts in the field by testing crews and results plotted as tests are made. When a single slump test reaches or goes beyond either the upper or lower action limit, immediately perform a second test. The results of the two tests shall be averaged and this average used as the slump of the batch to plot on both the control charts for slump and the chart for range, and for determining need for any remedial action. Set limits on separate control charts for slump for each type of mixture. The upper warning limit shall be set at 1/2 inch below the maximum allowable slump specified in paragraph Slump in PART 1 for each type of concrete and an upper action limit line and lower action limit line shall be set at the maximum and minimum allowable slumps, respectively, as specified in the same paragraph. The range between each consecutive slump test for each type of mixture shall be plotted on a single control chart for range on which an upper action limit is set at 2 inches. Take samples for slump at the mixer. However, the Contractor is responsible for delivering the concrete to the placement site at the stipulated slump. If the Contractor's materials or transportation methods cause slump loss between the mixer and the placement, take correlation samples at the placement site as required by the Owner's Representative, and the slump at the mixer controlled as directed.
3.10.5.4 Slump Corrective Action
Whenever points on the control charts for slump reach the upper warning limit, make an adjustment immediately in the batch weights of water and fine aggregate. The adjustments are to be made so that the total water content does not exceed that amount allowed by the maximum w/c ratio specified, based on aggregates which are in a saturated surface dry condition. When a single slump reaches the upper or lower action limit, no further concrete shall be delivered to the placing site until proper adjustments have been made. Immediately after each adjustment, another test shall be made to verify the correctness of the adjustment. Whenever two consecutive individual slump tests, made during a period when there was no adjustment of batch weights, produce a point on the control chart for range at or above the upper action limit, halt the concreting operation
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immediately, and take appropriate steps to bring the slump under control. Additional slump tests shall be made as directed.
3.10.5.5 Temperature
Measure the temperature of the concrete when compressive strength specimens are fabricated in accordance with ASTM C1064/C1064M. Report the temperature along with the compressive strength data.
3.10.5.6 Strength Specimens
Perform at least one set of test specimens, for compressive strength as appropriate, on each different concrete mixture placed during the day for each 50 cubic yards or portion thereof of that concrete mixture placed each day. Perform additional sets of test specimens, as directed by the Owner's Representative, when the mixture proportions are changed or when low strengths have been detected. Develop a truly random (not haphazard) sampling plan for approval by the Owner's Representative prior to the start of construction. The plan shall ensure that sampling is done in a completely random and unbiased manner. A set of test specimens for concrete with a 28-day specified strength in accordance with paragraph Strength Requirements in PART 1 shall consist of four specimens, two to be tested at 7 days and two at 28 days. Test specimens shall be molded and cured in accordance with ASTM C31/C31M and tested in accordance with ASTM C39/C39M for test cylinders. Results of all strength tests shall be reported immediately to the Owner's Representative. Quality control charts shall be kept for individual strength "tests", ("test" as defined in paragraph Strength Requirements in PART 1) moving average of last 3 "tests" for strength, and moving average for range for the last 3 "tests" for each mixture. The charts shall be similar to those found in ACI 214R.
3.10.6 Inspection Before Placing
Inspect foundations, construction joints, steel reinforcement, placement, headed anchor bolts, forms, waterstops, and embedded items in sufficient time prior to each concrete placement in order to certify to the Owner's Representative that they are ready to receive concrete. Report the results of each inspection in writing.
3.10.7 Placing
The placing foreman shall supervise placing operations, shall determine that the correct quality of concrete or grout is placed in each location as specified and as directed by the Owner's Representative, and shall be responsible for measuring and recording concrete temperatures and ambient temperature hourly during placing operations, weather conditions, time of placement, volume placed, and method of placement. The placing foreman shall not permit batching and placing to begin until it has been verified that an adequate number of vibrators in working order and with competent operators are available. Placing shall not be continued if any pile of concrete is inadequately consolidated. If any batch of concrete fails to meet the temperature requirements, immediate steps shall be taken to improve temperature controls.
3.10.8 Vibrators
Determine the frequency and amplitude of each vibrator in accordance with COE CRD-C 521 prior to initial use and at least once a month when concrete is being placed. Perform additional tests as directed when a vibrator does
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not appear to be adequately consolidating the concrete. The frequency shall be determined while the vibrator is operating in concrete with the tachometer being held against the upper end of the vibrator head while almost submerged and just before the vibrator is withdrawn from the concrete. Determine the amplitude with the head vibrating in air. Take two measurements, one near the tip and another near the upper end of the vibrator head, and these results averaged. Report the make, model, type, and size of the vibrator and frequency and amplitude results in writing. Any vibrator not meeting the requirements of paragraph Consolidation above, shall be immediately removed from service and repaired or replaced.
3.10.9 Cold-Weather Protection
At least once each shift and once per day on non-work days, an inspection shall be made of all areas subject to cold-weather protection. Any deficiencies shall be noted, corrected, and reported.
3.10.10 Mixer Uniformity
3.10.10.1 Stationary Mixers
Prior to the start of concrete placing and once every 6 months when concrete is being placed, or once for every 75,000 cubic yards of concrete placed, whichever results in the shortest time interval, uniformity of concrete mixing shall be determined in accordance with ASTM C94/C94M.
3.10.10.2 Truck Mixers
Prior to the start of concrete placing and at least once every 6 months when concrete is being placed, uniformity of concrete mixing shall be determined in accordance with ASTM C94/C94M. Select the truck mixers randomly for testing. When satisfactory performance is found in one truck mixer, the performance of mixers of substantially the same design and condition of the blades may be regarded as satisfactory.
3.10.10.3 Mixer Uniformity Corrective Action
When a mixer fails to meet mixer uniformity requirements, either the mixing time shall be increased, batching sequence changed, batch size reduced, or adjustments shall be made to the mixer until compliance is achieved.
3.10.11 Reports
Report all results of tests or inspections conducted, informally as they are completed and in writing daily. Prepare a weekly report for the updating of control charts covering the entire period from the start of the construction season through the current week. During periods of cold-weather protection, reports of pertinent temperatures shall be made daily. These requirements do not relieve the Contractor of the obligation to report certain failures immediately as required in preceding paragraphs. Such reports of failures and the action taken shall be confirmed in writing in the routine reports. The Owner's Representative has the right to examine all contractor quality control records.
-- End of Section --
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SECTION 03 35 00.00 10
CONCRETE FINISHING 11/10 08/19/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)
ACI 117 (2010; Errata 2011) Specifications for Tolerances for Concrete Construction and Materials and Commentary
ACI 305R (2010) Guide to Hot Weather Concreting
ASTM INTERNATIONAL (ASTM)
ASTM C1059/C1059M (1999; R 2008) Standard Specification for Latex Agents for Bonding Fresh to Hardened Concrete
ASTM C881/C881M (2010) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete
ASTM C940 (2010a) Expansion and Bleeding of Freshly Mixed Grouts for Preplaced-Aggregate Concrete in the Laboratory
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Latex Bonding Compound Epoxy Resin Custom Form Liners
SD-05 Design Data
Dry Shake Finish
PART 2 PRODUCTS
2.1 LATEX BONDING COMPOUND
Latex bonding compound agents for bonding fresh to hardened concrete shall conform to ASTM C1059/C1059M. Submit samples as required.
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2.2 EPOXY RESIN
Epoxy resin for use in repairs shall conform to ASTM C881/C881M, Type III, Grade I or II. Submit samples as required.
PART 3 EXECUTION
3.1 FINISHING FORMED SURFACES
Forms, form materials, and form construction are specified in Section 03 11 13.00 10 STRUCTURAL CAST-IN-PLACE CONCRETE FORMING. Finishing of formed surfaces shall be as specified herein. Unless another type of architectural or special finish is specified, surfaces shall be left with the texture imparted by the forms except that defective surfaces shall be repaired. Maintain uniform color of the concrete by use of only one mixture without changes in materials or proportions for any structure or portion of structure that requires a Class B finish. The form panels used to produce the finish shall be orderly in arrangement, with joints between panels planned in approved relation to openings, building corners, and other architectural features. Forms shall not be reused if there is any evidence of surface wear or defects that would impair the quality of the surface.
3.1.1 Class A Finish and Class B Finish
Class A finish is not required. Class B finish is required at vertical concrete surfaces exposed to view. Remove fins, ravelings, and loose material, all surface defects over 1/2 inch in diameter or more than 1/2 inch deep, shall be repaired and, except as otherwise indicated or as specified in Section 03 11 13.00 10 STRUCTURAL CONCRETE FORMWORK, holes left by removal of form ties shall be reamed and filled. Defects more than 1/2 inch in diameter shall be cut back to sound concrete, but in all cases at least 1 inch deep.
3.1.2 Class C and Class D Finish
Class C finish is required on vertical concrete surfaces not exposed to view and all remaining surfaces not covered by Class B or Class D. Class D finish is required at vertical concrete surfaces of foundations not exposed to view. Fins, ravelings, and loose material shall be removed, and, except as otherwise indicated or as specified in Section 03 11 13.00 10 STRUCTURAL CONCRETE FORMWORK, holes left by removal of form ties shall be reamed and filled. Honeycomb and other defects more than 1/2 inch deep or more than 2 inches in diameter shall be repaired. Defects more than 2 inches in diameter shall be cut back to sound concrete, but in all cases at least 1 inch deep.
3.1.3 Custom Form liner Finishes
A. Split Face Stone:
1. Split Face Limestone Surface Treatment (Refer to attachment 03 35 00.00 10A as a guide).
2. Maximum relief: 1.25 inches.
3. Average relief: 0.5 inches.
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4. Stone length: Varies between 12 and 48 inches.
5. Stone height: As indicated on the Drawings.
6. Extend Formliner a minimum of 2 feet below grade.
B. Smooth Face Stone:
1. Mankato Cut Stone Surface Treatment (Refer to attachment 03 35 00.00 10B as a guide).
2. Maximum relief: 0.3125 inches.
3. Average relief: 0.3125 inches.
4. Stone length:Varies between 12 and 48 inches and as indicated on the Drawings.
5. Stone height: Varies between 4 and 12 inches and as indiated on the Drawings.
6. Similar to pattern #12008 by Custom Rock (St. Paul, MN).
7. Extend form liner a minimum of 2 feet below grade.
3.1.4 Custom Form Liner Mock-Up
Build a mock-up in conjunction with work in Section 03 30 00.00 10, CAST-IN-PLACE CONCRETE.
Prior to permanent wall construction, construct mock-up.
A. Mock-up shall be as large as required to properly display all components and form conditions, however the mock-up shall be a minimum of 8 foot x 8 foot (L shaped) x 4 foot high.
B. Mock-up shall constitute minimum standard of quality for actual construction.
1. Maintain mock-up during construction.
2. If not aceptable, construct additional mock-ups as required.
3. Mock-up shall not be a part of the permanent wall.
3.2 REPAIRS
Except for major defects, as defined hereinafter, repair surface defects as specified herein within 24 hours after forms are removed. Repairs of the so-called "plaster-type" will not be permitted in any location. Tolerances of formed surfaces shall conform to the requirements of ACI 117. These tolerances apply to the finished concrete surface, not to the forms themselves; forms shall be set true to line and grade. Form tie holes requiring repair and other defects whose depth is at least as great as their surface diameter shall be repaired as specified in paragraph Damp-Pack Mortar Repair below. Defects whose surface diameter is greater than their depth shall be repaired as specified in paragraph Repair of Major Defects below. Repairs shall be finished flush with adjacent surfaces and with the same surface texture. The cement used for all
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repairs shall be a blend of job cement with white cement proportioned so that the final color after curing and aging will be the same as the adjacent concrete. Concrete with excessive honeycomb, or other defects which affect the strength of the member, will be rejected. Repairs shall be demonstrated to be acceptable and free from cracks or loose or drummy areas at the completion of the contract and, for Class B Finishes, shall be inconspicuous. Repairs not meeting these requirements will be rejected and shall be replaced.
3.2.1 Damp-Pack Mortar Repair
Form tie holes requiring repair and other defects, whose depth is at least as great as their surface diameter but not over 4 inches, shall be repaired by the damp-pack mortar method. Form tie holes shall be reamed and other similar defects shall be cut out to sound concrete. The void shall then be thoroughly cleaned, thoroughly wetted, brush-coated with a thin coat of neat cement grout and filled with mortar. Mortar shall be a stiff mix of 1 part portland cement to 2 parts fine aggregate passing the No. 16 mesh sieve, and minimum amount of water. Use only sufficient water to produce a mortar which, when used, will stick together on being molded into a ball by a slight pressure of the hands and will not exude water but will leave the hands damp. Mortar shall be mixed and allowed to stand for 30 to 45 minutes before use with remixing performed immediately prior to use. Mortar shall be thoroughly tamped in place in thin layers using a hammer and hardwood block. Holes passing entirely through walls shall be considered for repair of major defects. All holes shall be packed full. Damp-pack repairs shall be moist cured for at least 48 hours.
3.2.2 Repair of Major Defects
Major defects will be considered to be those more than 1/2 inch deep or, for Class B finishes, more than 1/2 inch in diameter and, for Class C and D finishes, more than 2 inches in diameter. Also included are any defects of any kind whose depth is over 4 inches or whose surface diameter is greater than their depth. Repair major defects as specified below.
3.2.2.1 Surface Application of Mortar Repair
Defective concrete shall be removed, and removal shall extend into completely sound concrete. Use approved equipment and procedures which will not cause cracking or microcracking of the sound concrete. If reinforcement is encountered, remove concrete so as to expose the reinforcement for at least 2 inches on all sides. All such defective areas greater than 12 square inches shall be outlined by saw cuts at least 1 inch deep. Defective areas less than 12 square inches shall be outlined by a 1 inch deep cut with a core drill in lieu of sawing. All saw cuts shall be straight lines in a rectangular pattern in line with the formwork panels. After concrete removal, the surface shall be thoroughly cleaned by high pressure washing to remove all loose material. Keep surfaces continually saturated for the first 12 of the 24 hours immediately before placing mortar and shall be damp but not wet at the time of commencing mortar placement. The Contractor, as an option, may use either hand-placed mortar or mortar placed with a mortar gun. If hand-placed mortar is used, the edges of the cut shall be perpendicular to the surface of the concrete. The prepared area shall be brush-coated with a thin coat of neat cement grout. The repair shall then be made using a stiff mortar, preshrunk by allowing the mixed mortar to stand for 30 to 45 minutes and then remixed, thoroughly tamped into place in thin layers. If hand-placed mortar is used, test each repair area for drumminess by firm tapping with a hammer
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and inspecting for cracks, both in the presence of the Owner's Representative, immediately before completion of the contract, and replacing any showing drumminess or cracking. If mortar placed with a mortar gun is used, the gun shall be a small compressed air-operated gun to which the mortar is slowly hand fed and which applies the mortar to the surface as a high-pressure stream, as approved. Repairs made using shotcrete equipment will not be accepted. The mortar used shall be the same mortar as specified for damp-pack mortar repair. If gun-placed mortar is used, the edges of the cut shall be beveled toward the center at a slope of 1:1. All surface applied mortar repairs shall be continuously moist cured for at least 7 days. Moist curing shall consist of several layers of saturated burlap applied to the surface immediately after placement is complete and covered with polyethylene sheeting, all held closely in place by a sheet of plywood or similar material rigidly braced against it. Keep burlap continually wet.
3.2.2.2 Repair of Deep and Large Defects
Deep and large defects will be those that are more than 6 inches deep and also have an average diameter at the surface more than 18 inches or that are otherwise so identified by the Project Office. Such defects shall be repaired as specified herein or directed, except that defects which affect the strength of the structure shall not be repaired and that portion of the structure shall be completely removed and replaced. Repair deep and large defects by procedures approved in advance including forming and placing special concrete using applied pressure during hardening. Preparation of the repair area shall be as specified for surface application of mortar. In addition, the top edge (surface) of the repair area shall be sloped at approximately 20 degrees from the horizontal, upward toward the side from which concrete will be placed. The special concrete shall be a concrete mixture with low water content and low slump, and shall be allowed to age 30 to 60 minutes before use. Concrete containing a specified expanding admixture may be used in lieu of the above mixture; design the paste portion of such concrete mixture to have an expansion between 2.0 and 4.0 percent when tested in accordance with ASTM C940. Provide a full width "chimney" at the top of the form on the placing side to ensure filling to the top of the opening. Use a pressure cap on the concrete in the chimney with simultaneous tightening and revibrating the form during hardening to ensure a tight fit for the repair. Remove the form after 24 hours and immediately the chimney shall be carefully chipped away to avoid breaking concrete out of the repair; the surface of the repair concrete shall be dressed as required.
3.3 FORMED SURFACE REPAIR
After removal of forms, all ridges, lips, and bulges on surfaces permanently exposed shall be removed. All repairs shall be completed within 48 hours after form removal.
3.3.1 Classes A, AHV, & B Finishes
Surfaces listed in Section 03 11 13.00 10 STRUCTURAL CAST-IN-PLACE CONCRETE FORMING and as shown to have classes A, AHV, and B finishes shall have surface defects repaired as follows: defective areas, voids, and honeycombs smaller than 16 square inches in area and less than 1/2 inch deep and bug holes exceeding 1/2 inch in diameter shall be chipped and filled with dry-packed mortar. Holes left by removal of tie rods shall be reamed and filled with dry-packed mortar as specified in paragraph MATERIAL AND PROCEDURE FOR REPAIRS below. Defective and unsound concrete areas
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larger than described shall be defined by 1/2 inch deep dovetailed saw cuts in a rectangular pattern with lines parallel to the formwork, the defective concrete removed by chipping, and the void repaired with replacement concrete. The prepared area shall be brush-coated with an epoxy resin meeting the requirements of paragraph EPOXY RESIN in PART 2, a latex bonding agent meeting the requirements of paragraph LATEX BONDING COMPOUND in PART 2, or a neat cement grout after dampening the area with water. The void shall be filled with replacement concrete in accordance with paragraph MATERIAL AND PROCEDURE FOR REPAIRS below.
3.3.2 Class C Finish
Surfaces listed in Section 03 11 13.00 10 STRUCTURAL CONCRETE FORMWORK and as shown shall have defects repaired as follows: defective areas, voids, and honeycombs smaller than 24 square inches and less than 2 inches deep; bug holes exceeding 1-1/2 inches in diameter shall be chipped and filled with dry-packed mortar; and holes left by removal of the tie rods shall be chipped and filled with dry-packed mortar. Defective and unsound concrete areas larger than 24 square inches and deeper than 1-1/2 inches shall be defined by 1/2 inch deep dovetailed saw cuts in a rectangular pattern, the defective concrete removed by chipping, and the void repaired with replacement concrete. The prepared area shall be brush-coated with an epoxy resin meeting the requirements of paragraph EPOXY RESIN in PART 2, a latex bonding agent meeting the requirements of paragraph LATEX BONDING COMPOUND in PART 2, or a neat cement grout after dampening the area with water. The void shall be filled with replacement concrete in accordance with paragraph MATERIAL AND PROCEDURE FOR REPAIRS below.
3.3.3 Class D Finish
Surfaces listed in Section 03 11 13.00 10 STRUCTURAL CONCRETE FORMWORK and as shown to have class D finish shall have surface defects repaired as follows: defective areas, voids, and honeycombs greater than 48 square inches in area or more than 2 inches deep shall be defined by 1/2 inch deep dovetailed saw cuts in a rectangular pattern, the defective concrete removed by chipping and the void repaired with replacement concrete. The prepared area shall be brush-coated with an epoxy resin meeting the requirements of paragraph EPOXY RESIN in PART 2, a latex bonding agent meeting the requirements of paragraph LATEX BONDING COMPOUND in PART 2, or a neat cement grout after dampening the area with water. The void shall be filled with replacement concrete as specified below.
3.3.4 Material and Procedure for Repairs
The cement used in the dry-packed mortar or replacement concrete shall be a blend of the cement used for production of project concrete and white portland cement properly proportioned so that the final color of the mortar or concrete will match adjacent concrete. Trial batches shall be used to determine the proportions required to match colors. Dry-packed mortar shall consist of one part cement to two and one-half parts fine aggregate. The fine aggregate shall be that used for production of project concrete. The mortar shall be remixed over a period of at least 30 minutes without addition of water until it obtains the stiffest consistency that will permit placing. Mortar shall be thoroughly compacted into the prepared void by tamping, rodding, ramming, etc. and struck off to match adjacent concrete. Replacement concrete shall be produced using project materials and shall be proportioned by the Owner's Representative. It shall be thoroughly compacted into the prepared void by internal vibration, tamping, rodding, ramming, etc. and shall be struck off and finished to match
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adjacent concrete. Forms shall be used to confine the concrete. If an expanding agent is used in the repair concrete, the repair shall be thoroughly confined on all sides including the top surface. Metal tools shall not be used to finish permanently exposed surfaces. The repaired areas shall be cured for 7 days. The temperature of the in situ concrete, adjacent air, and replacement mortar or concrete shall be above 40 degrees F during placement, finishing, and curing. Other methods and materials for repair may be used only when approved in writing by the Owner's Representative. Repairs of the so called "plaster-type" will not be permitted.
3.4 FINISHING UNFORMED SURFACES
The finish of all unformed surfaces shall meet the requirements of paragraph Tolerances in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE, when tested as specified herein.
3.4.1 General
The ambient temperature of spaces adjacent to unformed surfaces being finished and of the base on which concrete will be placed shall be not less than 50 degrees F. In hot weather all requirements of Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE paragraphs Hot Weather Requirements and Prevention of Plastic Shrinkage Cracking above shall be met.In hot weather when the rate of evaporation of surface moisture, as determined by use of Figure 2.1.5 of ACI 305R, may reasonably be expected to exceed 0.2 pounds per square foot per hour. Make provisions for windbreaks, shading, fog spraying, or wet covering with a light-colored material in advance of placement, and such protective measures shall be taken as quickly as finishing operations will allow. Unformed surfaces that are not to be covered by additional concrete or backfill shall have a float finish, with additional finishing as specified below, and shall be true to the elevation shown on the drawings. Surfaces to receive additional concrete or backfill shall be brought to the elevation shown on the drawings, properly consolidated, and left true and regular. Unless otherwise shown on the drawings, exterior surfaces shall be sloped for drainage. Where drains are provided, interior floors shall be evenly sloped to the drains. Joints shall be carefully made with a jointing or edging tool. The finished surfaces shall be protected from stains or abrasions. Grate tampers or "jitterbugs" shall not be used for any surfaces. The dusting of surfaces with dry cement or other materials or the addition of any water during finishing shall not be permitted. If bleedwater is present prior to finishing, the excess water shall be carefully dragged off or removed by absorption with porous materials such as burlap. During finishing operations, extreme care shall be taken to prevent over finishing or working water into the surface; this can cause "crazing" (surface shrinkage cracks which appear after hardening) of the surface. Any slabs with surfaces which exhibit significant crazing shall be removed and replaced. During finishing operations, surfaces shall be checked with a 10 foot straightedge, applied in both directions at regular intervals while the concrete is still plastic, to detect high or low areas.
3.4.2 Rough Slab Finish
As a first finishing operation for unformed surfaces and as final finish for slabs to receive mortar setting beds, the floor slab surface shall receive a rough slab finish prepared as follows. The concrete shall be uniformly placed across the slab area, consolidated as previously specified, and then screeded with straightedge strikeoffs immediately after
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consolidation to bring the surface to the required finish level with no coarse aggregate visible. Side forms and screed rails shall be provided, rigidly supported, and set to exact line and grade. Allowable tolerances for finished surfaces apply only to the hardened concrete, not to forms or screed rails. Forms and screed rails shall be set true to line and grade. "Wet screeds" shall not be used.
3.4.3 Floated Finish
Apply a floated finish to surfaces to receive a troweled finish. The screeding shall be followed immediately by darbying or bull floating before bleeding water is present, to bring the surface to a true, even plane. No water, cement, or mortar shall be added to the surface during the finishing operation. Then, after the concrete has stiffened so that it will withstand a man's weight without imprint of more than 1/4 inch and the water sheen has disappeared, it shall be floated to a true and even plane free of ridges. Perform floating by use of suitable hand floats or power driven equipment. Use sufficient pressure on the floats to bring a film of moisture to the surface. Hand floats shall be made of wood, magnesium, or aluminum. Concrete that exhibits stickiness shall be floated with a magnesium float. Care shall be taken to prevent over-finishing or incorporating water into the surface.
3.4.4 Troweled Finish
Apply a troweled finish to surface exposed to view. After floating is complete and after the surface moisture has disappeared, unformed surfaces shall be steel-troweled to a smooth, even, dense finish, free from blemishes including trowel marks. In lieu of hand finishing, an approved power finishing machine may be used in accordance with the directions of the machine manufacturer. Additional trowelings shall be performed, either by hand or machine until the surface has been troweled 2 times, with waiting period between each. Care shall be taken to prevent blistering and if such occurs, troweling shall immediately be stopped and operations and surfaces corrected. A final hard steel troweling shall be done by hand, with the trowel tipped, and using hard pressure, when the surface is at a point that the trowel will produce a ringing sound. The finished surface shall be thoroughly consolidated and shall be essentially free of trowel marks and be uniform in texture and appearance. The concrete mixture used for troweled finished areas shall be adjusted, if necessary, in order to provide sufficient fines (cementitious material and fine sand) to finish properly.
3.4.5 Non-Slip Finish
Construct non-slip floors in accordance with the following subparagraphs.
3.4.5.1 Broomed
The following areas exterior stoops, slabs, and ramps shall be given a broomed finish. After floating, the surface shall be lightly steel troweled, and then carefully scored by pulling a coarse fiber push-type broom across the surface. Brooming shall be transverse to traffic or at right angles to the slope of the slab. After the end of the curing period, the surface shall be vigorously broomed with a coarse fiber broom to remove all loose or semi-detached particles.
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SECTION 03 35 00.00 10 Page 8 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 03 39 00.00 10
CONCRETE CURING 11/10 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)
AASHTO M 182 (2005; R 2009) Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton Mats
ASTM INTERNATIONAL (ASTM)
ASTM C171 (2007) Standard Specification for Sheet Materials for Curing Concrete
ASTM C309 (2011) Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete
U.S. ARMY CORPS OF ENGINEERS (USACE)
COE CRD-C 400 (1963) Requirements for Water for Use in Mixing or Curing Concrete
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Curing Materials; G
Impervious Sheets; G
Membrane Forming Compound; G
SD-05 Design Data
Mass Concrete Thermal Monitoring Control Plan; G
SD-06 Test Reports
Testing and Inspection for CQC; G
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1.3 DELIVERY, STORAGE, AND HANDLING
Materials shall be stored in such a manner as to avoid contamination and deterioration. Materials shall be capable of being accurately identified after bundles or containers are opened.
PART 2 PRODUCTS
2.1 CURING MATERIALS
2.1.1 Impervious-Sheet
Impervious-sheet materials shall conform to ASTM C171, type optional, except, that polyethylene sheet shall not be used.
2.1.2 Membrane-Forming Curing Compound
Membrane-Forming curing compound shall conform to ASTM C309, Type 1-D or 2, except that only a styrene acrylate or chlorinated rubber compound meeting Class B requirements shall be used for surfaces that are to be painted or are to receive additional concrete, or waterproofing, or floors that are to receive adhesive applications of resilient flooring. The curing compound selected shall be compatible with additional placed concrete, any subsequent paint, waterproofing, or flooring specified. Nonpigmented compound shall contain a fugitive dye, and shall have the reflective requirements in ASTM C309 waived.
2.1.3 Burlap and Cotton Mat
Burlap and cotton mat used for curing shall conform to AASHTO M 182.
2.2 WATER
Water for curing shall be fresh, clean, potable, and free of injurious amounts of oil, acid, salt, or alkali, except that non-potable water may be used if it meets the requirements of COE CRD-C 400.
PART 3 EXECUTION
3.1 CURING AND PROTECTION
3.1.1 General
Concrete shall be cured by an approved method for the period of time given below:
Type III portland cement 3 days
Portland cement when accelerator is used to achieve high 3 days early strength, except when fly-ash is used
Type II portland cement 14 days
Portland cement blended with 25 percent of less fly-ash 14 days
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Portland cement blended with more than 25 percent fly-ash 21 days
Immediately after placement, protect concrete from premature drying, extremes in temperatures, rapid temperature change and mechanical injury for the duration of the curing period. Concrete shall be protected from the damaging effects of rain for 12 hours and from flowing water for 14 days or 7 days with Type III cement. No fire or excessive heat including welding shall be permitted near or in direct contact with concrete or concrete embedments at any time. Maintain air and forms in contact with concrete at a temperature above 50 degrees F for the first 3 days and at a temperature above 32 degrees F for the remainder of the specified curing period. Exhaust fumes from combustion heating units shall be vented to the outside of the enclosure, and heaters and ducts shall be placed and directed so as not to cause areas of overheating and drying of concrete surfaces or to create fire hazards. Materials and equipment needed for adequate curing and protection shall be available and at the site prior to placing concrete. No fire or excessive heat, including welding, shall be permitted near or in direct contact with the concrete at any time. Except as otherwise permitted by paragraph Membrane Forming Curing Compounds in PART 2, moist curing shall be provided for any areas to receive any paint or other applied coating, or to which other concrete is to be bonded. Except for plastic coated burlap, impervious sheeting alone shall not be used for curing.
3.1.2 Moist Curing
Maintain concrete, to be moist-cured, continuously wet for the entire curing period, commencing immediately after finishing. If water or curing materials used stain or discolor concrete surfaces which are to be permanently exposed, the concrete surfaces shall be cleaned as approved. When wooden forms are left in place during curing, they shall be kept wet at all times. If steel forms are used in hot weather, nonsupporting vertical forms shall be carefully broken loose from the concrete, soon after the concrete hardens, and curing water continuously applied into the void so as to continuously saturate the entire concrete surface. If the forms are removed before the end of the curing period, curing shall be carried out as on unformed surfaces, using suitable materials. Horizontal surfaces shall be cured by ponding, by continuous sprinkling, by sand kept continuously wet, by continuously saturated burlap or cotton mats, or by continuously saturated plastic coated burlap. Burlap and mats shall be clean and free from any contamination and shall be completely saturated before being placed on the concrete. Provide an approved work system to ensure that moist curing is continuous 24 hours per day. Horizontal construction joints may be allowed to dry for 12 hours immediately prior to the placing of the following lift.
3.1.3 Membrane Forming Curing Compounds
3.1.3.1 Application Restrictions
Concrete may be cured with an approved membrane-forming curing compound in lieu of moist curing except that membrane curing will not be permitted on any surface to which other concrete is to be bonded, on any surface containing protruding steel reinforcement. The curing compound selected shall be compatible with any subsequent paint, waterproofing or flooring specified. Membrane curing compound shall not be used on surfaces that are maintained at curing temperatures with free steam.
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3.1.3.2 Pigmented Curing Compound
A pigmented curing compound meeting the requirements of the above paragraph may be used on surfaces that will not be exposed to view when the project is completed.
3.1.3.3 Nonpigmented Curing Compound
A nonpigmented curing compound containing a fugitive dye may be used on surfaces that will be exposed to view when the project is completed. Concrete cured with nonpigmented curing compound must be shaded from the sun for the first 3 days when the ambient temperature is 90 degrees F or higher.
3.1.3.4 Application
Apply the curing compound to formed surfaces immediately after the forms are removed and prior to any patching or other surface treatment except the cleaning of loose sand, mortar, and debris from the surface. The surfaces shall be thoroughly moistened with water, and the curing compound applied as soon as free water disappears. The curing compound shall be applied to unformed surfaces as soon as free water has disappeared and bleeding has stopped. The curing compound shall be applied in a two-coat continuous operation by approved motorized power-spraying equipment operating at a minimum pressure of 75 psi, at a uniform coverage of not more than 400 square feet per gallon for each coat, and the second coat shall be applied perpendicular to the first coat. Concrete surfaces that have been subjected to rainfall within 3 hours after curing compound has been applied shall be resprayed by the method and at the coverage specified. All concrete surfaces on which the curing compound has been applied shall be adequately protected for the duration of the entire curing period from pedestrian and vehicular traffic and from any other cause that will disrupt the continuity of the curing membrane.
3.1.4 Impervious Sheeting (Evaporative Retardant)
Except for plastic coated burlap, impervious sheeting alone shall not be used for curing. Use impervious-sheet curing only on horizontal or nearly horizontal surfaces. Surfaces shall be thoroughly wetted and be completely covered with the sheeting. Sheeting shall be at least 18 inches wider than the concrete surface to be covered. Covering shall be laid with light-colored side up. Covering shall be lapped not less than 12 inches and securely weighted down or shall be lapped not less than 4 inches and taped to form a continuous cover with completely closed joints. The sheet shall be weighted to prevent displacement so that it remains in contact with the concrete during the specified length of curing. Coverings shall be folded down over exposed edges of slabs and secured by approved means. Sheets shall be immediately repaired or replaced if tears or holes appear during the curing period.
3.1.5 Ponding or Immersion
Concrete shall be continually immersed throughout the curing period. Water shall not be more than 20 degrees F less than the temperature of the concrete.
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3.1.6 Cold Weather Curing and Protection
When the daily ambient low temperature is less than 32 degrees F maintain the temperature of the concrete above 40 degrees F for the first seven days after placing. During the period of protection removal, control the air temperature adjacent to the concrete surfaces so that concrete near the surface will not be subjected to a temperature differential of more than 25 degrees F as determined by suitable temperature measuring devices furnished by the Contractor, as required, and installed adjacent to the concrete surface and 2 inches inside the surface of the concrete. Perform the installation of the thermometers as directed.
3.2 Mass Concrete
1. Mass Concrete s defined as any concrete member or pour that is equal or greater than 36 IN thick in the minimum direction 2. Curing: Method of curing shall be as described above. 3. Contractor shall submit a thermal monitoring control plan for each mass concrete placement, meeting the following requirements: a. Concrete mix used. b. Upper limit for concrete temperature at the time of each placement. c. Projected differential temperature between center and surface of mass concrete pour. d. Drawings showing location for temperature sensors in each concrete placement. 1) See ACI 301-10, Section 8.3 for temperature sensor location(s) and sensor requirements e. A sample of the format and frequency of temperature data presentation. This shall include the identification of the time when the maximum core temperature is reached and when all surface/core temperature differentials are exceeded. f. Description of the curing procedures including material and methods, and curing duration. g. Description of formwork removal procedures to ensure that the temperature difference along the temporarily exposed surface does not exceed the established temperature differential limit as well as how the curing process will be maintained. h. Thermal monitoring shall continue for the duration the concrete is insulated or unless otherwise directed by Contracting Officer. 4. Curing and Insulating Period: a. All formed and unformed exposed concrete surfaces shall be insulated during the curing. b. The insulation monitoring period shall last a minimum of seven days or longer as required as described in the "monitoring Period" section below. c. Insulation requirements shall be based on the air temperature surrounding the concrete. 1) A minimum of one layer of commercial available concrete insulating blankest will be used. 2) Other materials of similar R-Value may be approved by the Engineer. 5. Monitoring Period: a. Surface Temperature: 1) During the curing and insulating period the surface temperature of the concrete will be monitored a minimum of twice per day until the surface temperature of the mass concrete falls to within 30 DegF of the ambient air temperature surrounding the mass concrete. 2) During this monitoring period, the surface temperature of the mass concrete shall not be permitted to drop more than 15 DegF over a
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24 hour period. a) If the temperature drop is exceeded, insulation shall be reinstalled and left in place for a period of 12 hours. 3) During the monitoring period, the temperature difference between the center and surface of the mass concrete pour shall not be permitted to exceed the specified maximum difference. a) If the temperature difference is exceeded, provide additional insulation or other corrections as identified in the thermal monitoring control plan until the temperature difference is within specified limits. 4) Do not artificially cool the surface of the mass concrete with water or other means during the monitoring period. b. Core Temperature: 1) Insulation of the concrete surface(s) shall continue until the temperature differential between the concrete section core temperature and the concrete section surface temperature is consistently less than 35 DegF for longer than three days. c. Provide all necessary thermometers and temperature measuring equipment necessary for monitoring concrete and ambient air temperature during the Monitoring Period. 1) Record all times and temperatures during the Monitoring Period. Allow Engineer and/or Special Inspector to witness results of each temperature reading.
3.3 TESTING AND INSPECTION FOR CQC
Perform the inspection and tests described below and, based upon the results of these inspections and tests, take the action required. Submit certified copies of laboratory test reports, including curing compound proposed for use on this project.
3.3.1 Curing Inspection
a. Moist Curing Inspections. At least once each shift, and not less than twice per day on both work and non-work days, an inspection shall be made of all areas subject to moist curing. The surface moisture condition shall be noted and recorded.
b. Moist Curing Corrective Action. When a daily inspection report lists an area of inadequate curing, immediate corrective action shall be taken, and the required curing period for those areas shall be extended by 1 day.
c. Membrane Curing Inspection. No curing compound shall be applied until the Contractor has verified that the compound is properly mixed and ready for spraying. At the end of each operation, estimate the quantity of compound used by measurement of the container and the area of concrete surface covered, compute the rate of coverage in square feet/gallon, and note whether or not coverage is uniform.
d. Membrane Curing Corrective Action. When the coverage rate of the curing compound is less than that specified or when the coverage is not uniform, the entire surface shall be sprayed again.
e. Sheet Curing Inspection. At least once each shift and once per day on non-work days, an inspection shall be made of all areas being cured using impervious sheets. The condition of the covering and the tightness of the laps and tapes shall be noted and recorded.
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f. Sheet Curing Corrective Action. When a daily inspection report lists any tears, holes, or laps or joints that are not completely closed, the tears and holes shall promptly be repaired or the sheets replaced, the joints closed, and the required curing period for those areas shall be extended by 1 day.
-- End of Section --
SECTION 03 39 00.00 10 Page 7 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 03 45 33
PRECAST AND PRESTRESSED STRUCTURAL CONCRETE 04/08 08/15/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.
AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)
ACI 304R (2000; R 2009) Guide for Measuring, Mixing, Transporting, and Placing Concrete
ACI 305R (2010) Guide to Hot Weather Concreting
ACI 306.1 (1990; R 2002) Standard Specification for Cold Weather Concreting
ACI 309R (2005) Guide for Consolidation of Concrete
ACI 318 (2011; Errata 1 2011; Errata 2 2012; Errata 3-4 2013) Building Code Requirements for Structural Concrete and Commentary
AMERICAN WELDING SOCIETY (AWS)
AWS D1.1/D1.1M (2012; Errata 2011) Structural Welding Code - Steel
AWS D1.4/D1.4M (2011) Structural Welding Code - Reinforcing Steel
ASTM INTERNATIONAL (ASTM)
ASTM A1064/A1064M (2013) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete
ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ASTM A27/A27M (2013) Standard Specification for Steel Castings, Carbon, for General Application
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ASTM A307 (2012) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength
ASTM A325 (2010; E 2013) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength
ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel
ASTM A416/A416M (2012) Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete
ASTM A47/A47M (1999; R 2009) Standard Specification for Ferritic Malleable Iron Castings
ASTM A563 (2007a) Standard Specification for Carbon and Alloy Steel Nuts
ASTM A615/A615M (2013) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement
ASTM A706/A706M (2013) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement
ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
ASTM C1107/C1107M (2013) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)
ASTM C1218/C1218M (1999; R 2008) Standard Specification for Water-Soluble Chloride in Mortar and Concrete
ASTM C1260 (2007) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)
ASTM C136 (2006) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates
ASTM C150/C150M (2012) Standard Specification for Portland Cement
ASTM C260/C260M (2010a) Standard Specification for Air-Entraining Admixtures for Concrete
ASTM C33/C33M (2013) Standard Specification for Concrete Aggregates
ASTM C494/C494M (2013) Standard Specification for Chemical Admixtures for Concrete
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ASTM C94/C94M (2013a) Standard Specification for Ready-Mixed Concrete
ASTM F436 (2011) Hardened Steel Washers
ASTM F844 (2007a) Washers, Steel, Plain (Flat), Unhardened for General Use
PRECAST/PRESTRESSED CONCRETE INSTITUTE (PCI)
PCI MNL-116 (1999) Manual for Quality Control for Plants and Production of Structural Precast Concrete Products, 4th Edition
PCI MNL-120 (2010) PCI Design Handbook - Precast and Prestressed Concrete, 6th Edition
PCI MNL-124 (2011) Design for Fire Resistance of Precast Prestressed Concrete, Third Edition
UNDERWRITERS LABORATORIES (UL)
UL Fire Resistance (2012) Fire Resistance Directory
1.2 SYSTEM DESCRIPTION
The work includes the provision of precast non-prestressed concrete herein referred to as precast members and precast, prestressed concrete herein referred to as prestressed members. Precast and Prestressed members shall be the product of a manufacturer specializing in the production of precast prestressed concrete members.
1.2.1 Design Requirements
Design precast prestressed members in accordance with ACI 318 and the PCI MNL-120. Design precast prestressed members (including connections) for the design load conditions and spans indicated, and handling and erection stresses, and for additional loads imposed by openings and supports of the work of other trades. Design precast prestressed members for handling without cracking in accordance with the PCI MNL-120. Concrete toppings shall not be used in establishing the design strength of the precast prestressed members.
1.2.1.1 Loads
Loadings for members and connections shall include all dead load, live load, applicable lateral loads such as wind and earthquake, applicable construction loads such as handling, erection loads, and other applicable loads.
1.2.1.2 Drawing and Design Calculation Information
Submit drawings and design calculations indicating complete information for the fabrication, handling, and erection of the precast prestressed member. Drawings shall not be reproductions of contract drawings. Design calculations, drawings of precast members, and drawings of precast prestressed concrete members (including connections) shall be made by a registered professional engineer experienced in the design of precast prestressed concrete members and registered in the state where the project
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is located, and submitted for approval prior to fabrication. The drawings shall indicate, as a minimum, the following information:
a. Plans, elevations and other drawing views showing the following:
(1) Member piece marks locating and defining products furnished by the manufacturer.
(2) Headers for openings.
(3) Location and size of openings that cut prestressing strands or require the location of prestressing strands to miss field cut openings.
(4) Relationships to adjacent material.
(5) Joints and openings between members and between members and other construction.
(6) Location of field installed anchors.
(7) Erection sequences and handling requirements
(8) Areas receiving toppings and magnitude of topping thickness.
(9) Lifting and erection inserts
b. Elevations, sections and other details for each member showing the following:
(1) Connections between members and connections between members and other construction.
(2) Connections for work of other trades and cast-in items and their relation to other trades.
(3) Dimensioned size and shape for each member with quantities, position and other details of reinforcing steel, anchors, inserts and other embedded items.
(4) Lifting, erection and other handling devices and inserts.
(5) Surface finishes of each member.
(6) Estimated cambers
c. Magnitude, schedule and sequence of tensioning and detensioning prestressing strands.
d. Strength properties for concrete, steel and other materials.
e. Methods for storage and transportation.
f. Description of loose, cast-in and field hardware.
g. All dead, live, handling, erection and other applicable loads used in the design.
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1.2.2 Performance Requirements
Precast members shall have a fire rating in accordance with UL Fire Resistance, or as designed in accordance with PCI MNL-124.
1.3 MODIFICATION TO REFERENCE
In the ACI publications, the advisory provisions shall be considered to be mandatory, as though the word "shall" has been substituted for "should" wherever it appears; reference to the "Building Official," the "Structural Engineer" and the "Architect/Engineer" shall be interpreted to mean the Owner's Representative.
1.4 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Drawings of precast members; G
Drawings of precast prestressed concrete members; G
SD-03 Product Data
Anchorage and lifting inserts and devices
Bearing pads
SD-05 Design Data
Precast Prestressed concrete members design calculations; G,
Concrete mix design; G
SD-06 Test Reports
Contractor-furnished mix design; G
Submit copies of laboratory test reports showing that the mix has been successfully tested to produce concrete with the properties specified and that mix will be suitable for the job conditions. The laboratory test reports shall include mill test and all other test for cement, aggregates, and admixtures. Provide maximum nominal aggregate size, gradation analysis, percentage retained and passing sieve, and a graph of percentage retained versus sieve size. Test reports shall be submitted along with the concrete mix design. Obtain approval before concrete placement.
Cement
Air-Entraining Admixture
Water-Reducing Admixture
Accelerating Admixture
Aggregates
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Submit test results for aggregates in accordance with ASTM C1260 for potential alkali-silica reactions.
SD-07 Certificates
Quality control procedures
Submit quality control procedures established in accordance with PCI MNL-116 by the precast manufacturer.
Construction Records; G
Construction records of the manufacturing, handling, and erection of the precast prestressed concrete members shall be submitted.
SD-11 Closeout Submittals
Concrete batch ticket information
1.5 QUALITY ASSURANCE
1.5.1 Qualifications
1.5.1.1 Manufacturer Qualifications
PCI MNL-116. Plants shall be certified by the PCI Plant Certification Program for Category C3 work. At the Owner's Representative's option, PCI Plant quality control program records shall be available for review.
1.5.1.2 Designer Qualifications
The designer shall be a registered professional engineer in the state where the project is located experienced in the design of precast prestressed concrete.
1.5.1.3 Erector Qualifications
The erector shall be regularly engaged for at least three(3) years in the erection of precast prestressed structural concrete similar to the requirements of this project.
1.5.1.4 Welding Qualifications
Provide AWS D1.1/D1.1M qualified welders who are currently certified at contract award date and have maintained their certificates over the past year.
1.5.2 Regulatory Requirements
Provide precast prestressed members in conformance with ACI 318 and AWS D1.4/D1.4M.
1.5.3 Concrete Mix Design
Thirty days minimum prior to concrete placement, submit a mix design for each strength and type of concrete. Submit a complete list of materials including type; brand; source and amount of cement, and admixtures, and applicable reference specification. Provide mix proportion data using at
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least three different water-cement ratios for each class and type of concrete required. If source material changes, resubmit mix proportion data using revised source material. No material shall be provided unless proven by trial mix studies to meet the requirements of this specification, unless otherwise approved in writing by the Owner's Representative. The submittal shall clearly indicate where each mix design will be used when more than one mix design is submitted. Submit additional data regarding concrete aggregates if the source of aggregates changes.
1.5.4 Certificates: Record Requirement
ASTM C94/C94M. Submit mandatory batch ticket information for each load of ready-mixed concrete.
1.6 DELIVERY, STORAGE, AND HANDLING
1.6.1 Transportation
1.6.1.1 Transporting Members
In transporting members by truck, railroad car, or barge, provision shall be made for supporting the members as described above, except battens can be continuous over more than one stack of units, with adequate bracing to ensure their maintaining the vertical position and damping of dangerous vibrations. Trucks with double bolsters are satisfactory provided the members are fully seated on the outer bolsters at not more than 3 feet or the depth of the member from the end and the inner bolster is not more than 8 feet from the end of the member or the designated pickup point. Adequate padding material shall be provided between tie chains or cables to preclude chipping of concrete.
1.6.1.2 Lateral Deflection or Vibration
Any noticeable indication of lateral deflection or vibration during transportation shall be corrected by rigid bracing between members or by means of lateral trussing.
1.6.2 Storage
1.6.2.1 Storage Areas
Storage areas for precast prestressed members shall be stabilized, and suitable foundations shall be provided, so differential settlement or twisting of members will not occur.
1.6.2.2 Stacked members
Stacked members shall be separated and supported by battens placed across the full width of each bearing point. Battens shall be arranged in vertical planes at a distance not greater than the depth of the member from designated pickup points. Battens shall not be continuous over more than one stack of precast units. Stacking of members shall be such that lifting devices will be accessible and undamaged. The upper members of a stacked tier shall not be used as storage areas for shorter members or equipment.
1.6.3 Handling of Members
The location of pickup points for handling of the members and details of the pickup devices shall be shown in shop drawings. Members shall be
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handled only by means of approved devices at designated locations. Members shall be maintained in an upright position at all times and picked up and supported as shown in approved shop drawings.
PART 2 PRODUCTS
2.1 CONTRACTOR-FURNISHED MIX DESIGN
ACI 318. The minimum compressive strength of concrete at 28 days shall be 5000 psi, unless otherwise indicated. Add air-entraining admixtures at the mixer to produce between 4 and 6 percent air by volume. Ensure a dense concrete free of shrinkage cracks, with a minimum degree of permeability. The maximum water cement ratio shall be 0.40.
2.2 MATERIALS
2.2.1 Cement
ASTM C150/C150M, Type I, or III with a maximum alkali content of 0.40 percen. If no satisfactory test results are available (made within the past six months) to prove that the cement alkali content is less than 0.40 percent, then it shall be assumed that the cement contains greater than 0.40 percent alkali. Cement certificates shall include test results in accordance with ASTM C150/C150M, including equivalent alkalies indicated in the optional chemical requirements. 2.2.2 Water
Water shall be fresh, clean, and potable; free from injurious amounts of oils, acids, alkalis, salts, organic materials, or other substances deleterious to concrete, ACI 318.
2.2.3 Aggregates
2.2.3.1 Aggregates Selection
ASTM C33/C33M, Size 67 or the requirements of the State Department of Transportation, where the precat units are fabricated or in the State of North Dakotaexcept as modified herein. Obtain aggregates for exposed concrete surfaces from one source. Aggregates shall not contain any substance which may be deleteriously reactive with the alkalies in the cement, nor in an amount sufficient to cause excessive expansion of concrete. Prior to fabrication, submit certified test reports for the following tests specified in ASTM C33/C33M ,in addition, twice during each shift when the concrete plant is operating, the gradation of each size of aggregate shall be tested in accordance with ASTM C136:
a. Grading
b. Amount of material finer than No. 200 sieve
c. Organic impurities
d. Soundness
e. Clay lumps and friable particles
f. Coal and lignite
g. Weight of slag
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h. Abrasion of coarse aggregate
i. Fineness modulus
j. Reactive aggregates
k. Freezing and thawing
2.2.3.2 Alkali-Silica Reactivity
Evaluate and test fine and coarse aggregates to be used in all concrete for alkali-aggregate reactivity in accordance with ASTM C1260. Test both coarse aggregate size groups if from different sources. Evaluate the fine and coarse aggregates separately and in combination, which matches the Contractor's proposed mix design proportioning. Test results of the combination must have a measured expansion equal to or less than 0.08 percent at 16 days after casting.
If any of the above options does not lower the expansion to less than 0.08 percent at 16 days after casting, reject the aggregate(s) and submit new aggregate sources for retesting. Submit the results of testing to the Owner's Representative for evaluation and acceptance.
2.2.4 Grout
2.2.4.1 Nonshrink Grout
ASTM C1107/C1107M.
2.2.4.2 Cementitious Grout
Shall be a mixture of portland cement, sand, and water. Proportion one part cement to approximately 2.5 parts sand, with the amount of water based on placement method.
2.2.5 Admixtures
2.2.5.1 Air-Entraining
ASTM C260/C260M.
2.2.5.2 Accelerating
ASTM C494/C494M, Type C or E.
2.2.5.3 Water Reducing
ASTM C494/C494M, Type A, E, or F.
2.2.6 Reinforcement
2.2.6.1 Reinforcing Bars
ASTM A615/A615M, Grade 60; ASTM A706/A706M, Grade 60.
2.2.6.2 Wire
ASTM A1064/A1064M.
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2.2.6.3 Welded Wire Fabric
ASTM A1064/A1064M.
2.2.7 Prestressing Strands
Uncoated, 7-wire strand stressed relieved, ASTM A416/A416M, Grade 250 or 270, strand diameter as shown.
2.2.8 Metal Accessories
Provide ASTM A123/A123M or ASTM A153/A153M galvanized.
2.2.8.1 Inserts
ASTM A47/A47M, Grade 32510 or 35018, or ASTM A27/A27M Grade U-60-30.
2.2.8.2 Structural Steel
ASTM A36/A36M.
2.2.8.3 Bolts
ASTM A307; ASTM A325.
2.2.8.4 Nuts
ASTM A563.
2.2.8.5 Washers
ASTM F844 washers for ASTM A307 bolts, and ASTM F436 washers for ASTM A325 bolts.
2.2.9 Bearing Pads
1. Random, fiber-reinforced elastomeric pads.
2. Preformed, randomly oriented synthetic fibers set in elastomer.
3. Shore-A hardness: 70 to 90 per ASTM D2240.
4. Capable of supporting a compressive stress of 3000 psi with no cracking, splitting or delaminating in the internal portions of the pad.
5. Masticord as manufactured by JVI, Inc.2.2.10 Grout
2.2.10.1 Cementitious Grout
Shall be a mixture of portland cement, sand, and water. Proportion one part cement to approximately 2.5 parts sand, with the amount of water based on placement method. Provide air entrainment for grout exposed to the weather.
2.2.10.2 Nonshrink Grout
Nonshrink grout shall conform to ASTM C1107/C1107M and shall be a
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commercial formulation suitable for the application proposed.
2.3 PRODUCTION QUALITY CONTROL PROCEDURES
PCI MNL-116 unless specified otherwise.
2.3.1 Forms
Brace forms to prevent deformation. Forms shall produce a smooth, dense surface.
2.3.2 Reinforcement Placement
ACI 318 for placement and splicing. Reinforcement may be preassembled before placement in forms. Provide exposed connecting bars, or other approved connection methods, between precast prestressed and cast-in-place construction. Remove any excess mortar that adheres to the exposed connections.
2.3.3 Inserts
When the ends of the prestressed member will be exposed, recess the prestressing stands using inserts. After detensioning, remove inserts and fill the recess with nonshrink grout.
2.3.4 Concrete
2.3.4.1 Concrete Mixing
ASTM C94/C94M. Mixing operations shall produce batch-to-batch uniformity of strength, consistency, and appearance.
2.3.4.2 Concrete Placing
ACI 304R, ACI 305R for hot weather concreting , ACI 306.1 for cold weather concreting, and ACI 309R, unless otherwise specified.
2.3.4.3 Concrete Curing
Commence curing immediately following the initial set and completion of surface finishing. Provide curing procedures to keep the temperature of the concrete between 50 and 190 degrees F. When accelerated curing is used, apply heat at controlled rate and uniformly along the casting beds. Monitor temperatures at various points in a product line in different casts.
2.3.5 Prestressing
Do not transfer prestressing forces during detensioning until the concrete has reached a minimum compressive strength of 3500 psi, unless a higher strength is required by the Contractor furnished design.
2.3.6 Surface Finish
Repairs located in a bearing area shall be approved by the Owner's Representative prior to repairs. Prestressed members which contain honeycombed sections deep enough to expose prestressing strands shall be rejected. Precast prestressed members containing hairline cracks which are visible and are less than 0.01 inches in width, may be accepted, except that cracks larger than 0.005 inches in width for surfaces exposed to the
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weather shall be repaired. Defects that involve more than 36 square inches of concrete shall be grounds for rejection. Any precast prestressed member that is structurally impaired or contains honeycombed section deep enough to expose stressing tendons or reinforcing shall be rejected. Defects shall be repaired or rejected as specified in paragraph "Defects."
2.3.6.1 Unformed Surfaces
Where units are to receive concrete topping, provide units having heavy broom finish on top surface for bond.
1. Provide roughness of top surface to provide bond with topping and design for horizontal shear at topping and unit interface in accordance with requirements of ACI 318, Horizontal Shear Strength paragraph.
2.3.6.2 Formed Surfaces
PCI MNL-116 (Appendix A - Commentary), Chapter 3, for grades of surface finishes.
a. Unexposed Surfaces: Provide a standard grade surface finish.
b. Exposed Surfaces: Provide a finish Grade B surface finish. The combined area of acceptable defective areas shall not exceed 0.2 percent of the exposed to view surface area, and the patches shall be indistinguishable from the surrounding surfaces when dry. In addition to a Grade B surface finish, members shall have a smooth rubbed finish.
2.3.7 Acceptance/Rejection of Defects
2.3.7.1 Minor Defects
All honeycombed areas, chipped corners, air pockets over 1/4 inch in diameter, and other minor defects involve less than 36 square inches of concrete shall be repaired. Form offsets of fins over 1/8 inch shall be ground smooth. All unsound concrete shall be removed from defective areas prior to repairing. All surfaces permanently exposed to view shall be repaired by a blend of portland cement and white cement properly proportioned so that the final color when cured will be the same as adjacent concrete.
2.3.7.2 Major Defects
Major defects are those which involve more than 36 square inches of concrete or expose stressing tendons or reinforcing steel. If one or more major defects appear in a member, it shall be rejected. Cracks of a width of more than 0.01 inch shall be cause for rejection of the member.
2.4 FABRICATIONS
A. Do not fabricate units until Shop Drawings have been approved by Engineer and returned to Contractor and support locations have been field verified by Contractor
B. Manufacture, quality, dimensional and erection tolerances of all units to be in accordance with both PCI MNL-116 and PCI MNL-120.
C. Cast all members in smooth rigid forms which will provide
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straight, true members of uniform thickness and uniform color and finish.
D. Use sand cement grout mixture to fill all air pockets and voids, and to repair chipped edges.
E. Finish all repairs smooth and to match adjacent surface texture and color.
F. Incorporate embedded plates, angles, and flange welding strips into members at time of manufacture.
1. Provide embedded items as shown on the Drawings unless prior approval is received from Engineer to do otherwise.
2. Provide flange welding strips on all flanged edges of all double tee units as indicated on Drawings.
3. Space strips as shown on Drawings.
4. Cast lifting handles into units at or near support points.
a. Remove lifting handles after units are erected.
G. Cast openings larger than 6 inches square or 6 inches in diameter in units at time of manufacture.
1. Make smaller openings by neat cutting or neat drilling by trades requiring them.
2. Coordinate sizes and locations of all openings before fabrication of units.
H. Make provisions for support of suspended ceilings, lighting fixtures, ducts, piping, conduits and other suspended work.
1. When drilled expansion bolts or powder-driven fasteners are approved for use, coordinate prestress strand location with prestress concrete member supplier so that drilled expansion bolts or powder-driven fasteners do not hit or are drilled or driven into prestress strands.
2. Install powder-driven fasteners by means of a low velocity powder-actuated tool complying with requirements of OSHA.
a. Assure that the load to be supported by each in place drilled expansion bolt or powder-driven fastener does not exceed the maximum allowable load recommended by the bolt or fastener manufacturer for the concrete strength encountered and for the type, size and embedment length of expansion bolt or driven fastener installed.
I. Automatically weld headed studs and deformed bar anchors to members to provide full penetration weld between studs, bar anchors and members they are attached to.
J. Weld steel shapes and plates per AWS D1.1/D1.1M and reinforcing steel per AWS D1.4/D1.4M.
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K. Mark each unit as indicated on the erection plans.
1. Place mark on non-exposed-to-view surface.
L. Coat or finish ends of exposed prestressing strands to prevent rusting.
M. Fabricate the following types of precast and prestressed units (all units to be made with normal weight concrete unless noted otherwise on Drawings):
1. Prestressed double tees of sizes indicated on Drawings.
a. Weight of double tees, based on an 10 feet wide section, not to exceed following:
DEPTH (Inches) NORMAL WEIGHT CONCRETE (psf)
24 52
2. Precast items shown on Drawings including but not limited to:
a. Lintels.
2.5 TESTS, INSPECTIONS, AND VERIFICATIONS
2.5.1 Chloride Ion Concentration Test
Sampling and determination of water soluble chloride ion content in accordance with ASTM C1218/C1218M. Maximum water soluble chloride ion concentrations in hardened concrete at ages from 28 to 42 days contributed from the ingredients including water, aggregates, cementitious materials, and admixtures shall not exceed 0.06 percent by weight of cement.
2.5.2 Factory Inspection
At the option of the Owner's Representative, precast prestressed units may be inspected by the Owner's Representative precast prestressed units shall be inspected by the QC Representative prior to being transported to the job site. The Contractor shall give notice 14 days prior to the time the units will be available for plant inspection. Neither the exercise nor waiver of inspection at the plant will affect the Owner's Representative's right to enforce contractual provisions after units are transported or erected.
PART 3 EXECUTION
3.1 PREPARATION
A. Verify acceptability and location of supports to receive units.
1. Check bearing surfaces to determine that they are level and uniform.
B. Verify compressive strengths of concrete and masonry supports.
1. Do not start erection of units until supports have reached
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their 28 day required compressive strengths.
3.2 EXAMINATION
Prior to erection, and again after installation, precast prestressed members shall be checked for damage, such as cracking, spalling, and honeycombing. As directed by the Owner's Representative, precast prestressed members that do not meet the surface finish requirements specified in Part 2 in paragraph entitled "Surface Finish" shall be repaired, or removed and replaced with new precast prestressed members.
3.3 ERECTION
Precast prestresed members shall be erected after the concrete has attained the specified compressive strength, unless otherwise approved by the precast prestressing manufacturer. Erect in accordance with the approved shop drawings. PCI MNL-116 and PCI MNL-120 (Chapter 8), for tolerances. Provide a 1:500 tolerance, if no tolerance is specified. Brace precast prestressed members, unless design calculations submitted with the shop drawings indicate bracing is not required. Follow the manufacturer's recommendations for maximum construction loads. Place precast prestressed members level, plumb, square, and true within tolerances. Align member ends.
A. Sequence erection to provide a balance of loads across beams and columns.
B. Give consideration to possible lack of stability or capacity of partially completed frame or structure.
C. Contractor to be responsible for guying, shoring, and bracing of frame, walls and individual members as necessary to resist forces due to wind, erection, or any other source that may occur before structure is completed.
D. Use only erection equipment adequate for placing units at lines and elevations indicated on Drawings.
1. Do not damage units or existing construction during erection.
2. Erect units using lifting handles cast into the units.
3.4 BEARING SURFACES
Shall be flat, free of irregularities, and properly sized. Provide bearing pads where indicated or required. Do not use hardboard bearing pads. Place precast prestressed members at right angles to the bearing surface, unless indicated otherwise, and draw-up tight without forcing or distortion, with sides plumb.
A. Place each leg of all double tees on a 3/8 inch thick bearing pad held 1 inch back from edge of support.
1. Pad dimensions equal to length of bearing -1 inches x bearing width +2 inches.
B. After erection, verify that there is no direct contact between bottom of units and supporting members.
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1. Where direct contact occurs, install additional layers of bearing material to raise units off supports.
C. Lintels:
1. Length of lintel bearing on supports to be as indicated on Drawings.
a. If not indicated, minimum length of lintel bearing to be 8 inches.
2. Fill masonry cells under lintel bearing with masonry grout and reinforce cells as indicated.
3. Provide minimum 3/8 inches thick full bed joint of masonry mortar between underside of lintel and top surface of grouted masonry for complete lintel bearing length.
3.5 WELDING
AWS D1.4/D1.4M for welding connections and reinforcing splices. Do not weld prestressing strands. Protect the concrete and other reinforcing from heat during welding. Weld continuously along the entire area of contact. Grind smooth visible welds in the finished installation.
3.6 OPENINGS
Holes or cuts requiring reinforcing to be cut, which are not indicated on the approved shop drawing, shall only be made with the approval of the Owner's Representative and the precast manufacturer. Drill holes less than 12 inches in diameter with a diamond tipped core drill.
3.7 GALVANIZING REPAIR
Repair damage to galvanized coatings using ASTM A780/A780M zinc rich paint for galvanized surfaces damaged by handling, transporting, cutting, welding, bolting, or acid washing. Do not heat surfaces to which repair paint has been applied.
3.8 SEALANTS
Provide as indicated and as specified in Section 07 92 00 JOINT SEALANTS.
3.9 CONCRETE TOPPING
Provide as indicated and as specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.
3.10 CONSTRUCTION RECORDS
Complete construction records shall be kept of the manufacturing, handling, and erection of the precast-prestressed concrete members. Records shall be kept for, but not limited to, the following items:
a. Specifications of material used in the manufacture of the members.
b. Time-temperature history of the concrete members from casting to the transfer of the prestress force.
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c. Records of the tendon stressing operation including initial prestress force, measured elongation, how it was measured, and how the tendons were stressed and destressed.
d. Records of inspection of the members before and after the prestress force is transferred to the members.
e. Records of the inspection of the members each time they are moved.
f. Records of any defects in the member and any corrective measures taken.
-- End of Section --
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DIVISION 4 MASONRY
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 04 20 00
MASONRY 02/11 08/11/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)
ACI 530/530.1 (2011; Errata 2011; Errata 2013) Building Code Requirements and Specification for Masonry Structures and Related Commentaries
ACI SP-66 (2004) ACI Detailing Manual
ASTM INTERNATIONAL (ASTM)
ASTM A1064/A1064M (2013) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete
ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ASTM A615/A615M (2013) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement
ASTM A641/A641M (2009a) Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire
ASTM B633 (2013) Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel
ASTM C1019 (2013) Standard Test Method for Sampling and Testing Grout
ASTM C144 (2011) Standard Specification for Aggregate for Masonry Mortar
ASTM C150/C150M (2012) Standard Specification for Portland Cement
ASTM C207 (2006; R 2011) Standard Specification for Hydrated Lime for Masonry Purposes
ASTM C270 (2012a) Standard Specification for Mortar
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for Unit Masonry
ASTM C476 (2010) Standard Specification for Grout for Masonry
ASTM C494/C494M (2013) Standard Specification for Chemical Admixtures for Concrete
ASTM C593 (2006; R 2011) Fly Ash and Other Pozzolans for Use with Lime for Soil Stabilization
ASTM C641 (2009) Staining Materials in Lightweight Concrete Aggregates
ASTM C67 (2013) Standard Test Methods for Sampling and Testing Brick and Structural Clay Tile
ASTM C780 (2012a) Preconstruction and Construction Evaluation of Mortars for Plain and Reinforced Unit Masonry
ASTM C90 (2013) Loadbearing Concrete Masonry Units
ASTM C91/C91M (2012) Standard Specification for Masonry Cement
ASTM C94/C94M (2013a) Standard Specification for Ready-Mixed Concrete
ASTM D2000 (2012) Standard Classification System for Rubber Products in Automotive Applications
ASTM D2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness
ASTM D2287 (2012) Nonrigid Vinyl Chloride Polymer and Copolymer Molding and Extrusion Compounds
ASTM E514/E514M (2011) Standard Test Method for Water Penetration and Leakage Through Masonry
U.S. DEPARTMENT OF DEFENSE (DOD)
UFC 3-310-04 (2012) Seismic Design for Buildings
1.2 SYSTEM DESCRIPTION
1.2.1 Environmental Data
Submit manufacturer's descriptive data. Documentation indicating percentage of post-industrial and post-consumer recycled content per unit of product.
1.2.2 Design Requirements
1.2.2.1 Unit Strength Method
Compute compressive strength of masonry system "Unit Strength Method", ACI 530/530.1. Submit calculations and certifications of unit and mortar
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strength.
1.2.2.2 Special Inspection
Perform special inspections and testing for seismic-resisting systems and components in accordance with UFC 3-310-04 SEISMIC DESIGN FOR BUILDINGS.
1.2.2.3 Masonry Strength
Determine masonry strength in accordance with ACI 530/530.1; submit test reports on three prisms as specified in ACI 530/530.1. The cost of testing shall be paid by the Contractor.
1.2.3 Additional Requirements
a. Maintain at least one spare vibrator on site at all times.
b. Provide bracing and scaffolding necessary for masonry work. Design bracing to resist wind pressure as required by local code.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings; G
SD-03 Product Data
Cut Stone; G Cement; G Insulation; G Cold Weather Installation; G Water-Repellant Admixture; G
SD-04 Samples
Cut Stone; G
SD-05 Design Data
Pre-mixed Mortar; G Unit Strength Method; G
SD-06 Test Reports
Efflorescence Test; G Field Testing of Mortar; G Field Testing of Grout; G Prism tests; G Masonry Cement; G Masonry Inspector Qualifications; G Single-Wythe Masonry Wall Water Penetration Test
SD-07 Certificates
Concrete Brick
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Concrete Masonry Units (CMU) Anchors, Ties, and Bar Positioners Expansion-Joint Materials Joint Reinforcement Masonry Cement Insulation Precast Concrete Items Admixtures for Masonry Mortar Admixtures for Grout Contamination
SD-08 Manufacturer's Instructions
Masonry Cement
1.4 QUALITY ASSURANCE
1.4.1 Appearance
Manufacture bricks at one time and from the same batch. Blend all brick to produce a uniform appearance when installed. An observable "banding" or "layering" of colors or textures caused by improperly mixed brick is unacceptable.
1.4.2 Contamination
When using bricks containing contaminated soil, supplier shall certify that the hazardous waste is neutralized by the manufacturing process and that no additional pollutants will be released, or that the product is free from hazardous contaminants.
1.4.3 Sample Masonry Panels
After material samples are approved and prior to starting masonry work, construct a portable panel of stone and sample masonry panels for each type and color of masonry required. At least 48 hours prior to constructing the sample panel or panels, submit written notification to the Owner's Representative. Submit one panel of clay or shale brick, 2 by 2 feet, containing approximately 24 brick facings to establish range of color and texture. Sample panels shall not be built in, or as part of the structure, but shall be located where directed.
1.4.3.1 Configuration
Panels shall be L-shaped or otherwise configured to represent all of the wall elements. Panels shall be of the size necessary to demonstrate the acceptable level of workmanship for each type of masonry represented on the project. The minimum size of a straight panel or a leg of an L-shaped panel shall be 8 feet long by 4 feet high.
1.4.3.2 Composition
Panels shall show full color range, texture, and bond pattern of the masonry work. The Contractor's method for mortar joint tooling; grouting of reinforced vertical cores, collar joints, bond beams, and lintels; positioning, securing, and lapping of reinforcing steel; positioning and lapping of joint reinforcement (including prefabricated corners); and cleaning of masonry work shall be demonstrated during the construction of the panels. Installation or application procedures for anchors, wall
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ties, CMU control joints, stone expansion joints, insulation, flashing, and weep holes shall be shown in the sample panels. The panels shall contain a masonry bonded corner that includes a bond beam corner. Panels shall show installation of electrical boxes and conduit. Panels that represent reinforced masonry shall contain a 2 by 2 foot opening placed at least 2 feet above the panel base and 2 feet away from all free edges, corners, and control joints. Required reinforcing shall be provided around this opening as well as at wall corners and control joints.
1.4.3.3 Construction Method
Where anchored veneer walls are required, demonstrate and receive approval for the method of construction; i.e., either bring up the two wythes together or separately, with the insulation and appropriate ties placed within the specified tolerances across the cavity. Temporary provisions shall be demonstrated to preclude mortar or grout droppings in the cavity and to provide a clear open air space of the dimensions shown on the drawings. Where masonry is to be grouted, demonstrate and receive approval on the method that will be used to bring up the masonry wythes; support the reinforcing bars; and grout cells, bond beams, lintels, and collar joints using the requirements specified herein. If sealer is specified to be applied to the masonry units, sealer shall be applied to the sample panels. Panels shall be built on a properly designed concrete foundation.
1.4.3.4 Usage
The completed panels shall be used as the standard of workmanship for the type of masonry represented. (Masonry, Precast and Stone work shall not commence until the sample panel for that type of masonry construction has been completed and approved.) Panels shall be protected from the weather and construction operations until the masonry work has been completed and approved. After completion of the work, the sample panels, including all foundation concrete, shall become the property of the Contractor and shall be removed from the construction site.
1.4.4 Masonry Inspector Qualifications
A qualified masonry inspector approved by the Owner's Representative shall perform inspection of the masonry work. Minimum qualifications for the masonry inspector shall be 5 years of reinforced masonry inspection experience or acceptance by a State, municipality, or other governmental body having a program of examining and certifying inspectors for reinforced masonry construction. The masonry inspector shall be present during preparation of masonry prisms, sampling and placing of masonry units, placement of reinforcement (including placement of dowels in footings and foundation walls), inspection of grout space, immediately prior to closing of cleanouts, and during grouting operations. The masonry inspector shall assure compliance with the drawings and specifications. The masonry inspector shall keep a complete record of all inspections and shall submit daily written reports to the Quality Control Supervisory Representative reporting the quality of masonry construction. Submit copies of masonry inspector reports.
1.4.5 Detail Drawings
Submit detail drawings showing bar splice locations. . Bent bars shall be identified on a bending diagram and shall be referenced and located on the drawings. Wall dimensions, bar clearances, and wall openings greater than one masonry unit in area shall be shown. No approval will be given to the
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shop drawings until the Contractor certifies that all openings, including those for mechanical and electrical service, are shown. If, during construction, additional masonry openings are required, the approved shop drawings shall be resubmitted with the additional openings shown along with the proposed changes. Location of these additional openings shall be clearly highlighted. The minimum scale for wall elevations shall be 1/4 inch per foot. Reinforcement bending details shall conform to the requirements of ACI SP-66. Submit drawings including plans, elevations, and details of wall reinforcement; details of reinforcing bars at corners and wall intersections; offsets; tops, bottoms, and ends of walls; control and expansion joints; lintels; and wall openings.
1.5 DELIVERY, STORAGE, AND HANDLING
Materials shall be delivered, stored, handled, and protected to avoid chipping, breakage, and contact with soil or contaminating material. Store and prepare materials in already disturbed areas to minimize project site disturbance and size of project site.
1.5.1 Masonry Units and Stone
Cover and protect moisture-controlled concrete masonry units, stone, and cementitious materials from precipitation. Conform to all handling and storage requirements of ASTM C90. Mark prefabricated units to show the number and size of top and bottom bars.
1.5.2 Reinforcement, Anchors, and Ties
Steel reinforcing bars, coated anchors, ties, and joint reinforcement shall be stored above the ground. Steel reinforcing bars and uncoated ties shall be free of loose mill scale and rust.
1.5.3 Cementitious Materials, Sand and Aggregates
Cementitious and other packaged materials shall be delivered in unopened containers, plainly marked and labeled with manufacturers' names and brands. Cementitious material shall be stored in dry, weathertight enclosures or be completely covered. Cement shall be handled in a manner that will prevent the inclusion of foreign materials and damage by water or dampness. Store sand and aggregates in a manner to prevent contamination or segregation.
1.6 PROJECT/SITE CONDITIONS
Conform to ACI 530/530.1 for hot and cold weather masonry erection.
1.6.1 Hot Weather Installation
Take the following precautions if masonry is erected when the ambient air temperature is more than 99 degrees F in the shade and the relative humidity is less than 50 percent or the ambient air temperature exceeds 90 degrees F and the wind velocity is more than 8 mph. All masonry materials shall be shaded from direct sunlight; mortar beds shall be spread no more than 4 feet ahead of masonry; masonry units shall be set within one minute of spreading mortar; and after erection, masonry shall be protected from direct exposure to wind and sun for 48 hours.
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1.6.2 Cold Weather Installation
Before erecting masonry when ambient temperature or mean daily air temperature falls below 40 degrees F or temperature of masonry units is below 40 degrees F, submit a written statement of proposed cold weather construction procedures for approval.
PART 2 PRODUCTS
2.1 GENERAL REQUIREMENTS
The source of materials which will affect the appearance of the finished work shall not be changed after the work has started except with Owner's Representative's approval. Submit sample of colored mortar with applicable masonry unit and color samples of three stretcher units and one unit for each type of special shape. Units shall show the full range of color and texture. Submit test reports from an approved independent laboratory. Test reports on a previously tested material shall be certified as the same as that proposed for use in this project. Submit certificates of compliance stating that the materials meet the specified requirements.
2.2 CUT STONE
1. Custom random pattern and sizes to match form liner on floodwall, building, and screenwall. Reference Section 03 35 00.00 10, CONCRETE FINISHING.
2. Reinforcment shall be at 16 inches on center horizontal and vertical (where possible).
a. Mankato Cut Stone by American Artstone Company in New Ulm, MN.
2.3 CONCRETE MASONRY UNITS (CMU)
Submit samples and certificates as specified. Cement shall have a low alkali content and be of one brand. Units shall be of modular dimensions and air, water, or steam cured. Exposed surfaces of units shall be smooth and of uniform texture. All concrete masonry units shall have water-repellant admixture added during manufacture.
a. Hollow Load-Bearing and Non-Load Bearing Units: ASTM C90, made with normal weight aggregate. Provide load-bearing units for exterior walls, load-bearing walls, and shear walls.
b. Solid Load-Bearing Units: ASTM C90, normal weight units. Provide solid units as indicated.
2.3.1 Aggregates
Heavy aggregates used in producing the units, shall comply with the following requirements when tested for stain-producing iron compounds in accordance with ASTM C641: by visual classification method, the iron stain deposited on the filter paper shall not exceed the "light stain" classification.
2.3.2 Kinds and Shapes
Units shall be modular in size and shall include closer, jamb, and bond beam units and special shapes and sizes to complete the work as indicated.
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In exposed interior masonry surfaces, units having a bullnose shall be used for vertical external corners except at door and louver jambs. Radius of the bullnose shall be 1 inch. Units used in exposed masonry surfaces in any one building shall have a uniform fine to medium texture and a uniform color.
2.4 PRECAST CONCRETE ITEMS
Flood wall coping shall be factory-made units from a plant regularly engaged in producing precast concrete units. Unless otherwise indicated, concrete shall be 3000 psi minimum conforming to Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE using 1/2 inch to No. 4 nominal-size coarse aggregate, and minimum reinforcement shall be the reinforcement required for handling of the units. Clearance of 3/4 inch shall be maintained between reinforcement and faces of units. Unless precast-concrete items have been subjected during manufacture to saturated-steam pressure of at least 120 psi for at least 5 hours, the items, after casting, shall be either damp-cured for 24 hours or steam-cured and shall then be aged under cover for 28 days or longer. Cast-concrete members weighing over 80 pounds shall have built-in loops of galvanized wire or other approved provisions for lifting and anchoring. Units shall have beds and joints at right angles to the face, with sharp true arises and shall be cast with drip grooves on the underside where units overhang walls. Exposed-to-view surfaces shall be free of surface voids, spalls, cracks, and chipped or broken edges. Precast units exposed-to-view shall be of uniform appearance and color. Unless otherwise specified, units shall have a smooth dense finish. Prior to use, each item shall be wetted and inspected for crazing. Items showing evidence of dusting, spalling, crazing, or having surfaces treated with a protective coating will be rejected. Submit specified factory certificates.
2.4.1 Lintels
As detailed in the drawings.
2.4.2 Copings
Wall copings shall be cast with drip edges as indicated.
2.5 MORTAR FOR STRUCTURAL MASONRY
ASTM C270, Type S. Strength (f'm) as indicated. Test in accordance with ASTM C780. Use Type I or II portland cement. Do not use admixtures containing chlorides. When structural reinforcement is incorporated, maximum air-content shall be 12 percent in cement-lime mortar and 18 percent in masonry cement mortar. Use up to 40 percent Class F fly ash with type IP cement in cement-lime mortar. Fly ash shall comply with ASTM C593.
2.6 MASONRY MORTAR
Mortar Type S shall conform to the proportion specification of ASTM C270 except Type S cement-lime mortar proportions shall be 1 part cement, 1/2 part lime and 4-1/2 parts aggregate. Type S mortar shall be used for all masonry; except where higher compressive strength is indicated on structural drawings.
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2.6.1 Admixtures for Masonry Mortar
In cold weather, a non-chloride based accelerating admixture may be used subject to approval. Accelerating admixture shall be non-corrosive, shall contain less than 0.2 percent chlorides, and shall conform to ASTM C494/C494M, Type C. Submit the required certifications.
2.6.2 Hydrated Lime and Alternates
Hydrated lime shall conform to ASTM C207, Type S.
2.6.3 Cement
Portland cement shall conform to ASTM C150/C150M, Type I or II. Masonry cement shall conform to ASTM C91/C91M, Type S. Containers shall bear complete instructions for proportioning and mixing to obtain the required types of mortar. Incorporate to the maximum extent, without conflicting with other requirements of this section, up to 40 percent fly ash, up to 70 percent slag, up to 10 percent cenospheres, and up to 10 percent silica fume. When masonry cement is used, submit the manufacturer's printed instructions on proportions of water and aggregates and on mixing to obtain the type of mortar required. Additives shall conform to requirements in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.
2.6.4 Sand and Water
Sand shall conform to ASTM C144. Water shall be clean, potable, and free from substances which could adversely affect the mortar.
2.7 WATER-REPELLANT ADMIXTURE
Polymeric type formulated to reduce porosity and water penetration and water absorption of the mortar and masonry units required to provide for the exterior single-wythe masonry wall water penetration resistance indicated in Paragraph SINGLE-WYTHE MASONRY WALL WATER PENETRATION TEST.
2.8 GROUT AND READY-MIXED GROUT
Grout shall conform to ASTM C476, fine. Cement used in grout shall have a low alkali content. Grout slump shall be between 8 and 10 inches. Minimum grout strength shall be 2000 psi in 28 days, as tested by ASTM C1019. Use grout subject to the limitations of Table III. Do not change proportions and do not use materials with different physical or chemical characteristics in grout for the work unless additional evidence is furnished that the grout meets the specified requirements. Ready-Mixed grout shall conform to ASTM C94/C94M.
2.8.1 Admixtures for Grout
In cold weather, a non-chloride based accelerating admixture may be used subject to approval; accelerating admixture shall be non-corrosive, shall contain less than 0.2 percent chlorides, and shall conform to ASTM C494/C494M, Type C. In general, air-entrainment, anti-freeze or chloride admixtures shall not be used except as approved by the Owner's Representative. Submit required certifications.
2.8.2 Grout Barriers
Grout barriers for vertical cores shall consist of fine mesh wire,
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fiberglass, or expanded metal.
2.9 ANCHORS, TIES, AND BAR POSITIONERS
Anchors and ties shall be fabricated without drips or crimps and shall be zinc-coated in accordance with ASTM A153/A153M, Class B-2. Steel wire used for anchors and ties shall be fabricated from steel wire conforming to ASTM A1064/A1064M. Wire ties or anchors in exterior walls shall conform to ASTM A641/A641M. Joint reinforcement in interior walls, and in exterior or interior walls exposed to moist environment shall conform to ASTM A641/A641M; coordinate with paragraph JOINT REINFORCEMENT below. Anchors and ties shall be sized to provide a minimum of 5/8 inch mortar cover from either face. Submit two anchors, ties and bar positioners of each type used, as samples.
2.9.1 Wire Mesh Ties
Wire mesh for tying 4 inch thick concrete masonry unit partitions to other intersecting masonry partitions shall be 1/2 inch mesh of minimum 16 gauge steel wire. Minimum lengths shall be not less than 12 inches.
2.9.2 Wall Ties
Provide wall ties rectangular-shaped or Z-shaped fabricated of 3/16 inch diameter zinc-coated steel wire. Rectangular wall ties shall be no less than 4 inches wide. Wall ties may also be of a continuous type conforming to paragraph JOINT REINFORCEMENT. Adjustable type wall ties, if approved for use, shall consist of two essentially U-shaped elements fabricated of 3/16 inch diameter zinc-coated steel wire. Adjustable ties shall be of the double pintle to eye type and shall allow a maximum of 1/2 inch eccentricity between each element of the tie. Play between pintle and eye opening shall be not more than 1/16 inch. The pintle and eye elements shall be formed so that both can be in the same plane.
2.9.3 Dovetail Anchors
Provide dovetail anchors of the flexible wire type, 3/16 inch diameter zinc-coated steel wire, triangular shaped, and attached to a 12 gauge or heavier steel dovetail section. Use these anchors for anchorage of veneer wythes or composite-wall facings extending over the face of concrete columns, beams, or walls. Fill cells within vertical planes of these anchors solid with grout for full height of walls or partitions, or solid units may be used. Dovetail slots are specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.
2.9.4 Adjustable Anchors and Random Veneer Anchors
Adjustable anchors shall be 3/16 inch diameter steel wire, triangular-shaped. Anchors attached to steel shall be 5/16 inch diameter steel bars placed to provide 1/16 inch play between flexible anchors and structural steel members. Spacers shall be welded to rods and columns. Equivalent welded-on steel anchor rods or shapes standard with the flexible-anchor manufacturer may be furnished when approved. Welds shall be cleaned and given one coat of zinc-rich touch up paint.
2.9.5 Bar Positioners
Bar positioners, used to prevent displacement of reinforcing bars during the course of construction, shall be factory fabricated from 9 gauge steel
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wire or equivalent, and coated with a hot-dip galvanized finish. Not more than one wire shall cross the cell. Telescoping bar positioner shall be manufactured from AISI 1065 spring steel and coated in accordance with ASTM B633.
2.10 JOINT REINFORCEMENT
Joint reinforcement shall be factory fabricated from steel wire conforming to ASTM A1064/A1064M, welded construction. Tack welding will not be acceptable in reinforcement used for wall ties. Wire shall have zinc coating conforming to ASTM A153/A153M, Class B-2. All wires shall be a minimum of 9 gauge. Reinforcement shall be ladder type design, having one longitudinal wire in the mortar bed of each face shell for hollow units and one wire for solid units. Joint reinforcement shall be placed a minimum of 5/8 inch cover from either face. The distance between crosswires shall not exceed 16 inches. Joint reinforcement for straight runs shall be furnished in flat sections not less than 10 feet long. Joint reinforcement shall be provided with factory formed corners and intersections. If approved for use, joint reinforcement may be furnished with adjustable wall tie features. Submit one piece of each type used, including corner and wall intersection pieces, showing at least two cross wires.
2.11 REINFORCING STEEL BARS AND RODS
Reinforcing steel bars and rods shall conform to ASTM A615/A615M, Grade 60.
2.12 CONTROL JOINT KEYS
Control joint keys shall be a factory fabricated solid section of natural or synthetic rubber (or combination thereof) conforming to ASTM D2000or polyvinyl chloride conforming to ASTM D2287. The material shall be resistant to oils and solvents. The control joint key shall be provided with a solid shear section not less than 5/8 inch thick and 3/8 inch thick flanges, with a tolerance of plus or minus 1/16 inch. The control joint key shall fit neatly, but without forcing, in masonry unit jamb sash grooves. The control joint key shall be flexible at a temperature of minus 30 degrees F after five hours exposure, and shall have a durometer hardness of not less than 70 when tested in accordance with ASTM D2240.
2.13 RIGID BOARD-TYPE INSULATION
Provide rigid board-type insulation as specified in Section 07 21 13 BOARD AND BLOCK INSULATION. Submit one piece of each type used, including corner and wall intersection pieces, showing at least two cross wires.
2.14 EXPANSION-JOINT MATERIALS
Backer rod and sealant shall be adequate to accommodate joint compression equal to 50 percent of the width of the joint. The backer rod shall be compressible rod stock of polyethylene foam, polyurethane foam, butyl rubber foam, or other flexible, nonabsorptive material as recommended by the sealant manufacturer. Sealant shall conform to Section 07 92 00 JOINT SEALANTS. Submit one piece of each type of material used.
2.15 THROUGH WALL FLASHING
Provide one of the following types except that flashing indicated to terminate in reglets shall be metal or coated-metal flashing and except that the material shall be one which is not adversely affected by
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dampproofing material.
2.15.1 Reinforced Membrane Flashing
Polyester film core with a reinforcing fiberglass scrim bonded to one side. The membrane shall be impervious to moisture, flexible, and not affected by caustic alkalis. The material, after being exposed for not less than 1/2 hour to a temperature of 32 degrees F, shall show no cracking when, at that temperature, it is bent 180 degrees over a 1/16 inch diameter mandrel and then bent at the same point over the same size mandrel in the opposite direction 360 degrees.
2.16 WEEP HOLE VENTILATORS
Weep hole ventilators shall be prefabricated plastic blocking sized to form the proper size opening in head joints. Provide aluminum and plastic inserts with grill or screen-type openings designed to allow the passage of moisture from cavities and to prevent the entrance or insects. Ventilators shall be sized to match modular construction with a standard 3/8 inch mortar joint.
2.17 Grout Screen
1. Polypropylene Monofilament.
2. 1/4 inch x 1/4 inch mesh.
3. Width of grout screen to be 2 inches less than the nominal width of masonry.
PART 3 EXECUTION
3.1 PREPARATION
Prior to start of work, masonry inspector shall verify the applicable conditions as set forth in ACI 530/530.1, inspection. The Owner's Representative will serve as inspector or will select a masonry inspector.
3.1.1 Protection
Ice or snow formed on the masonry bed shall be thawed by the application of heat. Heat shall be applied carefully until the top surface of the masonry is dry to the touch. Sections of masonry deemed frozen and damaged shall be removed before continuing construction of those sections.
3.1.1.1 Air Temperature 40 to 32 Degrees F
Heat sand or mixing water to produce mortar temperatures between 40 and 120 degrees F
3.1.1.2 Air Temperature 32 to 25 Degrees F
Heat sand and mixing water to produce mortar temperatures between 40 and 120 degrees F. Maintain temperature of mortar on boards above freezing.
3.1.1.3 Air Temperature 25 to 20 Degrees F
Heat sand and mixing water to provide mortar temperatures between 40 and 120 degrees F. Maintain temperature of mortar on boards above freezing.
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Use sources of heat on both sides of walls under construction. Employ windbreaks when wind is in excess of 15 mph.
3.1.1.4 Air Temperature 20 Degrees F and Below
Heat sand and mixing water to provide mortar temperatures between 40 and 120 degrees F. Provide enclosure and auxiliary heat to maintain air temperature above 32 degrees F. Temperature of units when laid must not be less than 20 degrees F.
3.1.2 Completed Masonry and Masonry Not Being Worked On
3.1.2.1 Mean Daily Air Temperature 40 to 32 Degrees F
Protect masonry from rain or snow for 24 hours by covering with weather-resistive membrane.
3.1.2.2 Mean Daily Air Temperature 32 to 25 Degrees F
Completely cover masonry with weather-resistant membrane for 24 hours.
3.1.2.3 Mean Daily Air Temperature 25 to 20 Degrees F
Completey cover masonry with insulating blankets or equally protected for 24 hours.
3.1.2.4 Mean Daily Temperature 20 Degrees F and Below
Maintain masonry temperature above 32 degrees F for 24 hours by enclosure and supplementary heat, by electric heating blankets, infrared heat lamps, or other approved methods.
3.1.3 Stains
Protect exposed surfaces from mortar and other stains. When mortar joints are tooled, remove mortar from exposed surfaces with fiber brushes and wooden paddles. Protect base of walls from splash stains by covering adjacent ground with sand, sawdust, or polyethylene.
3.1.4 Loads
Do not apply uniform loads for at least 12 hours or concentrated loads for at least 72 hours after masonry is constructed. Provide temporary bracing as required.
3.1.5 Surfaces
Clean surfaces on which masonry is to be placed of laitance, dust, dirt, oil, organic matter, or other foreign materials and slightly roughen to provide a surface texture with a depth of at least 1/8 inch. Sandblast, if necessary, to remove laitance from pores and to expose the aggregate.
3.2 LAYING MASONRY UNITS AND STONE
a. Coordinate masonry work with the work of other trades to accommodate built-in items and to avoid cutting and patching. Masonry units shall be laid in running bond pattern. Facing courses shall be level with back-up courses, unless the use of adjustable ties has been approved in which case the tolerances shall be plus or minus 1/2 inch. Each unit
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shall be adjusted to its final position while mortar is still soft and plastic.
b. Units that have been disturbed after the mortar has stiffened shall be removed, cleaned, and relaid with fresh mortar. Air spaces, cavities, chases, expansion joints, and spaces to be grouted shall be kept free from mortar and other debris. Units used in exposed masonry surfaces shall be selected from those having the least amount of chipped edges or other imperfections detracting from the appearance of the finished work. Vertical joints shall be kept plumb.
c. Units being laid and surfaces to receive units shall be free of water film and frost. Solid units shall be laid in a nonfurrowed full bed of mortar. Mortar for veneer wythes shall be beveled and sloped toward the center of the wythe from the cavity side. Units shall be shoved into place so that the vertical joints are tight. Vertical joints of brick and the vertical face shells of concrete masonry units, except where indicated at control, expansion, and isolation joints, shall be completely filled with mortar. Mortar will be permitted to protrude up to 1/2 inch into the space or cells to be grouted. Means shall be provided to prevent mortar from dropping into the space below.
3.2.1 Forms and Shores
Provide bracing and scaffolding as required. Design bracing to resist wind pressure as required by local codes. Forms and shores shall be sufficiently rigid to prevent deflections which may result in cracking or other damage to supported masonry and sufficiently tight to prevent leakage of mortar and grout. Supporting forms and shores shall not be removed in less than 10 days.
3.2.2 Reinforced Concrete Masonry Units Walls
Where vertical reinforcement occurs, fill cores solid with grout. Lay units in such a manner as to preserve the unobstructed vertical continuity of cores to be filled. Embed the adjacent webs in mortar to prevent leakage of grout. Remove mortar fins protruding from joints before placing grout. Minimum clear dimensions of vertical cores shall be 2 by 3 inches. Position reinforcing accurately as indicated before placing grout. As masonry work progresses, secure vertical reinforcing in place at vertical intervals not to exceed 160 bar diameters. Use puddling rod or vibrator to consolidate the grout. Minimum clear distance between masonry and vertical reinforcement shall be not less than 1/2 inch. Unless indicated or specified otherwise, form splices by lapping bars not less than 40 bar diameters and wire tying them together.
3.2.3 Concrete Masonry Units
Units in starting courses on footings, solid foundation and beams, and where cells are to be filled with grout shall be full bedded in mortar under both face shells and webs. Other units shall be full bedded under both face shells. Head joints shall be filled solidly with mortar for a distance in from the face of the unit not less than the thickness of the face shell. Jamb units shall be of the shapes and sizes to conform with wall units. Solid units may be incorporated in the masonry work where necessary to fill out at corners and elsewhere as approved.
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3.2.4 Stone
Lay stone facing with the better face exposed. Lay stone in random bond as indicated in the drawings with each course bonded at corners, unless otherwise indicated.
3.2.4.1 Wetting of Units
Wetting of stone units having an initial rate of absorption of more than 1 gram per minute per square inch of bed surface shall be in conformance with ASTM C67. The method of wetting shall ensure that each unit is nearly saturated but surface dry when laid. Test clay or shale brick daily on the job, prior to laying, as follows: Using a wax pencil, draw a circle the size of a quarter on five randomly selected bricks. Apply 20 drops of water with a medicine dropper to the surface within the circle on each brick. If the average time that the water is completely absorbed in the five bricks is less than 1-1/2 minutes, wet bricks represented by the five bricks tested.
3.2.4.2 Solid Units
Completely fill bed, head, and collar joints with mortar.
3.2.4.3 Hollow Units
Lay hollow units as specified for concrete masonry units.
3.2.4.4 Stone-Faced Walls
For stone-faced walls bond the two wythes at 16 inches on center each way. Provide additional bonding ties spaced not more than 0.75 feet apart around the perimeter of and within 12 inches of all openings.
3.2.4.4.1 Collar Joints
Fill collar joints solid with mortar as each course of brick is laid. Do not disturb units in place.
3.2.4.5 Cavity Walls
Provide a continuous cavity as indicated. Securely tie the two wythes together with horizontal joint reinforcement. Bevel mortar beds away from cavity to prevent projection into cavity when bricks are shoved in place. Keep cavities clear and clean of mortar droppings. Provide weep holes of open head joints spaced 24 inches o.c. wherever the cavity is interrupted. Cavity face of interior wythe shall be dampproofed in accordance with Section 07 11 13 BITUMINOUS DAMPPROOFING.
3.2.5 Tolerances
Lay masonry plumb, true to line, with courses level. Keep bond pattern plumb throughout. Square corners unless noted otherwise. Except for walls constructed of prefaced concrete masonry units, lay masonry within the following tolerances (plus or minus unless otherwise noted):
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TABLE II TOLERANCES
Variation from the plumb in the lines and surfaces of columns, walls and arises In adjacent masonry units 1/8 inch
In 10 feet 1/4 inch
In 20 feet 3/8 inch
In 40 feet or more 1/2 inch
Variations from the plumb for external corners, expansion joints, and other conspicuous lines In 20 feet 1/4 inch
In 40 feet or more 1/2 inch
Variations from the level for exposed lintels, sills, parapets, horizontal grooves, and other conspicuous lines
In 20 feet 1/4 inch
In 40 feet or more 1/2 inch
Variation from level for bed joints and top surfaces of bearing walls
In 10 feet 1/4 inch
In 40 feet or more 1/2 inch
Variations from horizontal lines
In 10 feet 1/4 inch
In 20 feet 3/8 inch
In 40 feet or more 1/2 inch
Variations in cross sectional dimensions of columns and in thickness of walls Minus 1/4 inch
Plus 1/2 inch
3.2.6 Cutting and Fitting
Full units of the proper size shall be used wherever possible, in lieu of cut units. Cutting and fitting, including that required to accommodate the work of others, shall be done by masonry mechanics using power masonry saws. Concrete masonry units may be wet or dry cut. Wet cut units, before being placed in the work, shall be dried to the same surface-dry appearance as uncut units being laid in the wall. Cut edges shall be clean, true and sharp. Openings in the masonry shall be made carefully so that wall plates, cover plates or escutcheons required by the installation will completely conceal the openings and will have bottoms parallel with the
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masonry bed joints. Reinforced masonry lintels shall be provided above openings over 12 inches wide for pipes, ducts, cable trays, and other wall penetrations, unless steel sleeves are used.
3.2.7 Jointing
Joints shall be tooled when the mortar is thumbprint hard. Horizontal joints shall be tooled last. Joints shall be brushed to remove all loose and excess mortar. Mortar joints shall be finished as follows:
3.2.7.1 Flush Joints
Joints in concealed masonry surfaces and joints at electrical outlet boxes in wet areas shall be flush cut. Flush cut joints shall be made by cutting off the mortar flush with the face of the wall. Joints in unparged masonry walls below grade shall be pointed tight. Flush joints for architectural units, such as fluted units, shall completely fill both the head and bed joints.
3.2.7.2 Tooled Joints
Joints in exposed exterior and interior masonry surfaces shall be tooled slightly concave. Joints shall be tooled with a jointer slightly larger than the joint width so that complete contact is made along the edges of the unit. Tooling shall be performed so that the mortar is compressed and the joint surface is sealed. Jointer of sufficient length shall be used to obtain a straight and true mortar joint.
3.2.7.3 Door Frame Joints
On the exposed interior side of exterior frames, joints between frames and abutting masonry walls shall be raked to a depth of 3/8 inch. On the exterior side of exterior frames, joints between frames and abutting masonry walls shall be raked to a depth of 3/8 inch.
3.2.8 Joint Widths
Joint widths shall be as follows:
3.2.8.1 Concrete Masonry Units
Concrete masonry units shall have 3/8 inch joints, except for prefaced concrete masonry units.
3.2.8.2 Stone
Stone joint widths shall be 1/2 inch nominal dimensions. Stone expansion joint widths shall be 1/2 inch nominal.
3.2.9 Embedded Items
Fill spaces around built-in items with mortar. Point openings around flush-mount electrical outlet boxes in wet locations with mortar. Embed anchors, ties, wall plugs, accessories, flashing, pipe sleeves and other items required to be built-in as the masonry work progresses. Fully embed anchors, ties and joint reinforcement in the mortar. Fill cells receiving anchor bolts and cells of the first course below bearing plates with grout.
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3.2.10 Unfinished Work
Step back unfinished work for joining with new work. Toothing may be resorted to only when specifically approved. Remove loose mortar and thoroughly clean the exposed joints before laying new work.
3.2.11 Masonry Wall Intersections
Masonry bond each course at corners and elsewhere as shown. Masonry walls shall be anchored or tied together at corners and intersections with bond beam reinforcement and prefabricated corner or tee pieces of joint reinforcement as shown.
3.2.12 Partitions
Partitions shall be continuous from floor to underside of floor or roof deck where shown. An isolation joint shall be placed in the intersection between partitions and exterior walls as shown. Interior partitions having 4 inch nominal thick units shall be tied to intersecting partitions of 4 inch units, 5 inches into partitions of 6 inch units, and 7 inches into partitions of 8 inch or thicker units. Cells within vertical plane of ties shall be filled solid with grout for full height of partition or solid masonry units may be used. Interior partitions having masonry walls over 4 inches thick shall be tied together with joint reinforcement.
3.3 ANCHORED VENEER CONSTRUCTION
Completely separate the inner and outer wythes by a continuous airspace as indicated. Lay up both the inner and the outer wythes together except when adjustable joint reinforcement assemblies are approved for use. When both wythes are not brought up together, through-wall flashings shall be protected from damage until they are fully enclosed in the wall. The airspace between the wythes shall be kept clear and free of mortar droppings by temporary wood strips laid on the wall ties and carefully lifted out before placing the next row of ties. A drainage material shall be placed behind the weep holes in the cavity to a minimum depth of 10 inches (full depth) of drainage material to keep mortar droppings from plugging the weep holes.
3.4 WEEP HOLES
Wherever through-wall flashing occurs, provide weep holes to drain flashing to exterior at acceptable locations as indicated on drawings. Weep holes shall be open head joints at 24 inches o.c. Weep holes shall be provided not more than 24 inches on centers in mortar joints of the exterior wythe above wall flashing, over foundations, bond beams, and any other horizontal interruptions of the cavity. Weep holes shall be perfectly horizontal or slightly canted downward to encourage water drainage outward and not inward. Weep holes shall be constructed using weep hole ventilators. Weep holes shall be kept free of mortar and other obstructions.
3.5 MORTAR MIX
Mix mortar in a mechanically operated mortar mixer for at least 3 minutes, but not more than 5 minutes. Measure ingredients for mortar by volume. Ingredients not in containers, such as sand, shall be accurately measured by the use of measuring boxes. Mix water with the dry ingredients in sufficient amount to provide a workable mixture which will adhere to the vertical surfaces of masonry units. Retemper mortar that has stiffened
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because of loss of water through evaporation by adding water to restore the proper consistency and workability. Discard mortar that has reached its initial set or that has not been used within 2.5 hours after mixing.
3.6 REINFORCING STEEL
Do not use reinforcement that has loose and flaky rust. Clean reinforcement that has scale, grease, mortar, grout, or other coating which might destroy or reduce its bond prior to placing grout. Bars with kinks or bends not shown on the drawings shall not be used. Reinforcement shall be placed prior to grouting. Unless otherwise indicated, vertical wall reinforcement shall extend to within 2 inches of tops of walls.
3.6.1 Positioning Bars
Vertical bars shall be accurately placed within the cells at the positions indicated on the drawings. A minimum clearance of 1/2 inch shall be maintained between the bars and masonry units. Minimum clearance between parallel bars shall be one diameter of the reinforcement. Vertical reinforcing may be held in place using bar positioners located near the ends of each bar and at intermediate intervals of not more than 192 diameters of the reinforcement. Column and pilaster ties shall be wired in position around the vertical steel. Ties shall be in contact with the vertical reinforcement and shall not be placed in horizontal bed joints.
3.6.2 Splices
Bars shall be lapped a minimum of 48 diameters of the reinforcement. Welded or mechanical connections shall develop at least 125 percent of the specified yield strength of the reinforcement.
3.7 JOINT REINFORCEMENT INSTALLATION
Install joint reinforcement at 16 inches on center or as indicated. Reinforcement shall be lapped not less than 6 inches. Install prefabricated sections at corners and wall intersections. Place the longitudinal wires of joint reinforcement to provide not less than 5/8 inch cover to either face of the unit.
3.8 PLACING GROUT
Fill cells containing reinforcing bars with grout. Hollow masonry units in walls or partitions supporting plumbing, heating, or other mechanical fixtures, voids at door and window jambs, and other indicated spaces shall be filled solid with grout. Cells under lintel bearings on each side of openings shall be filled solid with grout for full height of openings. Walls below grade, lintels, and bond beams shall be filled solid with grout. Units other than open end units may require grouting each course to preclude voids in the units. Grout not in place within 1-1/2 hours after water is first added to the batch shall be discarded. Sufficient time shall be allowed between grout lifts to preclude displacement or cracking of face shells of masonry units. If blowouts, flowouts, misalignment, or cracking of face shells should occur during construction, the wall shall be torn down and rebuilt.
3.8.1 Vertical Grout Barriers for Fully Grouted Walls
Provide grout barriers not more than 30 feet apart, or as required, to limit the horizontal flow of grout for each pour.
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3.8.2 Horizontal Grout Barriers
Embed grout barriers in mortar below cells of hollow units receiving grout.
3.8.3 Grout Holes and Cleanouts
3.8.3.1 Grout Holes
Provide grouting holes in slabs, spandrel beams, and other in-place overhead construction. Locate holes over vertical reinforcing bars or as required to facilitate grout fill in bond beams. Provide additional openings spaced not more than 16 inches on centers where grouting of all hollow unit masonry is indicated. Openings shall not be less than 4 inches in diameter or 3 by 4 inches in horizontal dimensions. Upon completion of grouting operations, plug and finish grouting holes to match surrounding surfaces.
3.8.3.2 Cleanouts for Hollow Unit Masonry Construction
Provide cleanout holes at the bottom of every pour in cores containing vertical reinforcement when the height of the grout pour exceeds 5 feet. Where all cells are to be grouted, construct cleanout courses using bond beam units in an inverted position to permit cleaning of all cells. Provide cleanout holes at a maximum spacing of 32 inches where all cells are to be filled with grout. Establish a new series of cleanouts if grouting operations are stopped for more than 4 hours. Cleanouts shall not be less than 3 by 4 inch openings cut from one face shell. Manufacturer's standard cutout units may be used at the Contractor's option. Cleanout holes shall not be closed until masonry work, reinforcement, and final cleaning of the grout spaces have been completed and inspected. For walls which will be exposed to view, close cleanout holes in an approved manner to match surrounding masonry.
3.8.3.3 Cleanouts for Solid Unit Masonry Construction
Provide cleanouts for construction of walls consisting of a grout filled cavity between solid masonry wythes at the bottom of every pour by omitting every other masonry unit from one wythe. Establish a new series of cleanouts if grouting operations are stopped for more than 4 hours. Do not plug cleanout holes until masonry work, reinforcement, and final cleaning of the grout spaces have been completed and inspected. For walls which will be exposed to view, close cleanout holes in an approved manner to match surrounding masonry.
3.8.4 Grouting Equipment
3.8.4.1 Grout Pumps
Pumping through aluminum tubes will not be permitted. Operate pumps to produce a continuous stream of grout without air pockets, segregation, or contamination. Upon completion of each day's pumping, remove waste materials and debris from the equipment, and dispose of outside the masonry.
3.8.4.2 Vibrators
Internal vibrators shall maintain a speed of not less than 5,000 impulses per minute when submerged in the grout. Maintain at least one spare vibrator at the site at all times. Apply vibrators at uniformly spaced
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points not further apart than the visible effectiveness of the machine. Limit duration of vibration to time necessary to produce satisfactory consolidation without causing segregation.
3.8.5 Grout Placement
Lay masonry to the top of a pour before placing grout. Do no place grout in two-wythe solid unit masonry cavity until mortar joints have set for at least 3 days during hot weather and 5 days during cold damp weather. Grout shall not be placed in hollow unit masonry until mortar joints have set for at least 24 hours. Grout shall be placed using a hand bucket, concrete hopper, or grout pump to completely fill the grout spaces without segregation of the aggregates. Vibrators shall not be inserted into lower pours that are in a semi-solidified state. The height of grout pours and type of grout used shall be limited by the dimensions of grout spaces as indicated in Table III. Low-lift grout methods may be used on pours up to and including 4 feet in height. High-lift grout methods shall be used on pours exceeding 4 feet in height.
3.8.5.1 Low-Lift Method
Grout shall be placed at a rate that will not cause displacement of the masonry due to hydrostatic pressure of the grout. Mortar protruding more than 1/2 inch into the grout space shall be removed before beginning the grouting operation. Grout pours 12 inches or less in height shall be consolidated by mechanical vibration or by puddling. Grout pours over 12 inches in height shall be consolidated by mechanical vibration and reconsolidated by mechanical vibration after initial water loss and settlement has occurred. Vibrators shall not be inserted into lower pours that are in a semi-solidified state. Low-lift grout shall be used subject to the limitations of Table III.
3.9 BOND BEAMS
Bond beams shall be filled with grout and reinforced as indicated on the drawings. Grout barriers shall be installed under bond beam units to retain the grout as required. Reinforcement shall be continuous, including around corners, except through control joints or expansion joints, unless otherwise indicated on the drawings. Where splices are required for continuity, reinforcement shall be lapped 48 bar diameters. A minimum clearance of 1/2 inch shall be maintained between reinforcement and interior faces of units.
3.10 CONTROL JOINTS
Control joints shall be provided as indicated and shall be constructed by using special control-joint units in accordance with the details shown on the drawings. Sash jamb units shall have a 3/4 by 3/4 inch groove near the center at end of each unit. The vertical mortar joint at control joint locations shall be continuous, including through all bond beams. This shall be accomplished by utilizing half blocks in alternating courses on each side of the joint. The control joint key shall be interrupted in courses containing continuous bond beam steel. In single wythe exterior masonry walls, the exterior control joints shall be raked to a depth of 3/4 inch; backer rod and sealant shall be installed in accordance with Section 07 92 00 JOINT SEALANTS. Exposed interior control joints shall be raked to a depth of 1/4 inch. Concealed control joints shall be flush cut.
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3.11 INDICATED JOINTS
Brick expansion joints located, detailed, and constructed as indicated. Keep joints free of mortar and other debris.
3.12 LINTELS
3.12.1 Precast Concrete and Steel Lintels
Construct precast concrete and steel lintels as shown on the drawings. Lintels shall be set in a full bed of mortar with faces plumb and true. Steel and precast lintels shall have a minimum bearing length of 8 inches unless otherwise indicated on the drawings.
3.13 COPINGS
Copings shall be set in a full bed of mortar with faces plumb and true.
3.14 ANCHORAGE TO CONCRETE AND STRUCTURAL STEEL
3.14.1 Anchorage to Concrete
Anchorage of masonry to the face of concrete beams or walls shall be with dovetail anchors spaced not over 16 inches on centers vertically and 24 inches on center horizontally.
3.14.2 Anchorage to Structural Steel
Masonry shall be anchored to vertical structural steel framing with adjustable steel wire anchors spaced not over 16 inches on centers vertically, and if applicable, not over 24 inches on centers horizontally.
3.15 INSULATION
Anchored veneer walls shall be insulated, where shown, by installing board-type insulation on the cavity side of the inner wythe. Board type insulation shall be applied directly to the masonry or thru-wall flashing with adhesive. Insulation shall be neatly fitted between obstructions without impaling of insulation on ties or anchors. The insulation shall be applied in parallel courses with vertical joints breaking midway over the course below and shall be applied in moderate contact with adjoining units without forcing, and shall be cut to fit neatly against adjoining surfaces.
3.16 POINTING AND CLEANING
After mortar joints have attained their initial set, but prior to hardening, completely remove mortar and grout daubs or splashings from masonry-unit surfaces that will be exposed or painted. Before completion of the work, defects in joints of masonry to be exposed or painted shall be raked out as necessary, filled with mortar, and tooled to match existing joints. Immediately after grout work is completed, scum and stains which have percolated through the masonry work shall be removed using a high pressure stream of water and a stiff bristled brush. Masonry surfaces shall not be cleaned, other than removing excess surface mortar, until mortar in joints has hardened. Masonry surfaces shall be left clean, free of mortar daubs, dirt, stain, and discoloration, including scum from cleaning operations, and with tight mortar joints throughout. Metal tools and metal brushes shall NOT be used for cleaning.
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3.16.1 Dry-Brushing
a. Exposed concrete masonry unit
b. Exposed concrete brick surfaces
c. shall be dry-brushed at the end of each day's work and after any required pointing, using stiff-fiber bristled brushes.
3.16.2 Stone Surfaces
Clean exposed stone surfaces as necessary to obtain surfaces free of stain, dirt, mortar and grout daubs, efflorescence, and discoloration or scum from cleaning operations. After cleaning, examine the sample panel of similar material for discoloration or stain as a result of cleaning. If the sample panel is discolored or stained, change the method of cleaning to ensure that the stone surfaces in the structure will not be adversely affected. The exposed stone surfaces shall be cleaned by the stone products manufacturer. Do not use metal brushes on stone.
3.17 BEARING PLATES
Set bearing plates for precast concrete double tees and similar structural members to the proper line and elevation with damp-pack bedding mortar, except where bearing pads are indicated. Bedding mortar shall be as specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.
3.18 PROTECTION
Protect facing materials against staining. Cover top of walls with nonstaining waterproof covering or membrane when work is not in progress. Covering of the top of the unfinished walls shall continue until the wall is waterproofed with a complete roof or parapet system. Covering shall extend a minimum of 2 feet down on each side of the wall and shall be held securely in place. Before starting or resuming, top surface of masonry in place shall be cleaned of loose mortar and foreign material.
3.19 TEST REPORTS
3.19.1 Field Testing of Mortar
Take at least three specimens of mortar each day. Spread a layer of mortar 1/2 to 5/8 inch thick on the masonry units and allowed to stand for one minute. Prepare and test the specimens for compressive strength in accordance with ASTM C780. Submit test results.
3.19.2 Field Testing of Grout
Field sampling and testing of grout shall be in accordance with the applicable provisions of ASTM C1019. A minimum of three specimens of grout per day shall be sampled and tested. Each specimen shall have a minimum ultimate compressive strength of 2000 psi at 28 days. Submit test results.
3.19.3 Efflorescence Test
Test brick, which will be exposed to weathering, for efflorescence. Schedule tests far enough in advance of starting masonry work to permit retesting if necessary. Sampling and testing shall conform to the
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applicable provisions of ASTM C67. Units meeting the definition of "effloresced" will be subject to rejection. Submit test results.
3.19.4 Prism Tests
Perform at least one prism test sample for each 5,000 square feet of wall but not less than three such samples shall be made for any building. Three prisms will be used in each sample. Prisms shall be tested in accordance with ACI 530/530.1. Seven-day tests may be used provided the relationship between the 7- and 28-day strengths of the masonry is established by the tests of the materials used. Compressive strength shall not be less than 3000 psi at 28 days. If the compressive strength of any prism falls below the specified value by more than 500 psi, steps shall be taken to assure that the load-carrying capacity of the structure is not jeopardized. If the likelihood of low-strength masonry is confirmed and computations indicate that the load-carrying capacity may have been significantly reduced, tests of cores drilled, or prisms sawed, from the area in question may be required. In such case, three specimens shall be taken for each prism test more than 500 psi below the specified value. Masonry in the area in question shall be considered structurally adequate if the average compressive strength of three specimens is equal to at least 85 percent of the specified value, and if the compressive strength of no single specimen is less than 75 percent of the specified value. Additional testing of specimens extracted from locations represented by erratic core or prism strength test results will be permitted. Submit test results.
3.19.5 Single-Wythe Masonry Wall Water Penetration Test
Prior to start of field construction of the single-wythe masonry wall, perform masonry wall water penetration test on mock-up wall assemblies consisting of the identical design, materials, mix, and construction methods as the actual wall construction and in accordance with ASTM E514/E514M. Prepare a minimum of three specimens and cure for minimum 28 days prior to testing. Construct panels by the same methods, processes, and applications to be used on the project's construction site. The spray test duration shall be 6 hours for each specimen. No water shall be visible on back of test panels during the test and any areas of dampness on the backside of the test panels shall not exceed 25 percent of the wall area. Dampness is defined as any area of surface darkening or discoloration due to moisture penetration or accumulation below the observed surface. Construct additional test panels for each failed test performed until three test panels pass the test. Factors that can affect test performance include materials, mixing, and quality of application and workmanship. Materials, mixing, and methods adjustments may be necessary in order to provide construction that passes the water penetration test. Document and record the test specimen construction materials and application and provide written test report in accordance with ASTM E514/E514M, supplemented by a detailed discussion of the specifics of test panel construction, application methods and processes used, quality of construction, and any variances or deviations that may have occurred between test panels during test panel construction. For failed test panels, identify in the supplemental report any variances, deficiencies or flaws that contributed to test panel failure and itemize the precautions to be taken in field construction of the masonry wall to prevent similar deficiencies and assure the wall construction replicates test panel conditions that pass the water penetration test. Submit the complete, certified test report, including supplemental report, to the Owner's Representative prior to start of single-wythe masonry wall construction. Significant changes to materials, proportions, or construction techniques from those used in the passing
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water penetration test are grounds for performing new tests, at the discretion of the Owner's Representative.
-- End of Section --
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DIVISION 5 METALS
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 05 12 00
STRUCTURAL STEEL 11/11 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)
AISC 201 (2006) AISC Certification Program for Structural Steel Fabricators
AISC 317 (1999) Manual of Steel Construction, Volume II-Connections
AISC 325 (2011) Steel Construction Manual
AISC 326 (2009) Detailing for Steel Construction
AISC 341 (2010) Seismic Provisions for Structural Steel Buildings
AISC 348 (2009) Specification For Structural Joints Using High-Strength Bolts
AISC 360 (2010) Specification for Structural Steel Buildings
AMERICAN WELDING SOCIETY (AWS)
AWS A2.4 (2012) Standard Symbols for Welding, Brazing and Nondestructive Examination
AWS D1.1/D1.1M (2012; Errata 2011) Structural Welding Code - Steel
ASME INTERNATIONAL (ASME)
ASME B46.1 (2009) Surface Texture, Surface Roughness, Waviness and Lay
ASTM INTERNATIONAL (ASTM)
ASTM A108 (2007) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished
ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
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ASTM A143/A143M (2007) Standard Practice for Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement
ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ASTM A276 (2013a) Standard Specification for Stainless Steel Bars and Shapes
ASTM A307 (2012) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength
ASTM A325 (2010; E 2013) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength
ASTM A325M (2013) Standard Specification for Structural Bolts, Steel, Heat Treated, 830 MPa Minimum Tensile Strength (Metric)
ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel
ASTM A496/A496M (2007) Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement
ASTM A500/A500M (2013) Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes
ASTM A514/A514M (2013) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding
ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
ASTM A563 (2007a) Standard Specification for Carbon and Alloy Steel Nuts
ASTM A6/A6M (2013a) Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling
ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
ASTM A992/A992M (2011) Standard Specification for Structural Steel Shapes
ASTM B695 (2004; R 2009) Standard Specification for Coatings of Zinc Mechanically Deposited on
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Iron and Steel
ASTM C1107/C1107M (2013) Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink)
ASTM C827/C827M (2010) Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures
ASTM E164 (2008) Ultrasonic Contact Examination of Weldments
ASTM E165 (2009) Standard Test Method for Liquid Penetrant Examination
ASTM E709 (2008) Standard Guide for Magnetic Particle Examination
ASTM E94 (2004; R 2010) Radiographic Examination
ASTM F1554 (2007a; E 2011) Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield Strength
ASTM F436 (2011) Hardened Steel Washers
ASTM F436M (2011) Hardened Steel Washers (Metric)
ASTM F593 (2002; R 2008; E 2012) Stainless Steel Bolts, Hex Cap Screws, and Studs
ASTM F844 (2007a) Washers, Steel, Plain (Flat), Unhardened for General Use
ASTM F959 (2013) Compressible-Washer-Type Direct Tension Indicators for Use with Structural Fasteners
THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)
SSPC PA 1 (2000; E 2004) Shop, Field, and Maintenance Painting of Steel
SSPC Paint 25 (1997; E 2004) Zinc Oxide, Alkyd, Linseed Oil Primer for Use Over Hand Cleaned Steel, Type I and Type II
SSPC SP 3 (1982; E 2004) Power Tool Cleaning
SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning
1.2 SYSTEM DESCRIPTION
Provide the structural steel system, including shop primer and galvanizing, as indicated complete and ready for use. Structural steel systems including design, materials, installation, workmanship, fabrication, assembly, erection, inspection, quality control, and testing shall be provided in accordance with AISC 360 and AISC 341 except as modified in this contract.
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1.3 SUBMITTALS
Owner's Representative approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Owner's Representative. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Erection Plan, including description of temporary supports; G
Fabrication drawings including description of connections; G
SD-03 Product Data
Shop primer
Welding electrodes and rods
Load indicator washers
Non-Shrink Grout
Include test report for Class B primer.
SD-06 Test Reports
Bolts, nuts, and washers
Supply the certified manufacturer's mill reports which clearly show the applicable ASTM mechanical and chemical requirements together with the actual test results for the supplied fasteners.
SD-07 Certificates
Steel
Bolts, nuts, and washers
Galvanizing
AISC Quality Certification
Welding procedures and qualifications
1.4 AISC QUALITY CERTIFICATION
Work shall be fabricated in an AISC certified Category Std fabrication plant.
1.5 QUALITY ASSURANCE
1.5.1 Drawing Requirements
Submit fabrication drawings for approval prior to fabrication. Prepare in accordance with AISC 326 and AISC 325. Fabrication drawings shall not be
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reproductions of contract drawings. Include complete information for the fabrication and erection of the structure's components, including the location, type, and size of bolts, welds, member sizes and lengths, connection details, blocks, copes, and cuts. Use AWS A2.4 standard welding symbols. Member substitutions of details shown on the contract drawings shall be clearly highlighted on the fabrication drawings. Explain the reasons for any deviations from the contract drawings.
1.5.2 Certifications
1.5.2.1 Erection Plan
Submit for record purposes. Indicate the sequence of erection, temporary shoring and bracing.
1.5.2.2 Welding Procedures and Qualifications
Prior to welding, submit certification for each welder stating the type of welding and positions qualified for, the code and procedure qualified under, date qualified, and the firm and individual certifying the qualification tests. If the qualification date of the welding operator is more than one-year old, the welding operator's qualification certificate shall be accompanied by a current certificate by the welder attesting to the fact that he has been engaged in welding since the date of certification, with no break in welding service greater than 6 months.
Conform to all requirements specified in AWS D1.1/D1.1M.
PART 2 PRODUCTS
2.1 STEEL
2.1.1 Structural Steel
Channels, angles plates, and bars. ASTM A36/A36M.
2.1.2 Structural Shapes for Use in Metal Fabrications
Wide flange shapes, ASTM A992/A992M.
2.1.3 Structural Steel Tubing
Round: ASTM A500/A500M, Grade B Fy = 42 ksi; Square or rectangular ASTM A500/A500M, Grade B, F y= 46 ksi.
2.1.4 Steel Pipe
ASTM A53/A53M, Type E or S, Grade B, Fy = 35 ksi, weight class STD (Standard) unless noted otherwise.
2.2 BOLTS, NUTS, AND WASHERS
Provide the following unless indicated otherwise.
2.2.1 Structural Steel
2.2.1.1 Bolts
ASTM A307, Grade A. The bolt heads and the nuts of the supplied fasteners
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must be marked with the manufacturer's identification mark, the strength grade and type specified by ASTM specifications. Bolts shall only be used where indicated on the drawings.
2.2.1.2 Nuts
ASTM A563 Grade A, Heavy Hex Style, Grade and Style for applicable ASTM bolt standard recommended.
2.2.1.3 Washers
ASTM F844 washers for ASTM A307 bolts.
2.2.2 High-Strength Structural Steel and Structural Steel Tubing
2.2.2.1 Bolts
ASTM A325, Type 1 heavy hex steel structural bolts. Connections shall be bearing type with threads included in the shear plain. Finish shall be plain..
2.2.2.2 Nuts
ASTM A563, heavy hex carbon steel nuts. Grade and Style as specified in the applicable ASTM bolt standard. At galvanized steel locations the finish shall be mechanically deposited zinc coating, ASTM B695, Class 5.
2.2.2.3 Washers
ASTM F436, plain carbon steel. At galvanized steel locations the finish shall be mechanically deposited zinc coating, ASTM B695, Class 5.
2.2.3 Foundation Anchorage
2.2.3.1 Headed Anchor Rods
ASTM F1554 Gr 36 (where indicated on the drawings). Stainless steel Type 304 or 316 conforming to ASTM F593.
2.2.3.2 Anchor Nuts
ASTM A563, Grade A, hex style. Stainless steel Type 304 or Type 316 conforming to ASTM F593.
2.2.3.3 Anchor Washers
ASTM F436M, Plain hardened carbon steel. ASTM F844. Stainless steel Type 304 or Type 316 conforming to ASTM A276.
2.2.3.4 Anchor Plate Washers
ASTM A36/A36M Stainless steel Type 304 or Type 316 conforming to ASTM A276.
2.2.4 Load Indicator Washers
ASTM F959. Provide ASTM B695, Class 50, Type 1 galvanizing. Provide where indicated on the drawings.
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2.3 STRUCTURAL STEEL ACCESSORIES
2.3.1 Welding Electrodes and Rods
AWS D1.1/D1.1M, E70 series.
2.3.2 Non-Shrink Grout
ASTM C1107/C1107M, with no ASTM C827/C827M shrinkage. Grout shall be nonmetallic, nonstaining. See Section 03 30 00.00 10.
2.3.3 Welded Headed Studs
ASTM A108, Grades 1015 through 1020, headed-stud type, cold finished carbon steel, AWS D1.1/D1.1M, Type B.
2.3.3.1 Acceptable Manufacturers
Subject to compliance with the Contract Documents, the following manufacturer's are accpetable:
Headed studs and deformed bar anchors:
a. Nelson Stud Welding Div., TRW Inc.
b. Stud Welding Products, Inc.
2.3.4 Deformed Bar Anchors (DBA)
Cold drawn wire, conforming to ASTM A496/A496M, minimum tensile strength of 80,000 psi, and straight and solid fluxed.
2.4 SHOP PRIMER
SSPC Paint 25, (alkyd primer) Type 1. Primer shall conform to Federal, State, and local VOC regulations. If flash rusting occurs, re-clean the surface prior to application of primer.
2.5 GALVANIZING
ASTM A123/A123M or ASTM A153/A153M, with minimum coating of 2.0 OZ of zink per square foot of meter (average of specimens), unless specified otherwise galvanize after fabrication where practicable.
2.6 FABRICATION
2.6.1 Markings
Prior to erection, members shall be identified by a painted erection mark. Connecting parts assembled in the shop for reaming holes in field connections shall be match marked with scratch and notch marks. Do not locate erection markings on areas to be welded. Do not locate match markings in areas that will decrease member strength or cause stress concentrations. Affix embossed tags to hot-dipped galvanized members.
2.6.2 Shop Primer
Shop prime structural steel, except as modified herein, in accordance with SSPC PA 1. Do not prime steel surfaces embedded in concrete, galvanized
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surfaces, or surfaces within 0.5 inch of the toe of the welds prior to welding (except surfaces on which metal decking is to be welded). Slip critical surfaces shall be primed with a Class B coating. Prior to assembly, prime surfaces which will be concealed or inaccessible after assembly. Do not apply primer in foggy or rainy weather; when the ambient temperature is below 45 degrees F or over 95 degrees F; or when the primer may be exposed to temperatures below 40 degrees F within 48 hours after application, unless approved otherwise by the Owner's Representative.
2.6.2.1 Cleaning
SSPC SP 6/NACE No.3, except steel exposed in spaces above ceilings, attic spaces, furred spaces, and chases that will be hidden to view in finished construction may be cleaned to SSPC SP 3 when recommended by the shop primer manufacturer. Maintain steel surfaces free from rust, dirt, oil, grease, and other contaminants through final assembly.
2.6.2.2 Primer
Apply primer to a minimum dry film thickness of 2.0 mil except provide the Class B coating for slip critical joints in accordance with the coating manufacturer's recommendations. Repair damaged primed surfaces with an additional coat of primer.
2.7 DRAINAGE HOLES
Adequate drainage holes shall be drilled to eliminate water traps. Hole diameter shall be 1/2 inch and location shall be indicated on the detail drawings. Hole size and location shall not affect the structural integrity.
PART 3 EXECUTION
3.1 FABRICATION
Fabrication shall be in accordance with the applicable provisions of AISC 325. Fabrication and assembly shall be done in the shop to the greatest extent possible. The fabricating plant shall be certified under the AISC 201 for Category STD structural steelwork.
Compression joints depending on contact bearing shall have a surface roughness not in excess of 500 micro inch as determined by ASME B46.1, and ends shall be square within the tolerances for milled ends specified in ASTM A6/A6M.
Structural steelwork, except surfaces of steel to be encased in concrete, surfaces to be field welded, and contact surfaces of friction-type high-strength bolted connections shall be prepared for painting in accordance with endorsement "P" of AISC 201 and primed with the specified paint.
Shop splices of members between field splices will be permitted only where indicated on the Contract Drawings. Splices not indicated require the approval of the Owner's Representative.
3.2 ERECTION
a. Erection of structural steel, except as indicated in item b. below, shall be in accordance with the applicable provisions of AISC 325. Erection plan shall be reviewed, stamped and sealed by a licensed
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structural engineer.
Provide for drainage in structural steel. After final positioning of steel members, provide full bearing under base plates and bearing plates using nonshrink grout. Place nonshrink grout in accordance with the manufacturer's instructions.
3.2.1 Deformed Bar Anchors
Prepare steel surfaces as recommended by manufacturer of anchors. Use automatic end welding of anchors according to AWS D1.1/D1.1M and manufacturer's written instructions.
3.2.2 STORAGE
Material shall be stored out of contact with the ground in such manner and location as will minimize deterioration.
3.3 CONNECTIONS
Except as modified in this section, connections not detailed shall be designed in accordance with AISC 360. Build connections into existing work. Do not tighten anchor bolts set in concrete with impact torque wrenches. Punch, subpunch and ream, or drill bolt holes perpendicular to the surface of the member. Holes shall not be cut or enlarged by burning. Bolts, nuts, and washers shall be clean of dirt and rust, and lubricated immediately prior to installation.
3.3.1 Common Grade Bolts
ASTM A307 bolts shall be tightened to a "snug tight" fit. "Snug tight" is the tightness that exists when plies in a joint are in firm contact. If firm contact of joint plies cannot be obtained with a few impacts of an impact wrench, or the full effort of a man using a spud wrench, contact the Owner's Representative for further instructions.
3.3.2 High-Strength Bolts
ASTM A325 bolts shall be fully tensioned to 70 percent of their minimum tensile strength. Provide load indicator washers in all ASTM A325M bolted connections. Bolts shall be installed in connection holes and initially brought to a snug tight fit. After the initial tightening procedure, bolts shall then be fully tensioned, progressing from the most rigid part of a connection to the free edges.
3.3.2.1 Installation of Load Indicator Washers (LIW)
ASTM F959. Where possible, the LIW shall be installed under the bolt head and the nut shall be tightened. If the LIW is installed adjacent to the turned element, provide a flat ASTM F436 washer between the LIW and nut when the nut is turned for tightening, and between the LIW and bolt head when the bolt head is turned for tightening.
3.4 GAS CUTTING
Use of gas-cutting torch in the field for correcting fabrication errors will not be permitted on any major member in the structural framing. Use of a gas cutting torch will be permitted on minor members not under stress only after approval has been obtained from the Owner's Representative.
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3.5 WELDING
AWS D1.1/D1.1M, except use only shielded metal arc welding and low hydrogen electrodes for ASTM A514/A514M steel. Do not stress relieve ASTM A514/A514M steel by heat treatment. Grind exposed welds smooth as indicated. Provide AWS D1.1/D1.1M qualified welders, welding operators, and tackers.
The Contractor shall develop and submit the Welding Procedure Specifications (WPS) for all welding, including welding done using prequalified procedures. Prequalified procedures may be submitted for information only; however, procedures that are not prequalified shall be submitted for approval.
3.5.1 Removal of Temporary Welds, Run-Off Plates, and Backing Strips
Removal is not required Remove only from finished areas.
3.6 SHOP PRIMER REPAIR
Repair shop primer in accordance with the paint manufacturer's recommendation for surfaces damaged by handling, transporting, cutting, welding, or bolting.
3.6.1 Field Priming
Field priming of steel exposed to the weather, or located in building areas without HVAC for control of relative humidity. After erection, the field bolt heads and nuts, field welds, and any abrasions in the shop coat shall be cleaned and primed with paint of the same quality as that used for the shop coat.
3.7 GALVANIZING REPAIR
Provide as indicated or specified. Galvanize after fabrication where practicable. Repair damage to galvanized coatings using ASTM A780/A780M zinc rich paint for galvanizing damaged by handling, transporting, cutting, welding, or bolting. Do not heat surfaces to which repair paint has been applied.
3.8 FIELD QUALITY CONTROL
Perform field tests, and provide labor, equipment, and incidentals required for testing, except that electric power for field tests will be furnished as set forth in Division 1. The Owner's Representative shall be notified in writing of defective welds, bolts, nuts, and washers within 7 working days of the date of weld inspection.
3.8.1 Testing Agency
The Contractor will engage a qualified independent testing and inspection agency to perform field tests and inspections and prepare test and inspection reports. Any work that does not comply with the specified requirements will be removed and replaced or corrected as required. Additional testing at the Contractors expense will be performed to determine compliance of corrected work with specified requirements.
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3.8.2 Welds
3.8.2.1 Visual Inspection
AWS D1.1/D1.1M. Visually inspect all welds. Furnish the services of AWS-certified welding inspectors for fabrication and erection inspection and testing and verification inspections. Welding inspectors shall visually inspect and mark welds, including fillet weld end returns.
Inspection by the Owner's Representative will include proper preparation, size, gaging location, and acceptability of welds; identification marking; operation and current characteristics of welding sets in use.
3.8.2.2 Nondestructive Testing
In addition to Visual inspection, field welding will be tested according to AWS D1.1/D1.1M and the following inspection procedures, at testing agengy's option.
a. Liquid penetration: ASTM E165. Inspect 50% of full penetration welds and 20% of fillet welds.
b. Magnetic Particle Inspection: ASTM E709 Performed finished weld. Cracks or Zones of incomplete fusion or penetration will not be accepted.
c. Ultrasonic Inspection: ASTM E164. Test 20% of liquid dye penetrant tested full penetration welds with ultrasonic testing.
d. Radiographic Inspection: ASTM E94. Test 20% of liquid dye penetrant tested full penetration welds with radiographic testing.
If more than 20% of welds made by a welder contain defects identified by testing, then all welds made by that welder shall be tested by radiographic or ultrasonic testing, as approved by the Owner's Representative. When all welds made by an individual welder are required to be tested, magnetic particle testing shall be used only in areas in accessible to either radiographic or ultrasonic testing. Retest defective areas after repair. 3.8.3 Load Indicator Washers
3.8.3.1 Load Indicator Washer Compression
Load indicator washers shall be tested in place to verify that they have been compressed sufficiently to provide the 0.015 inch gap when the load indicator washer is placed under the bolt head and the nut is tightened, and to provide the 0.005 inch gap when the load indicator washer is placed under the turned element, as required by ASTM F959.
3.8.3.2 Load Indicator Gaps
In addition to the above testing, an independent testing agency as approved by the Owner's Representative, shall test in place the load indicator gaps on 20 percent of the installed load indicator washers to verify that the ASTM F959 load indicator gaps have been achieved. If more than 10 percent of the load indicators tested have not been compressed sufficiently to provide the average gaps required by ASTM F959, then all in place load indicator washers shall be tested to verify that the ASTM F959 load indicator gaps have been achieved. Test locations shall be selected by the
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Owner's Representative.
3.8.4 High-Strength Bolts
3.8.4.1 Testing Bolt, Nut, and Washer Assemblies
Test a minimum of 3 bolt, nut, and washer assemblies from each mill certificate batch in a tension measuring device at the job site prior to the beginning of bolting start-up. Demonstrate that the bolts and nuts, when used together, can develop tension not less than the provisions specified in AISC 348, Table 4, depending on bolt size and grade. The bolt tension shall be developed by tightening the nut. A representative of the manufacturer or supplier shall be present to ensure that the fasteners are properly used, and to demonstrate that the fastener assemblies supplied satisfy the specified requirements.
3.8.4.2 Inspection
Inspection procedures shall be in accordance with AISC 348, Section 9 . Confirm and report to the Owner's Representative that the materials meet the project specification and that they are properly stored. Confirm that the faying surfaces have been properly prepared before the connections are assembled. Observe the specified job site testing and calibration, and confirm that the procedure to be used provides the required tension. Monitor the work to ensure the testing procedures are routinely followed on joints that are specified to be fully tensioned.
Inspection by the Owner's Representative will include proper preparation, size, gaging location, and acceptability of welds; indentification marking; operation and current characteristics of welding sets in use; and calibration of torque wrenches for high-strength bolts.
The Contractor shall inspect proper preparation, size, gaging location, and acceptability of welds; identification marking, operation and current characteristics of welding sets in use; and calibration of torque wrenches for high-srength bolts.
The Contractor shall inspect high-strength bolted connections in accordance with AISC 317.
3.8.4.3 Testing
The Owner's Representative has the option to perform nondestructive tests on 5 percent of the installed bolts to verify compliance with pre-load bolt tension requirements. The Contractor shall allow access for the Owner's Representative to perform the tests. The nondestructive testing will be done in-place using an ultrasonic measuring device or any other device capable of determining in-place pre-load bolt tension. The test locations shall be selected by the Owner's Representative. If more than 10 percent of the bolts tested contain defects identified by testing, then all bolts used from the batch from which the tested bolts were taken, shall be tested at the Contractor's expense. Retest new bolts after installation at the Contractor's expense.
3.8.5 Testing for Embrittlement
ASTM A143/A143M for steel products hot-dip galvanized after fabrication.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
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MISCELLANEOUS METAL FABRICATIONS 05/10 09/17/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ALUMINUM ASSOCIATION (AA)
AA DAF45 (2003; Reaffirmed 2009) Designation System for Aluminum Finishes
AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)
AISC 303 (2010) Code of Standard Practice for Steel Buildings and Bridges
AMERICAN SOCIETY OF SAFETY ENGINEERS (ASSE/SAFE)
ASSE/SAFE A10.3 (2006) Operations - Safety Requirements for Powder Actuated Fastening Systems
AMERICAN WELDING SOCIETY (AWS)
AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel
ASME INTERNATIONAL (ASME)
ASME B18.2.1 (2012; Errata 2013) Square and Hex Bolts and Screws (Inch Series)
ASME B18.21.1 (2009) Washers: Helical Spring-Lock, Tooth Lock, and Plain Washers (Inch Series)
ASME B18.6.2 (1998; R 2010) Slotted Head Cap Screws, Square Head Set Screws, and Slotted Headless Set Screws: Inch Series
ASME B18.6.3 (2013) Machine Screws, Tapping Screws, and Machine Drive Screws (Inch Series)
ASTM INTERNATIONAL (ASTM)
ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A153/A153M (2009) Standard Specification for Zinc
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Coating (Hot-Dip) on Iron and Steel Hardware
ASTM A307 (2012) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength
ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel
ASTM A47/A47M (1999; R 2009) Standard Specification for Ferritic Malleable Iron Castings
ASTM A48/A48M (2003; R 2012) Standard Specification for Gray Iron Castings
ASTM A500/A500M (2013) Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes
ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
ASTM A653/A653M (2011) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process
ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
ASTM A786/A786M (2005; R 2009) Standard Specification for Hot-Rolled Carbon, Low-Alloy, High-Strength Low-Alloy, and Alloy Steel Floor Plates
ASTM A924/A924M (2013) Standard Specification for General Requirements for Steel Sheet, Metallic-Coated by the Hot-Dip Process
ASTM A992/A992M (2011) Standard Specification for Structural Steel Shapes
ASTM B108/B108M (2012; E 2012) Standard Specification for Aluminum-Alloy Permanent Mold Castings
ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM B221 (2013) Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
ASTM B26/B26M (2012) Standard Specification for Aluminum-Alloy Sand Castings
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ASTM C1513 (2013) Standard Specification for Steel Tapping Screws for Cold-Formed Steel Framing Connections
ASTM D1187/D1187M (1997; E 2011; R 2011) Asphalt-Base Emulsions for Use as Protective Coatings for Metal
MASTER PAINTERS INSTITUTE (MPI)
MPI 79 (Oct 2009) Alkyd Anti-Corrosive Metal Primer
NATIONAL ASSOCIATION OF ARCHITECTURAL METAL MANUFACTURERS (NAAMM)
NAAMM MBG 531 (2009) Metal Bar Grating Manual
THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)
SSPC SP 3 (1982; E 2004) Power Tool Cleaning
SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Floor Access doors , installation drawings; G
Cover plates and frames, installation drawings; G
Gratings installation drawings; G
Guard posts (Bollards); G
Embedded angles and plates, installation drawings; G
Roof hatch; G
Anchor Bolts; G
Mecahnical and Adhesive Anchors; G
Submit fabrication drawings showing layout(s), connections to structural system, and anchoring details as specified in AISC 303.
Submit templates, erection and installation drawings indicating thickness, type, grade, class of metal, and dimensions. Show construction details, reinforcement, anchorage, and installation with relation to the building construction.
SD-03 Product Data
Floor access doors; G
Access doors and panels
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Cover plates and frames; G
Floor gratings; G
Roof hatch; G
Anchor Bolts; G
Mecahnical and Adhesive Anchors; G
1.3 QUALIFICATION OF WELDERS
Qualify welders in accordance with AWS D1.1/D1.1M. Use procedures, materials, and equipment of the type required for the work.
1.4 DELIVERY, STORAGE, AND PROTECTION
Protect from corrosion, deformation, and other types of damage. Store items in an enclosed area free from contact with soil and weather. Remove and replace damaged items with new items.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Structural Carbon Steel
ASTM A36/A36M. ASTM A992/A992M, Grade 50.
2.1.2 Structural Tubing
ASTM A500/A500M, Grade B (46 ksi minimum yield).
2.1.3 Steel Pipe
ASTM A53/A53M, Type E or S, Grade B.
2.1.4 Fittings for Steel Pipe
Standard malleable iron fittings ASTM A47/A47M.
2.1.5 Gratings
a. Gray cast iron ASTM A48/A48M, Class 40.
b. Metal plank grating, non-slip requirement, aluminum ASTM B209, 6061-T6; steel ASTM A653/A653M, G90.
c. Metal bar type grating NAAMM MBG 531.
2.1.6 Floor Plates, Patterned
Floor plate ASTM A786/A786M. Steel plate shall not be less than 14 gage.
2.1.7 Anchor Bolts
ASTM A307. Where exposed, shall be of the same material, color, and finish as the metal to which applied.
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2.1.7.1 Acceptable Manufacturer's
Subject to compliance with Contract Documents, the following manufacturer's are acceptable:
1. Headed studs and deformed bar anchors:
a. Nelson Stud Welding Div., TRW Inc.
b. Stud Welding Products, Inc.
2. Mechanical anchors:
a. Simpson Strong-Tie "Stong-Bolt."
b. Simpson Strong-Tie "Titen-HD."
c. Hilti "HSL-3."
d. Hilti "Kwik Bolt TZ."
3. Adhesive anchors:a. Simpson Strong-Tie "Set-XP."
b. Hilti "Hit-RE 500-SD."
4. Self-tapping concrete anchors:
a. ITW Buildex.
5. Castings, trench covers and accessories:
a. Neenah Foundry Co.
b. Deeter Foundry Co.
c. Barry Craft Construction Casting Co.
d. McKinley Iron Works.
6. Galvanizing repair paint:
a. Clearco Products Co., Inc.
b. ZRC Products.
7. Metal (Modular) framing system:
a. Unistrut Building Systems.
b. B-Line Systems.
c. Kindorf.
d. Metal Products Div., USG Industries, Inc.
e. Mono-Systems, Inc.
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2.1.7.2 Mechanical Anchors and Adhesive Anchors
1. Stainless steel, Type 304, 314 or 316.
2. Provide minimum edge distance cover and spacing as recommended by manufacturer, or as indicated on Drawings whichever is larger.
a. Minimum embedment as recommended by manufacturer or eight (8) diameters of bolt, whichever is larger.
b. Notify Engineer if required depth of embedment cannot be achieved at a particular anchor bolt location.
c. Follow manufacturer's recommendations for installation and torque.
3. Submit manufacturer's load test data to verify at least the anchor bolt capacities at the following embedment depths:
a. Data must be based on actual tests performed in unreinforced mass of concrete of not more than 4000 psi compressive strength.
b. Capacity must be at a concrete temperature of at least 130 degrees Farnaheit.
ANCHOR BOLT EMBEDMENT MINIMUM ULTIMATE DIAMETER (inches) (inches) TENSION CAPACITY (KIP) *, **
3/8 3 4.8
1/2 4 8.1
5/8 5 11.4
3/4 6 15.4
7/8 7 20.0
1 8 24.7
1-1/4 10 34.3
* Data must be based on actual tests preformed in unreinforced mass concrete of not more than 4000 psi compressive strength.
** Capacity must be at a concrete temperature of at least 130 DegF.
4. Post-Installed Mechanical and Adhesive Anchors:
a. Use of expansion bolts requires approval by Engineer.
b. Stainless steel, Type 304 or 316.
c. Provide minimum edge distance cover as recommended by manufacturer or as indicated on Drawings.
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d. Unless noted otherwise on Plans, acceptable concrete anchor products shall be:
1) Mechanical anchors for use in cracked and uncracked concrete shall have been tested and qualified for use in accordance with ACI 355.2 and ICC-ES AC193. Pre-approved mechanical anchors include:
a) Simpson Strong-Tie "Strong-Bolt" (ICC-ES ESR-1771).
b) Simpson Strong-Tie "Titen-HD" (ICC-ES ESR 2713).
c) Hilti "HSL-3" (ICC-ES ESR 1545).
d) Hilti "Kwik Bolt TZ" (ICC-ES ESR 1917).
2) Adhesive anchors for use in cracked and uncracked concrete shall have been tested and qualified for use in accordance with ICC-ES AC308. Pre-approved adhesive anchors include:
a) Simpson Strong-Tie "Set-XP" (ICC-ES ESR-2508).
b) Hilti "Hit-RE 500-SD" (ICC-ES ESR 2322).
5. Self-tapping concrete anchors:
a. Tapcon by ITW Buildex.
b. 410 stainless steel.
c. 1/4 IN DIA with 5/16 IN hex head.
1) Minimum embedment as recommended by manufacturer.
d. #3 Phillips flat head.
2.1.7.3 Lag Screws and Bolts
ASME B18.2.1, type and grade best suited for the purpose.
2.1.7.4 Bolts and Nuts
ASTM A307, Grade A.
2.1.7.5 Bolts, Nuts, and Washers, High Strength
ASTM A325. Provide two (2) washers with all bolts.
2.1.7.6 Powder Actuated Fasteners
Follow safety provisions of ASSE/SAFE A10.3.
2.1.7.7 Screws
ASME B18.2.1, ASME B18.6.2, ASME B18.6.3 and ASTM C1513.
2.1.7.8 Washers
Provide plain washers to conform to ASME B18.21.1. Provide beveled washers
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for American Standard beams and channels, square or rectangular, tapered in thickness, and smooth. Provide lock washers to conform to ASME B18.21.1.
2.1.8 Aluminum Alloy Products
Conform to ASTM B209 for sheet plate, ASTM B221 for extrusions and ASTM B26/B26M or ASTM B108/B108M for castings, as applicable. Provide aluminum extrusions at least 1/8 inch thick and aluminum plate or sheet at least 0.050 inch thick.
2.2 FABRICATION FINISHES
2.2.1 Galvanizing
Hot-dip galvanize items specified to be zinc-coated, after fabrication where practicable. Galvanizing: ASTM A123/A123M, ASTM A153/A153M, ASTM A653/A653M or ASTM A924/A924M, G90, as applicable.
2.2.2 Galvanize
Anchor bolts, grating fasteners, washers, bolts and nuts where noted on drawings, and parts or devices necessary for proper installation, unless indicated otherwise.
2.2.3 Repair of Zinc-Coated Surfaces
Repair damaged surfaces with galvanizing repair method and paint conforming to ASTM A780/A780M or by application of stick or thick paste material specifically designed for repair of galvanizing, as approved by Owner's Representative. Clean areas to be repaired and remove slag from welds. Heat surfaces to which stick or paste material is applied, with a torch to a temperature sufficient to melt the metallics in stick or paste; spread molten material uniformly over surfaces to be coated and wipe off excess material.
2.2.4 Shop Cleaning and Painting
2.2.4.1 Surface Preparation
Blast clean surfaces in accordance with SSPC SP 6/NACE No.3. Surfaces that will be exposed in spaces above ceiling or in attic spaces, crawl spaces, furred spaces, and chases may be cleaned in accordance with SSPC SP 3 in lieu of being blast cleaned. Wash cleaned surfaces which become contaminated with rust, dirt, oil, grease, or other contaminants with solvents until thoroughly clean. Steel to be embedded in concrete shall be free of dirt and grease. Do not paint or galvanize bearing surfaces, including contact surfaces within slip critical joints, but coat with rust preventative applied in the shop.
2.2.4.2 Pretreatment, Priming and Painting
Apply pretreatment, primer, and paint in accordance with manufacturer's printed instructions. On surfaces concealed in the finished construction or not accessible for finish painting, apply an additional prime coat to a minimum dry film thickness of 1.0 mil. Tint additional prime coat with a small amount of tinting pigment.
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2.2.5 Nonferrous Metal Surfaces
Protect by plating, anodic, or organic coatings.
2.2.6 Aluminum Surfaces
2.2.6.1 Surface Condition
Before finishes are applied, remove roll marks, scratches, rolled-in scratches, kinks, stains, pits, orange peel, die marks, structural streaks, and other defects which will affect uniform appearance of finished surfaces.
2.2.6.2 Aluminum Finishes
Unexposed sheet, plate and extrusions may have mill finish as fabricated. Sandblast castings' finish, medium, AA DAF45. Unless otherwise specified, provide all other aluminum items with a standard mill finish. Provide a coating thickness not less than that specified for protective and decorative type finishes for items used in interior locations or architectural Class I type finish for items used in exterior locations in AA DAF45.
2.3 FLOOR ACCESS DOOR (INTERIOR)
Description:
Single or double leaf covers are constructed of 1/4 inch diamond pattern plate and reinforced for 150 psf live load.
Material:
Cover and frame are 1/4 inch aluminum.
Cover:
Diamond-pattern tread plate reinforced for 150 psf live load.
Frame:
Extruded aluminum angle frame with strap anchors bolted around the perimeter.
Hinges:
Heavy forged brass hinges with 3/8 inch Type 316 stainless steel hinge pins.
Latch:
Type 316 stainless steel slam lock with fixed interior handle and removable exterior turn/lift handle.
Lift Assistance:
Torsion bars that pivot on cam-action hinges. Automatic hold-open arm with grip handle release.
Finish:
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Mill finish aluminum with a bituminous coating applied to the exterior of the frame where contact with concrete occurs.
Hardware:
Zinc plated/chromate sealed.
2.4 FLOOR ACCESS DOOR (EXTERIOR)
Description:
Designed to withstand 300 psf live load. Single or double leaf covers are constructed of 1/4 inch diamond pattern plate reinforced 300 psf live load. Features reinforced composite spring tubes, heavy forged brass hinges, and zinc plated/chromate sealed hardware.
FAD-l05 to have a "custom" grated top in lieu of a checkered plate.
Design Base: Type "J-AL" or "JD-AL" by Bilco or approved equal.
Material:
Cover and frame are 1/4 inch aluminum.
Cover:
Aluminum diamond-pattern tread plate reinforced for 300 psf live load.
Frame:
Formed channel frame with full anchor angle welded around the perimeter. A 1-1/2 inch drain coupling is welded under the frame for a pipe connection to the dry well or disposal system.
Hinges:
Heavy forged brass hinges with 3/8 inch Type 316 stainless steel hinge pins.
Latch:
Type 316 stainless steel slam lock with fixed interior handle and removable exterior turn/lift handle. Latch release is protected by a flush, gasketed, removable screw plug.
Lift Assistance:
Compression spring operators enclosed in telescopic tubes. Automatic hold-open arm with grip handle release.
Finish:
Mill.
Hardware:
Engineered composite compression spring tubes. Steel compression springs with electrocoated acrylic finish. Slam lock and all fasteners are Type 316 stainless steel. All other hardware is zinc
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plated/chromate sealed.
2.5 FLOOR GRATINGS
Design aluminum grating in accordance with NAAMM MBG 531 for bar type grating or manufacturer's charts for plank grating.
a. Design floor gratings to support a live load of 100 pounds per square foot for the spans indicated, with maximum deflection of L/240.
b. NAAMM MBG 531, band edges of grating with bars of the same size as the bearing bars. Provide full depth banding unless otherwise indicated. Weld banding in accordance with the manufacturer's standard for trim unless otherwise indicated. Design tops of bearing bars, cross or intermediate bars to be in the same plane and match grating finish.
c. Attach gratings to structural members with clips and bolts (stainless steel).
d. Slip resistance requirements must exceed both wet and dry a static coefficient of friction of 0.5.
2.6 GUARD POSTS (BOLLARDS/PIPE GUARDS)
Provide 8 inch galvanized extra strong weight steel pipe as specified in ASTM A53/A53M. Anchor posts in concrete as indicated and fill solidly with concrete with minimum compressive strength of 3000 psi, and round off at top.
2.7 MISCELLANEOUS PLATES AND SHAPES
Provide for items that do not form a part of the structural steel framework, such as lintels, sill angles, miscellaneous mountings and frames. Provide lintels fabricated from structural steel shapes over openings in masonry walls and partitions as indicated and as required to support wall loads over openings. Provide with connections and welds. Construct to have at least 8 inches bearing on masonry at each end.
Provide angles and plates, ASTM A36/A36M, for embedment as indicated. Galvanize embedded items exposed to the elements according to ASTM A123/A123M.
PART 3 EXECUTION
3.1 GENERAL INSTALLATION REQUIREMENTS
Install items at locations indicated, according to manufacturer's instructions. Verify all measurements and take all field measurements necessary before fabrication. Exposed fastenings shall be compatible materials, shall generally match in color and finish, and harmonize with the material to which fastenings are applied. Include materials and parts necessary to complete each item, even though such work is not definitely shown or specified. Poor matching of holes for fasteners shall be cause for rejection. Conceal fastenings where practicable. Thickness of metal and details of assembly and supports shall provide strength and stiffness. Form joints exposed to the weather shall be formed to exclude water. Items listed below require additional procedures.
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3.2 WORKMANSHIP
Provide miscellaneous metalwork that is well formed to shape and size, with sharp lines and angles and true curves. Drilling and punching shall produce clean true lines and surfaces. Provide continuous welding along the entire area of contact except where tack welding is permitted. Do not tack weld exposed connections of work in place and ground smooth. Provide a smooth finish on exposed surfaces of work in place and unless otherwise approved, flush exposed riveting. Mill joints where tight fits are required. Corner joints shall be coped or mitered, well formed, and in true alignment. Accurately set work to established lines and elevations and securely fastened in place. Install in accordance with manufacturer's installation instructions and approved drawings, cuts, and details.
3.3 ANCHORAGE, FASTENINGS, AND CONNECTIONS
Provide anchorage where necessary for fastening miscellaneous metal items securely in place. Include for anchorage not otherwise specified or indicated slotted inserts, expansion shields, and powder-driven fasteners, when approved for concrete; toggle bolts and through bolts for masonry; machine and carriage bolts for steel; through bolts, lag bolts, and screws for wood. Do not use wood plugs in any material. Provide non-ferrous attachments for non-ferrous metal. Make exposed fastenings of compatible materials, generally matching in color and finish, to which fastenings are applied. Conceal fastenings where practicable.
3.4 BUILT-IN WORK
Form for anchorage metal work built-in with concrete or masonry, or provide with suitable anchoring devices as indicated or as required. Furnish metal work in ample time for securing in place as the work progresses.
3.5 WELDING
Perform welding, welding inspection, and corrective welding, in accordance with AWS D1.1/D1.1M. Use continuous welds on all exposed connections. Grind visible welds smooth in the finished installation.
3.6 FINISHES
3.6.1 Dissimilar Materials
Where dissimilar metals are in contact, protect surfaces with a coat conforming to MPI 79 to prevent galvanic or corrosive action. Where aluminum is in contact with concrete, plaster, mortar, masonry, wood, or absorptive materials subject to wetting, protect with ASTM D1187/D1187M, asphalt-base emulsion.
3.6.2 Field Preparation
Remove rust preventive coating just prior to field erection, using a remover approved by the rust preventive manufacturer. Surfaces, when assembled, shall be free of rust, grease, dirt and other foreign matter.
3.6.3 Environmental Conditions
Do not clean or paint surface when damp or exposed to foggy or rainy weather, when metallic surface temperature is less than 5 degrees F above the dew point of the surrounding air, or when surface temperature is below
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45 degrees F or over 95 degrees F, unless approved by the Owner's Representative.
3.7 ACCESS PANELS
Install a removable access panel not less than 12 by 12 inches directly below each valve, flow indicator, damper, or air splitter that is located above the ceiling, other than an acoustical ceiling, and that would otherwise not be accessible.
3.8 COVER PLATES AND FRAMES
Install the tops of cover plates and frames flush with floor.
3.9 ROOF HATCH (SCUTTLES)
Provide aluminum with 3 inch beaded flange, welded and ground at corner. Provide a minimum clear opening as indicated on drawings. Construction and accessories as follows:
a. Insulate cover and curb with one inch thick rigid fiberboard insulation covered and protected by aluminum sheet with 12 inches high curb, formed with 3 inch mounting flange with holes provided for securing to the roof deck. Equip the curb with an integral metal cap flashing of the same gage and metal as the curb, full welded and ground at corners for weather tightness.
b. Provide hatch completely assembled with pintle hinges, compression spring operators enclosed in telescopic tubes, positive snap latch with turn handles on inside and outside, and neoprene draft seal. Provide fasteners for padlocking on the inside. Equip the cover with an automatic hold-open arm complete with grip handle to permit one-hand release. Cover action shall be smooth through its entire range with an operating pressure of approximately 30 pounds.
3.10 INSTALLATION OF GUARD POSTS (BOLLARDS/PIPE GUARDS)
Set bollards/pipe guards vertically in 3000 psi concrete as detailed. 48 Inch projection above ground, 48 inch embedment in concrete unless detailed otherwise on drawings.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 05 50 14
STRUCTURAL METAL FABRICATIONS 11/08 08/15/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ALUMINUM ASSOCIATION (AA)
AA ADM (2010) Aluminum Design Manual
AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)
ANSI/AGMA 2005 (2003D; R 2008) Design Manual for Bevel Gears
ANSI/AGMA 6001 (2008E) Design and Selection of Components for Enclosed Gear Drives
AMERICAN WELDING SOCIETY (AWS)
AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel
AWS D1.2/D1.2M (2008) Structural Welding Code - Aluminum
ASME INTERNATIONAL (ASME)
ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts
ASME B46.1 (2009) Surface Texture, Surface Roughness, Waviness and Lay
ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications
ASTM INTERNATIONAL (ASTM)
ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A325 (2010; E 2013) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength
ASTM A380/A380M (2013) Standard Practice for Cleaning, Descaling, and Passivation of Stainless
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Steel Parts, Equipment, and Systems
ASTM A490 (2012) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength
ASTM A514/A514M (2013) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding
ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
ASTM D962 (1981; E 2008; R 2008) Aluminum Powder and Paste Pigments for Paints
ASTM E165/E165M (2012) Standard Practice for Liquid Penetrant Examination for General Industry
ASTM E709 (2008) Standard Guide for Magnetic Particle Examination
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings; G
SD-03 Product Data
Welding of Structural Steel; G Welding of Aluminum; G Structural Steel Welding Repairs; G Materials Orders Materials List Shipping Bill
SD-06 Test Reports
Tests, Inspections, and Verifications
SD-07 Certificates
Qualification of Welders and Welding Operators Application Qualification for Steel Studs; G Welding of Aluminum; G
1.3 QUALITY ASSURANCE
1.3.1 Qualification of Welders and Welding Operators
Certify that the qualification of welders and welding operators and tack welders who will perform structural steel welding have been qualified for the particular type of work to be done in accordance with the requirements of AWS D1.1/D1.1M, Section 4, Section IX, prior to commencing fabrication.
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a. List the qualified welders by name and specify the code and procedures under which qualified and the date of qualification within the certification. Prior qualification will be accepted if welders have performed satisfactory work under the code for which qualified within the preceding three months. Welders are required to repeat the qualifying tests when their work indicates a reasonable doubt as to proficiency. Those passing the requalification tests will be recertified. Those not passing will be disqualified until passing. Contractor incurs all expenses in connection with qualification and requalification.
b. Perform welding of aluminum conforming to AA ADM or AWS D1.2/D1.2M, Sections 1 through 7, 9 and 10. The welding process and welding operators shall be prequalified as required by AWS D1.2/D1.2M, Section 5 or AA ADM, Subsection 7.2.4 in accordance with the methods described in ASME BPVC SEC IX, Section IX. Furnish for approval a certified report giving the results of the qualifying tests, and a complete schedule of the welding process for each aluminum fabrication to be welded prior to commencing fabrication prior to commencing welding.
c. Maintain an approved inspection system and perform required inspections in accordance with Contract Clause CONTRACTOR INSPECTION SYSTEM. Welding will be subjected to inspection to determine conformance with the requirements of AWS D1.1/D1.1M, the approved welding procedures and provisions stated in other sections of these specifications.
1.3.2 Detail Drawings
Submit detail drawings for metalwork and machine work, prior to fabrication, include within the detail drawings catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate. Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the detail drawings.
PART 2 PRODUCTS
2.1 FABRICATION
2.1.1 Structural Fabrication
Material shall be straight before being laid off or worked. Perform straightening, if necessary, by methods that will not impair the metal. Sharp kinks or bends will be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Make bends using approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow it to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, will be subject to approval and shall be indicated on detail drawings. Shearing shall be accurate and all portions of the work neatly finished. Corners shall be square and true unless otherwise shown. Re-entrant cuts shall be filleted to a minimum radius of 3/4 inch unless otherwise approved. Provide finished members free of twists, bends and open joints. Bolts, nuts and screws shall be tight.
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2.1.1.1 Dimensional Tolerances for Structural Work
Measure dimensions using an approved calibrated steel tape of approximately the same temperature as the material being measured. The overall dimensions of an assembled structural unit shall be within the tolerances indicated on the drawings or as specified in the particular section of these specifications for the item of work. Where tolerances are not specified in other sections of these specifications or shown, an allowable variation of 1/32 inch is permissible in the overall length of component members with both ends milled; component members without milled ends shall not deviate from the dimensions shown by more than 1/16 inch for members 30 feet or less in length, and by more than 1/8 inch for members over 30 feet in length.
2.1.1.2 Structural Steel Fabrication
Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Prepare surfaces and edges in accordance with AWS D1.1/D1.1M, Subsection 3.2. Where structural steel is not to be welded, chipping or grinding will not be required except as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Chip, grind or machine to sound metal hand-guided cuts which are to be exposed or visible.
2.1.1.3 Structural Aluminum Fabrication
Lay out and cut aluminum in accordance with the AA ADM, Section 6.
2.1.2 Welding
2.1.2.1 Welding of Structural Steel
2.1.2.1.1 Welding Procedures for Structural Steel
Prequalify welding procedures for structural steel as described in AWS D1.1/D1.1M, Subsection 3.1 or qualify by tests as prescribed in AWS D1.1/D1.1M, Section 4. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish a welding procedure as prequalified. For welding procedures qualified by tests, the test welding and specimen testing will be witnessed and the test report document signed by the Owner's Representative. Approval of any welding procedure will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. The Contractor will be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the Contractor Officer. Submit a complete schedule of welding procedures for each steel structure to be welded prior to commencing fabrication. The schedule shall conform to the requirements specified in the provisions AWS D1.1/D1.1M, Sections 2, 3, 4, 6, 7 and applicable portions of Section 8. Provide within the schedule detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint. Include in the welding procedures filler metal, preheat, interpass temperature and stress-relief heat treatment requirements. Each welding procedure shall be clearly identified as being prequalified or required to be qualified by tests. Welding procedures shall show types and locations of welds designated or in the specifications to receive nondestructive examination.
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2.1.2.1.2 Welding Process
Perform welding of structural steel by an electric arc welding process using a method which excludes the atmosphere from the molten metal and conforms to the applicable provisions of AWS D1.1/D1.1M. Minimize residual stresses, distortion and shrinkage from welding.
2.1.2.1.3 Welding Technique
2.1.2.1.3.1 Filler Metal
The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal and welding process being used or be as shown where a specific choice of AWS specification allowables is required. Include the AWS designation of the electrodes to be used in the schedule of welding procedures. Use only low hydrogen electrodes for manual shielded metal-arc welding regardless of the thickness of the steel. Use a controlled temperature storage oven at the job site as prescribed by AWS D1.1/D1.1M, Subsection 3.5 to maintain low moisture of low hydrogen electrodes.
2.1.2.1.3.2 Preheat and Interpass Temperature
Perform preheating as required by AWS D1.1/D1.1M, Subsection 3.5 or as otherwise specified except that the temperature of the base metal shall be at least 70 degrees F. Slowly and uniformly preheat the weldments by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air.
2.1.2.1.3.3 Stress-Relief Heat Treatment
Where stress relief heat treatment is specified or shown, perform in accordance with the requirements of AWS D1.1/D1.1M, Subsection 5.8 unless otherwise authorized or directed.
2.1.2.1.4 Workmanship
Perform welding workmanship in accordance with AWS D1.1/D1.1M, Section 3 and other applicable requirements of these specifications.
2.1.2.1.4.1 Preparation of Base Metal
Prior to welding inspect surfaces to be welded to ensure compliance with AWS D1.1/D1.1M, Subsection 3.2.
2.1.2.1.4.2 Temporary Welds
Make temporary welds, required for fabrication and erection, under the controlled conditions prescribed for permanent work. Make temporary welds using low-hydrogen welding electrodes and by welders qualified for permanent work as specified in these specifications. Conduct preheating for temporary welds as required by AWS D1.1/D1.1M for permanent welds except that the minimum temperature shall be 120 degrees F in any case. In making temporary welds, arcs shall not be struck in other than weld locations. Remove each temporary weld and grind flush with adjacent surfaces after serving its purpose.
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2.1.2.1.4.3 Tack Welds
Subject tack welds that are to be incorporated into the permanent work to the same quality requirements as the permanent welds; clean and thoroughly fuse them with permanent welds. Perform preheating as specified above for temporary welds. Multiple-pass tack welds shall have cascaded ends. Remove defective tack welds before permanent welding.
2.1.2.2 Welding of Steel Castings
Remove unsound material from the surfaces of steel castings, to be incorporated into welded connections, by chipping, machining, air-arc gouging or grinding. Do not weld major connections designed for transfer of stresses if the temperature of the casting is lower than 100 degrees F. Castings containing over 0.35 percent carbon or over 0.75 percent manganese shall be preheated to a temperature not to exceed 450 degrees F and conduct welding while the castings are maintained at a temperature above 350 degrees F. Welding will not be permitted on castings containing carbon in excess of 0.45 percent except on written authorization. Castings requiring welding repairs after the first annealing and castings involving welding fabrication shall be stress-relieved annealed prior to receiving final machining unless otherwise permitted.
2.1.2.3 Welding of Steel Studs
Conform to the requirements of AWS D1.1/D1.1M, Section 7, except as otherwise specified for the procedures for welding steel studs to structural steel, including mechanical, workmanship, technique, stud application qualification, production quality control and fabrication and verification inspection procedures.
2.1.2.3.1 Application Qualification for Steel Studs
As a condition of approval of the stud application process, furnish certified test reports and certification that the studs conform to the requirements of AWS D1.1/D1.1M, Subsections 7.2 and 7.3, certified results of the stud manufacturer's stud base qualification test, and certified results of the stud application qualification test as required by AWS D1.1/D1.1M, Subsection 7.6, prior to commencing fabrication, except as otherwise specified.
2.1.2.3.2 Production Quality Control
Conform to the requirements of AWS D1.1/D1.1M, Subsection 7.7, except as otherwise specified for quality control for production welding of studs. Studs on which pre-production testing is to be performed shall be welded in the same general position as required on production studs (flat, vertical, overhead or sloping). If the reduction of the length of studs becomes less than normal as they are welded, stop welding immediately and do not resume until the cause has been corrected.
2.1.3 Bolted Connections
2.1.3.1 Bolted Structural Steel Connections
Provide bolts, nuts and washers of the type specified or indicated. Equip all nuts with washers except for high strength bolts. Use beveled washers where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis. Where the use of high strength bolts is specified
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or indicated, the materials, workmanship and installation shall conform to the applicable provisions of ASTM A325 or ASTM A490.
a. Bolt holes shall be accurately located, smooth, perpendicular to the member and cylindrical.
b. Holes for regular bolts shall be drilled or subdrilled and reamed in the shop and not be more than 1/16 inch larger than the diameter of the bolt.
c. Holes for fitted bolts shall be match-reamed or drilled in the shop. Remove burrs resulting from reaming. Keep bolt threads entirely outside of the holes. The body diameter of bolts shall have tolerances as recommended by ASME B4.1for the class of fit specified. Place fitted bolts in reamed holes by selective assembly to provide an LN-2 fit.
d. Holes for high strength bolts shall not have diameters more than 1/16 inch larger than bolt diameters. If the thickness of the material is not greater than the diameter of the bolts, the holes may be punched. If the thickness of the material is greater than the diameter of the bolts the holes may be drilled full size or subpunched or subdrilled at least 1/8 inch smaller than the diameter of the bolts and then reamed to full size. Poor matching of holes will be cause for rejection. Drifting occurring during assembly shall not distort the metal or enlarge the holes. Reaming to a larger diameter of the next standard size bolt will be allowed for slight mismatching.
2.1.3.2 Bolted Aluminum Connections
Conform to the requirements of AA ADM, Section 6 for punching, drilling, reaming and bolting for bolted aluminum connections.
2.1.4 Castings
Each casting and castings weighing more than 500 required pounds shall bear cast or stamped heat numbers. Deviations from the dimensions of castings shown shall not exceed amounts that will impair the strength of castings by more than 10 percent as computed from the dimensions shown. Dimensions of castings shown on approved detail drawings are finished dimensions. Castings that are warped or otherwise distorted or that are oversize to an extent that will interfere with proper fit with other parts of the machinery or structure will be rejected. The structure of metal in castings shall be homogeneous and free from excessive nonmetallic inclusions. Excessive segregation of impurities or alloys at critical points in castings will be cause for rejection. Do not make repairs to castings prior to approval. Minor surface imperfections not affecting the strength of casting may be welded in the "green" if approved. Surface imperfections will be considered minor when the depth of the cavity prepared for welding is the lesser of 20 percent of the actual wall thickness or 1 inch. Defects other than minor surface imperfections may be welded only when specifically authorized in accordance with the following requirements:
a. The defects have been entirely removed and are judged not to affect the strength, use or machineability of the castings when properly welded and stress relieved.
b. The proposed welding procedure, stress relief and method of examination
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of the repair work have been submitted and approved.
2.1.5 Machine Work
Tolerances, allowances and gauges for metal fits between plain, non-threaded, cylindrical parts shall conform to ASME B4.1 for the class of fit shown or required unless otherwise shown on approved detail drawings. Where fits are not shown they will be suitable as approved. Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64 inch. Sufficient machining stock will be allowed on placing pads to ensure true surfaces of solid material. Provide finished contact or bearing surfaces true and exact to secure full contact. Polish journal surfaces and finish all surfaces with sufficient smoothness and accuracy to ensure proper operation when assembled. Parts entering any machine shall be accurately machined and all like parts be interchangeable except that parts assembled together for drilling or reaming of holes or machining will not be required to be interchangeable with like parts. Accurately locate all drilled holes bolts.
2.1.5.1 Finished Surfaces
Provide surface finishes, indicated or specified, in accordance with ASME B46.1. Values of required roughness heights are arithmetical average deviations expressed in microinches. These values are maximum. Lesser degrees will be satisfactory unless otherwise indicated. Compliance with surface requirements shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ASME B46.1. Values of roughness width and waviness height shall be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified use that which is most suitable for the particular surface, provide the class of fit required and be indicated on the detail drawings by a symbol which conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.
2.1.5.2 Unfinished Surfaces
Lay out all work to secure proper matching of adjoining unfinished surfaces unless otherwise directed. Where there is a large discrepancy between adjoining unfinished surfaces chip and grind smooth or machine to secure proper alignment. Unfinished surfaces shall be true to the lines and dimensions shown and be chipped or ground free of all projections and rough spots. Fill in depressions or holes not affecting the strength or usefulness of the parts in an approved manner.
2.1.5.3 Pin Holes
Pin holes are to be bored true to gauges, smooth, straight and at right angles to the axis of the member. The boring shall be done after the member is securely fastened in position.
2.1.5.4 Gears
Provide gears that have machine cut teeth of a form conforming to applicable design requirements of ANSI/AGMA 2005 and ANSI/AGMA 6001 unless otherwise specified or shown.
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2.1.5.5 Shafting
Turn or grind shafting with hot-rolled or cold-rolled steel, as required, unless otherwise specified or authorized. Provide fillets where changes in section occur. Cold-finished shafting may be used where keyseating is the only machine work required.
2.1.5.6 Bearings
Bearings may be lined with babbit or bronze unless otherwise specified or shown. Where the bearing pressure is in excess of 200 psi, bearings shall be lined with bronze. Pressures on lined bearings shall not exceed 200 psi of projected area unless otherwise required or authorized. Anti-friction bearings of approved types and of sizes not less than those recommended by the bearing manufacturer for the duty intended will be permitted subject to approval. Properly align all bearings provided with a suitable means of lubrication. Install anti-friction bearings as required to provide for retention of the lubricant and to exclude dirt and grit.
2.1.6 Miscellaneous Provisions
2.1.6.1 Metallic Coatings
a. Zinc Coatings - Apply zinc coatings in a manner and of a thickness and quality conforming to ASTM A123/A123M. Where zinc coatings are destroyed by cutting, welding or other causes regalvanize the affected areas. Regalvanize coatings 2 ounces or heavier with a suitable low-melting zinc base alloy similar to the recommendations of the American Hot-Dip Galvanizers Association to the thickness and quality specified for the original zinc coating. Repair coatings less than 2 ounces in accordance with ASTM A780/A780M.
2.1.6.2 Cleaning of Corrosion-Resisting Steel
Remove oil, paint and other foreign substances from corrosion-resisting steel surfaces after fabrication. Perform cleaning by vapor degreasing or by the use of cleaners of the alkaline, emulsion or solvent type. After the surfaces have been cleaned give a final rinsing with clean water followed by a 24 hour period during which the surfaces are intermittently wet with clean water and then allowed to dry for the purpose of inspecting the clean surfaces. Visually inspect the surfaces for evidence of paint, oil, grease, welding slag, heat treatment scale, iron rust or other forms of contamination. If evidence of foreign substance is found, clean again in accordance with the applicable provisions of ASTM A380/A380M. Furnish the proposed method of treatment for approval. Visually reinspect after treatment. Use only stainless steel or nonmetallic bristle brushes to remove foreign substances. Any contamination occurring subsequent to the initial cleaning shall be removed by one or more of the methods indicated above.
2.1.6.3 Lubrication
The arrangement and details for lubrication shall be as shown. Thoroughly clean and lubricate, with an approved lubricant, all bearing surfaces before erection or assembly.
2.1.7 Shop Assembly
Assemble each structural unit furnished in the shop to determine the
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correctness of the fabrication and matching of the component parts unless otherwise specified. Do not exceed those tolerances shown. Closely check each unit assembled to ensure that all necessary clearances have been provided and that binding does not occur in any moving part. Assembly in the shop shall be in the same position as final installation in the field unless otherwise specified. Perform assembly and disassembly work in the presence of the Owner's Representative unless waived in writing. Immediately remedy errors or defects disclosed by the Contractor without cost to the Owner's Representative. Before disassembly for shipment each piece of a machinery or structural unit shall be match-marked to facilitate erection in the field. Indicate the location of match-marks by circling with a ring of white paint after the shop coat of paint has been applied or as otherwise directed.
2.2 TESTS, INSPECTIONS, AND VERIFICATIONS
Perform material tests and analyses certified by an approved laboratory to demonstrate that materials are in conformity with the specifications. These tests and analyses shall be performed and certified at the Contractor's expense. Perform tests, inspections, and verifications conforming to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Conduct tests in the presence of the Owner's Representative if so required. Furnish specimens and samples for additional independent tests and analyses upon request by the Owner's Representative. Properly label specimens and samples and prepare for shipment. Submit certified test reports for materials with all materials delivered to the site.
2.2.1 Nondestructive Testing
When doubt exists as to the soundness of any material part, such part may be subjected to any form of nondestructive testing determined by the Owner's Representative. This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Owner's Representative. Any defects will be cause for rejection; replace and retest rejected parts at the Contractor's expense.
2.2.2 Tests of Structural Units
The details for tests of structural units shall conform to the requirements of the particular sections of these specifications covering these items. Assemble each complete structural unit and test them in the shop, in the presence of the Owner's Representative, unless otherwise directed. Waiving of tests will not relieve the Contractor of responsibility for any fault in operation, workmanship or material that occurs before the completion of the contract or guarantee. After being installed at the site, each complete structural unit shall be operated through a sufficient number of complete cycles to demonstrate to the satisfaction of the Owner's Representative that it meets the specified operational requirements in all respects.
2.2.3 Inspection of Structural Steel Welding
Nondestructive examination of designated welds will be required. Supplemental examination of any joint or coupon cut from any location in any joint may be required.
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2.2.3.1 Visual Examination
Visually inspect all welds. For all visual examination of completed welds clean and carefully examine for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects to ensure compliance with the requirements of AWS D1.1/D1.1M, Section 6, subsection 6.9, Part C.
2.2.3.2 Nondestructive Examination
Perform as designated or described in the sections of these specifications, the nondestructive examination of shop and field welds covering the particular items of work.
2.2.3.2.1 Testing Agency
The nondestructive examination of welds and the evaluation of examination tests as to the acceptability of the welds shall be performed by a testing agency adequately equipped and competent to perform such services or by the Contractor using suitable equipment and qualified personnel. In either case, written approval of the examination procedures is required and the examination tests shall be made in the presence of the Owner's Representative. The evaluation of examination tests are subject to the approval and all records become the property of the Owner's Representative.
2.2.3.2.2 Examination Procedures
Conform to the following requirements.
2.2.3.2.2.1 Ultrasonic Testing
Making, evaluating and reporting ultrasonic testing of welds shall conform to the requirements of AWS D1.1/D1.1M, Section 6, Part C. Provide ultrasonic equipment capable of making a permanent record of the test indications. Make a record of each weld tested.
2.2.3.2.2.2 Radiographic Testing
Making, evaluating and reporting radiographic testing of welds shall conform to the requirements of AWS D1.1/D1.1M, Section 6, Parts C and E.
2.2.3.2.2.3 Magnetic Particle Inspection
Magnetic particle inspection of welds shall conform to the applicable provisions of ASTM E709.
2.2.3.2.2.4 Liquid Dye Penetrant Inspection
Perform dye penetrant inspection of welds conforming to the applicable provisions of ASTM E165/E165M. Inspect 50% of full penetration welds and 20% of fillet welds.
2.2.3.2.3 Acceptability of Welds
Welds will be unacceptable if shown to have defects prohibited by AWS D1.1/D1.1M, or possess any degree of incomplete fusion, inadequate penetration or undercutting.
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2.2.3.2.4 Welds to be Subject to Nondestructive Examination
Test 20% of liquid dye penetrant tested full penetration welds with untrasonic or radiographic testing.
2.2.3.3 Test Coupons
The Owner's Representative reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by nondestructive examination. Should tests of any two coupons cut from the work of any welder show strengths less than that specified for the base metal it will be considered evidence of negligence or incompetence and such welder will be removed from the work. When coupons are removed from any part of a structure, repair the members cut in a neat manner with joints of the proper type to develop the full strength of the members. Repaired joints shall be peened as approved or directed to relieve residual stress. The expense for removing and testing coupons, repairing cut members and the nondestructive examination of repairs shall be borne by the Owner's Representative or the Contractor in accordance with the Contract Clauses INSPECTION AND ACCEPTANCE.
2.2.3.4 Supplemental Examination
When the soundness of any weld is suspected of being deficient due to faulty welding or stresses that might occur during shipment or erection, the Owner's Representative reserves the right to perform nondestructive supplemental examinations before final acceptance. The cost of such inspection will be borne by the Owner's Representative.
2.2.4 Structural Steel Welding Repairs
Repair defective welds in the structural steel welding repairs in accordance with AWS D1.1/D1.1M, Subsection 3.7. Remove defective weld metal to sound metal by use of air carbon-arc or oxygen gouging. Do not use oxygen gouging on ASTM A514/A514M steel. Thoroughly clean surfaces before welding. Retest welds that have been repaired by the same methods used in the original inspection. Except for the repair of members cut to remove test coupons and found to have acceptable welds costs of repairs and retesting will be borne by the Contractor. Submit welding repair plans for steel, prior to making repairs.
2.2.5 Inspection and Testing of Steel Stud Welding
Perform fabrication and verification inspection and testing of steel stud welding conforming to the requirements of AWS D1.1/D1.1M, Subsection 7.8 except as otherwise specified. The Owner's Representative will serve as the verification inspector. One stud in every 100 and studs that do not show a full 360 degree weld flash, have been repaired by welding or whose reduction in length due to welding is less than normal shall be bent or torque tested as required by AWS D1.1/D1.1M, Subsection 7.8. If any of these studs fail, bend or torque test two additional studs. If either of the two additional studs fails, all of the studs represented by the tests will be rejected. Studs that crack under testing in either the weld, base metal or shank will be rejected and replaced.
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PART 3 EXECUTION
3.1 INSTALLATION
Thoroughly clean all parts to be installed. Remove packing compounds, rust, dirt, grit and other foreign matter. Clean holes and grooves for lubrication. Examine enclosed chambers or passages to make sure that they are free from damaging materials. Where units or items are shipped as assemblies they will be inspected prior to installation. Disassembly, cleaning and lubrication will not be required except where necessary to place the assembly in a clean and properly lubricated condition. Do not use pipe wrenches, cold chisels or other tools likely to cause damage to the surfaces of rods, nuts or other parts used for assembling and tightening parts. Tighten bolts and screws firmly and uniformly but take care not to overstress the threads. When a half nut is used for locking a full nut place the half nut first followed by the full nut. Lubricate threads of all bolts except high strength bolts, nuts and screws with an approved lubricant before assembly. Coat threads of corrosion-resisting steel bolts and nuts with an approved antigalling compound. Driving and drifting bolts or keys will not be permitted.
3.1.1 Alignment and Setting
Accurately align each machinery or structural unit by the use of steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place. The alignment of all parts with respect to each other shall be true within the respective tolerances required. Set true machines to the elevations shown.
3.1.2 Blocking and Wedges
Remove all blocking and wedges used during installation for the support of parts to be grouted in foundations before final grouting unless otherwise directed. Blocking and wedges left in the foundations with approval shall be of steel or iron.
3.1.3 Foundations and Grouting
Concreting of subbases and frames and the final grouting under parts of machines shall be in accordance with the procedures as specified in Section 03 30 00.00 10 MISCELLANEOUS CAST-IN-PLACE CONCRETE.
3.2 TESTS
3.2.1 Workmanship
Workmanship must be of the highest grade and in accordance with the best modern practices to conform with the specifications for the item of work being furnished.
3.2.2 Production Welding
Perform production welding conforming to the requirements of AWS D1.1/D1.1M or AWS D1.2/D1.2M, as applicable. Studs, on which pre-production testing is to be performed, shall be welded in the same general position as required on production items (flat, vertical, overhead or sloping). Test and production stud welding will be subjected to visual examination or inspection. If the reduction of the length of studs becomes less than normal as they are welded, stop welding immediately and do not resume until
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the cause has been corrected.
3.3 PROTECTION OF FINISHED WORK
3.3.1 Machined Surfaces
Thoroughly clean foreign matter off machined surfaces. All finished surfaces shall be protected by suitable means. Oil and wrap unassembled pins and bolts with moisture resistant paper or protect them by other approved means. Wash finished surfaces of ferrous metals to be in bolted contact, with an approved rust inhibitor and coat them with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Paint finished surfaces of metals which will be exposed after installation, except corrosion resisting steel or nonferrous metals as specified in Section 09 90 00 PAINTING AND COATING.
3.3.2 Lubrication After Assembly
After assembly fill all lubricating systems with the lubricant specified and apply additional lubricant at intervals as required to maintain the equipment in satisfactory condition until acceptance of the work.
3.3.3 Aluminum
Protect aluminum that will be in contact with grout or concrete from galvanic or corrosive action,with a coat of zinc-chromate primer and a coat of aluminum paint. Protect aluminum in contact with structural steel against galvanic or corrosive action with a coat of zinc-chromate primer and a coat of aluminum paint. Provide aluminum paint consisting of a aluminum paste conforming to ASTM D962, spar varnish and thinner compatible with the varnish. Field mix the aluminum paint in proportion of 2 pounds of paste, not more than one gallon of spar varnish and not more than one pint of thinner.
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SECTION 05 51 33
METAL LADDERS 05/10 08/07/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ALUMINUM ASSOCIATION (AA)
AA DAF45 (2003; Reaffirmed 2009) Designation System for Aluminum Finishes
AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)
ANSI A14.3 (2008) American National Standards for Ladders - Fixed - Safety Requirements
AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)
ASCE 7 (2010; Change 2010; Change 2011; Errata 2011; Change 2011) Minimum Design Loads for Buildings and Other Structures
AMERICAN WELDING SOCIETY (AWS)
AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel
ASTM INTERNATIONAL (ASTM)
ASTM B108/B108M (2012; E 2012) Standard Specification for Aluminum-Alloy Permanent Mold Castings
ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM B221 (2013) Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
ASTM B26/B26M (2012) Standard Specification for Aluminum-Alloy Sand Castings
ASTM D1187/D1187M (1997; E 2011; R 2011) Asphalt-Base Emulsions for Use as Protective Coatings for Metal
MASTER PAINTERS INSTITUTE (MPI)
MPI 79 (Oct 2009) Alkyd Anti-Corrosive Metal
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Primer
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
29 CFR 1910.27 Fixed Ladders
1.2 SYSTEM DESCRIPTION
The design, engineering, and construction of ladders is the responsibility of the Contractor. Engineer for contractor-designed system and components: Professional Structural Engineer in the State of North Dakota.
Design Submittals shall include:
a. Certification that manufactured units meet all design loads specified.
b. Shop Drawings and engineering design calculations:
1. Indicate design live loads.
2. Sealed by a professional structural engineer.
3. Engineer (A/E) will review for general compliance with Contract Documents.
Designed ladders to be as listed below:
c. Fully welded type.
1. All welds to be fully penetration welds.
d. All ladders of a particular material shall have consistent construction and material shapes and sizes unless detailed otherwise on the drawings.
e. Design ladder in accordance with ASHA Standards, ANSI A14.3, and ASCE 7 and applicable Building Codes.
f. Ladders shall be designed to support a minimum of concentrated live load of 300 pounds at any point to produce the maximum stress in the member being designed.
Apply additional 300 pound loads for each section of ladder exceeding 10 feet.
g. Maximum allowable stresses per AA ADM 1.
h. Maximum lateral deflection: Side rail span/240 when lateral load of 100 pounds is applied to any location.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Ladders, installation drawings; G
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SD-03 Product Data
Design; G
Ladders; G
Ladder Safety Extension Post; G
1.4 QUALIFICATION OF WELDERS
Qualify welders in accordance with AWS D1.1/D1.1M. Use procedures, materials, and equipment of the type required for the work.
1.5 DELIVERY, STORAGE, AND PROTECTION
Protect from corrosion, deformation, and other types of damage. Store items in an enclosed area free from contact with soil and weather. Remove and replace damaged items with new items.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Aluminum Alloy Products
Conform to ASTM B209 for sheet plate, ASTM B221 for extrusions and ASTM B26/B26M or ASTM B108/B108M for castings, as applicable. Provide aluminum extrusions at least 1/8 inch thick and aluminum plate or sheet at least 0.125 inch thick.
2.2 FABRICATION FINISHES
2.2.1 Aluminum
Mill finish.
2.2.2 Aluminum Surfaces
2.2.2.1 Surface Condition
Remove roll marks, scratches, rolled-in scratches, kinks, stains, pits, orange peel, die marks, structural streaks, and other defects which will affect uniform appearance of finished surfaces.
2.2.2.2 Aluminum Finishes
Unexposed plate and extrusions may have mill finish as fabricated. Sandblast castings' finish, medium, AA DAF45. Unless otherwise specified, provide all other aluminum items with standard mill finish.
2.3 LADDERS
Fabricate vertical ladders conforming to Section 7 of 29 CFR 1910.27. Use 3 by 1/2 inch aluminum flat bars for stringers and 2 1/4 inch (4) row traction tread ladder rungs. Rungs to be not less than 16 inches wide, spaced one foot apart, welded to stringers. Install ladders so that the distance from the rungs to the finished wall surface will not be less than
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7 inches. Provide heavy aluminum clip angles welded to the stringer as indicated. Provide intermediate clip angles not over 48 inches on centers.
2.4 LADDER SAFETY EXTENSION POST
Acceptable manufacturer is Bilco.
a. Telescoping tubular aluminum section that automatically locks into place when fully extended.
b. Non-ferrous cosrrosion-resistant spring and hardware.
c. Factory assembled with all hardware necessary for mounting to ladder.
d. Bilco "LadderUp" safety post.
PART 3 EXECUTION
3.1 GENERAL INSTALLATION REQUIREMENTS
Install items at locations indicated, according to manufacturer's instructions. Verify all measurements and take all field measurements necessary before fabrication. Provide Exposed fastenings of compatible materials, generally matching in color and finish, and harmonize with the material to which fastenings are applied. Include materials and parts necessary to complete each item, even though such work is not definitely shown or specified. Poor matching of holes for fasteners will be cause for rejection. Conceal fastenings where practicable. Thickness of metal and details of assembly and supports must provide strength and stiffness. Items listed below require additional procedures.
3.2 WORKMANSHIP
Metalwork must be well formed to shape and size, with sharp lines and angles and true curves. Drilling and punching must produce clean true lines and surfaces. Continuously weld along the entire area of contact. Do not tack weld exposed connections of work in place. Grid smooth exposed welds. Provide smooth finish on exposed surfaces of work in place, unless otherwise approved. Where tight fits are required, mill joints. Cope or miter corner joints, well formed, and in true alignment. Install in accordance with manufacturer's installation instructions and approved drawings, cuts, and details.
3.3 ANCHORAGE, FASTENINGS, AND CONNECTIONS
Provide anchorage where necessary for fastening metal items securely in place. Include for anchorage not otherwise specified or indicated slotted inserts, expansion anchors,and powder-actuated fasteners, when approved for concrete; toggle bolts and through bolts for masonry; machine bolts. Provide non-ferrous attachments. Make exposed fastenings of compatible materials, generally matching in color and finish, to which fastenings are applied. Conceal fastenings where practicable.
3.4 WELDING
Perform welding, welding inspection, and corrective welding, in accordance with AWS D1.1/D1.1M. Use continuous welds on all exposed connections. Grind visible welds smooth in the finished installation. Full penetration
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butt weld at bends in ladder side rails.
3.5 FINISHES
3.5.1 Dissimilar Materials
Where dissimilar metals are in contact, protect surfaces with a coat conforming to MPI 79 to prevent galvanic or corrosive action. Where aluminum is in contact with concrete, plaster, mortar, masonry, wood, or absorptive materials subject to wetting, protect with ASTM D1187/D1187M, asphalt-base emulsion.
3.5.2 Field Preparation
Remove rust preventive coating just prior to field erection, using a remover approved by the rust preventive manufacturer. Surfaces, when assembled, must be free of grease, dirt and other foreign matter.
3.5.3 Environmental Conditions
Do not clean surface when damp or exposed to foggy or rainy weather, when metallic surface temperature is less than 5 degrees F above the dew point of the surrounding air, or when surface temperature is below 45 degrees F or over 95 degrees F, unless approved by the Owner's Representative.
3.6 LADDERS
Secure to the adjacent construction with the clip angles attached to the stringer. Install intermediate clip angles not over 48 inches on center. Ends of ladders must not rest upon finished roof or floor.
Anchor ladder to concrete structure with a minimum 3/4 inch stainless steel bolts with minimum 6 inch embedment.
Anchor ladder to masonry structure with a minum 3/4 inch stinless steel anchor bolts with minimum 6 inch embedment.
1. When anchoring into masonry, fill masonry cores with grout at anchor locations and each masonry core within 8 inches of anchor
Install ladder safety extension post in accordance with manufacturer's instructions.
1. Mount device opposite the climbing side.
2. Provide ladder safety extension device as indicated.
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 05 72 00
DECORATIVE METAL SPECIALTIES 02/12 08/15/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN WELDING SOCIETY (AWS)
AWS D1.2/D1.2M (2008) Structural Welding Code - Aluminum
ASME INTERNATIONAL (ASME)
ASME B18.13 (1996; Addenda A 1998; R 2013) Screw and Washer Assemblies - Sems (Inch Series)
ASME B18.2.2 (2010) Nuts for General Applications: Machine Screw Nuts, Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)
ASME B18.21.1 (2009) Washers: Helical Spring-Lock, Tooth Lock, and Plain Washers (Inch Series)
ASME B18.24 (2004; Addenda A 2006; R 2011) Part Identifying Number (PIN) Code System Standard for B18 Fastener Products
ASME B18.6.3 (2013) Machine Screws, Tapping Screws, and Machine Drive Screws (Inch Series)
ASTM INTERNATIONAL (ASTM)
ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ASTM A27/A27M (2013) Standard Specification for Steel Castings, Carbon, for General Application
ASTM A283/A283M (2013) Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates
ASTM A47/A47M (1999; R 2009) Standard Specification for Ferritic Malleable Iron Castings
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ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Decorative Metal Items (Fence, Gates, Etc.); G
Construction Details; G
SD-03 Product Data
Decorative Metal Items; G
SD-04 Samples
Manufacturer's Standard Color Charts; G
SD-07 Certificates
Decorative Metal Items; G
Welder Qualifications; G
SD-08 Manufacturer's Instructions
Maintenance Instructions; G
1.3 DELIVERY, STORAGE, AND HANDLING
Store all Architectural metal items off the ground on clean raised platforms or pallets one level high in dry locations with adequate ventilation, such as an enclosed building or closed trailer.
Keep materials free from dirt and grease and protected from corrosion.
Store packaged materials in their original, unbroken containers in a dry area, until ready for installation.
PART 2 PRODUCTS
2.1 INSTALLATION MATERIALS
Submit manufacturer's catalog data for the following items listing all decorative metal accessories including casting, forgings, fasteners and anchorage devices.
2.1.1 Concrete Inserts
Use galvanized wedge-type concrete inserts , box-type, ferrous castings with integral anchor loop at back of box and designed to accept bolts having special wedge shape heads. Ferrous castings are to be malleable iron conforming to ASTM A47/A47M, Grade 32510 or Grade 35018, or
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medium-strength cast steel conforming to ASTM A27/A27M, Grade U-60-30. Inserts are to be hot-dip galvanized after fabrication in accordance with ASTM A153/A153M. Provide hot-dip galvanized carbon steel bolts with special wedge shape heads, nuts, washers, and shims, in accordance with ASTM A153/A153M.
Provide slotted-type concrete inserts, hot-dip galvanized, pressed steel plate, welded construction, box-type, with slot to receive square head bolt and to provide lateral adjustment of the bolt. Length of insert body less anchorage lugs is a minimum of 4-1/2 inches. Provide inserts with knockout cover. Steel plate can not be less than 1/8 inch thick conforming to ASTM A283/A283M, Grade C. Inserts are to be hot-dip galvanized after fabrication in accordance with ASTM A123/A123M.
Provide concrete inserts which are non-removable when embedded in concrete of 3,000 pounds per square inch compressive strength and subjected to a 6,000-pound tension load test in an axial direction. Concrete can not indicate any evidence of failure attributable to the anchoring device itself.
2.1.2 Standard Bolts and Nuts
Provide standard bolts, regular hexagon head, corrosion-resistant steel, coarse thread series, conforming to, Type II.
Provide standard nuts, plain hexagon, regular style, corrosion-resistant steel, conforming to ASME B18.2.2, Type II, Style 4.
2.1.3 Machine Screws
Provide machine screws, corrosion-resistant steel, cross-recess drive, flat head, conforming to ASME B18.6.3, Type III, Style 2C.
2.1.4 Plain Washers
Provide plain washers, round, general-assembly, corrosion-resistant steel, conforming to ASME B18.21.1, Type A, Grade I, Class B.
2.1.5 Lock Washers
Provide lock washers, helical spring, corrosion-resistant steel (nonmagnetic), conforming to ASME B18.13 and ASME B18.21.1.
2.2 GATE AND FENCE FABRICATION
A. Base Design:
1. Custom made similar to Montage Industrial Ornamental Steel Fence (Majestic Style) by Ameristar Fence Products, Inc. in Tulsa, Oklahoma.
B. Galvanized Steel Tubing, (ASTM A780/A780M).
1. Decorative picket swing gate frame:
a. 2.5 inch square, 12 GA metal thickness.
b. G60 Zinc coating.
2. Horizontal rails:
SECTION 05 72 00 Page 3 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
a. Horizontal rails to be prepunched and precut out of hot rolled, structural steel, 1.75 inches x 1.75 inches x 0.105 inches metal thickness.
b. Provide the third "optional" rail at top as indicated.
c. G90 Zinc coating.
3. Pickets:
a. Vertical pickets shall be solid steel bars 1 x 1 inch square.
b. Space pickets at 4.715 inches maximum on center.
c. G60 Zinc Coating.
4. Posts:
a. 2.5 inch square, 12 GA metal thickness.
5. Hardware:
a. Hinges shall have a load capacity of 1,000 pounds.
c. Hinges shall allow gate leaf to swing 180 degrees.
d. Provide a center drop rod for anchorage to concrete.
e. Provide a hasp for Owner's Representative provided padlock/chain.
2.2.1 Metals for Fasteners
Provide fastener identification conforming to ASME B18.24.
Provide corrosion-resistant steel fasteners made of chromium-nickel steel, AISI Type 302, 303, 304, 305, or 316, with form and condition best suited for the application.
2.2.2 Finish
Refer to Specification Section 09 90 00, PAINTS AND COATINGS.
2.3 FABRICATION IN GENERAL
Submit Manufacturer's Standard Color Charts for Shop Paint and Finish Paint for approval by the Owner's Representative prior to work. Submit fabrication drawings for Decorative Metal Items.
Submit Installation Drawings for Decorative Metal Items, Shop and Field Connections and Construction Details showing location, dimensions, size, and weight or gauge as applicable of each decorative item; type and location of shop and field connections; and other pertinent construction and erection details. Show on drawings location and details of anchorage devices embedded in cast-in-place concrete and masonry construction.
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2.3.1 Workmanship
Fabricate metalwork to the shape and size, with lines, angles, and curves true to form. Provide necessary rabbets, lugs, and brackets so that the work can be assembled. Conceal fasteners where practical.
Design exterior decorative metal items to withstand expansion and contraction of the component parts at an ambient temperature of100 degrees F without causing harmful buckling, opening of joints, overstressing of fasteners, or other harmful effects.
Welded fabrication to meet requirements as specified in AWS D1.2/D1.2M. Execute all welds behind finished surfaces without distortion or discoloration of the exposed side. Clean flux from welded joints and dress all exposed and contact surfaces.
Drill or punch holes for fasteners.
Mill all joints to a close fit. Cope or miter corner joints to a, well formed shape, and true alignment with the adjacent item. Fabricate and form joints exposed to weather to prevent water intrusion.
Ensure all castings are sound and free from warp or defects that impair their strength and appearance, with a smooth finish and sharp well-defined vertical and horizontal lines on all exposed surfaces.
2.3.2 Holes for Other Work
Provide holes where indicated for securing other work to metal work.
PART 3 EXECUTION
3.1 GENERAL PROVISIONS
Install decorative metal work in accordance with the approved shop drawings and descriptive data for each decorative metal item, as specified.
Securely fasten decorative metal items plumb and true to horizontal and vertical lines and levels.
3.2 ANCHORAGE EMBEDDED IN OTHER CONSTRUCTION
Provide setting drawings, templates, instructions, and directions for the installation of the fence and gates. Embed fences into concrete to a minimum of 54 inches below grade.
3.3 FASTENING TO CONSTRUCTION-IN-PLACE
Do not anchor fenceand gates to building or screenwalls.
3.4 CUTTING AND FITTING
Perform required cutting, drilling, and fitting for the installation of decorative metal work. Execute cutting, drilling, and fitting carefully; when required, fit in place work before fastening.
3.5 SETTING MASONRY ANCHORAGE DEVICES
Set all masonry anchorage devices in masonry or concrete-in-place
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construction in accordance with the anchorage device manufacturer's printed instructions. Drill anchorage holes to the recommended depth, diameter, and size recommended by the manufacturer of the particular anchorage device used. Leave drilled anchorage holes rough, not reamed, and free of drill dust.
3.6 WELDING PROCEDURES
Ensure procedures for welding, appearance, quality of welds made, and the methods used in correcting welding work conform to AWS D1.2/D1.2M.
Ground all exposed welds smooth.
3.7 THREADED CONNECTIONS
Countersink and provide flat bolt and screw heads where anchors are exposed to view, and tightly secure threaded connections so that the threads are entirely concealed by fitting, unless otherwise specified.
3.8 INSPECTION AND ACCEPTANCE PROVISIONS
3.8.1 Finished Decorative Metal Work Requirements
Decorative metal work will be rejected for any of the following deficiencies:
a. Installed decorative metal items that do not match the approved Shop Drawings.
3.8.2 Repair of Defective Work
Remove and/or replace defective work with decorative metal materials that meet the requirements of this section.
-- End of Section --
SECTION 05 72 00 Page 6 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 6 WOOD, PLASTICS, AND COMPOSITES
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 06 10 00
ROUGH CARPENTRY 02/12 08/07/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN LUMBER STANDARDS COMMITTEE (ALSC)
ALSC PS 20 (2010) American Softwood Lumber Standard
AMERICAN WOOD COUNCIL (AWC)
AWC NDS (2012) National Design Specification (NDS) for Wood Construction
AWC WFCM (2012) Wood Frame Construction Manual for One- and Two-Family Dwellings
AMERICAN WOOD PROTECTION ASSOCIATION (AWPA)
AWPA M2 (2011) Standard for Inspection of Treated Wood Products
AWPA M6 (2013) Brands Used on Preservative Treated Materials
ASME INTERNATIONAL (ASME)
ASME B18.2.1 (2012; Errata 2013) Square and Hex Bolts and Screws (Inch Series)
ASME B18.2.2 (2010) Nuts for General Applications: Machine Screw Nuts, Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)
ASME B18.5.2.1M (2006; R 2011) Metric Round Head Short Square Neck Bolts
ASME B18.5.2.2M (1982; R 2010) Metric Round Head Square Neck Bolts
ASME B18.6.1 (1981; R 2008) Wood Screws (Inch Series)
ASTM INTERNATIONAL (ASTM)
ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
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ASTM A307 (2012) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength
ASTM D2898 (2010) Accelerated Weathering of Fire-Retardant-Treated Wood for Fire Testing
ASTM F547 (2006; R 2012) Nails for Use with Wood and Wood-Base Materials
FM GLOBAL (FM)
FM 4435 (2013) Roof Perimeter Flashing
NATIONAL HARDWOOD LUMBER ASSOCIATION (NHLA)
NHLA Rules (2011) Rules for the Measurement & Inspection of Hardwood & Cypress
NORTHEASTERN LUMBER MANUFACTURERS ASSOCIATION (NELMA)
NELMA Grading Rules (2013) Standard Grading Rules for Northeastern Lumber
REDWOOD INSPECTION SERVICE (RIS) OF THE CALIFORNIA REDWOOD ASSOCIATION (CRA)
RIS Grade Use (1998) Redwood Lumber Grades and Uses
SOUTHERN CYPRESS MANUFACTURERS ASSOCIATION (SCMA)
SCMA Spec (1986; Supple. No. 1, Aug 1993) Standard Specifications for Grades of Southern Cypress
SOUTHERN PINE INSPECTION BUREAU (SPIB)
SPIB 1003 (2002) Standard Grading Rules for Southern Pine Lumber
U.S. GENERAL SERVICES ADMINISTRATION (GSA)
CID A-A-1923 (Rev A; Notice 2) Shield, Expansion (Lag, Machine and Externally Threaded Wedge Bolt Anchors)
CID A-A-1924 (Rev A; Notice 2) Shield, Expansion (Self Drilling Tubular Expansion Shell Bolt Anchors
CID A-A-1925 (Rev A; Notice 2) Shield Expansion (Nail Anchors)
WEST COAST LUMBER INSPECTION BUREAU (WCLIB)
WCLIB 17 (2004) Standard Grading Rules
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WESTERN WOOD PRODUCTS ASSOCIATION (WWPA)
WWPA G-5 (2011) Western Lumber Grading Rules
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Nailers and Nailing Strips
Drawings of field erection details, including materials and methods of fastening nailers in conformance with Factory Mutual wind uplift rated systems specified in other Sections of these specifications.
SD-03 Product Data
Fire-retardant treatment
SD-06 Test Reports
Preservative-treated lumber
SD-07 Certificates
Certificates of grade
Manufacturer's certificates (approved by an American Lumber Standards approved agency) attesting that lumber and material not normally grade marked meet the specified requirements. Certificate of Inspection for grade marked material by an American Lumber Standards Committee (ALSC) recognized inspection agency prior to shipment.
Preservative treatment
1.3 DELIVERY AND STORAGE
Deliver materials to the site in an undamaged condition. Store, protect, handle, and install prefabricated structural elements in accordance with manufacturer's instructions and as specified. Store materials off the ground to provide proper ventilation, with drainage to avoid standing water, and protection against ground moisture and dampness. Store materials with a moisture barrier at both the ground level and as a cover forming a well ventilated enclosure. Adhere to requirements for stacking, lifting, bracing, cutting, notching, and special fastening requirements. Remove defective and damaged materials and provide new materials. Store separated reusable wood waste convenient to cutting station and area of work.
1.4 GRADING AND MARKING
1.4.1 Lumber
Mark each piece of framing and board lumber or each bundle of small pieces of lumber with the grade mark of a recognized association or independent
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inspection agency. Such association or agency shall be certified by the Board of Review, American Lumber Standards Committee, to grade the species used. Surfaces that are to be exposed to view shall not bear grademarks, stamps, or any type of identifying mark. Hammer marking will be permitted on timbers when all surfaces will be exposed to view.
1.4.2 Preservative-Treated Lumber and Plywood
The Contractor shall be responsible for the quality of treated wood products. Each treated piece shall be inspected in accordance with AWPA M2 and permanently marked or branded, by the producer, in accordance with AWPA M6. The Contractor shall provide Owner's Representative (COR) with the inspection report of an approved independent inspection agency that offered products comply with applicable AWPA Standards. The appropriate Quality Mark on each piece will be accepted, in lieu of inspection reports, as evidence of compliance with applicable AWPA treatment standards.
1.4.3 Fire-Retardant Treated Lumber
Mark each piece in accordance with AWPA M6, except pieces that are to be natural or transparent finished. In addition, exterior fire-retardant lumber shall be distinguished by a permanent penetrating blue stain. Labels of a nationally recognized independent testing agency will be accepted as evidence of conformance to the fire-retardant requirements of AWPA M6.
1.5 SIZES AND SURFACING
ALSC PS 20 for dressed sizes of yard and structural lumber. Lumber shall be surfaced four sides. Size references, unless otherwise specified, are nominal sizes, and actual sizes shall be within manufacturing tolerances allowed by the standard under which the product is produced. Other measurements are IP or SI standard.
1.6 MOISTURE CONTENT
Air-dry or kiln-dry lumber. Kiln-dry treated lumber after treatment. Maximum moisture content of wood products shall be as follows at the time of delivery to the job site:
a. Framing lumber and board, 19 percent maximum
b. Materials other than lumber; moisture content shall be in accordance with standard under which the product is produced
1.7 PRESERVATIVE TREATMENT
Treat
a. 0.25 pcf intended for above ground use.
b. 0.40 pcf intended for ground contact and fresh water use. 0.60 pcf intended for Ammoniacal Copper Quaternary Compound (ACQ)-treated foundations. 0.80 to 1.00 pcf intended for ACQ-treated pilings. All wood shall be air or kiln dried after treatment. Specific treatments shall be verified by the report of an approved independent inspection agency, or the AWPA Quality Mark on each piece. Brush coat areas that are cut or drilled after treatment with either the same preservative used in the treatment or with a 2 percent copper naphthenate solution.
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All lumber and woodwork shall be preservative treated. The following items shall be preservative treated:
1. Nailers, edge strips, crickets, curbs, and cants for roof decks.
1.8 FIRE-RETARDANT TREATMENT
Fire-retardant treated wood shall be pressure treated Treatment and performance inspection shall be by an independent and qualified testing agency that establishes performance ratings. Each piece or bundle of treated material shall bear identification of the testing agency to indicate performance in accordance with such rating. Treated materials to be exposed to rain wetting shall be subjected to an accelerated weathering technique in accordance with ASTM D2898 prior to being tested. Such items which will not be inside a building, and such items which will be exposed to heat or high humidity, shall receive exterior fire-retardant treatment. Fire-retardant-treated wood products shall be free of halogens, sulfates, ammonium phosphate, and formaldehyde. Items to be treated include the following:
1. Nailers, edge strips, crickets, curbs, and cants for roof decks.
1.9 QUALITY ASSURANCE
1.9.1 Drawing Requirements
For fabricated members, indicate materials, details of construction, methods of fastening, and erection details. Include reference to design criteria used and manufacturers design calculations. Submit drawings for all proposed modifications of structural members. Do not proceed with modifications until the submittal has been approved.
1.9.2 Data Required
Submit calculations and drawings for all proposed modifications of structural members. Do not proceed with modifications until the submittal has been approved.
1.9.3 Certificates of Grade
Submit certificates attesting that products meet the grade requirements specified in lieu of grade markings where appearance is important and grade marks will deface material.
PART 2 PRODUCTS
2.1 LUMBER
2.1.1 Framing Lumber
Framing lumber such as plates, cant strips, bucks, sleepers, nailing strips, and nailers and board lumber. Minimum grade of species shall be as listed.
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Table of Grades for Framing and Board Lumber
Grading Rules Species Framing Board Lumber
WWPA G-5 standard Aspen, Douglas All Species: All Species: grading rules Fir-Larch, Standard Light No. 3 Common Douglas Fir Framing or South, Engelmann No. 3 Spruce-Lodgepole Structural Pine, Engelmann Light Framing Spruce, Hem-Fir, (Stud Grade Idaho White for 2x4 Pine, Lodgepole nominal size, Pine, Mountain 10 feet and Hemlock, shorter) Mountain Hemlock-Hem-Fir, Ponderosa Pine-Sugar Pine, Ponderosa Pine-Lodgepole Pine, Subalpine Fir, White Woods, Western Woods, Western Cedars, Western Hemlock
WCLIB 17 standard Douglas All Species: All Species: grading rules Fir-Larch, Standard Light Standard Hem-Fir, Framing or Mountain No. 3 Hemlock, Sitka Structural Spruce, Western Light Framing Cedars, Western (Stud Grade Hemlock for 2x4 nominal size, 10 feet and shorter)
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Table of Grades for Framing and Board Lumber
Grading Rules Species Framing Board Lumber
SPIB 1003 standard Southern Pine All Species: No. 2 Boards grading rules Standard Light Framing or No. 3 Structural Light Framing (Stud Grade for 2x4 nominal size, 10 feet and shorter)
SCMA Spec standard Cypress No. 2 Common No. 2 Common specifications
NELMA Grading Rules Balsam Fir, All Species: All Species: standard grading Eastern Standard Light No. 3 Common rules Hemlock-Tamarack, Framing or except Eastern Spruce, No. 3 Standard for Eastern White Structural Eastern White Pine, Northern Light Framing and Northern Pine, Northern (Stud Grade Pine Pine-Cedar for 2x4 nominal size, 10 feet and shorter)
RIS Grade Use Redwood All Species: Construction standard Standard Light Heart specifications Framing or No. 3 Structural Light Framing (Stud Grade for 2x4 nominal size, 10 feet and shorter)
SECTION 06 10 00 Page 7 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
Table of Grades for Framing and Board Lumber
Grading Rules Species Framing Board Lumber
NHLA Rules rules Cypress No. 2 Dimension No. 2 Common for the measurement and inspection of hardwood and cypress lumber
2.2 ROUGH HARDWARE
Unless otherwise indicated or specified, rough hardware shall be of the type and size necessary for the project requirements. Sizes, types, and spacing of fastenings of manufactured building materials shall be as recommended by the product manufacturer unless otherwise indicated or specified. Rough hardware exposed to the weather or embedded in or in contact with preservative treated wood, exterior masonry, or concrete walls or slabs shall be hot-dip zinc-coated in accordance with ASTM A153/A153M. Nails and fastenings for fire-retardant treated lumber and woodwork exposed to the weather shall be copper alloy or hot-dipped galvanized fasteners as recommended by the treated wood manufacturer.
2.2.1 Bolts, Nuts, Studs, and Rivets
ASME B18.2.1, ASME B18.5.2.1M, ASME B18.5.2.2M and ASME B18.2.2.
2.2.2 Anchor Bolts
ASTM A307, size as indicated, complete with nuts and washers.
2.2.3 Expansion Shields
CID A-A-1923, CID A-A-1924, and CID A-A-1925. Except as shown otherwise, maximum size of devices shall be 3/8 inch.
2.2.4 Lag Screws and Lag Bolts
ASME B18.2.1.
2.2.5 Wood Screws
ASME B18.6.1.
2.2.6 Nails
ASTM F547, size and type best suited for purpose. For sheathing and subflooring, length of nails shall be sufficient to extend 1 inch into supports. In general, 8-penny or larger nails shall be used for nailing through 1 inch thick lumber and for toe nailing 2 inch thick lumber; 16-penny or larger nails shall be used for nailing through 2 inch thick lumber. Nails used with treated lumber and sheathing shall be hot-dipped galvanized in accordance with ASTM A153/A153M. Nailing shall be in accordance with the recommended nailing schedule contained in AWC WFCM.
SECTION 06 10 00 Page 8 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
Where detailed nailing requirements are not specified, nail size and spacing shall be sufficient to develop an adequate strength for the connection. The connection's strength shall be verified against the nail capacity tables in AWC NDS. Reasonable judgment backed by experience shall ensure that the designed connection will not cause the wood to split. If a load situation exceeds a reasonable limit for nails, a specialized connector shall be used.
PART 3 EXECUTION
3.1 INSTALLATION
Conform to AWC WFCM unless otherwise indicated or specified. Select lumber sizes to minimize waste. Fit framing lumber and other rough carpentry, set accurately to the required lines and levels, and secure in place in a rigid manner.
3.1.1 Sills
3.1.1.1 Anchors in Concrete
Except where indicated otherwise, Embed anchor bolts not less than 8 inches in poured concrete walls and provide each with a nut and a 2 inch diameter washer at bottom end. A bent end may be substituted for the nut and washer; bend shall be not less than 90 degrees. Powder-actuated fasteners spaced 3 feet o.c. may be provided in lieu of bolts for single thickness plates on concrete.
3.2 MISCELLANEOUS
3.2.1 Wood Roof Nailers, Edge Strips, Crickets, Curbs, and Cants
Provide sizes and configurations indicated or specified and anchored securely to continuous construction. Provide at curbs for roof ventilators, skylight, and roof hatch.
3.2.1.1 Roof Nailing Strips
Provide roof nailing strips for roof decks as indicated. Apply nailing strips in straight parallel rows in the direction and spacing indicated. Strips shall be surface applied.
a. Surface-Applied Nailers: Shall be 6 inches wide (nominal) and of thickness to finish flush with the top of the insulation. Anchor strips securely to the roof deck with powder actuated fastening devices or expansion shields and bolts, spaced not more than 24 inches o.c.
3.2.1.2 Roof Edge Strips and Nailers
Provide at perimeter of roof, around openings through roof, and where roofs abut walls, curbs, and other vertical surfaces. Except where indicated otherwise, nailers shall be 6 inches wide and the same thickness as the insulation. Anchor nailers securely to underlying construction. Anchor perimeter nailers in accordance with FM 4435. Strips shall be grooved for edge venting; install at walls, curbs, and other vertical surfaces with a 1/4 to 1/2 inch air space.
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3.2.2 Temporary Closures
Provide with hinged doors and padlocks and install during construction at exterior doorways and other ground level openings that are not otherwise closed. Cover windows and other unprotected openings with polyethylene or other approved material, stretched on wood frames. Provide dustproof barrier partitions to isolate and secure areas as directed.
3.3 INSTALLATION OF TIMBER CONNECTORS
Installation of timber connectors shall conform to applicable requirements of AWC NDS.
-- End of Section --
SECTION 06 10 00 Page 10 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 7 THERMAL AND MOISTURE PROTECTION
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 07 11 13
BITUMINOUS DAMPPROOFING 08/11 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM D226/D226M (2009) Standard Specification for Asphalt-Saturated Organic Felt Used in Roofing and Waterproofing
ASTM D227/D227M (2003; R 2011; E 2012) Coal-Tar-Saturated Organic Felt Used in Roofing and Waterproofing
ASTM D41/D41M (2011) Asphalt Primer Used in Roofing, Dampproofing, and Waterproofing
ASTM D4263 (1983; R 2012) Indicating Moisture in Concrete by the Plastic Sheet Method
ASTM D4479/D4479M (2007; E 2012; R 2012) Asphalt Roof Coatings - Asbestos-Free
ASTM D449/D449M (2003; R 2014; E 2014) Asphalt Used in Dampproofing and Waterproofing
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-07 Certificates
Materials
1.3 DELIVERY AND STORAGE
Deliver materials in sealed containers bearing manufacturer's original labels. Labels shall include date of manufacture, contents of each container, performance standards that apply to the contents and recommended shelf life.
PART 2 PRODUCTS
2.1 ASPHALT
ASTM D449/D449M, Type I or Type II.
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2.2 ASPHALT PRIMER
ASTM D41/D41M.
2.3 FIBROUS ASPHALT
ASTM D4479/D4479M, Type I for horizontal surfaces, Type II for vertical surfaces.
2.4 SURFACE PROTECTION
2.4.1 Saturated Felt
ASTM D226/D226M, Asphalt Saturated, Type I, 15 pound; ASTM D227/D227M, Coal-Tar Saturated.
PART 3 EXECUTION
3.1 SURFACE PREPARATION
Remove or cut form ties and repair all surface defects as required in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE. Clean concrete and masonry surfaces to receive dampproofing of foreign matter and loose particles. Apply dampproofing to clean dry surfaces. Moisture test in accordance with ASTM D4263. If test indicates moisture, allow a minimum of 7 additional days after test completion for curing. If moisture still exists, redo test until substrate is dry.
3.1.1 Metal Surfaces
Metal surfaces shall be dry and be free of rust, scale, loose paint, oil, grease, dirt, frost and debris.
3.2 Protection of Surrounding Areas
Before starting the dampproofing work, the surrounding areas and surfaces shall be protected from spillage and migration of dampproofing material onto other work. Drains and conductors shall be protected from clogging with dampproofing material.
3.3 APPLICATION (Behind Stone Veneer)
Use either hot-application or cold-application method. Prime surfaces to receive fibrous asphaltic dampproofing unless recommended otherwise by dampproofing materials manufacturer. Apply dampproofing after priming coat is dry, but prior to any deterioration of primed surface, and when ambient temperature is above 40 degrees F.
3.3.1 Surface Priming
Prime surfaces to receive asphalt or fibrous asphalt dampproofing with asphalt primer. Apply primer when ambient temperature is above 40 degrees F and at rate of approximately one gallon per 100 square feet, fully covering entire surface to be dampproofed.
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3.3.2 Cold-Application Method
3.3.2.1 Fibrous Asphalt
Apply two coats of fibrous asphalt to surfaces to be dampproofed. Apply each coat uniformly using not less than one gallon fibrous asphalt per 50 square feet. Apply first coat by brush or spray to provide full bond with primed surface. Brush or spray second coat over thoroughly dry first coat unless recommended otherwise by dampproofing materials manufacturer. Provide finished surface that is of uniform thickness and impervious to moisture. Recoat porous areas.
-- End of Section --
SECTION 07 11 13 Page 3 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 07 14 00
FLUID-APPLIED WATERPROOFING 02/12 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM C578 (2012b) Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation
ASTM C836/C836M (2012) High Solids Content, Cold Liquid-Applied Elastomeric Waterproofing Membrane for Use With Separate Wearing Course
1.2 SUBMITTALS
Owner's Representative approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Owner's Representative. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Fluid-applied membrane
Membrane primer
Solvent
SD-11 Closeout Submittals
Information Card
Instructions To Owner's Representative Personnel
Include copies of Material Safety Data Sheets for maintenance/repair materials.
1.3 PREWATERPROOFING CONFERENCE
Prior to starting application of waterproofing system, arrange and attend a prewaterproofing conference to ensure a clear understanding of drawings and specifications. Give the Owner's Representative 7 days advance written notice of the time and place of meeting. Ensure that the mechanical and electrical subcontractor, flashing and sheetmetal subcontractor, and other
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trades that may perform other types of work on or over the membrane after installation, attend this conference.
1.4 DELIVERY, STORAGE, AND HANDLING
Deliver waterproofing materials in manufacturer's original, unopened containers, with labels intact and legible. Containers of materials covered by a referenced specification number shall bear the specification number, type, and class of the contents. Deliver materials in sufficient quantity to continue work without interruption. Store and protect materials in accordance with manufacturer's instructions, and use within their indicated shelf life. When hazardous materials are involved, adhere to special precautions of the manufacturer, unless precautions conflict with local, state, and federal regulations. Promptly remove from the site materials or incomplete work adversely affected by exposure to moisture or freezing. Store materials on pallets and cover from top to bottom with canvas tarpaulins.
1.5 ENVIRONMENTAL CONDITIONS
Apply materials when ambient temperature is 40 degrees F or above for a period of 24 hours prior to the application and when there is no ice, frost, surface moisture, or visible dampness on the substrate surface. Apply materials when air temperature is expected to remain above 40 degrees F during the cure period recommended by the manufacturer. Moisture test for substrate is specified under paragraph entitled "Moisture Test." Work may be performed within heated enclosures, provided the surface temperature of the substrate is maintained at a minimum of 40 degrees F for 24 hours prior to the application of the waterproofing, and remains above that temperature during the cure period recommended by the manufacturer.
PART 2 PRODUCTS
2.1 FLUID-APPLIED MEMBRANE (For Foundation Walls of Pump House Structure)
ASTM C836/C836M.
2.2 SEALANT
As specified in Section 07 92 00 JOINT SEALANTS.
2.3 SEALANT PRIMER
As specified in Section 07 92 00 JOINT SEALANTS.
2.4 JOINT FILLER
As specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.
2.5 INSULATION
Polystyrene foam conforming to ASTM C578, Class IV, thickness as indicated.
PART 3 EXECUTION
3.1 PREPARATION
Coordinate work with that of other trades to ensure that components to be incorporated into the waterproofing system are available when needed.
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Inspect and approve surfaces immediately before application of waterproofing materials. Remove laitance, loose aggregate, sharp projections, grease, oil, dirt, curing compounds, and other contaminants which could adversely affect the complete bonding of the fluid-applied membrane to the concrete surface.
3.1.1 Flashings
Make penetrations through sleeves in concrete slab watertight before application of waterproofing. After flashing is completed, cover elastomeric sheet with fluid-applied waterproofing during waterproofing application.
3.1.1.1 Drains
Make drain flanges flush with surface of structural slab. Apply a full elastomeric sheet around the drain, with edges fully adhered to drain flange and to structural slab. Do not adhere elastomeric sheet over joint between drain and concrete slab. Do not plug drainage or weep holes. Cover elastomeric sheet with fluid-applied waterproofing during waterproofing application. Lap elastomeric sheet a minimum of 4 inches onto concrete slab.
3.1.1.2 Penetrations and Projections
Flash penetrations and projections through structural slab with an elastomeric sheet adhered to the concrete slab and the penetration. Leave elastomeric sheet unadhered for one inch over joint between penetration and concrete slab. Adhere elastomeric sheet a minimum of 4 inches onto horizontal deck.
3.1.1.3 Walls and Vertical Surfaces
Flash wall intersections which are not of monolithic pour or constructed with reinforced concrete joints with an elastomeric sheet adhered to both vertical wall surfaces and concrete slab. Flash intersections which are monolithically poured or constructed with reinforced concrete joints with either an elastomeric sheet or a vertical grade of fluid-applied waterproofing adhered to vertical wall surfaces and concrete slab. Leave sheet unadhered for a distance of one inch from the corner on both vertical and horizontal surfaces.
3.1.2 Cracks and Joints
Prepare visible cracks and joints in substrate to receive fluid-applied waterproofing membrane by placing a bond breaker and an elastomeric slip sheet between membrane and substrate. Cracks that show movement shall receive a 2 inch bond breaker followed by an elastomeric sheet adhered to the deck. Nonmoving cracks shall be double coated with fluid-applied waterproofing.
3.1.3 Priming
Prime surfaces to receive fluid-applied waterproofing membrane. Apply primer as required by membrane manufacturer's printed instructions.
3.2 SPECIAL PRECAUTIONS
Protect waterproofing materials during transport and application. Do not
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dilute, unless specifically recommended by materials manufacturer. Keep containers closed except when removing contents. Do not mix remains of unlike materials. Thoroughly remove residual materials before using application equipment for mixing and transporting materials. Do not permit equipment on the project site that has residue of materials used on previous projects. Use cleaners only for cleaning, not for thinning primers or membrane materials. Ensure that workers and others who walk on cured membrane wear clean, soft-soled shoes to avoid damaging the waterproofing materials.
3.3 APPLICATION
Over primed surfaces, provide a uniform, wet, 2 coats of fluid-applied membrane, 60 mils thick each, plus or minus 5 mils by following manufacturer's printed instructions. Apply material by trowel, squeegee, roller, brush, spray apparatus, or other method recommended by membrane manufacturer. Check wet film thickness as specified in paragraph entitled "Film Thickness" and adjust application rate as necessary to provide a uniform coating of the thickness specified. Where possible, mark off surface to be coated in equal units to facilitate proper coverage. At expansion joints, control joints, prepared cracks, flashing, and terminations, carry membrane over preformed elastomeric sheet in a uniform 60 mil thick, plus or minus 5 mils, wet thickness to provide a monolithic coating. If membrane cures before next application, wipe previously applied membrane with a solvent to remove dirt and dust that could inhibit adhesion of overlapping membrane coat. Use solvent recommended by the membrane manufacturer, as approved.
3.3.1 Work Sequence
Perform work so that protection board is installed prior to using the waterproofed surface. Do not permanently install protection board until the membrane has passed the flood test specified under paragraph entitled "Flood Test." Move material storage areas as work progresses to prevent abuse of membrane and overloading of structural deck.
3.3.2 Protection Board
Protect fluid-applied membrane by placing protection board over membrane at a time recommended by the membrane manufacturer. Protect membrane application when protection board is not placed immediately. Butt protection boards together and do not overlap.
3.4 FIELD QUALITY CONTROL
3.4.1 Moisture Test
Prior to application of fluid-applied waterproofing, measure moisture content of substrate with a moisture meter in the presence of the Owner's Representative. An acceptable device is the Delmhorst Moisture Meter, Model BD7/2E/CS, Type 21 E. Similar meters by other manufacturers, which are suitable for the purpose, may be used as approved by the Owner's Representative. Do not begin application until meter reading indicates "dry" range.
3.4.2 Film Thickness
Measure wet film thickness every 100 square feetduring application by placing flat metal plates on the substrate or using a mil-thickness gage
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especially manufactured for the purpose.
3.5 INSTRUCTIONS TO OWNER'S PERSONNEL
Furnish written and verbal instructions on proper maintenance procedures to designated Owner's personnel. Furnish instructions by a competent representative of the roof membrane manufacturer and include a minimum of 4 hours on maintenance and emergency repair of the membrane. Include a demonstration of membrane repair, and give sources of required special tools. Furnish information on safety requirements during maintenance and emergency repair operations.
3.6 INFORMATION CARD
For each application, furnish a minimum 8-1/2 inch by 11 inch information card for facility records and a card laminated in plastic and framed for interior display at roof access point, or a photoengraved 0.032 inch thick aluminum card for exterior display. Identify facility name and number; location; contract number; approximate area; detailed system description, membrane, number of plies, method of application, and manufacturer; date of completion; installing contractor identification and contract information; membrane manufacturer warranty expiration, warranty reference number, and contact information. Install card at access location as directed by the Owner's Representative and provide a paper copy to the Owner's Representative.
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FORM 1
FLUID-APPLIED WATERPROOFING SYSTEM COMPONENTS
1. Contract Number
2. Date Work Completed
3. Project Specification Designation
4. Substrate Material
5. Slope of Substrate
6. Waterproofing
a. Membrane
b. Sealant
c. Elastomeric Sheet
d. Materials Manufacturer(s)
7. Wearing Course
a. Type
b. Joint System
c. Sealant/Gasket Type
8. Wearing Surface Type
Manufacturer's Name
9. Warranty
a. Manufacturer warranty expiration
b. Warranty reference number
10. Statement of Compliance or Exception
Contractor's Signature Date Signed
Inspector's Signature Date Signed
-- End of Section --
SECTION 07 14 00 Page 6 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 07 19 00
WATER REPELLENTS 05/11 08/07/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN ARCHITECTURAL MANUFACTURERS ASSOCIATION (AAMA)
AAMA 501.1 (2005) Standard Test Method for Water Penetration of Windows, Curtain Walls and Doors Using Dynamic Pressure
AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)
AASHTO T 259 (2002; R 2012) Standard Method of Test for Resistance of Concrete to Chloride Ion Penetration
AASHTO T 260 (1997; R 2011) Standard Method of Test for Sampling and Testing for Chloride Ion in Concrete and Concrete Raw Materials
ASTM INTERNATIONAL (ASTM)
ASTM C140/C140M (2013a) Standard Test Methods for Sampling and Testing Concrete Masonry Units and Related Units
ASTM C672/C672M (2012) Scaling Resistance of Concrete Surfaces Exposed to Deicing Chemicals
ASTM D2369 (2010; E 2011) Volatile Content of Coatings
ASTM D3278 (1996; R 2011) Flash Point of Liquids by Small Scale Closed-Cup Apparatus
ASTM E514/E514M (2011) Standard Test Method for Water Penetration and Leakage Through Masonry
ASTM E96/E96M (2012) Standard Test Methods for Water Vapor Transmission of Materials
ASTM G154 (2012a) Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials
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U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
29 CFR 1910.1000 Air Contaminants
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Water repellents
SD-06 Test Reports
Water absorption
Accelerated weathering
Resistance to chloride ion penetration
Moisture vapor transmission
Scaling resistance
Water Penetration and Leakage
SD-07 Certificates
Manufacturer's qualifications
Applicator's qualifications
Evidence of acceptable variation
Warranty
SD-08 Manufacturer's Instructions
Application instructions
Provide manufacturer's instructions including preparation, application, recommended equipment to be used, safety measures, and protection of completed application.
Manufacturer's material safety data sheets
1.3 QUALITY ASSURANCE
1.3.1 Qualifications
a. Manufacturer's qualifications: Minimum five years record of successful in-service experience of water repellent treatments manufactured for masonry application.
b. Applicator's qualifications: Minimum five years successful experience in projects of similar scope using specified or similar treatment materials and manufacturer's approval for application.
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1.3.2 Performance Requirements
a. Water absorption: ASTM C140/C140M. Comparison of treated and untreated specimens.
b. Moisture vapor transmission: ASTM E96/E96M. Comparison of treated and untreated specimens.
c. Water penetration and leakage through masonry: ASTM E514/E514M.
1.3.3 Evidence of Acceptable Variation
If a product proposed for use does not conform to requirements of the referenced specification, submit for approval to the Owner's Representative, evidence that the proposed product is either equal to or better than the product specified. Include the following:
a. Identification of the proposed substitution;
b. Reason why the substitution is necessary;
c. A comparative analysis of the specified product and the proposed substitution, including tabulations of the composition of pigment and vehicle;
d. The difference between the specified product and the proposed substitution; and
e. Other information necessary for an accurate comparison of the proposed substitution and the specified product.
1.4 SAMPLE TEST PANEL
The approved Sample Test Panel will serve as the standard of quality for all other water repellent coating work. Do not proceed with application until the sample panel has been approved by the Owner's Representative.
1.4.1 Sample Test Panel
Prior to commencing work, including bulk purchase and delivery of material, apply water repellent treatment to a minimum 4 feet high by 4 feet long masonry test-panel. Provide a full height expansion joint at mid-panel length. Prepare and seal joint with materials approved for project use.
1.4.1.1 Testing
AAMA 501.1 Provide field water testing of water repellent treated surfaces in the presence of the Owner's Representative and the water repellent treatment manufacturer's representative.
a. Apply water repellent to left side of mock-up and allow to cure prior to application of treatment to right side.
b. Twenty days after completion of application of treatment, test mock-up with 5/8 inch garden hose, with spray nozzle, located 10 feet from wall and aimed upward so water strikes wall at 45 degree downward angle. After water has run continuously for three hours observe back side of mock-up for water penetration and leakage. If leakage is detected make changes as needed and retest.
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c. Coordinate testing procedures and modify project treatment application as required to pass mock-up tests for water penetration and leakage resistance.
1.4.1.2 Approval
Proceed with water repellent treatment work only after completion of field test application and approval of mock-up and tests by the Owner's Representative.
1.4.2 Pre-Installation Meeting
a. Attend pre-installation meeting required prior to commencement of masonry installation.
b. Review procedures and coordination required between water repellent treatment work and work of other trades which could affect work to be performed under this section of the work.
c. Convene additional pre-installation meeting prior to water repellent treatment application for coordination with work not previously coordinated including joint sealants.
1.5 DELIVERY, STORAGE, AND HANDLING
Deliver materials in original sealed containers, clearly marked with the manufacturer's name, brand name, type of material, batch number, percent solids by weight and volume, and date of manufacturer. Store materials off the ground, in a dry area where the temperature will be not less 50 degrees F nor more than 85 degrees F.
1.6 SAFETY METHODS
Apply coating materials using safety methods, equipment and the following:
1.6.1 Toxic Materials
To protect personnel from overexposure to toxic materials, conform to the most stringent guidance of:
a. The coating manufacturer when using solvents or other chemicals. Use impermeable gloves, chemical goggles or face shield, and other recommended protective clothing and equipment to avoid exposure of skin, eyes, and respiratory system. Conduct work in a manner to minimize exposure of building occupants and the general public.
b. 29 CFR 1910.1000.
c. Threshold Limit Values (R) of the American Conference of Owner's Representativeal Industrial Hygienists.
d. Manufacturer's material safety data sheets.
1.7 ENVIRONMENTAL CONDITIONS
1.7.1 Weather and Substrate Conditions
Do not proceed with application of water repellents under any of the
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following conditions, except with written recommendations of manufacturer.
a. Ambient temperature is less than 40 degrees F.
b. Substrate faces have cured less than one month.
c. Rain or temperature below 40 degrees F are predicted for a period of 24 hours before or after treatment.
d. Earlier than three days after surfaces are wet.
e. Substrate is frozen or surface temperature is less than 40 degrees F and falling.
1.7.2 Moisture Condition
Determine moisture content of substrate meets manufacturer's requirements prior to application of water repellent material.
1.8 SEQUENCING AND SCHEDULING
1.8.1 Concrete Surfaces
Do not start water repellent coating until all concrete surfaces have cured per manufacturer's recommendations.
1.8.2 Masonry Surfaces
Do not start water repellent coating until all joint tooling, pointing and masonry cleaning operations have been completed. Allow masonry to cure for at least 60 days under normal weather conditions before applying water repellent.
1.8.3 Sealants
Do not apply water repellents until the sealants for joints adjacent to surfaces receiving water repellent treatment have been installed and cured.
a. Water repellent work may precede sealant application only if sealant adhesion and compatibility have been tested and verified using substrate, water repellent, and sealant materials identical to those used in the work.
b. Provide manufacturers' test results of compatibility.
1.9 INSPECTIONS
Notify the manufacturer's representative a minimum of 72 hours prior to scheduled application of water repellents for field inspection. Inspect surfaces and obtain approval in writing from the manufacturer's representative prior to any application of any water repellent coating.
1.10 SURFACES TO BE COATED
Coat all exposed exterior stone surfaces.
1.11 WARRANTY
Provide a warranty, issued jointly by the manufacturer and the applicator
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of the water repellent treatment against moisture penetration through the treated structurally sound surface for a period of five years. Warranty to provide the material, labor, and equipment necessary to remedy the problem. At the satisfactory completion of the work, complete the warranty sign, notarize, and submit to the Owner's Representative.
PART 2 PRODUCTS
2.1 MATERIALS
Water repellent solution shall be a clear, non-yellowing, deep-penetrating, VOC compliant solution. Material shall not stain or discolor and shall produce a mechanical and chemical interlocking bond with the substrate to the depth of the penetration.
2.2 WATER REPELLENTS
2.2.1 Siloxanes
Penetrating water repellent. Alkylalkoxysiloxanes that are oligomerous with alcohol, ethanol, mineral spirits, or water.
a. Solids by weight: ASTM D2369, 7.5 to 16.0 percent.
b. Volatile Organic Content (VOC) after blending: Less than 175 grams per liter.
c. Density, activated: 8.4 pounds per gallon, plus or minus one percent.
d. Flash point, ASTM D3278: Greater than 212 degrees F.
2.3 PERFORMANCE CRITERIA
2.3.1 Siloxanes
a. Dry time for recoat, if necessary: One to two hours depending on weather conditions.
b. Penetration: 3/8 inch, depending on substrate.
c. Water penetration and leakage through masonry, ASTM E514/E514M, percentage reduction of leakage: 97.0 percent minimum.
d. Moisture vapor transmission, ASTM E96/E96M: 47.5 perms or 82 percent maximum compared to untreated sample.
e. Resistance to accelerated weathering, ASTM G154. Testing 2,500 hours: No loss in repellency.
f. Resistance to chloride ion penetration, AASHTO T 259 and AASHTO T 260.
g. Scaling resistance,ASTM C672/C672M, non-air-entrained concrete: Zero rating, no scaling, 100 cycles treated concrete.
PART 3 EXECUTION
3.1 EXAMINATION
Examine masonry surfaces to be treated to ensure that:
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a. All visible cracks, voids or holes have been repaired.
b. All mortar joints in masonry are tight and sound, have not been re-set or misaligned and show no cracks or spalling.
c. Moisture contents of walls does not exceed 15 percent when measured on an electronic moisture register, calibrated for the appropriate substrate.
d. Concrete surfaces are free of form release agents, curing compounds and other compounds that would prevent full penetration of the water repellent material.
Do not start water repellent treatment work until all deficiencies have been corrected, examined and found acceptable to the Owner's Representative and the water repellent treatment manufacturer. Do not apply treatment to damp, dirty, dusty or otherwise unsuitable surfaces. Comply with the manufacturer's recommendations for suitability of surface.
3.2 PREPARATION
3.2.1 Surface Preparation
Prepare substrates in accordance with water repellent treatment manufacturer's recommendation. Clean surfaces of dust, dirt, efflorescence, alkaline, and foreign matter detrimental to proper application of water repellent treatment.
3.2.2 Protection
Provide masking or protective covering for materials which could be damaged by water repellent treatment.
a. Protect landscape materials with breathing type drop cloths: plastic covers are not acceptable.
3.2.3 Compatibility
a. Confirm treatment compatibility with each type of joint sealer within or adjacent to surfaces receiving water repellent treatment in accordance with manufacturer's recommendations.
b. When recommended by joint sealer manufacturer, apply treatment after application and cure of joint sealers. Coordinate treatment with joint sealers.
c. Mask surfaces indicated to receive joint sealers which would be adversely affected by water repellent treatment where treatment must be applied prior to application of joint sealers.
3.3 MIXING
Mix water repellent material thoroughly in accordance with the manufacturer's recommendations. Mix, in quantities required for that days work, all containers prior to application. Mix each container the same length of time.
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3.4 APPLICATION
In strict accordance with the manufacturers written requirements. Do not start application without the manufacturer's representative being present or his written acceptance of the surface to be treated.
3.4.1 Water Repellent Treatment
3.4.1.1 Spray Application
Spray apply water repellent material to exterior and masonry surfaces using low-pressure airless spray equipment in strict accordance with manufacturer's printed application, instructions, and precautions. Maintain copies at the job site. Apply flood coat in an overlapping pattern allowing approximately 8 to 10 inch rundown on the vertical surface. Maintain a wet edge at all overlaps, both vertical and horizontal. Hold gun maximum 18 inches from wall.
3.4.1.2 Brush or Roller Application
Brush or roller apply water repellent material only at locations where overspray would affect adjacent materials and where not practical for spray applications.
3.4.1.3 Covered Surfaces
Coat all exterior surfaces listed in Paragraph 1.10 of this Specification Section.
3.4.1.4 Rate of Application
Apply materials to exterior surfaces at the coverages recommended by the manufacturer and as determined from sample panel test. Increase or decrease application rates depending upon the surface texture and porosity of the substrate so as to achieve even appearance and total water repellency.
3.4.1.5 Number of Coats
The sample panel test shall determine the number of coats required to achieve full coverage and protection.
3.4.1.6 Appearance
If unevenness in appearance, lines of work termination or scaffold lines exist, or detectable changes from the approved sample panel occur, the Owner's Representative may require additional treatment at no additional cost to the Owner's Representative. Apply any required additional treatment to a natural break off point.
3.5 CLEANING
Clean all runs, drips, and overspray from adjacent surfaces while the water repellent treatment is still wet in a manner recommended by the manufacturer.
3.6 FIELD QUALITY CONTROL
Do not remove drums containing water repellent material from the job site until completion of all water repellent treatment and testing.
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3.6.1 Field Testing
AAMA 501.1. At a time not less than twenty days after completion of the water repellent coating application. Use a minimum 5/8 inch diameter hose and a fixed lawn sprinkler spray head which will direct a full flow of water against the wall for a period of 3 hours. Place the sprinkler head so that the water will strike the wall downward at a 45 degree angle to the wall. If the inside of the wall shows any trace of moisture during or following the test, apply another coat of water repellent, at the manufacturer's recommended coverage rate to the entire building. Repeat testing and re-coating process until no moisture shows on the inside wall face. Accomplish any required work retesting and re-coating at no additional cost to the Owner's Representative.
3.6.2 Site Inspection
Inspect treatment in progress by manufacturer's representative to verify compliance with manufacturer instructions and recommendations.
-- End of Section --
SECTION 07 19 00 Page 9 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 07 21 13
BOARD AND BLOCK INSULATION 05/11 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM C203 (2005; R 2012) Breaking Load and Flexural Properties of Block-Type Thermal Insulation
ASTM C272/C272M (2012) Standard Test Method for Water Absorption of Core Materials for Sandwich Constructions
ASTM C553 (2011) Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications
ASTM C578 (2012b) Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation
ASTM C930 (2012) Potential Health and Safety Concerns Associated with Thermal Insulation Materials and Accessories
ASTM D3833/D3833M (1996; R 2011) Water Vapor Transmission of Pressure-Sensitive Tapes
ASTM E136 (2012) Behavior of Materials in a Vertical Tube Furnace at 750 Degrees C
ASTM E84 (2013a) Standard Test Method for Surface Burning Characteristics of Building Materials
ASTM E96/E96M (2012) Standard Test Methods for Water Vapor Transmission of Materials
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 211 (2013) Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances
NFPA 54 (2012) National Fuel Gas Code
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
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1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Block or board insulation; G
Pressure sensitive tape
Accessories
SD-08 Manufacturer's Instructions
Block or Board Insulation
Adhesive
1.3 DELIVERY, STORAGE, AND HANDLING
1.3.1 Delivery
Deliver materials to the site in original sealed wrapping bearing manufacturer's name and brand designation, specification number, type, grade, R-value, and class. Store and handle to protect from damage. Do not allow insulation materials to become wet, soiled, crushed, or covered with ice or snow. Comply with manufacturer's recommendations for handling, storing, and protecting of materials before and during installation.
1.3.2 Storage
Inspect materials delivered to the site for damage; unload and store out of weather in manufacturer's original packaging. Store only in dry locations, not subject to open flames or sparks, and easily accessible for inspection and handling.
1.4 SAFETY PRECAUTIONS
1.4.1 Other Safety Considerations
Consider safety concerns and measures as outlined in ASTM C930.
PART 2 PRODUCTS
2.1 BLOCK OR BOARD INSULATION
Provide only thermal insulating materials recommended by manufacturer for type of application indicated. Provide board or block thermal insulation conforming to the following standards and the physical properties listed below:
a. Extruded Preformed Cellular Polystyrene: ASTM C578.
2.1.1 Thermal Resistance
As indicated.
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2.1.2 Fire Protection Requirement
a. Flame spread index of 75 or less when tested in accordance with ASTM E84.
b. Smoke developed index of 200 or less when tested in accordance with ASTM E84.
2.1.3 Other Material Properties
Provide thermal insulating materials with the following properties:
a. Flexural strength: Not less than 25 psi when measured according to ASTM C203.
b. Water Vapor Permeance: Not more than 1.1 Perms or less when measured according to ASTM E96/E96M, desiccant method, in the thickness required to provide the specified thermal resistance, including facings, if any.
c. Water Absorption: Not more than 2 percent by total immersion, by volume, when measured according to ASTM C272/C272M.
d. Water Adsorption: Not more than 1 percent by volume when measured in accordance with paragraph 14 of ASTM C553.
2.1.4 Prohibited Materials
Do not provide materials containing more than one percent of asbestos.
2.2 DAMPPROOFING
2.2.1 Dampproofing for Masonry Cavity Walls
Bituminous material is specified in Section 07 11 13 BITUMINOUS DAMPPROOFING.
2.3 PRESSURE SENSITIVE TAPE
As recommended by manufacturer of vapor retarder and having a water vapor permeance rating of one perm or less when tested in accordance with ASTM D3833/D3833M.
2.4 ACCESSORIES
2.4.1 Adhesive
As recommended by insulation manufacturer.
PART 3 EXECUTION
3.1 EXISTING CONDITIONS
Before installing insulation, ensure that all areas that will be in contact with the insulation are dry and free of projections which could cause voids, compressed insulation, or punctured vapor retarders. If installing perimeter or under slab insulation, check that the fill is flat, smooth, dry, and well tamped. If moisture or other conditions are found that do not allow the proper installation of the insulation, do not proceed but notify the Owner's Representative of such conditions.
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3.2 PREPARATION
3.2.1 Blocking Around Heat Producing Devices
Unless using insulation board that passes ASTM E136 in addition to the requirements in Part 2, install non-combustible blocking around heat producing devices to provide the following clearances:
a. Recessed lighting fixtures, including wiring compartments, ballasts, and other heat producing devices, unless certified for installation surrounded by insulation: 3 inches from outside face of fixtures and devices or as required by NFPA 70and, if insulation is to be placed above fixture or device, 24 inches above fixture.
b. Vents and vent connectors used for venting products of combustion, flues, and chimneys other than masonry chimneys: minimum clearances as required by NFPA 211.
c. Gas Fired Appliances: Clearances as required in NFPA 54.
3.3 INSTALLATION
3.3.1 Insulation Board
Install and handle insulation in accordance with the manufacturer's installation instructions. Keep material dry and free of extraneous materials. Observe safe work practices.
3.3.2 Electrical Wiring
Do not install insulation in a manner that would sandwich electrical wiring between two layers of insulation.
3.3.3 Cold Climate Requirement
Place insulation to the outside of pipes.
3.3.4 Continuity of Insulation
Butt tightly against adjoining boards and obstructions. Provide continuity and integrity of insulation at corners, wall to ceiling joint, roof, and floor. Avoid creating any thermal bridges or voids.
3.4 INSTALLATION ON WALLS
3.4.1 Installation on Masonry Walls
Apply board directly to masonry with adhesive or fasteners as recommended by the insulation manufacturer. Fit between obstructions without impaling board on ties or anchors. Apply in parallel courses with joints breaking midway over course below. Put ends in moderate contact with adjoining insulation without forcing. Cut and shape as required to fit around wall penetrations, projections or openings to accommodate conduit or other services. Seal around cut-outs with sealant. Install board in wall cavities so that it leaves at least a nominal one inch free air space outside of the insulation to allow for cavity drainage.
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3.4.2 Adhesive Attachment to Concrete and Masonry Walls
Apply adhesive to wall and completely cover wall with insulation.
a. As recommended by the insulation manufacturer.
b. Use only full back method for pieces of one square foot or less.
c. Butt all edges of insulation and seal edges with tape. Seal around all wall penetrations.
3.5 PERIMETER AND UNDER SLAB INSULATION
Install perimeter thermal insulation where heated spaces are adjacent to exterior walls or slab edges in slab-on-grade or floating-slab construction.
3.5.1 Manufacturer's Instructions
Install, attach, tape edges, provide vapor retarder and other requirements such as protection against vermin, insects, damage during construction as recommended in manufacturer's instructions.
3.5.2 Insulation on Vertical Surfaces
Install thermal insulation as indicated on exterior of foundation walls. Fasten insulation with adhesive.
3.5.3 Protection of Insulation
Protect insulation on vertical surfaces from damage during construction and back filling by application of protection board or coating. Do not leave installed vertical insulation unprotected overnight.
-- End of Section --
SECTION 07 21 13 Page 5 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 07 22 00
ROOF AND DECK INSULATION 08/11 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM C1289 (2013) Standard Specification for Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board
ASTM C208 (2012) Cellulosic Fiber Insulating Board
ASTM C726 (2012) Mineral Fiber Roof Insulation Board
ASTM D312 (2000; R 2006) Standard Specification for Asphalt Used in Roofing
ASTM D41/D41M (2011) Asphalt Primer Used in Roofing, Dampproofing, and Waterproofing
ASTM D4263 (1983; R 2012) Indicating Moisture in Concrete by the Plastic Sheet Method
ASTM D4586/D4586M (2007; E 2012; R 2012) Asphalt Roof Cement, Asbestos-Free
ASTM E84 (2013a) Standard Test Method for Surface Burning Characteristics of Building Materials
FM GLOBAL (FM)
FM 4470 (2010) Single-Ply, Polymer-Modified Bitumen Sheet, Built-up Roof (BUR), and Liquid Applied Roof Assemblies for Use in Class 1 and Noncombustible Roof Deck Construction
FM APP GUIDE (updated on-line) Approval Guide http://www.approvalguide.com/
FM P9513 (2002) Specialist Data Book Set for Roofing Contractors; contains 1-22 (2001), 1-28 (2002), 1-29 (2002), 1-28R/1-29R (1998), 1-30 (2000), 1-31 (2000), 1-32 (2000), 1-33 (2000), 1-34 (2001), 1-49 (2000), 1-52 (2000), 1-54 (2001)
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UNDERWRITERS LABORATORIES (UL)
UL Bld Mat Dir (2012) Building Materials Directory
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Tapered roof insulation system; G
Taper cants and crickets
Show location and spacing of wood nailers that are required for securing insulation. Show a complete description of the procedures for the installation of each phase of the system indicating the type of materials, thicknesses, identity codes, sequence of laying insulation, location of ridges and valleys, special methods for cutting and fitting of insulation, and special precautions. The drawings shall be based on field measurements.
SD-03 Product Data
Fasteners and/or Asphalt; G
Insulation; G
Certification
Include minimum thickness of insulation for concrete decks.
SD-06 Test Reports
Flame spread and smoke developed ratings
Submit in accordance with ASTM E84.
SD-07 Certificates
Installer qualifications
SD-08 Manufacturer's Instructions
Nails and fasteners
Roof insulation, including field of roof and perimeter attachment requirements.
1.3 MANUFACTURER'S CERTIFICATE
Submit certificate from the insulation manufacturer attesting that the installer has the proper qualifications for installing tapered roof insulation systems.
Certificate attesting that the expanded perlite or polyisocyanurate insulation contains recovered material and showing estimated percent of
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recovered material. Certificates of compliance for felt materials.
1.4 QUALITY ASSURANCE
1.4.1 Concrete Decks
Roof insulation shall have a flame spread rating not greater than 75 and a smoke developed rating not greater than 150, exclusive of covering, when tested in accordance with ASTM E84. Insulation bearing the UL label and listed in the UL Bld Mat Dir as meeting the flame spread and smoke developed ratings will be accepted in lieu of copies of test reports. Compliance with flame spread and smoke developed ratings will not be required when insulation has been tested as part of a roof construction assembly of the type used for this project and the construction is listed as fire-classified in the UL Bld Mat Dir or listed as Class I roof deck construction in the FM APP GUIDE. Insulation tested as part of a roof construction assembly shall bear UL or FM labels attesting to the ratings specified herein.
1.5 DELIVERY, STORAGE, AND HANDLING
1.5.1 Delivery
Deliver materials to site in manufacturer's unopened and undamaged standard commercial containers bearing the following legible information:
a. Name of manufacturer;
b. Brand designation;
c. Specification number, type, and class, as applicable, where materials are covered by a referenced specification; and
d. Asphalt's flashpoint (FP), equiviscous temperature (EVT), and finished blowing temperature (FBT).
Deliver materials in sufficient quantity to allow continuity of the work.
1.5.2 Storage and Handling
Store and handle materials in a manner to protect from damage, exposure to open flame or other ignition sources, and from wetting, condensation or moisture absorption. Store in an enclosed building or trailer that provides a dry, adequately ventilated environment. Replace damaged material with new material.
1.6 ENVIRONMENTAL CONDITIONS
Do not install roof insulation during inclement weather or when air temperature is below 40 degrees F and interior humidity is 45 percent or greater, or when there is visible ice, frost, or moisture on the roof deck.
1.7 PROTECTION OF PROPERTY
1.7.1 Flame-Heated Equipment
Locate and use flame-heated equipment so as not to endanger the structure or other materials on the site or adjacent property. Do not place flame-heated equipment on the roof. Provide and maintain a fire
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extinguisher near each item of flame-heated equipment.
1.7.2 Protective Coverings
Install protective coverings at paving and building walls adjacent to hoist and kettles prior to starting the work. Lap protective coverings at least 6 inches, secure them against wind, and vent them to prevent collection of moisture on the covered surfaces. Keep protective coverings in place for the duration of the work with asphalt products.
1.7.3 Special Protection
Provide special protection approved by the insulation manufacturer, or avoid heavy traffic on completed work when ambient temperature is above 80 degrees F.
1.7.4 Drippage of Bitumen
Seal joints in and at edges of deck as necessary to prevent drippage of asphalt into building or down exterior walls.
PART 2 PRODUCTS
2.1 INSULATION
2.1.1 Insulation Types
Roof insulation shall be:
a. Polyisocyanurate Board: ASTM C1289 Type I -- foil faced both sides or Type II, fibrous felt or glass mat membrane both sides, except minimum compressive strength shall be 20 pounds per square inch (psi).
ASTM C208 Type II, Grade 1 or 2, roof insulating board, treated with sizing, wax or bituminous impregnation. Bituminous impregnation shall be limited to 4 percent by weight when used over steel decks. Maximum board size: 4 feet by 4 feet.
2.1.2 Mineral-Fiber Insulation Board
ASTM C726.
2.1.3 Insulation Thickness
As necessary to provide a thermal resistance (R value) of 25 or more for average thickness of tapered system. Thickness shall be based on the "R" value for aged insulation.
2.1.4 Tapered Roof Insulation
One layer of the tapered roof insulation assembly shall be factory tapered to a slope of not less than 1/4 inch per foot. Provide starter and filler blocks as required to provide the total thickness of insulation necessary to meet the specified slope and thermal conductance. Mitered joints shall be factory fabricated and shall consist of two diagonally cut boards or one board shaped to provide the required slopes. Identify each piece of tapered insulation board by color or other identity coding system, allowing the identification of different sizes of tapered insulation board required to complete the roof insulation system.
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2.1.5 Cants and Tapered Edge Strips
Provide preformed cants and tapered edge strips of the same material as the roof insulation; or, when roof insulation material is unavailable, provide pressure-preservative treated wood, wood fiberboard, or rigid perlite board cants and edge strips as recommended by the roofing manufacturer, unless otherwise indicated. Face of cant strips shall have incline of 45 degrees and vertical height of 4 inches. Taper edge strips at a rate of one to 1 1/2 inch per foot down to approximately 1/8 inch thick.
2.2 PROTECTION BOARD
For use as a adhesively-applied roofing membrane over roof insulation.
2.3 BITUMENS
2.3.1 Asphalt Primer
ASTM D41/D41M.
2.3.2 Asphalt
ASTM D312, Type III or IV. Asphalt flash point, finished blowing temperature, and equiviscous temperature (EVT) for mop and for mechanical spreader application shall be indicated on bills of lading or on individual containers.
2.3.3 Asphalt Roof Cement
ASTM D4586/D4586M, Type I for horizontal surfaces and for surfaces sloped from 0 to 3 inches per foot, Type II for vertical and surfaces sloped more than 3 inches per foot.
2.4 FASTENERS
Flush-driven through flat round or hexagonal steel or plastic plates. Steel plates shall be zinc-coated, flat round not less than 1 3/8 inch diameter or hexagonal not less than 28 gage. Plastic plates shall be high-density, molded thermoplastic with smooth top surface, reinforcing ribs and not less than 3 inches in diameter. Fastener head shall recess fully into the plastic plate after it is driven. Plates shall be formed to prevent dishing. Do not use bell-or cup-shaped plates. Fasteners for concrete decks shall conform to FM APP GUIDE for Class I roof deck construction, and shall be spaced to withstand an uplift pressure of 90 pounds per square foot.
2.4.1 Fasteners for Poured Concrete Decks
Approved hardened fasteners or screws to penetrate deck at least one inch but not more than 1 1/2 inches, conforming to FM 4470, and listed in FM APP GUIDE for Class I roof deck construction. Quantity and placement to withstand an uplift pressure of 90 psf conforming to FM APP GUIDE.
2.5 WOOD NAILERS
Pressure-preservative-treated as specified in Section 06 10 00 ROUGH CARPENTRY.
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PART 3 EXECUTION
3.1 EXAMINATION AND PREPARATION
3.1.1 Surface Inspection
Surfaces shall be clean, smooth, and dry. Check roof deck surfaces for defects before starting work.
The Owner's Representative will inspect and approve the surfaces immediately before starting installation. Prior to installing vapor retarder, perform the following:
a. Prior to installing any roof system on a concrete deck, conduct a test per ASTM D4263. The deck is acceptable for roof system application when there is no visible moisture on underside of plastic sheet after 24 hours.
3.1.2 Surface Preparation
Correct defects and inaccuracies in roof deck surface to eliminate poor drainage and hollow or low spots and perform the following:
a. Install wood nailers the same thickness as insulation at edges, curbs, walls, and roof openings for securing cant strips, gravel stops, and flashing flanges.
b. Solidly apply asphalt primer to poured concrete decks at the rate of one gallon per 100 square feet of roof surface. Allow primer to dry thoroughly.
3.2 INSTALLATION OF VAPOR RETARDER
Install vapor retarder in direct contact with roof deck surface. Vapor retarder shall consist of one layer of asphalt-saturated felt base sheet. Lay vapor retarder at right angles to direction of slope. Install as specified herein for the specific deck. Do not heat asphalt above asphalt's FBT or 525 degrees F, whichever is less. Use thermometers to check temperatures during heating and application. Side and end laps shall be completely sealed. Asphalt shall be visible beyond all edges of each ply as it is being installed. Plies shall be laid free of wrinkles, buckles, creases or fishmouths. Workers shall not walk on mopped surfaces when the asphalt is sticky. Press out air bubbles to obtain complete adhesion between surfaces. At walls and other vertical surfaces, the vapor retarder organic felts shall be extended 9 inches, or separate organic felt plies shall be extended 9 inches, with not less than 9 inches on the substrate, and the extended portion turned back and mopped in over the top of the insulation. At roof penetrations other than walls and vertical surfaces, the vapor retarder or separate plies shall be extended 9 inches to form a lap which shall later be folded back over the edge of the insulation. Asphalt roof cement shall be used under the vapor retarder for at least 9 inches from walls and other penetrations.
3.2.1 Vapor Retarder on Poured Concrete Decks
Solidly mop primed substrate with asphalt at rate of 20 to 35 lbs per 100 square feet before installing vapor retarder. Lay first ply of 2 ply system with each sheet lapping 19 inches over the preceding sheet. Lap ends not less than 4 inches. Stagger laps a minimum of 12 inches. For a
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vapor retarder consisting of one layer of asphalt base sheet, provide side and end laps not less than 4 inches. Stagger laps a minimum of 12 inches. Cement base sheets together with a solid mopping of asphalt.
3.3 INSULATION INSTALLATION
Apply insulation in two layers with staggered joints when total required thickness of insulation exceeds 1/2 inch. Lay insulation so that continuous longitudinal joints are perpendicular to direction of roofing and end joints of each course are staggered with those of adjoining courses. When using multiple layers of insulation, joints of each succeeding layer shall be parallel and offset in both directions with respect to layer below. Keep insulation 1/2 inch clear of vertical surfaces penetrating and projecting from roof surface.
3.3.1 Installation Using Asphalt
Firmly embed each layer in solid asphalt mopping; mop only sufficient area to provide complete embedment of one board at a time. Provide 20 to 35 lbs of asphalt per 100 square feet of roof deck for each layer of insulation. Apply asphalt when temperature is within plus or minus 25 degrees F of EVT. Do not heat asphalt above asphalt's FBT or 525 degrees F, whichever is less, for longer than 4 consecutive hours. Use thermometers to check temperatures during heating and application.
3.3.2 Installation Using Only Mechanical Fasteners
Secure total thickness of insulation with penetrating type fasteners.
3.3.3 Special Precautions for Installation of Foam Insulation
3.3.3.1 Polyisocyanurate Insulation
Where polyisocyanurate foam board insulation is provided, install 1/2 inch thick, glass mat gypsum roof board, over top surface of foam board insulation. Stagger joints of insulation with respect to foam board insulation below.
3.3.4 Cant Strips
Where indicated, provide cant strips at intersections of roof with walls, parapets, and curbs extending above roof. Wood cant strips shall bear on and be anchored to wood blocking. Fit cant strips flush against vertical surfaces. Where possible, nail cant strips to adjoining surfaces. Where cant strips are installed against non-nailable materials, install in an approved adhesive.
3.4 PROTECTION
3.4.1 Protection of Applied Insulation
Completely cover each day's installation of insulation with the finished roofing specified in 07 51 13 on same day. Do not permit phased construction. Protect open spaces between insulation and parapets or other walls and spaces at curbs, scuttles, and expansion joints, until permanent roofing and flashing are applied. Do not permit storing, walking, wheeling, or trucking directly on insulation or on roofed surfaces. Provide smooth, clean board or plank walkways, runways, and platforms near supports, as necessary, to distribute weight to conform to
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indicated live load limits of roof construction. Exposed edges of the insulation shall be protected by cutoffs at the end of each work day or whenever precipitation is imminent. Cutoffs shall be 2 layers of bituminous-saturated felt set in plastic bituminous cement or single ply or EPDM membrane set in roof cement. Fill all profile voids in cut-offs to prevent entrapping of moisture into the area below the membrane. Cutoffs shall be removed when work is resumed.
3.4.2 Damaged Work and Materials
Restore work and materials that become damaged during construction to original condition or replace with new materials.
3.5 INSPECTION
The Contractor shall establish and maintain an inspection procedure to assure compliance of the installed roof insulation with the contract requirements. Any work found not to be in compliance with the contract shall be promptly removed and replaced or corrected in an approved manner. Quality control shall include, but not be limited to, the following:
a. Observation of environmental conditions; number and skill level of insulation workers; start and end time of work.
b. Verification of certification, listing or label compliance with FM P9513.
c. Verification of proper storage and handling of insulation and vapor retarder materials before, during, and after installation.
d. Inspection of vapor retarder application, including edge envelopes and mechanical fastening.
e. Inspection of mechanical fasteners; type, number, length, and spacing.
f. Coordination with other materials, cants, sleepers, and nailing strips.
g. Inspection of insulation joint orientation and laps between layers, joint width and bearing of edges of insulation on deck.
h. Installation of cutoffs and proper joining of work on subsequent days.
i. Continuation of complete roofing system installation to cover insulation installed same day.
-- End of Section --
SECTION 07 22 00 Page 8 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 07 53 23
ETHYLENE-PROPYLENE-DIENE-MONOMER ROOFING 05/12 08/07/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)
ASCE 7 (2010; Errata 2011; Supp 1 2013) Minimum Design Loads for Buildings and Other Structures
ASTM INTERNATIONAL (ASTM)
ASTM D4637/D4637M (2013) EPDM Sheet Used in Single-Ply Roof Membrane
ASTM D4811/D4811M (2006; E 2013; R 2013) Nonvulcanized (Uncured) Rubber Sheet Used as Roof Flashing
ASTM D6369 (1999; R 2006) Design of Standard Flashing Details for EPDM Roof Membranes
ASTM E108 (2011) Fire Tests of Roof Coverings
FM GLOBAL (FM)
FM 4470 (2010) Single-Ply, Polymer-Modified Bitumen Sheet, Built-up Roof (BUR), and Liquid Applied Roof Assemblies for Use in Class 1 and Noncombustible Roof Deck Construction
FM APP GUIDE (updated on-line) Approval Guide http://www.approvalguide.com/
NATIONAL ROOFING CONTRACTORS ASSOCIATION (NRCA)
NRCA RoofMan (2013) The NRCA Roofing Manual
UNDERWRITERS LABORATORIES (UL)
UL 790 (2004; Reprint Jul 2013) Standard Test Methods for Fire Tests of Roof Coverings
UL RMSD (2012) Roofing Materials and Systems Directory
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1.2 DESCRIPTION OF ROOF MEMBRANE SYSTEM
Loose laid EPDM roof membrane system with ballast applied over recovery board substrate.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Roof Plan Drawing
Wind Load Calculations
Boundaries of Enhanced Perimeter
Corner Attachments of Roof System Components
Location of Perimeter Half-Sheets
Spacing of Perimeter, Corner, and Infield Fasteners
Slopes and Scupper Locations
SD-03 Product Data
Cement
EPDM Sheet; G
Seam Tape
Bonding Adhesive
Lap Splice Adhesive
Water Cutoff Mastic/Water Block
Lap Cleaner, Lap Sealant, and Edge Treatment
Flashings
Flashing Accessories
Flashing Tape
Fasteners and Plates; G
Roof Insulation; G
Ballast; G
Pre-Manufactured Accessories
Sample warranty certificate; G
Submit all data required together with requirements of this
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section. Include a written acceptance by the roof membrane manufacturer of the insulation and other products and accessories to be provided. List products in the applicable wind uplift and fire rating classification listings, unless approved otherwise by the Owner's Representative.
SD-05 Design Data
Wind Uplift Calculations; G
Engineering calculations validating the wind resistance of roof system.
SD-07 Certificates
Qualification of Manufacturer
Certify that the manufacturer of the roof membrane meets requirements specified under paragraph entitled "Qualification of Manufacturer."
Qualification of Applicator
Certify that the applicator meets requirements specified under paragraph entitled "Qualification of Applicator."
Wind Uplift Resistance classification, as applicable; G
Fire Resistance classification; G
Submit the roof system assembly wind uplift and fire rating classification listings.
SD-11 Closeout Submittals
Warranty
Information Card
Instructions To Owner's Personnel
Include copies of Material Safety Data Sheets for maintenance/repair materials.
1.3.1 Shop Drawings
Computer generated roof plan drawing depicting wind load calculations and boundaries of enhanced perimeter and corner attachments of roof system components, spacing of perimeter, corner, and infield fasteners, as applicable. The drawing must reflect the project roof plan of each roof level and conditions indicated. Provide all slopes and drain locations.
1.4 QUALITY ASSURANCE
1.4.1 Qualification of Manufacturer
EPDM sheet roofing membrane manufacturer must have at least 10 years experience in manufacturing EPDM roofing products.
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1.4.2 Qualification of Applicator
Roofing system applicator must be approved, authorized, or licensed in writing by the roof membrane manufacturer and must have a minimum of five years experience as an approved, authorized, or licensed applicator with that manufacturer and be approved at a level capable of providing the specified warranty. The applicator must supply the names, locations and client contact information of 5 projects of similar size and scope that the applicator has constructed using the manufacturer's roofing products submitted for this project within the previous three years.
1.4.3 Fire Resistance
Complete roof covering assembly must:
a. Be Class A rated in accordance with ASTM E108, FM 4470, or UL 790; and
b. Be listed as part of Fire-Classified roof deck construction in the UL RMSD or Class I roof deck construction in the FM APP GUIDE.
FM or UL approved components of the roof covering assembly must bear the appropriate FM or UL label.
1.4.4 Wind Uplift Resistance
The complete roof system assembly shall be rated and installed to resist wind loads calculated in accordance with ASCE 7 and validated by uplift resistance testing in accordance with Factory Mutual (FM) test procedures. Do not installnon-rated systems except as approved by the Owner's Representative. Submit licensed engineer's wind uplift calculations and substantiating data to validate any non-rated roof system. Base wind uplift measurements based on a basic wind speed (ultimate) of 120 mph in accordance with ASCE 7 and/or other applicable building code requirements
1.4.5 Preroofing Conference
After approval of submittals and before performing roofing and insulation system installation work, hold a preroofing conference to review the following:
a. Drawings, specifications and submittals related to the roof work;
b. Roof system components installation;
c. Procedure for the roof manufacturer's technical representative's onsite inspection and acceptance of the roofing substrate, the name of the manufacturer's technical representatives, the frequency of the onsite visits, distribution of copies of the inspection reports from the manufacturer's technical representative;
d. Contractor's plan for coordination of the work of the various trades involved in providing the roofing system and other components secured to the roofing; and
e. Quality control plan for the roof system installation;
f. Safety requirements.
Coordinate preroofing conference scheduling with the Owner's Representative.
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The conference must be attended by the Contractor, the Owner's Representative's designated personnel, personnel directly responsible for the installation of roofing and insulation, flashing and sheet metal work, mechanical and electrical work, other trades interfacing with the roof work, and representative of the roofing materials manufacturer. Before beginning roofing work, provide a copy of meeting notes and action items to all attending parties. Note action items requiring resolution prior to start of roof work.
1.5 DELIVERY, STORAGE, AND HANDLING
1.5.1 Delivery
Deliver materials in their original, unopened containers or wrappings with labels intact and legible. Where materials are covered by a referenced specification number, the labels must bear the specification number, type, class, and shelf life expiration date where applicable. Deliver materials in sufficient quantity to allow continuity of work.
1.5.2 Storage
Store and protect materials from damage and weather in accordance with manufacturer's printed instructions, except as specified otherwise. Keep materials clean and dry. Store and maintain adhesives, sealants, primers and other liquid materials above 60 degrees F. Insulated hot boxes or other enclosed warming devices must be required in cold weather. Mark and remove damaged materials from the site. Use pallets to support and canvas tarpaulins to completely cover material materials stored outdoors. Do not use polyethylene as a covering. Locate materials temporarily stored on the roof in approved areas, and distribute the load to stay within the live load limits of the roof construction. Remove unused materials from the roof at the end of each days work.
1.5.3 Handling
Prevent damage to edges and ends of roll materials. Do not install damaged materials in the work. Select and operate material handling equipment so as not to damage materials or applied roofing. Do not use materials contaminated by exposure or moisture. Remove contaminated materials from the site. When hazardous materials are involved, adhere to the special precautions of the manufacturer. Adhesives may contain petroleum distillates and may be extremely flammable; prevent personnel from breathing vapors, and do not use near sparks or open flame.
1.6 ENVIRONMENTAL REQUIREMENTS
Do not install EPDM sheet roofing during high winds or inclement weather, or when there is ice, frost, moisture, or visible dampness on the substrate surface, or when condensation develops on surfaces during application. Unless recommended otherwise by the EPDM sheet manufacturer and approved by the Owner's Representative, do not install EPDM sheet when air temperature is below 40 degrees F or within 5 degrees F of the dewpoint. Follow manufacturer's printed instructions for installation during cold weather conditions.
1.7 SEQUENCING
Coordinate the work with other trades to ensure that components which are to be secured to or stripped into the roofing system are available and that
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permanent flashing and counterflashing are installed as the work progresses. Ensure temporary protection measures are in place to preclude moisture intrusion or damage to installed materials. Application of roofing must immediately follow application of insulation as a continuous operation. Coordinate roofing operations with insulation work so that all roof insulation applied each day is covered with roof membrane installation the same day.
1.8 WARRANTY
Provide roof system material and workmanship warranties meeting specified requirements. Provide revision or amendment to standard membrane manufacturer warranty as required to comply with the specified requirements. Minimum manufacturer warranty shall have no dollar limit, cover full system water-tightness, and shall have a minimum duration of 20 years.
1.8.1 Roof Membrane Manufacturer Warranty
Furnish the roof membrane manufacturer's 20 year no dollar limit roof system materials and installation workmanship warranty, including flashing, insulation, and accessories necessary for a watertight roof system construction. The warranty must run directly to the Owner's Representative and commence at time of Owner's Representative's acceptance of the roof work. The warranty must state that:
a. If within the warranty period the roof system, as installed for its intended use in the normal climatic and environmental conditions of the facility, becomes non-watertight, shows evidence of moisture intrusion within the assembly, splits, tears, cracks, delaminates, separates at the seams, shrinks to the point of bridging or tenting membrane at transitions, or shows evidence of excessive weathering due to defective materials or installation workmanship, the repair or replacement of the defective and damaged materials of the roof system assembly and correction of defective workmanship must be the responsibility of the roof membrane manufacturer. The roof membrane manufacturer is responsible for all costs associated with the repair or replacement work.
b. When the manufacturer or his approved applicator fail to perform the repairs within 72 hours of notification, emergency temporary repairs performed by others does not void the warranty.
1.8.2 Roofing System Installer Warranty
The roof system installer must warrant for a period of two years that the roof system, as installed, is free from defects in installation workmanship, to include the roof membrane, flashing, insulation, accessories, attachments, and sheet metal installation integral to a complete watertight roof system assembly. Write the warranty directly to the Owner's Representative. The roof system installer is responsible for correction of defective workmanship and replacement of damaged or affected materials. The roof system installer is responsible for all costs associated with the repair or replacement work.
1.8.3 Continuance of Warranty
Approve repair or replacement work that becomes necessary within the warranty period and accomplish in a manner so as to restore the integrity
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of the roof system assembly and validity of the roof membrane manufacturer warranty for the remainder of the manufacturer warranty period.
1.9 CONFORMANCE AND COMPATIBILITY
The entire roofing and flashing system must be in accordance with specified and indicated requirements, including fire and wind resistance requirements. Work not specifically addressed and any deviation from specified requirements must be in general accordance with recommendations of the NRCA RoofMan, membrane manufacturer published recommendations and details, ASTM D6369, and compatible with surrounding components and construction. Submit any deviation from specified or indicated requirements to the Owner's Representative for approval prior to installation.
1.10 ELIMINATION, PREVENTION OF FALL HAZARDS
1.10.1 Fall Protection
Contractor is solely responsible for safety.
PART 2 PRODUCTS
2.1 MATERIALS
Coordinate with other specification sections related to the roof work. Furnish a combination of specified materials that comprise a roof system acceptable to the roof membrane manufacturer and meeting specified requirements. Protect materials provided from defects and make suitable for the service and climatic conditions of the installation.
2.1.1 EPDM Sheet
Ethylene Propylene Diene Terpolymer (EPDM), ASTM D4637/D4637M, Type II, scrim or fabric reinforced, 0.090 inch nominal thickness for loose laid application. The minimum thickness must not be less than minus 10 percent of the specified thickness value. EPDM membrane thickness specified is exclusive of backing material on the EPDM membrane. Principal polymer used in manufacture of the membrane sheet must be greater than 95 percent EPDM. Width and length of sheet must be as recommended by the manufacturer. Color: Black.
2.1.2 Seam Tape
Double-sided synthetic rubber tape, minimum 0.03 inch thick, minimum 3 inch wide. The roof membrane manufacturer must supply seam tape recommended by the manufacturer's printed data for forming watertight bond of EPDM sheet materials to each other for the application specified and conditions encountered. 6 inch wide tape is required for seam seals along lines of mechanical attachment of membrane. Color: Black.
2.1.3 Lap Splice Adhesive
Low volatile organic compound (VOC) synthetic rubber adhesive as supplied by roof membrane manufacturer and recommended by the manufacturer's printed data for forming watertight bond of EPDM sheet membrane materials to each other in areas of membrane flashing. Do not use splice adhesive to form membrane seams in field of roof or at standard base flashing conditions.
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2.1.4 Lap Cleaner, Lap Sealant, and Edge Treatment
As supplied by the roof membrane manufacturer and recommended by the manufacturer's printed data.
2.1.5 Water Cutoff Mastic/Water Block
As supplied by the roof membrane manufacturer and recommended by the manufacturer's printed data.
2.1.6 Membrane Flashings and Flashing Accessories
Membrane flashing, including self-adhering membrane flashing, perimeter flashing, flashing around roof penetrations, and prefabricated pipe seals, must be minimum 0.045 inch minimum cured EPDM, as recommended by the roof membrane manufacturer or minimum 0.055 inch thick uncured EPDM sheet in compliance with ASTM D4811/D4811M, Type I. Use cured EPDM membrane to the maximum extent recommended by the roof membrane manufacturer. Limit uncured flashing material to reinforcing inside and outside corners and angle changes in plane of membrane, and to flash scuppers, pourable sealer pockets, and other formed penetrations or unusually shaped conditions as recommended by the roof membrane manufacturer where the use of cured material is impractical. Color: Black.
2.1.6.1 Flashing Tape
EPDM-backed synthetic rubber tape, minimum 6 inch wide as supplied by the roof membrane manufacturer and recommended by the manufacturer's printed data.
2.1.7 Membrane Fasteners and Plates
Coated, corrosion-resistant fasteners as recommended by the roof membrane manufacturer and meeting the requirements of FM 4470 and FM APP GUIDE for Class I roof deck construction and the wind uplift resistance specified. As supplied and warranted for the substrate type(s) by EPDM sheet manufacturer and recommended by EPDM sheet manufacturer's printed data.
2.1.7.1 Stress Plates for Fasteners
Flat corrosion-resistant round stress plates as recommended by the roof membrane manufacturer's printed instructions and meeting the requirements of FM 4470; not less than 2 inch in diameter. Provide pre-formed discs to prevent dishing or cupping.
2.1.7.2 Auxiliary Fasteners
Corrosion resistance screws, nails, or anchors suitable for intended attachment purpose and as recommended by the roof membrane manufacturer.
2.1.7.3 Metal Disks
Provide flat metal disks of minimum 1 inch in diameter. Metal disks must be of nonferrous material compatible with the nails or fasteners.
2.1.8 Pre-Manufactured Accessories
Pre-manufactured accessories must be manufacturer's standard for intended purpose, compatible with the membrane roof system and approved for use by
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the roof membrane manufacturer.
2.1.8.1 Pre-fabricated Curbs
Provide 12 gauge G90 galvanized curbs with minimum 4 inch flange for attachment to roof nailers. Provide minimum height of 10 inch above the finished roof membrane surface.
2.1.9 Roof Insulation Below EPDM Sheet
Insulation system and facer material must be compatible with membrane application specified and as approved by the roof membrane manufacturer.
2.1.10 Wood Products
Do not allow fire retardant treated materials be in contact with EPDM membrane or EPDM accessory products, unless approved by the membrane manufacturer and the Owner's Representative.
2.1.11 Membrane Liner
Self-adhering EPDM membrane liner conforming to ASTM D4637/D4637M, or other waterproof membrane liner material as approved by the roof membrane manufacturer and the Owner's Representative.
2.2 FLASHING CEMENT
Provide a self-vulcanizing butyl compound flashing cement for splicing laps and for flashings workable at 20 degrees F. Obtain a recommendation for such flashing cement from the roofing membrane manufacturer.
PART 3 EXECUTION
3.1 EXAMINATION
Ensure that the following conditions exist prior to application of the roofing materials:
a. Drains, curbs, perimeter walls, roof penetrating components, and equipment supports are in place.
b. Surfaces are rigid, clean, dry, smooth, and free from cracks, holes, and sharp changes in elevation.
c. The plane of the substrate does not vary more than 1/4 inch within an area 10 by 10 feet when checked with a 10 foot straight edge placed anywhere on the substrate.
d. Substrate is sloped to provide positive drainage.
e. Walls and vertical surfaces are constructed to receive counterflashing, and will permit mechanical fastening of the base flashing materials.
f. Treated wood nailers are in place on non-nailable surfaces, to permit nailing of base flashing at minimum height of 8 inch above finished roofing surface.
g. Pressure-preservative treated wood nailers are fastened in place at eaves, gable ends, openings, and intersections with vertical surfaces
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for securing of membrane, edging strips, attachment flanges of sheet metal, and roof fixtures. Surface-applied nailers are the same thickness as the roof insulation.
h. Avoid contact of EPDM materials with fire retardant treated wood, except as approved by the roof membrane manufacturer and Owner's Representative.
i. Cants are securely fastened in place in the angles formed by walls and other vertical surfaces. The angle of the cant is 45 degrees and the height of the vertical leg is not less than 3-1/2 inch.
j. Exposed nail heads in wood substrates are properly set. Warped and split boards have been replaced. There are no cracks or end joints 1/4 inch in width or greater.
k. Insulation boards are installed smoothly and evenly, and are not broken, cracked, or curled. There are no gaps in insulation board joints exceeding 1/4 inch in width. Insulation is being roofed over on the same day the insulation is installed.
3.2 APPLICATION
Apply entire EPDM sheet utilizing fully adhered application method. Apply roofing materials as specified herein unless approved otherwise by the Owner's Representative.
3.2.1 Special Precautions
a. Do not dilute coatings or sealants unless specifically recommended by the materials manufacturer's printed application instructions. Do not thin liquid materials with cleaners used for cleaning EPDM sheet.
b. Keep liquids in airtight containers, and keep containers closed except when removing materials.
c. Use liquid components, including adhesives, within their shelf life period. Store adhesives at 60 to 80 degrees F prior to use. Avoid excessive adhesive application and adhesive spills, as they can be destructive to some elastomeric sheets and insulations; follow adhesive manufacturer's printed application instructions. Mix and use liquid components in accordance with label directions and manufacturer's printed instructions.
d. Provide clean, dry cloths or pads for applying membrane cleaners and cleaning of membrane
e. Do not use heat guns or open flame to expedite drying of adhesives or primers.
f. Require workmen and others who walk on the membrane to wear clean, soft-soled shoes to avoid damage to roofing materials.
g. Do not use equipment with sharp edges which could puncture the EPDM sheet.
h. Shut down air intakes and any related mechanical systems and seal open vents and air intakes when applying solvent-based materials in the area of the opening or intake. Coordinate shutdowns with the Owner's
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Representative.
3.2.2 EPDM Sheet Roofing
Provide a watertight roof membrane sheet free of contaminants and defects that might affect serviceability. Provide a uniform, straight, and flat edge. Unroll EPDM sheet roofing in position without stretching membrane. Inspect for holes. Remove sections of EPDM sheet roofing that are damaged. Allow sheets to relax minimum 30 minutes before seaming. Lap sheets as specified, to shed water, and as recommended by the roof membrane manufacturer's published installation instructions for the application required but not less than 3 inch in any case.
3.2.3 Application Method
3.2.3.1 Loose Laid Membrane Application
Layout membrane and side lap adjoining sheets in accordance with membrane manufacturer's printed installation instructions. Allow for sufficient membrane to form proper membrane terminations. Remove dusting agents and dirt from membrane and substrate areas where bonding adhesives are to be applied. Form field lap splices or seams as specified. Check all seams and ensure full lap seal. Apply lap sealant to all adhesive formed seams and all cut edges of reinforced membrane materials.
3.2.4 Tape Seams / Lap Splices
Field form seams, or lap splices, with seam tape in accordance with membrane manufacturer's printed instructions and as specified. Clean and prime mating surfaces in the seam area. After primer has dried or set in accordance with membrane manufacturer's instructions, apply seam tape to bottom membrane and roll with a 3 inch to 4 inch wide smooth silicone or steel hand roller, or other manufacturer approved rolling device, to ensure full contact and adhesion of tape to bottom membrane. Tape end laps must be minimum 1 inch. Roll top membrane into position to check for proper overlap and alignment. Remove release paper from top of seam tape and form seam splice. Ensure top membrane contact with seam tape as release paper is removed. Roll the closed seam with a smooth silicone or steel hand roller, rolling first across the width of the seam then along the entire length, being careful not to damage the membrane. Apply minimum 9 inch long strip of membrane-backed flashing tape over T-intersections of roof membrane. Roll tape to ensure full adhesion and seal over T-joint.
3.2.5 Adhesive Seams / Lap Splices
Use only field-applied adhesive formed seams where approved by the membrane manufacturer and the Owner's Representative. Do not use adhesive formed seams for field of roof membrane seaming, except as approved by the membrane manufacturer and the Owner's Representative. Thoroughly and completely clean mating surfaces of materials throughout the lap area. Remove all dirt, dust, and contaminants and allow to dry.
Apply primer as recommended by the membrane manufacturer. Apply splice adhesive with a 3 inch to 4 inch wide, 1/2 inch thick, solvent-resistant brush in a smooth, even coat with long brush strokes. Bleed out brush marks. Do not apply adhesive in a circular motion. Simultaneously apply adhesive to both mating surfaces in an approximate 0.025 to 0.030 inch wet film thickness, or other thickness as recommended by the roof membrane manufacturer's printed instructions.
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Allow the splice adhesive to set-up in accordance with membrane manufacturer's printed instructions. Perform manufacturer recommended field check to test for adhesive readiness prior to closing seam. Apply a 1/8 inch to 1/4 inch bead of in-seam sealant approximately 1/2 inch from the inside edge of the lower membrane sheet prior to closing the seam. Ensure the in-seam sealant does not extend onto the splice adhesive. Maintain the full adhered seam width required. Roll the top membrane onto the mating surface. Roll the seam area with a 2 inch to 3 inch wide, smooth silicone or steel hand roller. A minimum of 2 hours after joining sheets and when the lap edge is dry, clean the lap edge with membrane manufacturer's recommended cleaner and apply a 1/4 inch to 3/8 inch bead of lap sealant centered on the seam edge. With a feathering tool, immediately feather the lap sealant to completely cover the splice edge, leaving a mound of sealant over the seam edge. Apply lap sealant to all adhesive formed seams.
3.2.6 Perimeter Attachment
Adhesive bond or mechanically secure roof membrane sheet at roof perimeter in a manner to comply with wind resistance requirements and in accordance with membrane manufacturer's printed application instructions. When adhesively bonding a mechanically fastened system in perimeter areas, the perimeter boundary of the adhesive bond must be the same as the boundary required for additional perimeter mechanical fastening to meet wind resistance requirements.
3.2.7 Securement at Base Tie-In Conditions
Mechanically fasten the roof membrane at penetrations, at base of curbs and walls, and at all locations where the membrane turns and angle greater than 4 degrees (1:12). Space fasteners a maximum of 12 inch on center, except where more frequent attachment is required to meet specified wind resistance or where recommended by the roof membrane manufacturer. Flash over fasteners with a fully adhered layer of material as recommended by the roof membrane manufacturer's printed data.
3.3 FLASHINGS
3.3.1 General
Provide flashings in the angles formed at walls and other vertical surfaces and where required to make the work watertight, except where metal flashings are indicated.
Provide a one-ply flashing membrane, as specified for the system used, and install immediately after the roofing membrane is placed and prior to finish coating where a finish coating is required. Flashings must be stepped where vertical surfaces abut sloped roof surfaces. Provide sheet metal reglet in which sheet metal cap flashings are installed of not more than 16 inch nor less than 8 inch above the roofing surfaces. Exposed joints and end laps of flashing membrane must be made and sealed in the manner required for roofing membrane.
3.3.2 Membrane Flashing
Install flashing and flashing accessories as the roof membrane is installed. Apply flashing to cleaned surfaces and as recommended by the roof membrane manufacturer and as specified. Utilize cured EPDM membrane
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flashing and prefabricated accessory flashings to the maximum extent recommended by the roof membrane manufacturer. Limit uncured flashing material to reinforcing inside and outside corners and angle changes in plane of membrane, and to flashing scuppers, pourable sealer pockets, and other formed penetrations or unusually shaped conditions as recommended by the roof membrane manufacturer where the use of cured material is impractical. Extend base flashing not less than 8 inch above roofing surface and as necessary to provide for seaming overlap on roof membrane as recommended by the roof membrane manufacturer.
Seal flashing membrane for a minimum of 3 inch on each side of fastening device used to anchor roof membrane to nailers. Completely adhere flashing sheets in place. Seam flashing membrane in the same manner as roof membrane, except as otherwise recommended by the membrane manufacturer's printed instructions and approved by the Owner's Representative. Reinforce all corners and angle transitions by applying uncured membrane to the area in accordance with roof membrane manufacturer recommendations. Mechanically fasten top edge of base flashing with manufacturer recommended termination bar fastened at maximum 12 inch on center. Install sheet metal flashing over the termination bar in the completed work. Mechanically fasten top edge of base flashing for all other terminations in a manner recommended by the roof membrane manufacturer. Apply membrane liner over top of exposed nailers and blocking and to overlap top edge of base flashing installation at curbs, parapet walls, expansion joints and as otherwise indicated to serve as waterproof lining under sheet metal flashing components.
3.3.3 Flashing at Roof Drain
Provide a tapered insulation to drain area. Do not exceed tapered slope of 5 degrees for reinforced membrane. Provide tapered insulation with surface suitable for adhering membrane. Avoid field seams running through or within 24 inch of roof drain or as otherwise recommended by the roof membrane manufacturer. Adhere the membrane to the tapered in the drain area. Apply water block mastic and extend membrane sheets over edge of drain opening in accordance with membrane manufacturer's printed application instructions. Insure membrane free of wrinkles and folds in the drain area.
3.3.4 PRE-FABRICATED CURBS
Securely anchor prefabricated curbs to nailer or other base substrate and flashed with EPDM membrane flashing materials.
3.3.5 Set-On Accessories
Where pipe or conduit blocking, supports and similar roof accessories, or isolated paver block, are set on the membrane, adhere reinforced membrane or walkpad material, as recommended by the roof membrane manufacturer, to bottom of accessories prior to setting on roofing membrane. Specific method of installing set-on accessories must permit normal movement due to expansion, contraction, vibration, and similar occurrences without damaging roofing membrane. Do not mechanically secure set-on accessories through roofing membrane into roof deck substrate.
3.4 CORRECTION OF DEFICIENCIES
Where any form of deficiency is found, additional measures must be taken as deemed necessary by the Owner's Representative to determine the extent of the deficiency and corrective actions must be as directed by the Owner's
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Representative.
3.5 CLEAN UP
Remove debris, scraps, containers and other rubbish and trash resulting from installation of the roofing system from job site each day.
3.6 PROTECTION OF APPLIED ROOFING
At the end of the day's work and when precipitation is imminent, protect applied membrane roofing system from water intrusion.
3.6.1 Temporary Flashing for Permanent Roofing
Provide temporary flashing at drains, curbs, walls and other penetrations and terminations of roofing sheets until permanent flashings can be applied. Remove temporary flashing before applying permanent flashing.
3.6.2 Temporary Walkways, Runways, and Platforms
Do not permit storing, walking, wheeling, and trucking directly on applied roofing materials. Provide temporary walkways, runways, and platforms of smooth clean boards, mats or planks as necessary to avoid damage to applied roofing materials, and to distribute weight to conform to live load limits of roof construction. Use rubber-tired equipment for roofing work.
3.7 FIELD QUALITY CONTROL
3.7.1 Construction Monitoring
During progress of the roof work, Contractor must make visual inspections as necessary to ensure compliance with specified parameters. Additionally, verify the following:
a. Equipment is in working order. Metering devices are accurate.
b. Materials are not installed in adverse weather conditions.
c. Substrates are in acceptable condition, in compliance with specification, prior to application of subsequent materials.
Nailers and blocking are provided where and as needed.
Insulation substrate is smooth, properly secured to its substrate, and without excessive gaps prior to membrane application.
The proper number, type, and spacing of fasteners are installed.
Materials comply with the specified requirements.
All materials are properly stored, handled and protected from moisture or other damages. Liquid components are properly mixed prior to application.
Membrane is allowed to relax prior to seaming. Adhesives are applied uniformly to both mating surfaces and checked for proper set prior to bonding mating materials. Mechanical attachments are spaced as required, including additional fastening of membrane in corner and perimeter areas as required.
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Membrane is properly overlapped.
Membrane seaming is as specified and seams are hand rolled to ensure full adhesion and bond width. All seams are checked at the end of each work day.
Applied membrane is inspected and repaired as necessary prior to ballast installation.
Installer adheres to specified and detailed application parameters.
Associated flashings and sheet metal are installed in a timely manner in accord with the specified requirements.
Ballast is within the specified weight range.
Temporary protection measures are in place at the end of each work shift.
3.7.2 Manufacturer's Inspection
Manufacturer's technical representative must visit the site a minimum of two times during the installation for purposes of reviewing materials installation practices and adequacy of work in place. Inspections must occur during the first 2 squares of membrane installation, and at substantial completion, at a minimum. After each inspection, submit a report signed by the manufacturer's technical representative to the Owner's Representative within 3 working days. Note overall quality of work, deficiencies and any other concerns, and recommended corrective action.
3.8 INSTRUCTIONS TO OWNER'S PERSONNEL
Furnish written and verbal instructions on proper maintenance procedures to designated Owner's personnel. Furnish instructions by a competent representative of the roof membrane manufacturer and include a minimum of 4 hours on maintenance and emergency repair of the membrane. Include a demonstration of membrane repair, and give sources of required special tools. Furnish information on safety requirements during maintenance and emergency repair operations.
3.9 INFORMATION CARD
For each roof, furnish a typewritten information card for facility records anda photoengraved 0.032 inch thick aluminum card for exterior display. Card must be 8-1/2 by 11 inch minimum. Information card must identify facility name and number; location; contract number; approximate roof area; detailed roof system description, including deck type, membrane, number of plies, method of application, manufacturer, insulation and cover board system and thickness; presence of tapered insulation for primary drainage, presence of vapor retarder; date of completion; installing contractor identification and contact information; membrane manufacturer warranty expiration, warranty reference number, and contact information. Install card at roof top or access location as directed by the Owner's Representative and provide a paper copy to the Owner's Representative.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 07 60 00
FLASHING AND SHEET METAL 08/08 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM A653/A653M (2011) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process
ASTM B69 (2013) Standard Specification for Rolled Zinc
ASTM D1784 (2011) Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds
ASTM D226/D226M (2009) Standard Specification for Asphalt-Saturated Organic Felt Used in Roofing and Waterproofing
ASTM D41/D41M (2011) Asphalt Primer Used in Roofing, Dampproofing, and Waterproofing
ASTM D4586/D4586M (2007; E 2012; R 2012) Asphalt Roof Cement, Asbestos-Free
SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)
SMACNA 1793 (2012) Architectural Sheet Metal Manual, 7th Edition
1.2 GENERAL REQUIREMENTS
Finished sheet metalwork will form a weathertight construction without waves, warps, buckles, fastening stresses or distortion, which allows for expansion and contraction. Sheet metal mechanic is responsible for cutting, fitting, drilling, and other operations in connection with sheet metal required to accommodate the work of other trades. Coordinate installation of sheet metal items used in conjunction with roofing with roofing work to permit continuous roofing operations.
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1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Covering on flat or sloped surfaces; G
Expansion joints; G
Base flashing; G
Counterflashing; G
Flashing at roof penetrations; G
Reglets; G
Copings; G
Indicate thicknesses, dimensions, fastenings and anchoring methods, expansion joints, and other provisions necessary for thermal expansion and contraction. Scaled manufacturer's catalog data may be submitted for factory fabricated items.
SD-11 Closeout Submittals
Quality Control Plan
Submit for sheet metal work in accordance with paragraph entitled "Field Quality Control."
1.4 DELIVERY, HANDLING, AND STORAGE
Package and protect materials during shipment. Uncrate and inspect materials for damage, dampness, and wet-storage stains upon delivery to the job site. Remove from the site and replace damaged materials that cannot be restored to like-new condition. Handle sheet metal items to avoid damage to surfaces, edges, and ends. Store materials in dry, weather-tight, ventilated areas until immediately before installation.
PART 2 PRODUCTS
2.1 MATERIALS
Do not use lead, lead-coated metal, or galvanized steel. Use any metal listed by SMACNA Arch. Manual for a particular item, unless otherwise specified or indicated. Conform to the requirements specified and to the thicknesses and configurations established in SMACNA Arch. Manual for the materials. Different items need not be of the same metal, except that if copper is selected for any exposed item, all exposed items must be copper.
Furnish sheet metal items in 8 to 10 foot lengths. Single pieces less than 8 feet long may be used to connect to factory-fabricated inside and outside corners, and at ends of runs. Factory fabricate corner pieces with minimum 12 inch legs. Provide accessories and other items essential to complete the sheet metal installation. Provide accessories made of the same or compatible materials as the items to which they are applied. Fabricate
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sheet metal items of the materials specified below and to the gage, thickness, or weight shown in Table I at the end of this section. Provide sheet metal items with mill finish unless specified otherwise. Where more than one material is listed for a particular item in Table I, each is acceptable and may be used except as follows:
2.1.1 Exposed Sheet Metal Items
Must be of the same material. Consider the following as exposed sheet metal: Roof edge, cap, base, and other flashings and related accessories.
2.1.2 Steel Sheet, Zinc-Coated (Galvanized)
ASTM A653/A653M.
2.1.2.1 Finish
Exposed exterior items of zinc-coated steel sheet must have a baked-on, factory-applied color coating of polyvinylidene fluoride or other equivalent fluorocarbon coating applied after metal substrates have been cleaned and pretreated. Provide finish coating dry-film thickness of 0.8 to 1.3 mils and color to be selected by Engineer.
2.1.3 Zinc Sheet and Strip
ASTM B69, Type I, a minimum of 0.024 inch thick.
2.1.4 Polyvinyl Chloride Reglet
ASTM D1784, Type II, Grade 1, Class 14333-D, 0.075 inch minimum thickness.
2.1.5 Bituminous Plastic Cement
ASTM D4586/D4586M, Type I.
2.1.6 Roofing Felt
ASTM D226/D226M Type I or Type II.
2.1.7 Asphalt Primer
ASTM D41/D41M.
2.1.8 Fasteners
Use the same metal or a metal compatible with the item fastened. Use stainless steel fasteners to fasten dissimilar materials.
PART 3 EXECUTION
3.1 INSTALLATION
3.1.1 Workmanship
Make lines and angles sharp and true. Free exposed surfaces from visible wave, warp, buckle, and tool marks. Fold back exposed edges neatly to form a 1/2 inch hem on the concealed side. Make sheet metal exposed to the weather watertight with provisions for expansion and contraction.
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Make surfaces to receive sheet metal plumb and true, clean, even, smooth, dry, and free of defects and projections. For installation of items not shown in detail or not covered by specifications conform to the applicable requirements of SMACNA 1793, Architectural Sheet Metal Manual. Provide sheet metal flashing in the angles formed where roof decks abut walls, curbs, ventilators, pipes, or other vertical surfaces and wherever indicated and necessary to make the work watertight. Join sheet metal items together as shown in Table II.
3.1.2 Nailing
Confine nailing of sheet metal generally to sheet metal having a maximum width of 18 inch. Confine nailing of flashing to one edge only. Space nails evenly not over 3 inch on center and approximately 1/2 inch from edge unless otherwise specified or indicated. Face nailing will not be permitted. Where sheet metal is applied to other than wood surfaces, include in shop drawings, the locations for sleepers and nailing strips required to secure the work.
3.1.3 Cleats
Provide continuous cleats for sheet metal 18 inch and over in width. Space cleats evenly not over 12 inch on center unless otherwise specified or indicated. Unless otherwise specified, provide cleats of 2 inch wide by 3 inch long and of the same material and thickness as the sheet metal being installed. Secure one end of the cleat with two nails and the cleat folded back over the nailheads. Lock the other end into the seam. Where the fastening is to be made to concrete or masonry, use screws and drive in expansion shields set in concrete or masonry.
3.1.4 Bolts, Rivets, and Screws
Install bolts, rivets, and screws where indicated or required. Provide compatible washers where required to protect surface of sheet metal and to provide a watertight connection. Provide mechanically formed joints in aluminum sheets 0.040 inch or less in thickness.
3.1.5 Seams
Straight and uniform in width and height showing on the face.
3.1.6 Counterflashing
Except where indicated or specified otherwise, insert counterflashing in reglets located from 9 to 10 inch minimum above roof decks, extend down vertical surfaces over upturned vertical leg of base flashings not less than 3 inch. Fold the exposed edges of counterflashings 1/2 inch. Provide end laps in counterflashings not less than 3 inch and make it weathertight with plastic cement. Do not make lengths of metal counterflashings exceed 10 feet. Form the flashings to the required shapes before installation. Factory-form the corners not less than 12 inch from the angle. Secure the flashings in the reglets with lead wedges and space not more than 18 inch apart. Fill caulked-type reglets or raked joints which receive counterflashing with caulking compound. Turn up the concealed edge of counterflashings built into masonry or concrete walls not less than 1/4 inch and extend not less than 2 inch into the walls. Install counterflashing to provide a spring action against base flashing. Factory form counter flashing to provide spring action against the base flashing.
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3.1.7 Metal Reglets
Provide factory fabricated caulked type or friction type reglets with a minimum opening of 1/4 inch and a depth of 1 1/4 inch, as approved.
3.1.7.1 Caulked Reglets
Provide with rounded edges and metal strap brackets or other anchors for securing to the concrete forms. Provide reglets with a core to protect them from injury during the installation. Provide built-up mitered corner pieces for internal and external angles. Wedge the flashing in the reglets with lead wedges every 18 inch, caulked full and solid with an approved compound.
3.1.7.2 Friction Reglets
Provide with flashing receiving slots not less than 5/8 inch deep, one inch jointing tongues, and upper and lower anchoring flanges installed at 24 inch maximum snaplock receiver. Insert the flashing the full depth of the slot and lock by indentations made with a dull-pointed tool, wedges, and filled with a sealant. For friction reglets, install flashing snaplock receivers at 24 inch on center maximum. When the flashing has been inserted the full depth, caulk the slot and lock with wedges and fill with sealant.
3.1.8 Polyvinyl Chloride Reglets Temporary Construction Installation
Rigid polyvinyl chloride reglets ASTM D1784, Type II, Grade 1, Class 14333-D, 0.075 inch minimum thickness may be provided in lieu of metal reglets for temporary construction.
3.1.9 Gravel Stops and Metal Coping
3.1.9.1 Joints
Leave open the section ends of coping 1/4 inch and backed with a formed flashing plate, mechanically fastened in place and lapping each section end a minimum of 4 inch set laps in plastic cement. Face nailing will not be permitted. Install prefabricated coping in accordance with the manufacturer's printed instructions and details.
3.1.10 Downspouts
3.1.10.1 Terminations
Neatly fit into the drainage connection the downspouts terminating in drainage lines and fill the joints with a portland cement mortar cap sloped away from the downspout. Provide downspouts terminating in splash blocks with elbow-type fittings. Provide splash pans as specified.
3.1.11 Flashing at Roof Penetrations and Equipment Supports
Provide metal flashing for all pipes, ducts, and conduits projecting through the roof surface and for equipment supports, guy wire anchors, and similar items supported by or attached to the roof deck. Power roof ventilators, and other items not listed but are specified in Mechanical and Electrical Sections.
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3.1.12 Single Pipe Vents
See Table I, footnote (d). Set flange of sleeve in bituminous plastic cement and nail 3 inch on center. Bend the top of sleeve over and extend down into the vent pipe a minimum of 2 inch. For long runs or long rises above the deck, where it is impractical to cover the vent pipe with lead, use a two-piece formed metal housing. Set metal housing with a metal sleeve having a 4 inch roof flange in bituminous plastic cement and nailed 3 inch on center. Extend sleeve a minimum of8 inch above the roof deck and lapped a minimum of 3 inch by a metal hood secured to the vent pipe by a draw band. Seal the area of hood in contact with vent pipe with an approved sealant.
3.2 PAINTING
Field-paint sheet metal for separation of dissimilar materials.
3.3 CLEANING
Clean exposed sheet metal work at completion of installation. Remove grease and oil films, handling marks, contamination from steel wool, fittings and drilling debris, and scrub-clean. Free the exposed metal surfaces of dents, creases, waves, scratch marks, and other marks.
3.4 REPAIRS TO FINISH
Scratches, abrasions, and minor surface defects of finish may be repaired in accordance with the manufacturer's printed instructions and as approved. Repair damaged surfaces caused by scratches, blemishes, and variations of color and surface texture. Replace items which cannot be repaired.
3.5 FIELD QUALITY CONTROL
Establish and maintain a Quality Control Plan for sheet metal used in conjunction with roofing to assure compliance of the installed sheet metalwork with the contract requirements. Remove work that is not in compliance with the contract and replace or correct. Include quality control, but not be limited to, the following:
a. Observation of environmental conditions; number and skill level of sheet metal workers; condition of substrate.
b. Verification that specified material is provided and installed.
c. Inspection of sheet metalwork, for proper size(s) and thickness(es), fastening and joining, and proper installation.
3.5.1 Procedure
Submit for approval prior to start of roofing work. Include a checklist of points to be observed. Document the actual quality control observations and inspections. Furnish a copy of the documentation to the Owner's Representative at the end of each day.
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TABLE I. SHEET METAL WEIGHTS, THICKNESSES, AND GAGES
Sheet Metal Items Zinc-Coated Steel, U.S. Std. Gage
Flashings:
Base - 22
Counter-flashing - 22
Coping - 22
Sheets, smooth - 22
Reglets (a) - 22
(a) May be polyvinyl chloride.
TABLE II. SHEET METAL JOINTS
TYPE OF JOINT
Item Designation Zinc-Coated Steel and Remarks Stainless Steel
Flashings
Base One inch Fill each metal 3 inch lap for expansion expansion joint with a joint joint sealing compound compound.
Cap-in reglet 3 inch lap Seal groove with joint sealing compound.
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TABLE II. SHEET METAL JOINTS
TYPE OF JOINT
Item Designation Zinc-Coated Steel and Remarks Stainless Steel
Reglets Butt joint Seal reglet groove with joint sealing compound.
Sheet, smooth Butt with 1/4 inch space Use sheet flashing backup plate.
(a) Provide a 3 inch lap elastomeric flashing with manufacturer's recommended sealant.
(b) Seal Polyvinyl chloride reglet with manufacturer's recommended sealant.
-- End of Section --
SECTION 07 60 00 Page 8 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 07 92 00
JOINT SEALANTS 01/07 08/07/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM C1311 (2010) Standard Specification for Solvent Release Agents
ASTM C834 (2010) Latex Sealants
ASTM C920 (2011) Standard Specification for Elastomeric Joint Sealants
ASTM D1056 (2007) Standard Specification for Flexible Cellular Materials - Sponge or Expanded Rubber
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Sealants
Primers
Bond breakers
Backstops
Manufacturer's descriptive data including storage requirements, shelf life, curing time, instructions for mixing and application, and primer data (if required). Provide a copy of the Material Safety Data Sheet for each solvent, primer or sealant material.
SD-07 Certificates
Sealant
Certificates of compliance stating that the materials conform to the specified requirements.
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1.3 ENVIRONMENTAL CONDITIONS
Apply sealant when the ambient temperature is between 40 and 90 degrees F.
1.4 DELIVERY AND STORAGE
Deliver materials to the job site in unopened manufacturers' external shipping containers, with brand names, date of manufacture, color, and material designation clearly marked thereon. Label elastomeric sealant containers to identify type, class, grade, and use. Carefully handle and store materials to prevent inclusion of foreign materials or subjection to sustained temperatures exceeding 90 degrees F or less than 0 degrees F.
1.5 QUALITY ASSURANCE
1.5.1 Compatibility with Substrate
Verify that each of the sealants are compatible for use with joint substrates.
1.5.2 Joint Tolerance
Provide joint tolerances in accordance with manufacturer's printed instructions.
1.5.3 Mock-Up
Project personnel are responsible for installing sealants in mock-up prepared by other trades, using materials and techniques approved for use on the project. Refer to mock-up on Section 04 20 00, Masonry.
1.6 SPECIAL WARRANTY
Guarantee sealant joint against failure of sealant and against water penetration through each sealed joint for five years.
PART 2 PRODUCTS
2.1 SEALANTS
Provide sealant that has been tested and found suitable for the substrates to which it will be applied.
2.1.1 Interior Sealant
Provide ASTM C834, ASTM C920, Type S or M, Grade NS, Class 12.5, Use NT. Location(s) and color(s) of sealant for the following:
LOCATION COLOR a. Small voids between walls or partitions and door Match frames, built-in or surface-mounted equipment and Adjacent fixtures, and similar items. Surface
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LOCATION COLOR b. Perimeter of frames at doors and access panels which Match adjoin exposed interior concrete and masonry surfaces. Adjacent Surface c. Joints of interior masonry walls and partitions which Grey adjoin pilasters and exterior walls unless otherwise detailed. d. Interior locations, not otherwise indicated or Match specified, where small voids exist between materials Adjacent specified to be painted. Surface e. Behind escutcheon plates at valve pipe penetrations. Grey
2.1.2 Exterior Sealant
For joints in vertical surfaces, provide ASTM C920, Type S or M, Grade NS, Class 25, Use NT. For joints in horizontal surfaces, provide ASTM C920, Type S or M, Grade P, Class 25, Use T. Provide location(s) and color(s) of sealant as follows:
LOCATION COLOR a. Joints and recesses formed where Match adjacent frames of doors, louvers, and vents surface color adjoin masonry, or concrete. Use sealant at both exterior and interior surfaces of exterior wall penetrations.
b. Joints between stone and exterior Match grout concrete form lined walls. color c. Masonry and stone control joints. Match adjacent surface color d. Voids where items pass through Match adjacent exterior walls. surface color e. Metal reglets, where flashing is Match adjacent inserted into masonry joints, and where surface color flashing is penetrated by coping dowels. f. Metal-to-metal joints where sealant Match adjacent is indicated or specified. surface color h. Joints between ends of copings and Match adjacent adjacent walls. surface color
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2.1.3 Floor Joint Sealant
ASTM C920, Type S or M, Grade P, Class 25, Use T. Provide location(s) and color(s) of sealant as follows:
LOCATION COLOR a. Seats of metal thresholds for Gray exterior doors. b. Control joints in floors, slabs, Gray and walkways.
2.1.4 Preformed Sealant
Provide preformed sealant of polybutylene or isoprene-butylene based pressure sensitive weather resistant tape or bead sealant capable of sealing out moisture, air and dust when installed as recommended by the manufacturer. At temperatures from minus 30 to plus 160 degrees F, the sealant must be non-bleeding and no loss of adhesion.
2.2 PRIMERS
Provide a nonstaining, quick-drying type and consistency recommended by the sealant manufacturer for the particular application.
2.3 BOND BREAKERS
Provide the type and consistency recommended by the sealant manufacturer to prevent adhesion of the sealant to backing or to bottom of the joint.
2.4 BACKSTOPS
Provide glass fiber roving or neoprene, butyl, polyurethane, or polyethylene foams free from oil or other staining elements as recommended by sealant manufacturer. Provide 25 to 33 percent oversized backing for closed cell and 40 to 50 percent oversized backing for open cell material, unless otherwise indicated. Make backstop material compatible with sealant. Do not use oakum and other types of absorptive materials as backstops.
2.4.1 Neoprene
Conform to ASTM D1056, closed cell expanded neoprene cord Type 2, Class C, Grade 2C2 for Neoprene backing.
2.4.2 Butyl Rubber Based
Provide Butyl Rubber Based Sealants of single component, solvent release, color as selected, conforming to ASTM C1311.
2.4.3 Silicon Rubber Base
Provide Silicon Rubber Based Sealants of single component, solvent release, color as selected, conforming to ASTM C920, Non-sag, Type 5, Grade NS, Class 25.
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2.5 CLEANING SOLVENTS
Provide type(s) recommended by the sealant manufacturer except for aluminum and bronze surfaces that will be in contact with sealant.
PART 3 EXECUTION
3.1 SURFACE PREPARATION
Clean surfaces from dirt frost, moisture, grease, oil, wax, lacquer, paint, or other foreign matter that would tend to destroy or impair adhesion. Remove oil and grease with solvent. Surfaces must be wiped dry with clean cloths. When resealing an existing joint, remove existing caulk or sealant prior to applying new sealant. For surface types not listed below, contact sealant manufacturer for specific recommendations.
3.1.1 Steel Surfaces
Remove loose mill scale by sandblasting or, if sandblasting is impractical or would damage finish work, scraping and wire brushing. Remove protective coatings by sandblasting or using a residue-free solvent.
3.1.2 Aluminum or Bronze Surfaces
Remove temporary protective coatings from surfaces that will be in contact with sealant. When masking tape is used as a protective coating, remove tape and any residual adhesive just prior to sealant application. For removing protective coatings and final cleaning, use nonstaining solvents recommended by the manufacturer of the item(s) containing aluminum or bronze surfaces.
3.1.3 Concrete and Masonry Surfaces
Where surfaces have been treated with curing compounds, oil, or other such materials, remove materials by sandblasting or wire brushing. Remove laitance, efflorescence and loose mortar from the joint cavity.
3.1.4 Wood Surfaces
Keep wood surfaces to be in contact with sealants free of splinters and sawdust or other loose particles.
3.2 SEALANT PREPARATION
Do not add liquids, solvents, or powders to the sealant. Mix multicomponent elastomeric sealants in accordance with manufacturer's instructions.
3.3 APPLICATION
3.3.1 Joint Width-To-Depth Ratios
a. Acceptable Ratios:
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JOINT WIDTH JOINT DEPTH
Minimum Maximum
For metal, glass, or other nonporous surfaces:
1/4 inch (minimum) 1/4 inch 1/4 inch over 1/4 inch 1/2 of width Equal to width
For concrete or masonry:
1/4 inch (minimum) 1/4 inch 1/4 inch over 1/4 inch to 1/2 inch 1/4 inch Equal to width over 1/2 inch to 2 inch 1/2 inch 5/8 inch
Over 2 inch As recommended by sealant manufacturer
b. Unacceptable Ratios: Where joints of acceptable width-to-depth ratios have not been provided, clean out joints to acceptable depths and grind or cut to acceptable widths without damage to the adjoining work. Grinding is not required on metal surfaces.
3.3.2 Masking Tape
Place masking tape on the finish surface on one or both sides of a joint cavity to protect adjacent finish surfaces from primer or sealant smears. Remove masking tape within 10 minutes after joint has been filled and tooled.
3.3.3 Backstops
Install backstops dry and free of tears or holes. Tightly pack the back or bottom of joint cavities with backstop material to provide a joint of the depth specified. Install backstops in the following locations:
a. Where indicated.
b. Where backstop is not indicated but joint cavities exceed the acceptable maximum depths specified in paragraph entitled, "Joint Width-to-Depth Ratios".
3.3.4 Primer
Immediately prior to application of the sealant, clean out loose particles from joints. Where recommended by sealant manufacturer, apply primer to joints in concrete masonry units, wood, and other porous surfaces in accordance with sealant manufacturer's instructions. Do not apply primer to exposed finish surfaces.
3.3.5 Bond Breaker
Provide bond breakers to the back or bottom of joint cavities, as recommended by the sealant manufacturer for each type of joint and sealant used, to prevent sealant from adhering to these surfaces. Carefully apply
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the bond breaker to avoid contamination of adjoining surfaces or breaking bond with surfaces other than those covered by the bond breaker.
3.3.6 Sealants
Provide a sealant compatible with the material(s) to which it is applied. Do not use a sealant that has exceeded shelf life or has jelled and can not be discharged in a continuous flow from the gun. Apply the sealant in accordance with the manufacturer's printed instructions with a gun having a nozzle that fits the joint width. Force sealant into joints to fill the joints solidly without air pockets. Tool sealant after application to ensure adhesion. Make sealant uniformly smooth and free of wrinkles. Upon completion of sealant application, roughen partially filled or unfilled joints, apply sealant, and tool smooth as specified. Apply sealer over the sealant when and as specified by the sealant manufacturer.
3.4 PROTECTION AND CLEANING
3.4.1 Protection
Protect areas adjacent to joints from sealant smears. Masking tape may be used for this purpose if removed 5 to 10 minutes after the joint is filled.
3.4.2 Final Cleaning
Upon completion of sealant application, remove remaining smears and stains and leave the work in a clean and neat condition.
a. Masonry and Other Porous Surfaces: Immediately scrape off fresh sealant that has been smeared on masonry and rub clean with a solvent as recommended by the sealant manufacturer. Allow excess sealant to cure for 24 hour then remove by wire brushing or sanding.
b. Metal and Other Non-Porous Surfaces: Remove excess sealant with a solvent-moistened cloth.
-- End of Section --
SECTION 07 92 00 Page 7 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 8 OPENINGS
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 08 11 16
ALUMINUM DOORS AND FRAMES 08/08 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel
ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM B221 (2013) Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
ASTM E1300 (2012a; E 2012) Determining Load Resistance of Glass in Buildings
ASTM E283 (2004; R 2012) Determining the Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen
ASTM E331 (2000; R 2009) Water Penetration of Exterior Windows, Skylights, Doors, and Curtain Walls by Uniform Static Air Pressure Difference
ASTM F1642 (2012) Standard Test Method for Glazing and Glazing Systems Subject to Airblast Loadings
ASTM F2248 (2012) Standard Practice for Specifying an Equivalent 3-Second Duration Design Loading for Blast Resistant Glazing Fabricated with Laminated Glass
1.2 PERFORMANCE REQUIREMENTS
1.2.1 Structural
Exterior doors, frames and hardware shall be designed to resist equivalent static design loads in accordance with ASTM F1642. Frame deflections shall not exceed L/160 of the unsupported member lengths. Equivalent static design loads for connections of window or door frame to the surrounding walls or hardware and associated connections, and glazing stop connections
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shall be in accordance with ASTM F2248 and ASTM E1300. Design supporting elements and their connections based on their ultimate capacities. Provide calculations of a Professional Engineer that substantiates compliance with these requirements. Use frames that provide an equivalent level of performance. Shapes and thicknesses of framing members shall be sufficient to withstand a design wind load of not less than 30 pounds per square foot of supported area the design wind load indicated with a deflection of not more than 1/175 times the length of the member and a safety factor of not less than 1.65.
1.2.2 Air Infiltration
When tested in accordance with ASTM E283, air infiltration shall not exceed 0.06 cubic feet per minute per square footof fixed area at a test pressure of 6.24 pounds per square foot ( 50 mile per hour wind).
1.2.3 Water Penetration
When tested in accordance with ASTM E331, there shall be no water penetration at a pressure of 8 pounds per square foot of fixed area.
1.3 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Doors and frames; G
Show elevations of each door type, size of doors and frames, metal gages, details of door and frame construction, methods of anchorage, glazing details, weatherstripping, provisions for and location of hardware, and details of installation.
SD-04 Samples
Finish sample
SD-05 Design Data
Structural calculations for deflection; G
SD-08 Manufacturer's Instructions
Doors and frames
Submit detail specifications and instructions for installation, adjustments, cleaning, and maintenance.
1.4 DELIVERY, STORAGE, AND HANDLING
Inspect materials delivered to the site for damage. Unload and store with minimum handling. Provide storage space in dry location with adequate ventilation, free from dust or water, and easily accessible for inspection and handling. Stack materials on nonabsorptive strips or wood platforms. Do not cover doors and frames with tarps, polyethylene film, or similar coverings. Protect finished surfaces during shipping and handling using manufacturer's standard method, except that no coatings or lacquers shall
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be applied to surfaces to which caulking and glazing compounds must adhere.
1.5 QUALITY CONTROL
1.5.1 Shop Drawing Requirements
Drawings shall indicate elevations of doors and frames, full-size sections, thickness and gages of metal, fastenings, proposed method of anchoring, size and spacing of anchors, details of construction, method of glazing, details of operating hardware, method and materials for weatherstripping, material and method of attaching subframes, trim, installation details, and other related items.
1.5.2 Sample Requirements
1.5.2.1 Finish Sample Requirements
Submit color chart of standard factory-finish color coatings.
PART 2 PRODUCTS
2.1 DOORS AND FRAMES
Swing-type aluminum doors and frames of size, design, and location indicated. Provide doors complete with frames, framing members , trim, and accessories.
2.2 MATERIALS
2.2.1 Anchors
Stainless steel .
2.2.2 Weatherstripping
Continuous wool pile, silicone treated, or type recommended by door manufacturer.
2.2.3 Aluminum Alloy for Doors and Frames
ASTM B221, Alloy 6063-T5 for extrusions. ASTM B209, alloy and temper best suited for aluminum sheets and strips.
2.2.4 Fasteners
Hard aluminum or stainless steel.
2.2.5 Structural Steel
ASTM A36/A36M.
2.2.6 Aluminum Paint
Aluminum door manufacturer's standard aluminum paint.
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2.3 FABRICATION
2.3.1 Aluminum Frames
Extruded aluminum shapes with contours approximately as indicated. Use countersunk stainless steel Phillips screws for exposed fastenings, and space not more than 12 inches on center. Mill joints in frame members to a hairline fit, reinforce, and secure mechanically.
2.3.2 Aluminum Doors
Of type, size, and design indicated and not less than 1-3/4 inch thick. Minimum wall thickness, 0.125 inch, except beads and trim, 0.050 inch. Door sizes shown are nominal and shall include standard clearances as follows: 0.093 inch at hinge and lock stiles, 0.125 inch between meeting stiles, 0.125 inch at top rails, 0.187 inch between bottom and threshold, and 0.687 inch between bottom and floor. Bevel single-acting doors 0.063 or 0.125 inch at lock, hinge, and meeting stile edges.
2.3.2.1 Flush Doors
Use facing sheets with an embossed surface. Use the following construction:
a. A solid fibrous core (R-7 min.), surrounded at edges and cross-braced at intermediate points with extruded aluminum shapes. Use aluminum facing sheets of not less than 0.050 inch thickness laminated to a 0.10 inch thick tempered hardboard backing. Bond facing sheets to core under heat and pressure with a thermosetting adhesive, and mechanically lock to the extruded edge members.
2.3.3 Welding and Fastening
Where possible, locate welds on unexposed surfaces. Dress welds on exposed surfaces smoothly. Select welding rods, filler wire, and flux to produce a uniform texture and color in finished work. Remove flux and spatter from surfaces immediately after welding. Exposed screws or bolts will be permitted only in inconspicuous locations, and shall have countersunk heads. Weld concealed reinforcements for hardware in place.
2.3.4 Weatherstripping
Provide on stiles and rails of exterior doors. Fit into slots which are integral with doors or frames. Weatherstripping shall be replaceable without special tools, and adjustable at meeting rails of pairs of doors. Installation shall allow doors to swing freely and close positively. Air leakage of a single leaf weatherstripped door shall not exceed 0.5 cubic feet per minute of air per square foot of door area when tested in accordance with ASTM E283.
2.3.5 Anchors
Place anchors near top and bottom of each jamb and at intermediate points not more than 25 inch apart.
2.3.6 Provisions for Hardware
Coordinate with Section 08 71 00 DOOR HARDWARE. Deliver hardware templates and hardware (except field-applied hardware) to the door manufacturer for use in fabrication of aluminum doors and frames. Cut, reinforce, drill,
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and tap doors and frames at the factory to receive template hardware. Provide doors to receive surface-applied hardware, except push plates, kick plates, and mop plates, with reinforcing only; drill and tap in the field. Provide hardware reinforcements of stainless steel or steel with hot-dipped galvanized finish, and secure with stainless steel screws. Provide reinforcement in core of flush doors as required to receive locks, door closers, and other hardware.
2.3.7 Finishes
Provide exposed aluminum surfaces with factory applied high performance organic coating with a minimum 70 percent PNDF resin content. Color shall be per Section 09 06 90, COLOR SCHEDULE.
PART 3 EXECUTION
3.1 INSTALLATION
Plumb, square, level, and align frames to receive doors. Anchor frames to adjacent construction as indicated and in accordance with manufacturer's printed instructions. Anchor bottom of each frame to rough floor construction with 3/32 inch thick stainless steel angle clips secured to back of each jamb and to floor construction; use stainless steel bolts and expansion rivets for fastening clip anchors. Hang doors to produce clearances specified in paragraph entitled "Aluminum Doors," of this section. After erection and glazing, adjust doors and hardware to operate properly.
3.2 PROTECTION FROM DISSIMILAR MATERIALS
3.2.1 Dissimilar Metals
Where aluminum surfaces come in contact with metals other than stainless steel, zinc, or small areas of white bronze, protect from direct contact to dissimilar metals.
3.2.1.1 Protection
Provide one of the following systems to protect surfaces in contact with dissimilar metals:
a. Paint the dissimilar metal with one coat of heavy-bodied bituminous paint.
3.2.2 Drainage from Dissimilar Metals
In locations where drainage from dissimilar metals has direct contact with aluminum, provide protective paint to prevent aluminum discoloration.
3.2.3 Masonry and Concrete
Provide aluminum surfaces in contact with mortar, concrete, or other masonry materials with one coat of heavy-bodied bituminous paint.
3.3 CLEANING
Upon completion of installation, clean door and frame surfaces in accordance with door manufacturer's written recommended procedure. Do not use abrasive, caustic, or acid cleaning agents.
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3.4 PROTECTION
Protect doors and frames from damage and from contamination by other materials such as cement mortar. Prior to completion and acceptance of the work, restore damaged doors and frames to original condition, or replace with new ones.
-- End of Section --
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SECTION 08 60 45
SKYLIGHTS 02/12 08/06/2014
PART 1 GENERAL
1.1 SUMMARY
Provide commercially available vaulted metal framed skylights which satisfy all requirements contained in this section and have been verified by load testing and independent design analyses (if required) to meet specified design requirements. Provide environmentally preferable products and work practices, applicable to skylights, considering raw materials acquisition, production, manufacturing, packaging, distribution, reuse, operation, maintenance, and/or disposal of the products or services used in the skylights. The skylight system shall be UV-stabilized, shatter proof and energy efficient. The plastics used in the manufacture of the skylights shall be light transmitting plastics for daylighting applications. Systems shall meet requirements of UFC 4-010-01.
1.2 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN ARCHITECTURAL MANUFACTURERS ASSOCIATION (AAMA)
AAMA 2605 (2011) Voluntary Specification, Performance Requirements and Test Procedures for Superior Performing Organic Coatings on Aluminum Extrusions and Panels
ASTM INTERNATIONAL (ASTM)
ASTM E108 (2011) Fire Tests of Roof Coverings
ASTM E283 (2004; R 2012) Determining the Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen
ASTM E331 (2000; R 2009) Water Penetration of Exterior Windows, Skylights, Doors, and Curtain Walls by Uniform Static Air Pressure Difference
ASTM E661 (2003; R 2009) Standard Test Method for Performance of Wood and Wood-Based Floor and Roof Sheathing Under Concentrated Static and Impact Loads
ASTM E695 (2003; R 2009) Measuring Relative Resistance of Wall, Floor, and Roof Construction to Impact Loading
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INTERNATIONAL CODE COUNCIL (ICC)
ICC IBC (2012) International Building Code
NATIONAL FENESTRATION RATING COUNCIL (NFRC)
NFRC 100 (2010) Procedure for Determining Fenestration Product U-Factors
NFRC 200 (2010) Procedure for Determining Fenestration Product Solar Heat Gain Coefficient and Visible Transmittance at Normal Incidence
U.S. DEPARTMENT OF DEFENSE (DOD)
UFC 4-010-01 (2012) DoD Minimum Antiterrorism Standards for Buildings
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
29 CFR 1910.23 Guarding Floor and Wall Openings and Holes
UNDERWRITERS LABORATORIES (UL)
UL 972 (2006; Reprint Jul 2011) Standard for Burglary Resisting Glazing Material Type
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Shop Drawings; G
SD-03 Product Data
SKYLIGHTS Warranty
SD-06 Test Reports
Test Reports
SD-07 Certificates
Systems Qualifications
1.4 QUALITY ASSURANCE
a. Provide documentation of Qualifications for the following: The manufacturer shall be a company specializing in the manufacture of the specified products with a minimum of 10 years documented experience. The installer shall have documented experience of 5 years minimum performing the work specified.
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1.5 DELIVERY, STORAGE, AND HANDLING
System modules shall be factory assembled to the greatest extent possible. Panels shall be shipped to the jobsite in rugged shipping units and shall be ready for erection. All skylights shall have conspicuous decals affixed warning individuals against sitting or stepping on the units. Skylight panels shall be stored on the long edge, several inches above the ground, blocked and under cover to prevent warping. Deliver unit skylights in manufacturer's original containers, dry, undamaged, with seals and labels intact. All products shall be delivered, stored and protected in accordance with manufacturer's recommendations.
1.6 WARRANTY
Provide to the Owner the manufacturer's complete warranty for materials, workmanship, and installation. The warranty shall be for 5 years from the time of project completion and shall not be prorated. The warranty shall guarantee, but shall not be limited to, the following:
a. Provide a single source warranty for the glazing panels and the framing system. Third party warranty for the glazing panels will not be accepted.
PART 2 PRODUCTS
2.1 SKYLIGHTS
Skylight panels shall be fabricated of glass panels conforming to the specified requirements and other appropriate lab test specified criteria. Submit certified Test Reports from independent testing laboratory for each type and class of panel system. Reports shall verify that the material meets specified performance requirements. Previously completed test reports will be acceptable if they are current and indicative of products used on this project. Where a Class A, B or C roof is part of the project, a listing certificate for roof covering systems category shall be provided certifying that the product complies with the safety standards of ASTM E108 and ICC IBC. Size and color of skylight panels shall be as indicated in Section 08 81 00, GLAZING.
a. Skylight System to be similar to WASCO Classic System, Model C-PYH or CPI "clearsky" series glass skylights or approved equal.
2.2 GLASS PANELS
Reference Specification Section 08 81 00, GLAZING (Paragraph 2.2.1). 2.3 COMMON PANEL REQUIREMENTS
2.3.1 Thermal Performance
Skylights (including frames and glass) shall be certified by the National Fenestration Rating Council with a whole-unit Solar Heat Gain Coefficient (SHGC) maximum of .24 determined according to NFRC 200 procedures and a U-factor maximum of .29 Btu/hr-ft2-F in accordance with NFRC 100.
2.3.2 Condensation Index Rating
The condensation index rating shall be 62 as determined using National Fenestration Rating Council approved software THERM.
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2.4 SKYLIGHT SYSTEMS
Submit manufacturer's certificate that the systems meet or exceed specified requirements. Systems shall be evaluated and listed (the whole skylight as a unit, not just a glazing material in the unit) by the recognized building code authorities: ICC and SBCCI-Public Safety Testing and Evaluation Services Inc. Product ratings determined using NFRC 100 and NFRC 200 shall be authorized for certification and properly labeled by the manufacturer. Provide skylight systems meeting the following requirements:
a. Integral perimeter framing system assembly shall be by the manufacturer.
b. Air infiltration at 1.57 psf shall be less than 0.04 cfm/ft2 and at 6.24 psf shall be less than 0.07 cfm/ft2 in accordance with ASTM E283.
c. Water penetration at test pressure of 15 psf shall be zero in accordance with ASTM E331.
d. Manufacturer shall be responsible for maximum system deflection, in accordance with the applicable building code, and without damage to system performance. Deflection shall be calculated in accordance with engineering principles.
e. Proper weepage elements shall be incorporated within the perimeter framework of the glazing system for drainage of any condensation or water penetration.
f. System shall accommodate movement within the system; movement between the system and perimeter framing components; dynamic loading and release of loads; and deflection of supporting members. This shall be achieved without damage to system or components, deterioration of weather seals and fenestration properties specified.
g. The exterior panel face shall repel an impact of 200 foot-pounds without fracture or tear when impacted by a 3.25 inch diameter, 5 pound free falling ball dropped from a vertical distance of 40 feet when tested in accordance with UL 972.
h. System shall meet the fall through requirements of 29 CFR 1910.23 as demonstrated by testing in accordance with ASTM E661 or ASTM E695, thereby not requiring supplemental screens or railings.
i. Exposed aluminum color shall be a bronze shade selected from the manufacturer's standard range. Corrosion resistant finish shall be oven dried Kynar 500, 70 percent fluoropolymer, two coat superior-performance organic finish in accordance with AAMA 2605.
j. The system shall require no scheduled recoating to maintain its performance or for UV resistance.
k. Design criteria shall be:
(1) Wind Load 30; snow load 42.
l. Extruded aluminum shall be 6063-T6 and 6063-T5; all fasteners shall be stainless steel or cadmium plated steel.
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2.4.1 Framed Skylights
Framed skylights shall be designed to size on Drawings. Framing members shall be tubular aluminum. A registered professional engineer shall size all framing members and design all structural connections; submit a copy of the calculations. Framing shall include a primary gutter system with secondary gutters to control water infiltration and condensation runoff from the underside of the glazing material and channel it to the exterior. Skylight structural members shall be designed for a live load of 42 psf and wind load of 30 psf; no objectionable distortion or stress in fastenings and joinery due to expansion and contraction shall be induced when subjected to a 100 degree F temperature change.
2.5 FLEXIBLE SEALING TAPE
Sealing tape shall be manufacturer's standard pre-applied to closure system at the factory under controlled conditions.
PART 3 EXECUTION
3.1 EXAMINATION
Field verify all submitted opening sizes, dimensions and tolerances; preparation of openings shall include isolating dissimilar materials from aluminum system to avoid damage by electrolysis. The installer shall examine area of installation to verify readiness of site conditions and to notify the Contractor about any defects requiring correction. Verify when structural support is ready to receive all specified work and to convene a pre-installation conference, if approved by the Owner's Representative, including the Contractor, skylight installer and all parties directly affecting and affected by the specified work. Do not commence work until conditions are satisfactory.
3.2 ERECTION
Erect skylight system in accordance with the approved shop drawings supplied by the manufacturer. Submit drawings showing fabrication details, materials, dimensions, installation methods, anchors, and relationship to adjacent construction. Fastening and sealing shall be in accordance with the manufacturer's shop drawings. All panel protection shall be removed and, after other trades have completed work on adjacent materials, panel installation shall be carefully inspected and adjusted, if necessary, to ensure proper installation and weather-tight conditions. All staging, lifts and hoists required for the complete installation and field measuring shall be provided. System shall be installed clean of dirt, debris or staining and thoroughly examined for removal of all protective material prior to final inspection of the designated work area. Snow rakes shall not be used on skylights.
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 08 71 00
DOOR HARDWARE 08/08 08/07/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM E283 (2004; R 2012) Determining the Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen
BUILDERS HARDWARE MANUFACTURERS ASSOCIATION (BHMA)
ANSI/BHMA A156.1 (2013) Butts and Hinges
ANSI/BHMA A156.13 (2012) Mortise Locks & Latches Series 1000
ANSI/BHMA A156.16 (2013) Auxiliary Hardware
ANSI/BHMA A156.18 (2012) Materials and Finishes
ANSI/BHMA A156.21 (2009) Thresholds
ANSI/BHMA A156.3 (2008) Exit Devices
ANSI/BHMA A156.4 (2013) Door Controls - Closers
ANSI/BHMA A156.6 (2010) Architectural Door Trim
ANSI/BHMA A156.7 (2003; R 2009) Template Hinge Dimensions
ANSI/BHMA A156.8 (2010) Door Controls - Overhead Stops and Holders
BHMA A156.22 (2012) Door Gasketing and Edge Seal Systems
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 101 (2012; Amendment 1 2012) Life Safety Code
STEEL DOOR INSTITUTE (SDI/DOOR)
SDI/DOOR A250.8 (2003; R2008) Recommended Specifications for Standard Steel Doors and Frames
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UNDERWRITERS LABORATORIES (UL)
UL Bld Mat Dir (2012) Building Materials Directory
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES.
SD-02 Shop Drawings
Hardware schedule; G
Keying system; G
SD-03 Product Data
Hardware items; G
SD-08 Manufacturer's Instructions
Installation
SD-10 Operation and Maintenance Data
Hardware Schedule items, Data Package 1; G
SD-11 Closeout Submittals
Key Bitting
1.3 HARDWARE SCHEDULE
Prepare and submit hardware schedule in the following form:
Hardware QuantitySize Reference Finish Mfr Key UL BHMA Item Publi- Name Control Mark Finish cation and Symbols (If Desig- Type No. Catalog fire nation No. rated and listed)
1.4 KEY BITTING CHART REQUIREMENTS
Submit key bitting charts to the Owner's Representative prior to completion of the work. Include:
a. Complete listing of all keys (AA1, AA2, etc.).
b. Complete listing of all key cuts (AA1-123456, AA2-123458).
c. Tabulation showing which key fits which door.
d. Copy of floor plan showing doors and door numbers.
e. Listing of 20 percent more key cuts than are presently required in each
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master system.
1.5 QUALITY ASSURANCE
1.5.1 Hardware Manufacturers and Modifications
Provide, as far as feasible, locks, hinges, and closers of one lock, hinge, or closer manufacturer's make. Modify hardware as necessary to provide features indicated or specified.
1.5.2 Key Shop Drawings Coordination Meeting
Prior to the submission of the key shop drawing, the Owner's Representative, Contractor and Door Hardware subcontractor shall meet to discuss key requirements for the facility.
1.6 DELIVERY, STORAGE, AND HANDLING
Deliver hardware in original individual containers, complete with necessary appurtenances including fasteners and instructions. Mark each individual container with item number as shown in hardware schedule. Deliver permanent keys and removable cores to the Owner's Representative, either directly or by certified mail. Deliver construction master keys with the locks.
PART 2 PRODUCTS
2.1 TEMPLATE HARDWARE
Provide hardware to be applied to prefinished doors manufactured to template. Promptly furnish template information or templates to door and frame manufacturers. Conform to ANSI/BHMA A156.7 for template hinges. Coordinate hardware items to prevent interference with other hardware.
2.2 HARDWARE FOR EXIT DOORS
Provide all hardware necessary to meet the requirements of NFPA 101 for exit doors, as well as to other requirements indicated, even if such hardware is not specifically mentioned under paragraph entitled "Hardware Schedule." Provide the label of Underwriters Laboratories, Inc. for such hardware listed in UL Bld Mat Dir or labeled and listed by another testing laboratory acceptable to the Owner's Representative.
2.3 HARDWARE ITEMS
Clearly and permanently mark with the manufacturer's name or trademark, hinges, locks, latches, exit devices, bolts and closers where the identifying mark will be visible after the item is installed. For closers with covers, the name or trademark may be beneath the cover.
2.3.1 Hinges
ANSI/BHMA A156.1, 4-1/2 by 4-1/2 inch unless otherwise indicated. Construct loose pin hinges for exterior doors so that pins will be nonremovable when door is closed.
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2.3.2 Locks
2.3.2.1 Mortise Locks
ANSI/BHMA A156.13, Series 1000, Operational Grade 1, Security Grade 1. Provide mortise locks with escutcheons not less than 7 by 2-1/4 inch with a bushing at least 1/4 inch long. Cut escutcheons to suit cylinders and provide trim items with straight, beveled, or smoothly rounded sides, corners, and edges. 2-3/4 inch backset.
2.3.3 Exit Devices
ANSI/BHMA A156.3, Grade 1. Provide adjustable strikes for rim type and vertical rod devices. Provide open back strikes for pairs of doors with mortise and vertical rod devices.
2.3.4 Cylinders and Cores
Provide cylinders for new locks, including locks provided under other sections of this specification. Provide fully compatible cylinders with products of the Best Lock Corporation with interchangeable cores which are removable by a special control key. Factory set the cores with six pin tumblers using the A4 system and F keyway. Submit a core code sheet with the cores. Provide master keyed cores in one system for this project. Provide construction interchangeable cores.
2.3.5 Keying System
Provide an extension of the existing keying system. Existing locks were manufactured by Best and have interchangeable cores. Provide construction interchangeable cores.
Provide sub-master keying system for the building, and keyed to the existing Best removable-core master and grand master keying systems. 2.3.6 Lock Trim
Cast, forged, or heavy wrought construction and commercial plain design.
2.3.6.1 Lever Handles
Provide lever handles in lieu of knobs. Conform to the minimum requirements of ANSI/BHMA A156.13 for mortise locks of lever handles for exit devices. Provide lever handle locks with a breakaway feature (such as a weakened spindle or a shear key) to prevent irreparable damage to the lock when force in excess of that specified in ANSI/BHMA A156.13 is applied to the lever handle. Provide lever handles return to within 1/2 inch of the door face.
2.3.6.2 Texture
Provide knurled or abrasive coated lever handles for doors which lead to dangerous areas.
2.3.7 Keys
Furnish one file key, one duplicate key, and one working key for each key change. Furnish one additional working key for each lock of each keyed-alike group. Stamp each key with appropriate key control symbol and " Do not duplicate." Do not place room number on keys.
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2.3.8 Door Bolts
ANSI/BHMA A156.16. Provide dustproof strikes for bottom bolts, except for doors having metal thresholds. Automatic latching flush bolts: ANSI/BHMA A156.3, Type 25.
2.3.9 Closers
ANSI/BHMA A156.4, Series C02000, Grade 1, with PT 4C. Provide with brackets, arms, mounting devices, fasteners, full size covers and other features necessary for the particular application. Size closers in accordance with manufacturer's recommendations, or provide multi-size closers, Sizes 1 through 6, and list sizes in the Hardware Schedule. Provide manufacturer's 10 year warranty.
2.3.9.1 Identification Marking
Engrave each closer with manufacturer's name or trademark, date of manufacture, and manufacturer's size designation located to be visible after installation.
2.3.10 Overhead Holders
ANSI/BHMA A156.8.
2.3.11 Door Protection Plates
ANSI/BHMA A156.6.
2.3.11.1 Sizes of Armor Plates
2 inch less than door width for single doors; one inch less than door width for pairs of doors. Provide a minimum 36 inch armor plates for flush doors.
2.3.12 Thresholds
ANSI/BHMA A156.21. Use J35100, with vinyl or silicone rubber insert in face of stop, for exterior doors opening out, unless specified otherwise.
2.3.13 Weather Stripping Gasketing
BHMA A156.22. Provide the type and function designation where specified in paragraph entitled "Hardware Schedule". Provide a set to include head and jamb seals, sweep strips, and, for pairs of doors, astragals. Air leakage of weather stripped doors not to exceed 1.25 cubic feet per minute of air per square foot of door area when tested in accordance with ASTM E283. Provide weather stripping with one of the following:
2.3.13.1 Extruded Aluminum Retainers
Extruded aluminum retainers not less than 0.050 inch wall thickness with vinyl, neoprene, silicone rubber, or polyurethane inserts. Provide clear bronze anodized aluminum.
2.3.14 Rain Drips
Extruded aluminum, not less than 0.08 inch thick, bronze anodized. Set
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drips in sealant and fasten with stainless steel screws.
2.3.14.1 Door Rain Drips
Approximately 1-1/2 inch high by 5/8 inch projection. Align bottom with bottom edge of door.
2.3.14.2 Overhead Rain Drips
Approximately 1-1/2 inch high by 2-1/2 inch projection, with length equal to overall width of door frame. Align bottom with door frame rabbet.
2.3.15 Special Tools
Provide special tools, such as spanner and socket wrenches and dogging keys, required to service and adjust hardware items.
2.4 FASTENERS
Provide fasteners of proper type, quality, size, quantity, and finish with hardware. Provide stainless steel or nonferrous metal fasteners that are exposed to weather. Provide fasteners of type necessary to accomplish a permanent installation.
2.5 FINISHES
ANSI/BHMA A156.18. Provide hardware in BHMA 630 finish (satin stainless steel), unless specified otherwise. Provide items not manufactured in stainless steel in BHMA 626 finish (satin chromium plated) over brass or bronze, except aluminum paint finish for surface door closers. Provide hinges for exterior doors in stainless steel with BHMA 630 finish or chromium plated brass or bronze with BHMA 626 finish. Furnish exit devices in BHMA 626 finish in lieu of BHMA 630 finish. Match exposed parts of concealed closers to lock and door trim.
PART 3 EXECUTION
3.1 INSTALLATION
Install hardware in accordance with manufacturers' printed installation instructions. Provide machine screws set in expansion shields for fastening hardware to solid concrete and masonry surfaces. Provide through bolts where necessary for satisfactory installation.
3.1.1 Weather Stripping Installation
Handle and install weather stripping to prevent damage. Provide full contact, weather-tight seals. Operate doors without binding.
3.1.1.1 Stop-Applied Weather Stripping
Fasten in place with color-matched sheet metal screws not more than 9 inch on center after doors and frames have been finish painted.
3.1.2 Threshold Installation
Extend thresholds the full width of the opening and notch end for jamb stops. Set thresholds in a full bed of sealant and anchor to floor with cadmium-plated, countersunk, steel screws.
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3.2 EXIT DOORS
Install hardware in accordance with NFPA 101 for exit doors.
3.3 HARDWARE LOCATIONS
SDI/DOOR A250.8, unless indicated or specified otherwise.
a. Armor Plates: Push side of single-acting doors.
3.4 FIELD QUALITY CONTROL
After installation, protect hardware from paint, stains, blemishes, and other damage until acceptance of work. Submit notice of testing 15 days before scheduled, so that testing can be witnessed by the Owner's Representative. Adjust hinges, locks, latches, bolts, holders, closers, and other items to operate properly. Demonstrate that permanent keys operate respective locks, and give keys to the Owner's Representative. Correct, repair, and finish, as directed, errors in cutting and fitting and damage to adjoining work.
3.5 HARDWARE SETS
Provide hardware for aluminum doors under this section. Deliver Hardware templates and hardware, except field-applied hardware to the aluminum door and frame manufacturer for use in fabricating the doors and frames.
3.6 SCHEDULES
HW-1: 8 Hinges 2 locksets 1 cylinder 2 exit devices 1 threshold 2 corrosion resilient closers with hold open devices 2 armorplates 1 rain drip 2 door rain drips 2 door sweeps 1 astragal (Removable with key)
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 08 81 00
GLAZING 08/11 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)
ANSI Z97.1 (2009; Errata 2010) Safety Glazing Materials Used in Buildings - Safety Performance Specifications and Methods of Test
ASTM INTERNATIONAL (ASTM)
ASTM C1036 (2010; E 2012) Standard Specification for Flat Glass
ASTM C1048 (2012; E 2012) Standard Specification for Heat-Treated Flat Glass - Kind HS, Kind FT Coated and Uncoated Glass
ASTM C1184 (2013) Standard Specification for Structural Silicone Sealants
ASTM C509 (2006; R 2011) Elastomeric Cellular Preformed Gasket and Sealing Material
ASTM C864 (2005; R 2011) Dense Elastomeric Compression Seal Gaskets, Setting Blocks, and Spacers
ASTM C920 (2011) Standard Specification for Elastomeric Joint Sealants
ASTM D2287 (2012) Nonrigid Vinyl Chloride Polymer and Copolymer Molding and Extrusion Compounds
ASTM D395 (2003; R 2008) Standard Test Methods for Rubber Property - Compression Set
ASTM E1300 (2012a; E 2012) Determining Load Resistance of Glass in Buildings
GLASS ASSOCIATION OF NORTH AMERICA (GANA)
GANA Glazing Manual (2004) Glazing Manual
GANA Sealant Manual (2008) Sealant Manual
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INSULATING GLASS MANUFACTURERS ALLIANCE (IGMA)
IGMA TB-3001 (2001) Guidelines for Sloped Glazing
IGMA TM-3000 (1990; R 2004) North American Glazing Guidelines for Sealed Insulating Glass Units for Commercial & Residential Use
IGMA TR-1200 (1983; R 2007) Guidelines for Commercial Insulating Glass Dimensional Tolerances
NATIONAL FENESTRATION RATING COUNCIL (NFRC)
NFRC 100 (2010) Procedure for Determining Fenestration Product U-Factors
NFRC 200 (2010) Procedure for Determining Fenestration Product Solar Heat Gain Coefficient and Visible Transmittance at Normal Incidence
U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA)
Energy Star (1992; R 2006) Energy Star Energy Efficiency Labeling System (FEMP)
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
16 CFR 1201 Safety Standard for Architectural Glazing Materials
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Installation
Drawings showing complete details of the proposed setting methods, mullion details, edge blocking, size of openings, frame details, materials, and types and thickness of glass.
SD-03 Product Data
Insulating Glass; G
Documentation for Energy Star qualifications.
Glazing Accessories
Manufacturer's descriptive product data, handling and storage recommendations, installation instructions, and cleaning instructions.
SD-04 Samples
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Insulating Glass
Two 12 by 12 inch samples of each glazing type.
SD-07 Certificates
Insulating Glass
Certificates stating that the glass meets the specified requirements. Labels or manufacturers marking affixed to the glass will be accepted in lieu of certificates.
Glazing Accessories
Certificates from the manufacturer attesting that the units meet the luminous and solar radiant transmission requirements for heat absorbing glass.
SD-08 Manufacturer's Instructions
Setting and sealing materials
Glass setting
Submit glass manufacturer's recommendations for setting and sealing materials and for installation of each type of glazing material specified.
1.3 SYSTEM DESCRIPTION
Glazing systems shall be fabricated and installed watertight and airtight to withstand thermal movement and wind loading without glass breakage, gasket failure, deterioration of glazing accessories, and defects in the work. Glazed panels shall comply with the safety standards, as indicated in accordance with ANSI Z97.1. Glazed panels shall comply with indicated wind/snow loading in accordance with ASTM E1300.
1.4 DELIVERY, STORAGE, AND HANDLING
Deliver products to the site in unopened containers, labeled plainly with manufacturers' names and brands. Store glass and setting materials in safe, enclosed dry locations and do not unpack until needed for installation. Handle and install materials in a manner that will protect them from damage.
1.5 ENVIRONMENTAL REQUIREMENTS
Do not start glazing work until the outdoor temperature is above 40 degrees F and rising, unless procedures recommended by the glass manufacturer and approved by the Owner's Representative are made to warm the glass and rabbet surfaces. Provide ventilation to prevent condensation of moisture on glazing work during installation. Do not perform glazing work during damp or rainy weather.
1.6 WARRANTY
1.6.1 Warranty for Insulating Glass Units
Warranty insulating glass units against development of material obstruction
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to vision (such as dust, fogging, or film formation on the inner glass surfaces) caused by failure of the hermetic seal, other than through glass breakage, for a 10-year period following acceptance of the work. Provide new units for any units failing to comply with terms of this warranty within 45 working days after receipt of notice from the Owner's Representative. For control tower units, the warranty period shall be 10 years; warranty shall be signed by the manufacturer.
PART 2 PRODUCTS
2.1 GLASS
ASTM C1036, unless specified otherwise. In doors and sidelights, provide safety glazing material conforming to 16 CFR 1201.
2.1.1 Heat-Strengthened Glass
ASTM C1048, Kind HS (heat strengthened), Condition A (uncoated), Type I, Class 1 (clear), Quality q3, 1/4 inch thick.
2.2 INSULATING GLASS UNITS
Two panes of glass separated by a dehydrated 1/2 inch airspace, filled with argon and hermetically sealed. Glazed systems (including frames and glass) shall be certified by the National Fenestration Rating Council with a whole-window Solar Heat Gain Coefficient (SHGC) maximum of 0.24 determined according to NFRC 200 procedures and a U-factor maximum of 0.31 Btu/hr-ft2-F in accordance with NFRC 100. Glazing shall meet or exceed a luminous efficacy of 1.0. Dimensional tolerances shall be as specified in IGMA TR-1200. Spacer shall be black, roll-formed, gaugethermally broken aluminum, with bent or tightly welded or keyed and sealed joints to completely seal the spacer periphery and eliminate moisture and hydrocarbon vapor transmission into airspace through the corners. Primary seal shall be compressed polyisobutylene and the secondary seal shall be a specially formulated silicone.
2.2.1 Laminated Insulated
a. 1/4 inch clear HS with VE6-42 #2.
b. 0.60 clear PVB.
c. 1/4 inch clear HS.
d. 1/2 inch airspace (argon).
e. 1/4 inch clear HS.2.2.2 Solar Performance
a. Visible transmittance: 19%.
b. U Valve (winter): 0.31.
c. SCHG: 0.18.
d. Silk screen: 50% V175.
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2.3 SETTING AND SEALING MATERIALS
Provide as specified in the GANA Glazing Manual, IGMA TM-3000, IGMA TB-3001, and manufacturer's recommendations, unless specified otherwise herein. Do not use metal sash putty, nonskinning compounds, nonresilient preformed sealers, or impregnated preformed gaskets. Materials exposed to view and unpainted shall be gray or neutral color.
2.3.1 Putty and Glazing Compound
Glazing compound shall be as recommended by manufacturer for face-glazing metal sash. Putty shall be linseed oil type. Putty and glazing compounds shall not be used with insulating glass or laminated glass.
2.3.2 Glazing Compound
Use for face glazing metal sash. Do not use with insulating glass units or laminated glass.
2.3.3 Sealants
Provide elastomeric and structural sealants.
2.3.3.1 Elastomeric Sealant
ASTM C920, Type S, Grade NS, Class 12.5, Use G. Use for channel or stop glazing metal sash. Sealant shall be chemically compatible with setting blocks, edge blocks, and sealing tapes, with sealants used in manufacture of insulating glass units. Color of sealant shall be white.
2.3.3.2 Structural Sealant
ASTM C1184, Type S.
2.3.4 Joint Backer
Joint backer shall have a diameter size at least 25 percent larger than joint width; type and material as recommended in writing by glass and sealant manufacturer.
2.3.5 Preformed Channels
Neoprene, vinyl, or rubber, as recommended by the glass manufacturer for the particular condition.
2.3.6 Sealing Tapes
Preformed, semisolid, PVC-based material of proper size and compressibility for the particular condition, complying with ASTM D2287. Use only where glazing rabbet is designed for tape and tape is recommended by the glass or sealant manufacturer. Provide spacer shims for use with compressible tapes. Tapes shall be chemically compatible with the product being set.
2.3.7 Setting Blocks and Edge Blocks
Closed-cell neoprene setting blocks shall be dense extruded type conforming to ASTM C509 and ASTM D395, Method B, Shore A durometer between 70 and 90. Edge blocking shall be Shore A durometer of 50 (plus or minus 5). Silicone setting blocks shall be required when blocks are in contact with silicone
SECTION 08 81 00 Page 5 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
sealant. Profiles, lengths and locations shall be as required and recommended in writing by glass manufacturer. Block color shall be black.
2.3.8 Glazing Gaskets
Glazing gaskets shall be extruded with continuous integral locking projection designed to engage into metal glass holding members to provide a watertight seal during dynamic loading, building movements and thermal movements. Glazing gaskets for a single glazed opening shall be continuous one-piece units with factory-fabricated injection-molded corners free of flashing and burrs. Glazing gaskets shall be in lengths or units recommended by manufacturer to ensure against pull-back at corners. Glazing gasket profiles shall be as recommended by the manufacturer for the intended application.
2.3.8.1 Fixed Glazing Gaskets
Fixed glazing gaskets shall be closed-cell (sponge) smooth extruded compression gaskets of cured elastomeric virgin neoprene compounds conforming to ASTM C509, Type 2, Option 1.
2.3.8.2 Wedge Glazing Gaskets
Wedge glazing gaskets shall be high-quality extrusions of cured elastomeric virgin neoprene compounds, ozone resistant, conforming to ASTM C864, Option 1, Shore A durometer between 65 and 75.
2.3.8.3 Aluminum Framing Glazing Gaskets
Glazing gaskets for aluminum framing shall be permanent, elastic, non-shrinking, non-migrating, watertight and weathertight.
2.3.9 Accessories
Provide as required for a complete installation, including glazing points, clips, shims, angles, beads, and spacer strips. Provide noncorroding metal accessories. Provide primer-sealers and cleaners as recommended by the glass and sealant manufacturers.
PART 3 EXECUTION
3.1 PREPARATION
Preparation, unless otherwise specified or approved, shall conform to applicable recommendations in the GANA Glazing Manual, GANA Sealant Manual, IGMA TB-3001, IGMA TM-3000, and manufacturer's recommendations. Determine the sizes to provide the required edge clearances by measuring the actual opening to receive the glass. Grind smooth in the shop glass edges that will be exposed in finish work. Leave labels in place until the installation is approved, except remove applied labels on heat-absorbing glass and on insulating glass units as soon as glass is installed. Securely fix movable items or keep in a closed and locked position until glazing compound has thoroughly set.
3.2 GLASS SETTING
Shop glaze or field glaze items to be glazed using glass of the quality and thickness specified or indicated. Glazing, unless otherwise specified or approved, shall conform to applicable recommendations in the
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GANA Glazing Manual, GANA Sealant Manual, IGMA TB-3001, IGMA TM-3000, and manufacturer's recommendations. Aluminum windows, wood doors, and wood windows may be glazed in conformance with one of the glazing methods described in the standards under which they are produced, except that face puttying with no bedding will not be permitted. Handle and install glazing materials in accordance with manufacturer's instructions. Use beads or stops which are furnished with items to be glazed to secure the glass in place. Verify products are properly installed, connected, and adjusted.
3.2.1 Sheet Glass
Cut and set with the visible lines or waves horizontal.
3.2.2 Insulating Glass Units
Do not grind, nip, or cut edges or corners of units after the units have left the factory. Springing, forcing, or twisting of units during setting will not be permitted. Handle units so as not to strike frames or other objects. Installation shall conform to applicable recommendations of IGMA TB-3001 and IGMA TM-3000.
3.2.3 Installation of Laminated Glass
Sashes which are to receive laminated glass shall be weeped to the outside to allow water drainage into the channel.
3.3 ADDITIONAL REQUIREMENTS FOR GLAZING CONTROL TOWER WINDOWS
3.3.1 Tolerances and Clearances of Units
Design to prevent the transfer of stress in the setting frames to the glass. Springing, twisting, or forcing of units during setting will not be permitted.
3.4 CLEANING
Clean glass surfaces and remove labels, paint spots, putty, and other defacement as required to prevent staining. Glass shall be clean at the time the work is accepted.
3.5 PROTECTION
Glass work shall be protected immediately after installation. Glazed openings shall be identified with suitable warning tapes, cloth or paper flags, attached with non-staining adhesives. Reflective glass shall be protected with a protective material to eliminate any contamination of the reflective coating. Protective material shall be placed far enough away from the coated glass to allow air to circulate to reduce heat buildup and moisture accumulation on the glass. Upon removal, separate protective materials for reuse or recycling. Glass units which are broken, chipped, cracked, abraded, or otherwise damaged during construction activities shall be removed and replaced with new units.
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SECTION 08 81 00 Page 7 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 08 91 00
METAL WALL LOUVERS 05/11 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)
AMCA 500-D (2012) Laboratory Methods of Testing Dampers for Rating
AMCA 511 (2010) Certified Ratings Program for Air Control Devices
AMERICAN ARCHITECTURAL MANUFACTURERS ASSOCIATION (AAMA)
AAMA 2603 (2002) Voluntary Specification, Performance Requirements and Test Procedures for Pigmented Organic Coatings on Aluminum Extrusions and Panels
ASTM INTERNATIONAL (ASTM)
ASTM A167 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip
ASTM A653/A653M (2011) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process
ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM B221 (2013) Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Wall louvers
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SD-03 Product Data
Metal Wall Louvers
SD-04 Samples
Wall louvers; G
1.3 DELIVERY, STORAGE, AND PROTECTION
Deliver materials to the site in an undamaged condition. Carefully store materials off the ground to provide proper ventilation, drainage, and protection against dampness. Louvers shall be free from nicks, scratches, and blemishes. Replace defective or damaged materials with new.
1.4 DETAIL DRAWINGS
Show all information necessary for fabrication and installation of wall louvers. Indicate materials, sizes, thicknesses, fastenings, and profiles.
1.5 COLOR SAMPLES
Colors of finishes for wall louvers and door louvers shall closely approximate colors indicated. Where color is not indicated, submit the manufacturer's standard colors to the Owner's Representative for selection.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Galvanized Steel Sheet
ASTM A653/A653M, coating designation G90.
2.1.2 Aluminum Sheet
ASTM B209, alloy 3003 or 5005 with temper as required for forming.
2.1.3 Extruded Aluminum
ASTM B221, alloy 6063-T5 or -T52.
2.1.4 Stainless Steel
ASTM A167, Type 302 or 304, with 2B finish.
2.2 METAL WALL LOUVERS
Weather resistant type, with bird screens and made to withstand a wind load of not less than 30 pounds per square foot. Wall louvers shall bear the AMCA certified ratings program seal for air performance and water penetration in accordance with AMCA 500-D and AMCA 511. The rating shall show a water penetration of 0.20 or less ounce per square foot of free area at a free velocity of 800 feet per minute.
2.2.1 Extruded Aluminum Louvers
Fabricated of extruded 6063-T5 or -T52 aluminum with a wall thickness of not less than 0.081 inch.
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2.2.2 Mullions and Mullion Covers
Same material and finish as louvers. Provide mullions where indicated. Provide mullions covers on both faces of joints between louvers.
2.2.3 Screens and Frames
For aluminum louvers, provide 1/2 inch square mesh, 14 or 16 gage aluminum or 1/4 inch square mesh, 16 gage aluminum bird screening. Mount screens in removable, rewirable frames of same material and finish as the louvers.
2.3 FASTENERS AND ACCESSORIES
Provide stainless steel screws and fasteners for aluminum louvers and zinc-coated or stainless steel screws and fasteners for steel louvers. Provide other accessories as required for complete and proper installation.
2.4 FINISHES
2.4.1 Aluminum
Exposed aluminum surfaces shall be factory finished with an organic coating. Color shall be Medium Bronze. Louvers shall have the same finish.
2.4.1.1 Organic Coating
Clean and prime exposed aluminum surfaces. Provide a baked enamel finish conforming to AAMA 2603, with total dry film thickness not less than 0.8 mil, color to be selected by Engineer.
PART 3 EXECUTION
3.1 INSTALLATION
3.1.1 Wall Louvers
Install using stops or moldings, flanges, strap anchors, or jamb fasteners as appropriate for the wall construction and in accordance with manufacturer's recommendations.
3.1.2 Screens and Frames
Attach frames to louvers with screws or bolts.
3.2 PROTECTION FROM CONTACT OF DISSIMILAR MATERIALS
3.2.1 Aluminum
Where aluminum contacts metal other than zinc, paint the dissimilar metal with a primer and two coats of aluminum paint.
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SECTION 08 91 00 Page 3 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 9 FINISHES
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 09 06 90
COLOR SCHEDULE 05/09 08/07/2014
PART 1 GENERAL
1.1 SUMMARY
This section covers only the color of exterior and interior materials and products that are exposed to view in the finished construction. The word "color", as used herein, includes surface color and pattern. Requirements for quality, product specifications, and method of installation are covered in other appropriate sections of the specifications. Specific locations where the various materials are required are shown on the drawings if not identified in this specification. Items not designated for color in this section may be specified in other sections. When color is not designated for items, propose a color for approval.
PART 2 PRODUCTS
2.1 COLOR SCHEDULE
The color schedule information provided in the following paragraphs lists the colors, patterns and textures required for exterior and interior finishes, including both factory applied and field applied colors. Where color is shown as being specific to one manufacturer, an equivalent color by another manufacturer may be submitted for approval. Manufacturers and materials specified are not intended to limit the selection of equal colors from other manufacturers. In the case of difference between the drawings and specifications, colors identified in this specification govern.
2.2 EXTERIOR FINISHES
2.2.1 Exterior Walls
Exterior wall colors apply to exterior wall surfaces. When applicable, paint conduit to closely match the adjacent surface color. Provide wall colors to match the colors listed below.
2.2.1.1 Stone
To be selected by Owner's Representative.
2.2.1.2 Mortar
Standard Gray.
2.2.1.3 Paint
To be selected by Owner's Representative.
2.2.2 Exterior Trim
Provide exterior trim to match the colors listed below.
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2.2.2.1 Aluminum Doors and Door Frames
Medium Bronze.
2.2.2.2 Louvers
Medium Bronze.
2.2.2.3 Flashings
Match adjacent material in color.
2.2.2.4 Coping
Medium Bronze.
2.2.2.5 Ladders
Mill finish.
2.2.2.6 Precast Concrete Coping
To be selected by Engineer.
2.2.2.7 Caulking and Sealants
Match adjacent material in color.
2.2.2.8 Bollards
Meduim Bronze.
2.2.2.9 Signage
To be selected by Owner's Representative.
2.2.2.10 Control Joints
Match adjacent material in color.
2.2.3 Exterior Roof
Apply roof color to exterior roof surfaces including sheet metal flashings and copings, snow guards, mechanical units, mechanical penthouses, roof trim, pipes, conduits, electrical appurtenances, and similar items. Provide roof color to match the colors listed below.
2.2.3.1 EPDM
Black
2.2.3.2 Penetrations
Black
2.2.3.3 Ballast
To be selected by Owner's Representative.
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2.3 INTERIOR FINISHES
2.3.1 Interior Floor Finishes
Provide flooring materials to match the colors listed below.
2.3.1.1 Industrial Floor Coating
Clear Hardener/Sealer.
2.3.2 Interior Wall Finishes
Apply interior wall color to the entire wall surface, including reveals, vertical furred spaces and columns, grilles, diffusers, electrical and access panels, and piping and conduit adjacent to wall surfaces unless otherwise specified. Paint items not specified in other paragraphs to match adjacent wall surface. Provide wall materials to match the colors listed below.
2.3.2.1 Paint
White.
2.3.3 Interior Ceiling Finishes
Apply ceiling color to underside of roof deck, and conduit and piping where deck are exposed and required to be painted. Provide ceiling materials to match the colors listed below.
2.3.3.1 Paint (Ceilings)
White.
2.3.4 Interior Trim
Provide interior trim to match the colors listed below.
2.3.4.1 Exposed Ductwork
White.
2.3.4.2 Bollards
Medium Bronze.
2.3.5 Interior Miscellaneous
2.3.5.1 Wall Switch Handles and Standard Receptacle Bodies
Mill.
2.3.5.2 Electrical Device Cover Plates
Mill.
2.3.5.3 Electrical Panels
Mill.
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PART 3 EXECUTION
Not Used
-- End of Section --
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SECTION 09 90 00
PAINTS AND COATINGS 05/11 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN CONFERENCE OF GOVERNMENTAL INDUSTRIAL HYGIENISTS (ACGIH)
ACGIH 0100 (2001; Supplements 2002-2008) Documentation of the Threshold Limit Values and Biological Exposure Indices
ASME INTERNATIONAL (ASME)
ASME A13.1 (2007; R 2013) Scheme for the Identification of Piping Systems
ASTM INTERNATIONAL (ASTM)
ASTM D235 (2002; R 2012) Mineral Spirits (Petroleum Spirits) (Hydrocarbon Dry Cleaning Solvent)
ASTM D4263 (1983; R 2012) Indicating Moisture in Concrete by the Plastic Sheet Method
ASTM D523 (2008) Standard Test Method for Specular Gloss
ASTM D6386 (2010) Standard Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product and Hardware Surfaces for Painting
ASTM F1869 (2011) Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride
MASTER PAINTERS INSTITUTE (MPI)
MPI 101 (Oct 2009) Epoxy Anti-Corrosive Metal Primer
MPI 107 (Oct 2009) Rust Inhibitive Primer (Water-Based)
MPI 108 (Oct 2009) High Build Epoxy Coating, Low Gloss
MPI 11 (Oct 2009) Exterior Latex, Semi-Gloss, MPI
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Gloss Level 5
MPI 134 (Oct 2009) Galvanized Primer (Waterbased)
MPI 138 (Oct 2009) Interior High Performance Latex, MPI Gloss Level 2
MPI 153 (Oct 2009) Interior W.B. Light Industrial Coating, Semi-Gloss, MPI Gloss Level 5
MPI 163 (Oct 2009) Exterior W.B. Light Industrial Coating, Semi-Gloss, MPI Gloss Level 5
MPI 2 (Oct 2009) Aluminum Heat Resistant Enamel (up to 427 C and 800 F
MPI 21 (Oct 2009) Heat Resistant Enamel, Gloss (up to 205 degrees C and 400 degrees F), MPI Gloss Level 6
MPI 22 (Oct 2009) Aluminum Paint, High Heat (up to 590 degrees C and 1100 degrees F.
MPI 23 (Oct 2009) Surface Tolerant Metal Primer
MPI 4 (Oct 2009) Interior/Exterior Latex Block Filler
MPI 47 (Oct 2009) Interior Alkyd, Semi-Gloss, MPI Gloss Level 5
MPI 77 (Oct 2009) Epoxy Gloss
MPI 79 (Oct 2009) Alkyd Anti-Corrosive Metal Primer
MPI 94 (Oct 2009) Exterior Alkyd, Semi-Gloss, MPI Gloss Level 5
MPI 95 (Oct 2009) Quick Drying Primer for Aluminum
THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)
SSPC 7/NACE No.4 (2007; E 2004) Brush-Off Blast Cleaning
SSPC PA 1 (2000; E 2004) Shop, Field, and Maintenance Painting of Steel
SSPC PA Guide 3 (1982; E 1995) A Guide to Safety in Paint Application
SSPC QP 1 (1998; E 2004) Standard Procedure for Evaluating Painting Contractors (Field Application to Complex Industrial Structures)
SSPC SP 1 (1982; E 2004) Solvent Cleaning
SSPC SP 10/NACE No. 2 (2007) Near-White Blast Cleaning
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SSPC SP 12/NACE No.5 (2002) Surface Preparation and Cleaning of Metals by Waterjetting Prior to Recoating
SSPC SP 13/NACE No. 13 (2013) Surface Preparation of Concrete
SSPC SP 2 (1982; E 2000; E 2004) Hand Tool Cleaning
SSPC SP 3 (1982; E 2004) Power Tool Cleaning
SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning
SSPC VIS 1 (2002; E 2004) Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning
SSPC VIS 3 (2004) Guide and Reference Photographs for Steel Surfaces Prepared by Hand and Power Tool Cleaning
SSPC VIS 4/NACE VIS 7 (1998; E 2000; E 2004) Guide and Reference Photographs for Steel Surfaces Prepared by Waterjetting
U.S. GENERAL SERVICES ADMINISTRATION (GSA)
FED-STD-313 (Rev D; Notice 1) Material Safety Data, Transportation Data and Disposal Data for Hazardous Materials Furnished to Owner's Representative Activities
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
29 CFR 1910.1000 Air Contaminants
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
The current MPI, "Approved Product List" which lists paint by brand, label, product name and product code as of the date of contract award, will be used to determine compliance with the submittal requirements of this specification. The Contractor may choose to use a subsequent MPI "Approved Product List", however, only one list may be used for the entire contract and each coating system is to be from a single manufacturer. All coats on a particular substrate must be from a single manufacturer. No variation from the MPI Approved Products List is acceptable.
Samples of specified materials may be taken and tested for compliance with specification requirements.
SD-02 Shop Drawings
Piping identification
Submit color stencil codes
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SD-03 Product Data
Certification
Coating; G
Manufacturer's Technical Data Sheets
SD-04 Samples
Color; G
Submit manufacturer's samples of paint colors. Cross reference color samples to color scheme as indicated.
SD-07 Certificates
Applicator's qualifications
Qualification Testing laboratory for coatings; G
SD-08 Manufacturer's Instructions
Application instructions
Mixing
Detailed mixing instructions, minimum and maximum application temperature and humidity, potlife, and curing and drying times between coats.
Manufacturer's Material Safety Data Sheets
Submit manufacturer's Material Safety Data Sheets for coatings, solvents, and other potentially hazardous materials, as defined in FED-STD-313.
SD-10 Operation and Maintenance Data
Coatings:; G
Preprinted cleaning and maintenance instructions for all coating systems shall be provided.
1.3 APPLICATOR'S QUALIFICATIONS
1.3.1 Contractor Qualification
Submit the name, address, telephone number, FAX number, and e-mail address of the contractor that will be performing all surface preparation and coating application. Submit evidence that key personnel have successfully performed surface preparation and application of coatings on concrete and concrete masonry on a minimum of three similar projects within the past three years. List information by individual and include the following:
a. Name of individual and proposed position for this work.
b. Information about each previous assignment including:
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Position or responsibility
Employer (if other than the Contractor)
Name of facility owner
Mailing address, telephone number, and telex number (if non-US) of facility owner
Name of individual in facility owner's organization who can be contacted as a reference
Location, size and description of structure
Dates work was carried out
Description of work carried out on structure
1.3.2 SSPC QP 1 Certification
All contractors and subcontractors that perform surface preparation or coating application shall be certified by the Society for Protective Coatings (formerly Steel Structures Painting Council) (SSPC) to the requirements of SSPC QP 1 prior to contract award, and shall remain certified while accomplishing any surface preparation or coating application. The painting contractors and painting subcontractors must remain so certified for the duration of the project. If a contractor's or subcontractor's certification expires, the firm will not be allowed to perform any work until the certification is reissued. Requests for extension of time for any delay to the completion of the project due to an inactive certification will not be considered and liquidated damages will apply. Notify the Owner's Representative of any change in contractor certification status.
1.3.3 SSPC QP 1 Waiver of Requirement
In lieu of SSPC QP 1 certification, surface preparation and coating Contractors and subcontractors may submit for waiver of this requirement if the following items are submitted and approved by the Engineer prior to approval of submittals or commencement of work:
1. Identify 5 similar sized or larger projects, including both process piping and exterior coating work, completed in the last three (3) years.
2. Provide written letters of recommendation from a minimum of three (3) separate clients (not Contractors or Engineers).
1.4 REGULATORY REQUIREMENTS
1.4.1 Environmental Protection
In addition to requirements specified elsewhere for environmental protection, provide coating materials that conform to the restrictions of the local Air Pollution Control District and regional jurisdiction. Notify Owner's Representative of any paint specified herein which fails to conform.
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1.4.2 Lead Content
Do not use coatings having a lead content over 0.06 percent by weight of nonvolatile content.
1.4.3 Chromate Content
Do not use coatings containing zinc-chromate or strontium-chromate.
1.4.4 Asbestos Content
Materials shall not contain asbestos.
1.4.5 Mercury Content
Materials shall not contain mercury or mercury compounds.
1.4.6 Silica
Abrasive blast media shall not contain free crystalline silica.
1.4.7 Human Carcinogens
Materials shall not contain ACGIH 0100 confirmed human carcinogens (A1) or suspected human carcinogens (A2).
1.5 PACKAGING, LABELING, AND STORAGE
Paints shall be in sealed containers that legibly show the contract specification number, designation name, formula or specification number, batch number, color, quantity, date of manufacture, manufacturer's formulation number, manufacturer's directions including any warnings and special precautions, and name and address of manufacturer. Pigmented paints shall be furnished in containers not larger than 5 gallons. Paints and thinners shall be stored in accordance with the manufacturer's written directions, and as a minimum, stored off the ground, under cover, with sufficient ventilation to prevent the buildup of flammable vapors, and at temperatures between 40 to 95 degrees F.
1.6 SAFETY AND HEALTH
Apply coating materials using safety methods and equipment in accordance with the following:
Work shall comply with applicable Federal, State, and local laws and regulations, and with the ACCIDENT PREVENTION PLAN. The Activity Hazard Analysis shall include analyses of the potential impact of painting operations on painting personnel and on others involved in and adjacent to the work zone.
1.6.1 Safety Methods Used During Coating Application
Comply with the requirements of SSPC PA Guide 3.
1.6.2 Toxic Materials
To protect personnel from overexposure to toxic materials, conform to the most stringent guidance of:
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a. The applicable manufacturer's Material Safety Data Sheets (MSDS) or local regulation.
b. 29 CFR 1910.1000.
c. ACGIH 0100, threshold limit values.
1.7 ENVIRONMENTAL CONDITIONS
Comply, at minimum, with manufacturer recommendations for space ventilation during and after installation.
1.7.1 Coatings
Do not apply coating when air or substrate conditions are:
a. Less than 5 degrees F above dew point;
b. Below 50 degrees F or over 95 degrees F, unless specifically pre-approved by the Owner's Representative and the product manufacturer. Under no circumstances shall application conditions exceed manufacturer recommendations.
1.8 COLOR SELECTION
Colors of finish coats shall be as indicated or specified. Where not indicated or specified, colors shall be selected by the Owner's Representative. Manufacturers' names and color identification are used for the purpose of color identification only. Named products are acceptable for use only if they conform to specified requirements. Products of other manufacturers are acceptable if the colors approximate colors indicated and the product conforms to specified requirements.
Tint each coat progressively darker to enable confirmation of the number of coats.
Color, texture, and pattern of wall coating systems shall be in accordance with Section 09 06 90 COLOR SCHEDULE.
1.9 LOCATION AND SURFACE TYPE TO BE PAINTED
1.9.1 Painting Included
Where a space or surface is indicated to be painted, include the following unless indicated otherwise.
a. Surfaces behind portable objects and surface mounted articles readily detachable by removal of fasteners, such as screws and bolts.
b. New factory finished surfaces that require identification or color coding and factory finished surfaces that are damaged during performance of the work.
c. Existing coated surfaces that are damaged during performance of the work.
1.9.1.1 Exterior Painting
Includes new surfaces and new coated surfaces, of the building and
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appurtenances. Also included are existing coated surfaces made bare by cleaning operations.
1.9.1.2 Interior Painting
Includes new surfaces of the building and appurtenances as indicated. Where a space or surface is indicated to be painted, include the following items, unless indicated otherwise.
a. Exposed CMU, precast concrete and Formlined concrete walls.
b. Other contiguous surfaces.
1.9.2 Painting Excluded
Do not paint the following unless indicated otherwise.
a. Surfaces concealed and made inaccessible by panelboards, fixed ductwork, machinery, and equipment fixed in place.
b. Surfaces in concealed spaces. Concealed spaces are defined as enclosed spaces such as chases.
c. Steel to be embedded in concrete, except steel embedded into precast concrete lintels.
d. Copper, stainless steel, aluminum, brass, and lead except existing coated surfaces.
e. Hardware, fittings, and other factory finished items.
f. Skylights.
g. Stone/Precast concrete coping.
h. Aluminum doors and frames.
i. Louvers.
j. Floodwall, screenwalls, and exterior Building form lining.
1.9.3 Mechanical and Electrical Painting
Includes field coating of interior and exterior surfaces.
a. Where a space or surface is indicated to be painted, include the following items unless indicated otherwise.
(1) Exposed piping, conduit, and ductwork;
(2) Supports, hangers, air grilles, and registers;
(3) Miscellaneous metalwork and insulation coverings.
(4) Rooftop exhaust fans.
(5) Roof Hatch.
b. Do not paint the following, unless indicated otherwise:
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(1) New zinc-coated, aluminum, and copper surfaces under insulation
(2) New aluminum jacket on piping
(3) New interior ferrous piping under insulation.
1.9.4 Exterior Painting of Site Work Items
Field coat the following items:
a. Bollards
b. Decorative Gates and Fences
c. All Gate Operators
d. New Surfaces
1.9.5 Definitions and Abbreviations
1.9.5.1 Qualification Testing
Qualification testing is the performance of all test requirements listed in the product specification. This testing is accomplished by MPI to qualify each product for the MPI Approved Product List, and may also be accomplished by Contractor's third party testing lab if an alternative to Batch Quality Conformance Testing by MPI is desired.
1.9.5.2 Batch Quality Conformance Testing
Batch quality conformance testing determines that the product provided is the same as the product qualified to the appropriate product specification. This testing shall only be accomplished by MPI testing lab.
1.9.5.3 Coating
A film or thin layer applied to a base material called a substrate. A coating may be a metal, alloy, paint, or solid/liquid suspensions on various substrates (metals, plastics, wood, paper, leather, cloth, etc.). They may be applied by electrolysis, vapor deposition, vacuum, or mechanical means such as brushing, spraying, calendaring, and roller coating. A coating may be applied for aesthetic or protective purposes or both. The term "coating" as used herein includes emulsions, enamels, stains, varnishes, sealers, epoxies, and other coatings, whether used as primer, intermediate, or finish coat. The terms paint and coating are used interchangeably.
1.9.5.4 DFT or dft
Dry film thickness, the film thickness of the fully cured, dry paint or coating.
1.9.5.5 DSD
Degree of Surface Degradation, the MPI system of defining degree of surface degradation. Five (5) levels are generically defined under the Assessment sections in the MPI Maintenance Repainting Manual.
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1.9.5.6 EPP
Environmentally Preferred Products, a standard for determining environmental preferability in support of Executive Order 13101.
1.9.5.7 EXT
MPI short term designation for an exterior coating system.
1.9.5.8 INT
MPI short term designation for an interior coating system.
1.9.5.9 micron / microns
The metric measurement for 0.001 mm or one/one-thousandth of a millimeter.
1.9.5.10 mil / mils
The English measurement for 0.001 in or one/one-thousandth of an inch, equal to 25.4 microns or 0.0254 mm.
1.9.5.11 mm
The metric measurement for millimeter, 0.001 meter or one/one-thousandth of a meter.
1.9.5.12 MPI Gloss Levels
MPI system of defining gloss. Seven (7) gloss levels (G1 to G7) are generically defined under the Evaluation sections of the MPI Manuals. Traditionally, Flat refers to G1/G2, Eggshell refers to G3, Semigloss refers to G5, and Gloss refers to G6.
Gloss levels are defined by MPI as follows:
Gloss Description Units Units Level at 60 degrees at 85 degrees
G1 Matte or Flat 0 to 5 10 max G2 Velvet 0 to 10 10 to 35 G3 Eggshell 10 to 25 10 to 35 G4 Satin 20 to 35 35 min G5 Semi-Gloss 35 to 70 G6 Gloss 70 to 85 G7 High Gloss
Gloss is tested in accordance with ASTM D523. Historically, the Owner's Representative has used Flat (G1 / G2), Eggshell (G3), Semi-Gloss (G5), and Gloss (G6).
1.9.5.13 MPI System Number
The MPI coating system number in each Division found in either the MPI Architectural Painting Specification Manual or the Maintenance Repainting Manual and defined as an exterior (EXT/REX) or interior system (INT/RIN). The Division number follows the CSI Master Format.
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1.9.5.14 Paint
See Coating definition.
1.9.5.15 REX
MPI short term designation for an exterior coating system used in repainting projects or over existing coating systems.
1.9.5.16 RIN
MPI short term designation for an interior coating system used in repainting projects or over existing coating systems.
PART 2 PRODUCTS
2.1 MATERIALS
Conform to the coating specifications and standards referenced in PART 3. Submit manufacturer's technical data sheets for specified coatings and solvents. Comply with applicable regulations regarding toxic and hazardous materials.
PART 3 EXECUTION
3.1 PROTECTION OF AREAS AND SPACES NOT TO BE PAINTED
Prior to surface preparation and coating applications, remove, mask, or otherwise protect, hardware, hardware accessories, machined surfaces, plates, lighting fixtures, public and private property, and other such items not to be coated that are in contact with surfaces to be coated. Following completion of painting, workmen skilled in the trades involved shall reinstall removed items. Restore surfaces contaminated by coating materials, to original condition and repair damaged items.
3.2 SURFACE PREPARATION
Remove dirt, splinters, loose particles, grease, oil, disintegrated coatings, and other foreign matter and substances deleterious to coating performance as specified for each substrate before application of paint or surface treatments. Oil and grease shall be removed prior to mechanical cleaning. Cleaning shall be programmed so that dust and other contaminants will not fall on wet, newly painted surfaces. Exposed ferrous metals such as nail heads on or in contact with surfaces to be painted with water-thinned paints, shall be spot-primed with a suitable corrosion-inhibitive primer capable of preventing flash rusting and compatible with the coating specified for the adjacent areas.
3.3 PREPARATION OF METAL SURFACES
3.3.1 New Ferrous Surfaces
a. Ferrous Surfaces including Shop-coated Surfaces and Small Areas That Contain Rust, Mill Scale and Other Foreign Substances: Solvent clean in accordance with SSPC SP 1 to remove oil and grease. Where shop coat is missing or damaged, clean according to SSPC SP 6/NACE No.3, or SSPC SP 10/NACE No. 2. Brush-off blast remaining surface in accordance with SSPC 7/NACE No.4; Water jetting to SSPC SP 12/NACE No.5 WJ-4 may be used to remove loose coating and other loose materials. Use
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inhibitor as recommended by coating manufacturer to prevent premature rusting. Shop-coated ferrous surfaces shall be protected from corrosion by treating and touching up corroded areas immediately upon detection.
b. Surfaces With More Than 20 Percent Rust, Mill Scale, and Other Foreign Substances: Clean entire surface in accordance with SSPC SP 10/NACE No. 2/SSPC SP 12/NACE No.5 WJ-2.
3.3.2 Final Ferrous Surface Condition:
For tool cleaned surfaces, the requirements are stated in SSPC SP 2 and SSPC SP 3. As a visual reference, cleaned surfaces shall be similar to photographs in SSPC VIS 3.
For abrasive blast cleaned surfaces, the requirements are stated in SSPC 7/NACE No.4, SSPC SP 6/NACE No.3, and SSPC SP 10/NACE No. 2. As a visual reference, cleaned surfaces shall be similar to photographs in SSPC VIS 1.
For waterjet cleaned surfaces, the requirements are stated in SSPC SP 12/NACE No.5. As a visual reference, cleaned surfaces shall be similar to photographs in SSPC VIS 4/NACE VIS 7.
3.3.3 Galvanized Surfaces
a. New Galvanized Surfaces With Only Dirt and Zinc Oxidation Products: Clean with solvent, or non-alkaline detergent solution in accordance with SSPC SP 1. If the galvanized metal has been passivated or stabilized, the coating shall be completely removed by brush-off abrasive blast. New galvanized steel to be coated shall not be "passivated" or "stabilized" If the absence of hexavalent stain inhibitors is not documented, test as described in ASTM D6386, Appendix X2, and remove by one of the methods described therein.
b. Galvanized with Slight Coating Deterioration or with Little or No Rusting: Water jetting to SSPC SP 12/NACE No.5 WJ3 to remove loose coating from surfaces with less than 20 percent coating deterioration and no blistering, peeling, or cracking. Use inhibitor as recommended by the coating manufacturer to prevent rusting.
c. Galvanized With Severe Deteriorated Coating or Severe Rusting: Spot abrasive blast rusted areas as described for steel in SSPC SP 6/NACE No.3, and waterjet to SSPC SP 12/NACE No.5, WJ3 to remove existing coating.
3.3.4 Non-Ferrous Metallic Surfaces
Aluminum and aluminum-alloy, lead, copper, and other nonferrous metal surfaces.
Surface Cleaning: Solvent clean in accordance with SSPC SP 1 and wash with mild non-alkaline detergent to remove dirt and water soluble contaminants.
3.3.5 Terne-Coated Metal Surfaces
Solvent clean surfaces with mineral spirits, ASTM D235. Wipe dry with clean, dry cloths.
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3.3.6 Existing Surfaces with a Bituminous or Mastic-Type Coating
Remove chalk, mildew, and other loose material by washing with a solution of 1/2 cup trisodium phosphate, 1/4 cup household detergent, one quart 5 percent sodium hypochlorite solution and 3 quarts of warm water.
3.4 PREPARATION OF CONCRETE AND CEMENTITIOUS SURFACE
3.4.1 Concrete and Masonry
a. Curing: Concrete, stucco and masonry surfaces shall be allowed to cure at least 30 days before painting, except concrete slab on grade, which shall be allowed to cure 90 days before painting.
b. Surface Cleaning: Remove the following deleterious substances.
(1) Dirt, Chalking, Grease, and Oil: Wash new surfaces with a solution composed of 1/2 cup trisodium phosphate, 1/4 cuphousehold detergent, and 4 quarts of warm water. Then rinse thoroughly with fresh water. For large areas, water blasting may be used.
(2) Fungus and Mold: Wash surfaces with a solution composed of 1/2 cup trisodium phosphate, 1/4 cup household detergent, 1 quart 5 percent sodium hypochlorite solution and 3 quarts of warm water. Rinse thoroughly with fresh water.
(3) Paint and Loose Particles: Remove by wire brushing.
(4) Efflorescence: Remove by scraping or wire brushing followed by washing with a 5 to 10 percent by weight aqueous solution of hydrochloric (muriatic) acid. Do not allow acid to remain on the surface for more than five minutes before rinsing with fresh water. Do not acid clean more than 4 square feet of surface, per workman, at one time.
c. Cosmetic Repair of Minor Defects: Repair or fill mortar joints and minor defects, including but not limited to spalls, in accordance with manufacturer's recommendations and prior to coating application.
d. Allowable Moisture Content: Do not apply coatings to damp surfaces as determined by ASTM D4263 or horizontal surfaces that exceed 3 lbs of moisture per 1000 square feet in 24 hours as determined by ASTM F1869. In all cases follow manufacturers recommendations. Allow surfaces to cure a minimum of 30 days before painting.
3.5 APPLICATION
3.5.1 Coating Application
Painting practices shall comply with applicable federal, state and local laws enacted to insure compliance with Federal Clean Air Standards. Apply coating materials in accordance with SSPC PA 1. SSPC PA 1 methods are applicable to all substrates, except as modified herein.
At the time of application, paint shall show no signs of deterioration. Uniform suspension of pigments shall be maintained during application.
Unless otherwise specified or recommended by the paint manufacturer, paint may be applied by brush, roller, or spray. Use trigger operated spray
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nozzles for water hoses. Rollers for applying paints and enamels shall be of a type designed for the coating to be applied and the surface to be coated. Wear protective clothing and respirators when applying oil-based paints or using spray equipment with any paints.
Paints, except water-thinned types, shall be applied only to surfaces that are completely free of moisture as determined by sight or touch.
Thoroughly work coating materials into joints, crevices, and open spaces. Special attention shall be given to insure that all edges, corners, crevices, welds, and rivets receive a film thickness equal to that of adjacent painted surfaces.
Each coat of paint shall be applied so dry film shall be of uniform thickness and free from runs, drops, ridges, waves, pinholes or other voids, laps, brush marks, and variations in color, texture, and finish. Hiding shall be complete.
Touch up damaged coatings before applying subsequent coats. Interior areas shall be broom clean and dust free before and during the application of coating material.
3.5.2 Mixing and Thinning of Paints
Reduce paints to proper consistency by adding fresh paint, except when thinning is mandatory to suit surface, temperature, weather conditions, application methods, or for the type of paint being used. Obtain written permission from the Owner's Representative to use thinners. The written permission shall include quantities and types of thinners to use.
When thinning is allowed, paints shall be thinned immediately prior to application with not more than 1 pint of suitable thinner per gallon. The use of thinner shall not relieve the Contractor from obtaining complete hiding, full film thickness, or required gloss. Thinning shall not cause the paint to exceed limits on volatile organic compounds. Paints of different manufacturers shall not be mixed.
3.5.3 Two-Component Systems
Two-component systems shall be mixed in accordance with manufacturer's instructions. Any thinning of the first coat to ensure proper penetration and sealing shall be as recommended by the manufacturer for each type of substrate.
3.5.4 Coating Systems
a. Systems by Substrates: Apply coatings that conform to the respective specifications listed in the following Tables:
Table
Division 5. Exterior Metal, Ferrous and Non-Ferrous Paint Table
Division 3. Interior Concrete Paint Table Division 4. Interior Concrete Masonry Units Paint Table Division 5. Interior Metal, Ferrous and Non-Ferrous Paint Table
b. Minimum Dry Film Thickness (DFT): Apply paints, primers, varnishes, enamels, undercoats, and other coatings to a minimum dry film thickness
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of 1.5 mil each coat unless specified otherwise in the Tables. Coating thickness where specified, refers to the minimum dry film thickness.
c. Coatings for Surfaces Not Specified Otherwise: Coat surfaces which have not been specified, the same as surfaces having similar conditions of exposure.
d. Existing Surfaces Damaged During Performance of the Work, Including New Patches In Existing Surfaces: Coat surfaces with the following:
(1) One coat of primer.
(2) One coat of undercoat or intermediate coat.
(3) One topcoat to match adjacent surfaces.
e. Existing Coated Surfaces To Be Painted: Apply coatings conforming to the respective specifications listed in the Tables herein, except that pretreatments, sealers and fillers need not be provided on surfaces where existing coatings are soundly adhered and in good condition. Do not omit undercoats or primers.
3.6 COATING SYSTEMS FOR METAL
Apply coatings of Tables in Division 5 for Exterior and Interior.
a. Apply specified ferrous metal primer on the same day that surface is cleaned, to surfaces that meet all specified surface preparation requirements at time of application.
b. Inaccessible Surfaces: Prior to erection, use one coat of specified primer on metal surfaces that will be inaccessible after erection.
c. Shop-primed Surfaces: Touch up exposed substrates and damaged coatings to protect from rusting prior to applying field primer.
d. Surface Previously Coated with Epoxy or Urethane: Apply MPI 101, 1.5 mils DFT immediately prior to application of epoxy or urethane coatings.
e. Pipes and Tubing: The semitransparent film applied to some pipes and tubing at the mill is not to be considered a shop coat, but shall be overcoated with the specified ferrous-metal primer prior to application of finish coats.
f. Exposed Nails, Screws, Fasteners, and Miscellaneous Ferrous Surfaces. On surfaces to be coated with water thinned coatings, spot prime exposed nails and other ferrous metal with latex primer MPI 107.
3.7 COATING SYSTEMS FOR CONCRETE AND CEMENTITIOUS SUBSTRATES
Apply coatings of Tables in Division 3, 4 and 9 for Exterior and Interior.
3.8 PIPING IDENTIFICATION
Piping Identification, Including Surfaces In Concealed Spaces: Provide in accordance with ASME A13.1. Place stenciling in clearly visible locations. On piping not covered by ASME A13.1, stencil approved names or code letters, in letters a minimum of 1/2 inch high for piping and a minimum of 2 inches high elsewhere. Stencil arrow-shaped markings on
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piping to indicate direction of flow using black stencil paint.
3.9 INSPECTION AND ACCEPTANCE
In addition to meeting previously specified requirements, demonstrate mobility of moving components, including swinging and sliding doors, cabinets, and windows with operable sash, for inspection by the Owner's Representative. Perform this demonstration after appropriate curing and drying times of coatings have elapsed and prior to invoicing for final payment.
3.10 WASTE MANAGEMENT
As specified in the Waste Management Plan and as follows. Do not use kerosene or any such organic solvents to clean up water based paints. Properly dispose of paints or solvents in designated containers. Close and seal partially used containers of paint to maintain quality as necessary for reuse. Store in protected, well-ventilated, fire-safe area at moderate temperature. Place materials defined as hazardous or toxic waste in designated containers. Set aside extra paint for future color matches or reuse by the Owner's Representative.
3.11 PAINT TABLES
All DFT's are minimum values. Acceptable products are listed in the MPI Green Approved Products List, available at http://www.specifygreen.com/APL/ProductIdxByMPInum.asp.
3.11.1 EXTERIOR PAINT TABLES
DIVISION 5: EXTERIOR METAL, FERROUS AND NON-FERROUS PAINT TABLE
STEEL / FERROUS SURFACES
A. New Steel that has been hand or power tool cleaned to SSPC SP 2 or SSPC SP 3
1. Alkyd New; MPI EXT 5.1Q-G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 23 MPI 94 MPI 94 System DFT: 5.25 mils
B. New Steel that has been blast-cleaned to SSPC SP 6/NACE No.3:
1. Alkyd New; MPI EXT 5.1D-G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 79 MPI 94 MPI 94 System DFT: 5.25 mils
C. New steel blast cleaned to SSPC SP 10/NACE No. 2:
1. Waterborne Light Industrial MPI EXT 5.1R-G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 101 MPI 108 MPI 163 System DFT: 8.5 mils
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STEEL / FERROUS SURFACES
EXTERIOR GALVANIZED SURFACES
D. New Galvanized surfaces:
1. Waterborne Primer / Latex MPI EXT 5.3H-G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 134 MPI 11 MPI 11 System DFT: 4.5 mils
E. Galvanized surfaces with slight coating deterioration; little or no rusting:
1. Waterborne Light Industrial Coating MPI REX 5.3J-G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 134 N/A MPI 163 System DFT: 4.5 mils
F. Galvanized surfaces with severely deteriorated coating or rusting:
1. Waterborne Light Industrial Coating MPI REX 5.3L-G5(Semigloss) Primer: Intermediate: Topcoat: MPI 101 MPI 108 MPI 163 System DFT: 8.5 mils
EXTERIOR SURFACES, OTHER METALS (NON-FERROUS)
G. Aluminum, aluminum alloy and other miscellaneous non-ferrous metal items not otherwise specified except hot metal surfaces, roof surfaces, and new prefinished equipment. Match surrounding finish:
1. Waterborne Light Industrial Coating MPI EXT 5.4G-G5(Semigloss) Primer: Intermediate: Topcoat: MPI 95 MPI 163 MPI 163 System DFT: 5 mils
H. Surfaces adjacent to painted surfaces; Mechanical, Electrical, exposed copper piping, and miscellaneous metal items not otherwise specified except floors, hot metal surfaces, and new prefinished equipment. Match surrounding finish:
1. Waterborne Light Industrial Coating MPI EXT 5.1C-G5(Semigloss) Primer: Intermediate: Topcoat: MPI 79 MPI 163 MPI 163 System DFT: 5 mils
I. Hot metal surfaces subject to temperatures up to 400 degrees F:
1. Heat Resistant Enamel MPI EXT 5.2A Primer: Intermediate: Topcoat: MPI 21 Surface preparation and number of coats per
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EXTERIOR SURFACES, OTHER METALS (NON-FERROUS) manufacturer's instructions. System DFT: Per Manufacturer
J. Ferrous metal subject to high temperature, up to 750 degrees F:
1. Heat Resistant Aluminum Enamel MPI EXT 5.2B (Aluminum Finish) Primer: Intermediate: Topcoat: MPI 2 Surface preparation and number of coats per manufacturer's instructions. System DFT: Per Manufacturer
K. New surfaces made bare cleaning to SSPC SP 10/NACE No. 2 subject to temperatures up to 593 degrees C (1100 degrees F):
1. Heat Resistant Coating MPI EXT 5.2D Primer: Intermediate: Topcoat: MPI 22 Surface preparation and number of coats per manufacturer's instructions. System DFT: Per Manufacturer
3.11.2 INTERIOR PAINT TABLES
DIVISION 3: INTERIOR CONCRETE PAINT TABLE
A. New Concrete, vertical surfaces, not specified otherwise:
1. Epoxy New; MPI INT 3.1F G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 77 MPI 77 MPI 77 System DFT: 8 mils minimum
B. Concrete ceilings, uncoated:
1. Epoxy MPI INT 3.2C G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 77 MPI 77 MPI 77 System DFT: 8 mils minimum
Surface preparation, number of coats, and primer in accordance with manufacturer's instructions. Topcoat: Coating to match adjacent surfaces.
C. Channel Walls:
1. Surfacer: Apply Tnemec series 218 Mortar Clad at a minimum of 1/16 inch. 2. Top Coat: Apply Tnemec series 22 Pota-Pox 100 at 30.0 to 40.0 dry mils. 3. Surface Preparation: Abrasive blast in accordance with SSPC SP 13/NACE No. 13 to create a surface profile similar to an ICRI CSP5. Care shall be taken to fill ALL bugholes, voids, and depressions.
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DIVISION 4: INTERIOR CONCRETE MASONRY UNITS PAINT TABLE
A. New Concrete masonry units in building unless otherwise specified:
1. Waterborne Light Industrial Coating MPI INT 4.2K-G5(Semigloss) Filler: Primer: Intermediate: Topcoat: MPI 4 N/A MPI 153 MPI 153 System DFT: 11 mils
Fill all holes in masonry surface
DIVISION 5: INTERIOR METAL, FERROUS AND NON-FERROUS PAINT TABLE
INTERIOR STEEL / FERROUS SURFACES
A. Metal, Mechanical, Electrical, Surfaces adjacent to painted surfaces (Match surrounding finish), exposed copper piping, and miscellaneous metal items not otherwise specified except floors, hot metal surfaces, and new prefinished equipment:
1. High Performance Architectural Latex MPI INT 5.1R-G2 (Flat) Primer: Intermediate: Topcoat: MPI 79 MPI 138 MPI 138 System DFT: 5 mils
B. Metal in building not otherwise specified except floors, hot metal surfaces, and new prefinished equipment:
1. Alkyd MPI INT 5.1T-G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 23 MPI 47 MPI 47 System DFT: 5.25 mils
C. Miscellaneous non-ferrous metal items not otherwise specified except floors, hot metal surfaces, and new prefinished equipment. Match surrounding finish:
1. Alkyd MPI INT 5.4J-G5 (Semigloss) Primer: Intermediate: Topcoat: MPI 95 MPI 47 MPI 47 System DFT: 5 mils
D. Hot metal surfaces subject to temperatures up to 400 degrees F:
1. Heat Resistant Enamel MPI INT 5.2A Primer: Intermediate: Topcoat: MPI 21 Surface preparation and number of coats per manufacturer's instructions. System DFT: Per Manufacturer
E. Ferrous metal subject to high temperature, up to 750 degrees F:
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INTERIOR STEEL / FERROUS SURFACES 1. Heat Resistant Aluminum Paint MPI INT 5.2B (Aluminum Finish) Primer: Intermediate: Topcoat: MPI 2 Surface preparation and number of coats per manufacturer's instructions. System DFT: Per Manufacturer
F. New surfaces made bare cleaning to SSPC SP 10/NACE No. 2 subject to temperatures up to 593 degrees C (1100 degrees F):
1. High Heat Resistant Coating MPI INT 5.2D Primer: Intermediate: Topcoat: MPI 22 Surface preparation and number of coats per manufacturer's instructions. System DFT: Per Manufacturer
G. Ferrous Steel in Wetwell, Gatewell, Pumps:
1. Polyamidoamine Epoxy Primer with Polyamidoamine Epoxy or Waterborne Acrylic Polyurethane Top Coat(s). a. Prime coat: 1) P1 = 1 coat, 5 mils, Series L69 Epoxoline (Polyamidoamine Epoxy) by Tnemec or approved equal. b. Finish coat(s): 1) Interior: a) F1 = 1 coat, 5 mils, Series L69 Expoline (Polyamidoamine Epoxy) by Tnemec or aproved equal.
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DIVISION 10 SPECIALTIES
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 10 14 00.20
SIGNAGE 11/12 08/07/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.
AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)
ANSI Z97.1 (2009; Errata 2010) Safety Glazing Materials Used in Buildings - Safety Performance Specifications and Methods of Test
ASTM INTERNATIONAL (ASTM)
ASTM D635 (2010) Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Self-Supporting Plastics in a Horizontal Position
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
36 CFR 1191 Americans with Disabilities Act (ADA) Accessibility Guidelines for Buildings and Facilities; Architectural Barriers Act (ABA) Accessibility Guidelines
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings; G
SD-03 Product Data
Signage; G
SD-04 Samples
Signage; G
SD-10 Operation and Maintenance Data
Approved Manufacturer's Instructions Protection and Cleaning
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1.3 EXTRA MATERIALS
Provide 1 extra frame and extra stock of the following: One (1) blank plate of each color and size for typical sign types.
1.4 QUALITY ASSURANCE
1.4.1 Samples
Submit signage samples of each of the following sign types showing typical quality, workmanship and color: Standard Room sign. The samples may be installed in the work, provided each sample is identified and location recorded.
1.4.2 Detail Drawings
Submit detail drawings showing elevations of each type of sign, dimensions, details and methods of mounting or anchoring, mounting height, shape and thickness of materials, and details of construction. Include a schedule showing the location, each sign type, and message.
1.5 DELIVERY, STORAGE, AND HANDLING
Materials shall be packaged to prevent damage and deterioration during shipment, handling, storage and installation. Product shall be delivered to the jobsite in manufacturer's original packaging and stored in a clean, dry area in accordance with manufacturer's instructions.
1.6 WARRANTY
Warrant the signage for a period of 2 years against defective workmanship and material. Warranties shall be signed by the authorized representative of the manufacturer. Submit warranty accompanied by the document authenticating the signer as an authorized representative of the guarantor. Guarantee that the signage products and the installation are free from any defects in material and workmanship from the date of delivery.
PART 2 PRODUCTS
2.1 STANDARD PRODUCTS
Signs shall be the standard product of a manufacturer regularly engaged in the manufacture of such products that essentially duplicate signs that have been in satisfactory use at least 2 years prior to bid opening. Obtain signage from a single manufacturer with edges and corners of finished letterforms and graphics true and clean.
2.2 ROOM IDENTIFICATION
2.2.1 Standard Room Signs
Signs shall consist of acrylic plastic 0.080 inch thickness minimum conforming to ANSI Z97.1 and shall conform to the following:
a. Units shall be frameless. Corners of signs shall be squared.
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2.2.2 Type of Mounting For Signs
Surface mounted signs shall be mounted flush with stainless steel fasteners (counter sunk).
2.2.3 Graphics
Signage graphics for modular signs shall conform to the following:
2.2.3.1 Engraved Copy
Machine engrave letters into panel sign on face to produce precisely formed copy and sharp images, incised to uniform depth. Melamine plastic engraving stock shall be three-ply lamination contrasting color core meeting ASTM D635.
2.2.4 Character Proportions and Heights
Letters and numbers on signs conform to 36 CFR 1191.
2.3 COLOR, FINISH, AND CONTRAST
Color shall be in accordance with Section 09 06 90 COLOR SCHEDULE. Finish of all signs shall be eggshell, matte, or other non-glare finish.
2.4 TYPEFACE
San-Serif font for Room Signs.
PART 3 EXECUTION
3.1 INSTALLATION
Signs shall be installed plumb and true and in accordance with approved manufacturer's instructions at locations shown on the schedule below. Submit six copies of operating instructions outlining the step-by-step procedures required for system operation. The instructions shall include simplified diagrams for the system as installed, the manufacturer's name and model number. Each set shall be permanently bound and shall have a hard cover. The following identification shall be inscribed on the covers: the words "OPERATING AND MAINTENANCE INSTRUCTIONS", name and location of the facility, name of the Contractor, and contract number. Mounting height and mounting location shall conform to 36 CFR 1191. Signs on doors or other surfaces shall not be installed until finishes on such surfaces have been installed.
SIGNAGE PLACEMENT SCHEDULE
Door Sign Type Text Symbol Number /Remarks 101A Standard Room Sign Authorized Personnel Only None
102A Standard Room Sign Authorized Personnel Only None
3.1.1 Protection and Cleaning
Protect the work against damage during construction. Hardware and electrical equipment shall be adjusted for proper operation. Glass,
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frames, and other sign surfaces shall be cleaned at completion of sign installation in accordance with the manufacturer's approved instructions. Submit six copies of maintenance instructions listing routine procedures, repairs, and guides.
-- End of Section --
SECTION 10 14 00.20 Page 4 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 10 44 16
FIRE EXTINGUISHERS 05/12 08/07/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
INTERNATIONAL CODE COUNCIL (ICC)
ICC IFC (2012) International Fire Code
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 1 (2012; TIA 11-1) Fire Code
NFPA 10 (2013) Standard for Portable Fire Extinguishers
NFPA 101 (2012; Amendment 1 2012) Life Safety Code
NFPA 505 (2013) Fire Safety Standard for Powered Industrial Trucks Including Type Designations, Areas of Use, Conversions, Maintenance, and Operations
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
29 CFR 1910.157 (2003) Portable Fire Extinguishers
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-01 Preconstruction Submittals
Manufacturer's Data
SD-02 Shop Drawings
Fire Extinguishers
Accessories
Wall Brackets
SD-03 Product Data
Fire Extinguishers; G
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Accessories; G
Wall Brackets; G
Replacement Parts
SD-07 Certificates
Fire Extinguishers
Manufacturer's Warranty with Inspection Tag
1.3 DELIVERY, HANDLING, AND STORAGE
Protect materials from weather, soil, and damage during delivery, storage, and construction.
Deliver materials in their original packages, containers, or bundles bearing the brand name and the name and type of the material.
Provide portable fire extinguishers in compliance with NFPA 505 for all ancillary vehicles where Fire Safety Standard for Powered Industrial Trucks, including type designations, special c conditions relating to areas of use, conversions, maintenance, or specific operations apply.
1.4 WARRANTY
Guarantee that Fire Extinguishers are free of defects in materials, fabrication, finish, and installation and that they will remain so for a period of not less than 2 years after completion.
PART 2 PRODUCTS
Submit fabrication drawings consisting of fabrication and assembly details performed in the factory and product data for the following items: Fire Extinguishers; Accessories, Cabinets, Wall Brackets.
2.1 TYPES
Submit certificates that show Fire Extinguishers comply with local codes and regulations.
Provide Fire Extinguishers conforming to NFPA 10. Provide quantity and placement in compliance with the applicable sections of ICC IFC, Section 1414 and ICC IFC, Section 906, NFPA 1, NFPA 101, and 29 CFR 1910.157.
Submit Manufacturer's Data for each type of Fire Extinguisher required, detailing all related Wall Mounting and Accessories information, complete with Manufacturer's Warranty with Inspection Tag.
2.2 MATERIAL
Provide corrosion-resistant steel extinguisher shell. Provide clean agent, colorless, odorless, electronically non-conductive UL rated 2A-10BC.
2.3 SIZE
20 pounds extinguishers.
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2.4 ACCESSORIES
Forged brass valve
Fusible plug
Safety release
Antifreeze
Pressure gage
2.5 WALL BRACKETS
Provide wall-hook fire extinguisher wall brackets.
Provide wall bracket and accessories as approved.
PART 3 EXECUTION
3.1 INSTALLATION
Install Fire Extinguishers where indicated on the drawings. Verify exact locations prior to installation.
Comply with the manufacturer's recommendations for all installations.
Provide extinguishers which are fully charged and ready for operation upon installation. Provide extinguishers complete with Manufacturer's Warranty with Inspection Tag attached.
3.2 ACCEPTANCE PROVISIONS
3.2.1 Repairing
Remove and replace damaged and unacceptable portions of completed work with new work at no additional cost to the Owner's Representative.
Submit Replacement Parts list indicating specified items replacement part, replacement cost, and name, address and contact for replacement parts distributor.
3.2.2 Cleaning
Clean all surfaces of the work, and adjacent surfaces which are soiled as a result of the work. Remove from the site all construction equipment, tools, surplus materials and rubbish resulting from the work.
-- End of Section --
SECTION 10 44 16 Page 3 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 22 PLUMBING
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 22 00 00
PLUMBING, GENERAL PURPOSE 11/11 08/19/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)
ASHRAE 90.1 - IP (2010; Errata 1-4 2011; INT 1-12 2011; Addenda A, B, C, G, H, J, K, O, P, S, Y, Z, BZ, CG, CI and DS 2012; Errata 5-9 2012; INT 13-16 2012; Errata 10-12 2013; INT 17-18 2013) Energy Standard for Buildings Except Low-Rise Residential Buildings
AMERICAN SOCIETY OF SANITARY ENGINEERING (ASSE)
ASSE 1010 (2004) Performance Requirements for Water Hammer Arresters (ANSI approved 2004)
ASME INTERNATIONAL (ASME)
ASME B1.20.1 (2013) Pipe Threads, General Purpose (Inch)
ASME B16.18 (2012) Cast Copper Alloy Solder Joint Pressure Fittings
ASME B16.21 (2011) Nonmetallic Flat Gaskets for Pipe Flanges
ASME B16.22 (2013) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings
ASME B16.5 (2013) Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24 Metric/Inch Standard
ASTM INTERNATIONAL (ASTM)
ASTM A105/A105M (2013) Standard Specification for Carbon Steel Forgings for Piping Applications
ASTM A193/A193M (2012a) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications
ASTM A515/A515M (2010) Standard Specification for Pressure
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Vessel Plates, Carbon Steel, for Intermediate- and Higher-Temperature Service
ASTM A516/A516M (2010) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-Temperature Service
ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM B88 (2009) Standard Specification for Seamless Copper Water Tube
ASTM C564 (2012) Standard Specification for Rubber Gaskets for Cast Iron Soil Pipe and Fittings
ASTM D3139 (1998; R 2011) Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals
ASTM D3212 (2007; R 2013) Standard Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals
ASTM F477 (2010) Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe
INTERNATIONAL ASSOCIATION OF PLUMBING AND MECHANICAL OFFICIALS (IAPMO)
IAPMO PS 117 (2005b) Press Type Or Plain End Rub Gasketed W/ Nail CU & CU Alloy Fittings 4 Install On CU Tubing
UNIFORM PLUMBING CODE (UPC)
UPC (2009) North Dakota State Plumbing Code
MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)
MSS SP-25 (2013) Standard Marking System for Valves, Fittings, Flanges and Unions
MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation
MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems
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NSF INTERNATIONAL (NSF)
NSF 372 (2011) Drinking Water System Components - Lead Content
NSF/ANSI 61 (2013) Drinking Water System Components - Health Effects
PLUMBING AND DRAINAGE INSTITUTE (PDI)
PDI WH 201 (2010) Water Hammer Arresters Standard
U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA)
PL 93-523 (1974; A 1999) Safe Drinking Water Act
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
PL 109-58 Energy Policy Act of 2005 (EPAct05)
1.2 STANDARD PRODUCTS
Specified materials and equipment shall be standard products of a manufacturer regularly engaged in the manufacture of such products. Specified equipment shall essentially duplicate equipment that has performed satisfactorily at least two years prior to bid opening. Standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year use shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2 year period.
1.2.1 Alternative Qualifications
Products having less than a two-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, can be shown.
1.2.2 Service Support
The equipment items shall be supported by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
1.2.3 Manufacturer's Nameplate
Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.
1.2.4 Modification of References
In each of the publications referred to herein, consider the advisory
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provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction", or words of similar meaning, to mean the Owner's Representative.
1.2.4.1 Definitions
For the International Code Council (ICC) Codes referenced in the contract documents, advisory provisions shall be considered mandatory, the word "should" shall be interpreted as "shall." Reference to the "code official" shall be interpreted to mean the "Owner's Representative." For Navy owned property, references to the "owner" shall be interpreted to mean the " Owner's Representative." For leased facilities, references to the "owner" shall be interpreted to mean the "lessor." References to the "permit holder" shall be interpreted to mean the "Contractor."
1.2.4.2 Administrative Interpretations
For ICC Codes referenced in the contract documents, the provisions of Chapter 1, "Administrator," do not apply. These administrative requirements are covered by the applicable Federal Acquisition Regulations (FAR) included in this contract and by the authority granted to the Officer in Charge of Construction to administer the construction of this project. References in the ICC Codes to sections of Chapter 1, shall be applied appropriately by the Owner's Representative as authorized by his administrative cognizance and the FAR.
1.3 DELIVERY, STORAGE, AND HANDLING
Handle, store, and protect equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Owner's Representative. Replace damaged or defective items.
1.4 REGULATORY REQUIREMENTS
Unless otherwise required herein, plumbing work shall be in accordance with UPC. Energy consuming products and systems shall be in accordance with PL 109-58 and ASHRAE 90.1 - IP
1.5 PROJECT/SITE CONDITIONS
The Contractor shall become familiar with details of the work, verify dimensions in the field, and advise the Owner's Representative of any discrepancy before performing any work.
1.6 INSTRUCTION TO OWNER PERSONNEL
When specified in other sections, furnish the services of competent instructors to give full instruction to the designated Owner's Representative personnel in the adjustment, operation, and maintenance, including pertinent safety requirements, of the specified equipment or system. Instructors shall be thoroughly familiar with all parts of the installation and shall be trained in operating theory as well as practical operation and maintenance work.
Instruction shall be given during the first regular work week after the equipment or system has been accepted and turned over to the Owner's Representative for regular operation. The number of man-days (8 hours per
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day) of instruction furnished shall be as specified in the individual section. When more than 4 man-days of instruction are specified, use approximately half of the time for classroom instruction. Use other time for instruction with the equipment or system.
When significant changes or modifications in the equipment or system are made under the terms of the contract, provide additional instruction to acquaint the operating personnel with the changes or modifications.
1.7 ACCESSIBILITY OF EQUIPMENT
Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors.
PART 2 PRODUCTS
2.1 Materials
Materials for various services shall be as indicated on the contract drawings. Cement pipe shall contain recycled content as specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE. Steel pipe shall contain a minimum of 25 percent recycled content. Pipe schedules shall be selected based on service requirements. Pipe fittings shall be compatible with the applicable pipe materials. Pipe threads (except dry seal) shall conform to ASME B1.20.1. Grooved pipe couplings and fittings shall be from the same manufacturer. Material or equipment containing a weighted average of greater than 0.25 percent lead shall not be used in any potable water system intended for human consumption, and shall be certified in accordance with NSF/ANSI 61, Annex G or NSF 372. In line devices such as water meters, building valves, check valves, meter stops, valves, fittings and back flow preventers shall comply with PL 93-523 and NSF/ANSI 61, Section 8. Hubless cast-iron soil pipe shall not be installed underground, under concrete floor slabs.
2.1.1 Pipe Joint Materials
Grooved pipe and hubless cast-iron soil pipe shall not be used under ground. Solder containing lead shall not be used with copper pipe. Cast iron soil pipe and fittings shall be marked with the collective trademark of the Cast Iron Soil Institute. Joints and gasket materials shall conform to the following:
a. Flange Gaskets: Gaskets shall be made of non-asbestos material in accordance with ASME B16.21. Gaskets shall be flat, 1/16 inch thick, and contain Aramid fibers bonded with Styrene Butadiene Rubber (SBR) or Nitro Butadiene Rubber (NBR). Gaskets shall be the full face or self centering flat ring type. Gaskets used for hydrocarbon service shall be bonded with NBR.
b. Rubber Gaskets for Cast-Iron Soil-Pipe and Fittings (hub and spigot type and hubless type): ASTM C564.
c. Flexible Elastomeric Seals: ASTM D3139, ASTM D3212 or ASTM F477.
d. Flanged fittings including flanges, bolts, nuts, bolt patterns, etc., shall be in accordance with ASME B16.5 class 150 and shall have the
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manufacturer's trademark affixed in accordance with MSS SP-25. Flange material shall conform to ASTM A105/A105M. Blind flange material shall conform to ASTM A516/A516M cold service and ASTM A515/A515M for hot service. Bolts shall be high strength or intermediate strength with material conforming to ASTM A193/A193M.
e. Press fittings for Copper Pipe and Tube: Copper press fittings shall conform to the material and sizing requirements of ASME B16.18 or ASME B16.22 and performance criteria of IAPMO PS 117. Sealing elements for copper press fittings shall be EPDM, FKM or HNBR. Sealing elements shall be factory installed or an alternative supplied fitting manufacturer. Sealing element shall be selected based on manufacturer's approved application guidelines.
f. Copper tubing shall conform to ASTM B88, Type K, L or M.
2.2 PIPE HANGERS, INSERTS, AND SUPPORTS
Pipe hangers, inserts, and supports shall conform to MSS SP-58 and MSS SP-69.
2.3 MISCELLANEOUS PIPING ITEMS
2.3.1 Pipe Sleeves
Provide where piping passes entirely through walls, ceilings, roofs, and floors. Sleeves are not required where supply drain, waste, and vent (DWV) piping passes through concrete floor slabs located on grade, except where penetrating a membrane waterproof floor.
2.3.1.1 Sleeves in Masonry and Concrete
Provide steel pipe sleeves. Sleeves are not required where drain, waste, and vent (DWV) piping passes through concrete floor slabs located on grade. Core drilling of masonry and concrete may be provided in lieu of pipe sleeves when cavities in the core-drilled hole are completely grouted smooth.
2.3.2 Pipe Hangers (Supports)
Provide MSS SP-58 and MSS SP-69, Type 1 with adjustable type steel support rods, except as specified or indicated otherwise. Attach to steel joists with Type 19 or 23 clamps and retaining straps. Attach to Steel W or S beams with Type 21, 28, 29, or 30 clamps. Attach to steel angles and vertical web steel channels with Type 20 clamp with beam clamp channel adapter. Attach to horizontal web steel channel and wood with drilled hole on centerline and double nut and washer. Attach to concrete with Type 18 insert or drilled expansion anchor. Provide Type 40 insulation protection shield for insulated piping.
PART 3 EXECUTION
3.1 GENERAL INSTALLATION REQUIREMENTS
Piping located in air plenums shall conform to NFPA 90A requirements. Piping located in shafts that constitute air ducts or that enclose air ducts shall be noncombustible in accordance with NFPA 90A.
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3.1.1 Water Pipe, Fittings, and Connections
3.1.1.1 Cutting and Repairing
The work shall be carefully laid out in advance, and unnecessary cutting of construction shall be avoided. Damage to building, piping, wiring, or equipment as a result of cutting shall be repaired by mechanics skilled in the trade involved.
3.1.1.2 Mains, Branches, and Runouts
Piping shall be installed as indicated. Pipe shall be accurately cut and worked into place without springing or forcing. Structural portions of the building shall not be weakened. Aboveground piping shall run parallel with the lines of the building, unless otherwise indicated. Changes in pipe sizes shall be made with reducing fittings. Use of bushings will not be permitted except for use in situations in which standard factory fabricated components are furnished to accommodate specific accepted installation practice. Change in direction shall be made with fittings. Bent pipe showing kinks, wrinkles, flattening, or other malformations will not be acceptable.
3.1.1.3 Thrust Restraint
Plugs, caps, tees, valves and bends deflecting 11.25 degrees or more, either vertically or horizontally, in waterlines 4 inches in diameter or larger shall be provided with thrust blocks, where indicated, to prevent movement. Thrust blocking shall be concrete of a mix not leaner than: 1 cement, 2-1/2 sand, 5 gravel; and having a compressive strength of not less than 2000 psi after 28 days. Blocking shall be placed between solid ground and the fitting to be anchored. Unless otherwise indicated or directed, the base and thrust bearing sides of the thrust block shall be poured against undisturbed earth. The side of the thrust block not subject to thrust shall be poured against forms. The area of bearing will be as shown. Blocking shall be placed so that the joints of the fitting are accessible for repair. Steel rods and clamps, protected by galvanizing or by coating with bituminous paint, shall be used to anchor vertical down bends into gravity thrust blocks.
3.1.1.4 Commercial-Type Water Hammer Arresters
Commercial-type water hammer arresters shall be provided on hot- and cold-water supplies and shall be located as generally indicated, with precise location and sizing to be in accordance with PDI WH 201. Water hammer arresters, where concealed, shall be accessible by means of access doors or removable panels. Commercial-type water hammer arresters shall conform to ASSE 1010. Vertical capped pipe columns will not be permitted.
3.1.2 Joints
Installation of pipe and fittings shall be made in accordance with the manufacturer's recommendations. Mitering of joints for elbows and notching of straight runs of pipe for tees will not be permitted. Joints shall be made up with fittings of compatible material and made for the specific purpose intended.
3.1.2.1 Threaded
Threaded joints shall have American Standard taper pipe threads conforming
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to ASME B1.20.1. Only male pipe threads shall be coated with graphite or with an approved graphite compound, or with an inert filler and oil, or shall have a polytetrafluoroethylene tape applied.
3.1.3 Dissimilar Pipe Materials
Connections between ferrous and non-ferrous copper water pipe shall be made with dielectric unions or flange waterways. Dielectric waterways shall have temperature and pressure rating equal to or greater than that specified for the connecting piping. Waterways shall have metal connections on both ends suited to match connecting piping. Dielectric waterways shall be internally lined with an insulator specifically designed to prevent current flow between dissimilar metals. Dielectric flanges shall meet the performance requirements described herein for dielectric waterways. Connecting joints between plastic and metallic pipe shall be made with transition fitting for the specific purpose.
3.1.4 Supports
3.1.4.1 General
Hangers used to support piping 2 inches and larger shall be fabricated to permit adequate adjustment after erection while still supporting the load. Pipe guides and anchors shall be installed to keep pipes in accurate alignment, to direct the expansion movement, and to prevent buckling, swaying, and undue strain. Piping subjected to vertical movement when operating temperatures exceed ambient temperatures shall be supported by variable spring hangers and supports or by constant support hangers. In the support of multiple pipe runs on a common base member, a clip or clamp shall be used where each pipe crosses the base support member. Spacing of the base support members shall not exceed the hanger and support spacing required for an individual pipe in the multiple pipe run. Threaded sections of rods shall not be formed or bent.
3.1.4.2 Pipe Supports and Structural Bracing, Seismic Requirements
Piping and attached valves shall be supported and braced to resist seismic loads. Structural steel required for reinforcement to properly support piping, headers, and equipment, but not shown, shall be provided. Material used for supports shall be as specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.
3.1.4.3 Pipe Hangers, Inserts, and Supports
Installation of pipe hangers, inserts and supports shall conform to MSS SP-58 and MSS SP-69, except as modified herein.
a. Types 5, 12, and 26 shall not be used.
b. Type 3 shall not be used on insulated pipe.
c. Type 18 inserts shall be secured to concrete forms before concrete is placed. Continuous inserts which allow more adjustment may be used if they otherwise meet the requirements for type 18 inserts.
d. Type 19 and 23 C-clamps shall be torqued per MSS SP-69 and shall have both locknuts and retaining devices furnished by the manufacturer. Field-fabricated C-clamp bodies or retaining devices are not acceptable.
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e. Type 20 attachments used on angles and channels shall be furnished with an added malleable-iron heel plate or adapter.
f. Type 24 may be used only on trapeze hanger systems or on fabricated frames.
g. Type 39 saddles shall be used on insulated pipe 4 inches and larger when the temperature of the medium is 60 degrees F or higher. Type 39 saddles shall be welded to the pipe.
h. Type 40 shields shall:
(1) Be used on insulated pipe less than 4 inches.
(2) Be used on insulated pipe 4 inches and larger when the temperature of the medium is 60 degrees F or less.
(3) Have a high density insert for all pipe sizes. High density inserts shall have a density of 8 pcf or greater.
i. Horizontal pipe supports shall be spaced as specified in MSS SP-69 and a support shall be installed not over 1 foot from the pipe fitting joint at each change in direction of the piping. Pipe supports shall be spaced not over 5 feet apart at valves. Horizontal pipe runs shall include allowances for expansion and contraction.
j. Vertical pipe shall be supported at each floor, except at slab-on-grade, at intervals of not more than 15 feet nor more than 8 feet from end of risers, and at vent terminations. Vertical pipe risers shall include allowances for expansion and contraction.
k. Type 35 guides using steel, reinforced polytetrafluoroethylene (PTFE) or graphite slides shall be provided to allow longitudinal pipe movement. Slide materials shall be suitable for the system operating temperatures, atmospheric conditions, and bearing loads encountered. Lateral restraints shall be provided as needed. Where steel slides do not require provisions for lateral restraint the following may be used:
(1) On pipe 4 inches and larger when the temperature of the medium is 60 degrees F or higher, a Type 39 saddle, welded to the pipe, may freely rest on a steel plate.
(2) On pipe less than 4 inches a Type 40 shield, attached to the pipe or insulation, may freely rest on a steel plate.
(3) On pipe 4 inches and larger carrying medium less that 60 degrees F a Type 40 shield, attached to the pipe or insulation, may freely rest on a steel plate.
l. Pipe hangers on horizontal insulated pipe shall be the size of the outside diameter of the insulation. The insulation shall be continuous through the hanger on all pipe sizes and applications.
m. Where there are high system temperatures and welding to piping is not desirable, the type 35 guide shall include a pipe cradle, welded to the guide structure and strapped securely to the pipe. The pipe shall be separated from the slide material by at least 4 inches or by an amount adequate for the insulation, whichever is greater.
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3.1.4.4 Structural Attachments
Attachment to building structure concrete and masonry shall be by cast-in concrete inserts, built-in anchors, or masonry anchor devices. Inserts and anchors shall be applied with a safety factor not less than 5. Supports shall not be attached to metal decking. Supports shall not be attached to the underside of concrete filled floor or concrete roof decks unless approved by the Owner's Representative. Masonry anchors for overhead applications shall be constructed of ferrous materials only.
3.2 VIBRATION-ABSORBING FEATURES
Mechanical equipment, shall be isolated from the building structure by approved vibration-absorbing features, unless otherwise shown. Each foundation shall include an adequate number of standard isolation units. Each unit shall consist of machine and floor or foundation fastening, together with intermediate isolation material, and shall be a standard product with printed load rating. Piping connected to mechanical equipment shall be provided with flexible connectors. Isolation unit installation shall limit vibration to 10 percent of the lowest equipment rpm.
3.3 IDENTIFICATION SYSTEMS
3.3.1 Identification Tags
Identification tags made of brass, engraved laminated plastic, or engraved anodized aluminum, indicating service and valve number shall be installed on valves. Tags shall be 1-3/8 inch minimum diameter, and marking shall be stamped or engraved. Indentations shall be black, for reading clarity. Tags shall be attached to valves with No. 12 AWG, copper wire, chrome-plated beaded chain, or plastic straps designed for that purpose.
3.3.2 Pipe Color Code Marking
Color code marking of piping shall be as specified in Section 09 90 00 PAINTS AND COATINGS.
3.4 PAINTING
Painting of pipes, hangers, supports, and other iron work, either in concealed spaces or exposed spaces, is specified in Section 09 90 00 PAINTS AND COATINGS.
3.4.1 Painting of New Equipment
New equipment painting shall be factory applied or shop applied, and shall be as specified herein, and provided under each individual section.
3.4.1.1 Factory Painting Systems
Manufacturer's standard factory painting systems may be provided subject to certification that the factory painting system applied will withstand 125 hours in a salt-spray fog test, except that equipment located outdoors shall withstand 500 hours in a salt-spray fog test. Salt-spray fog test shall be in accordance with ASTM B117, and for that test the acceptance criteria shall be as follows: immediately after completion of the test, the paint shall show no signs of blistering, wrinkling, or cracking, and no loss of adhesion; and the specimen shall show no signs of rust creepage
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beyond 0.125 inch on either side of the scratch mark.
The film thickness of the factory painting system applied on the equipment shall not be less than the film thickness used on the test specimen. If manufacturer's standard factory painting system is being proposed for use on surfaces subject to temperatures above 120 degrees F, the factory painting system shall be designed for the temperature service.
3.4.1.2 Shop Painting Systems for Metal Surfaces
Clean, pretreat, prime and paint metal surfaces; except aluminum surfaces need not be painted. Apply coatings to clean dry surfaces. Clean the surfaces to remove dust, dirt, rust, oil and grease by wire brushing and solvent degreasing prior to application of paint, except metal surfaces subject to temperatures in excess of 120 degrees F shall be cleaned to bare metal.
Where more than one coat of paint is specified, apply the second coat after the preceding coat is thoroughly dry. Lightly sand damaged painting and retouch before applying the succeeding coat. Color of finish coat shall be aluminum or light gray.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 22 10 00.00 10
VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE 07/07 09/17/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ACOUSTICAL SOCIETY OF AMERICA (ASA)
ASA S2.19 (1999; R 2004) Mechanical Vibration - Balance Quality Requirements of Rigid Rotors, Part 1: Determination of Permissible Residual Unbalance, Including Marine Applications
AMERICAN PETROLEUM INSTITUTE (API)
API RP 686 (2009) Recommended Practice for Machinery Installation and Installation Design
AMERICAN WATER WORKS ASSOCIATION (AWWA)
AWWA C200 (2012) Steel Water Pipe - 6 In. (150 mm) and Larger
AWWA C203 (2008) Coal-Tar Protective Coatings and Linings for Steel Water Pipelines - Enamel and Tape - Hot-Applied
AWWA C207 (2013) Standard for Steel Pipe Flanges for Waterworks Service-Sizes 100 mm through 3600 mm 4 in. through 144 in.
AWWA C208 (2012) Standard for Dimensions for Fabricated Steel Water Pipe Fittings
AMERICAN WELDING SOCIETY (AWS)
AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel
ASME INTERNATIONAL (ASME)
ASME B46.1 (2009) Surface Texture, Surface Roughness, Waviness and Lay
ASTM INTERNATIONAL (ASTM)
ASTM A108 (2013) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished
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ASTM A217/A217M (2012) Standard Specification for Steel Castings, Martensitic Stainless and Alloy, for Pressure-Containing Parts, Suitable for High-Temperature Service
ASTM A269 (2013) Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service
ASTM A27/A27M (2013) Standard Specification for Steel Castings, Carbon, for General Application
ASTM A276 (2013a) Standard Specification for Stainless Steel Bars and Shapes
ASTM A285/A285M (2012) Standard Specification for Pressure Vessel Plates, Carbon Steel, Low- and Intermediate-Tensile Strength
ASTM A312/A312M (2013b) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes
ASTM A351/A351M (2013) Standard Specification for Castings, Austenitic, for Pressure-Containing Parts
ASTM A352/A352M (2006; R 2012) Standard Specification for Steel Castings, Ferritic and Martensitic, for Pressure-Containing Parts, Suitable for Low-Temperature Service
ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel
ASTM A48/A48M (2003; R 2012) Standard Specification for Gray Iron Castings
ASTM A516/A516M (2010) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-Temperature Service
ASTM A576 (1990b; R 2012) Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality
ASTM A609/A609M (2012) Standard Specification for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Thereof
ASTM A668/A668M (2013) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use
ASTM B148 (1997; R 2009) Standard Specification for Aluminum-Bronze Sand Castings
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ASTM B584 (2013) Standard Specification for Copper Alloy Sand Castings for General Applications
ASTM D2000 (2012) Standard Classification System for Rubber Products in Automotive Applications
ASTM E165/E165M (2012) Standard Practice for Liquid Penetrant Examination for General Industry
ASTM E709 (2008) Standard Guide for Magnetic Particle Examination
ASTM F1476 (2007; R 2013) Standard Specification for Performance of Gasketed Mechanical Couplings for Use in Piping Applications
HYDRAULIC INSTITUTE (HI)
HI 2.6 (2000) Vertical Pump Tests
HI 9.1-9.5 (2000) Pumps - General Guidelines for Types, Applications, Definitions, Sound Measurements and Documentation
HI 9.8 (2012) Rotodynamic Pumps for Pump Intake Design Standard
ISA - INTERNATIONAL SOCIETY OF AUTOMATION (ISA)
ISA RP2.1 (1978) Manometer Tables
1.2 SYSTEM DESCRIPTION
Design, furnish, and install 5 identical vertical axial-flow or mixed-flow, single stage impeller-type pumps.
1.2.1 Design Requirements
a. Pumps are for the purpose of pumping stormwater from the Lift-Station Wetwell into Gatewell Structure. Water pumped will not exceed 120 degrees F, will be relatively turbid, and may contain sand, silt, and vegetative trash capable of passing trashrack. Trash-racks will have 2 inch clear openings. Pumps shall be designed to operate in the dry for a minimum of 15 minutes.
b. Pumps shall be driven by the vertical motors described in Section 26 29 01.00 10 ELECTRIC MOTORS, 3-PHASE VERTICAL INDUCTION TYPE. Pump manufacturer shall be designated to have single source responsibility for coordination of the pump and electric motor. Pumps shall be tested with actual motors provided for this project.
c. Design pump so that no major modifications, alterations, or additions will be required to the pumping station or suction bays to accommodate it. However, requests for changes in setting of pump, supports, and accessories, which would involve only minor modifications, will be considered. Design pump so that pump parts will fit within the limiting horizontal and vertical dimensions shown and so installation and maintenance can be accomplished by exterior crane using hatch in
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roof. Pumps, or pump parts assembled at pumping station shall be capable of being lowered through floor openings shown with minimum of 1 inch clearance around each side.
d. Pump shall discharge into discharge system shown. System loss curve, which includes friction losses from pump inlet to end of discharge line, including bend losses, exit loss, and velocity head, is included as Figure 1 at end of this section to permit determination of total head. Losses within pump shall be determined by Contractor.
1.2.2 Capacities
The pump shall:
a. Discharge not less than 13,000 gal/min against total dynamic head of 28.0 feet with water surface in sump at Elevation 876.00 feet.
b. Discharge not less than 15,000 gal/min against total dynamic head of 21.5 feet with water surface in sump at Elevation 884.50 feet.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings; G
SD-03 Product Data
Paint System; G Pump Curves; G Materials; G Spare Parts; G Total Head; G Shipping Bills Installation and Erection Instructions Manual Field Tests
SD-05 Design Data
Dynamic Analysis
SD-06 Test Reports
Witness Test. Factory Test
SD-10 Operation and Maintenance Data
Operation and Maintenance Instructions Manual; G
1.4 QUALITY ASSURANCE
Furnish one or more competent erecting engineers fluent in English language who is knowledgeable about the installation of the vertical pumps and associated drive machinery. Erecting engineers provided by this section shall include those from Contractor's suppliers. When so requested,
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erecting engineers shall provide and be responsible for providing complete and correct direction during initial starting and subsequent operation of equipment until field tests are completed. Erecting engineer shall initiate instructions for actions necessary for proper receipt, inspection, handling, uncrating, assembly, and testing of equipment. The Erecting Engineer(s) shall also keep a record of measurements taken during erection, and shall furnish one copy to Owner's Representative on request or on completion of installation of assembly or part. Erecting engineer shall instruct Owner's Representative in operation and maintenance features of work.
1.4.1 Freeze Protection
All parts of the pump shall have drain holes to eliminate trapped water that could freeze. These drain provisions shall be self-draining without any requirement to enter the sump.
1.4.2 Detail Drawings
Submit drawings of sufficient size to be easily read, within 90 days of notice of award of contract.. Submit information in the English language. Dimensions shall be in English.
a. Outline drawings of pump showing pertinent dimensions and weight of each component of the pump.
b. Drawing showing details and dimensions of pump mounting design or layout including any embedded items.
c. Cross-sectional drawings of pump showing each component. Show major or complicated sections of pump in detail. Indicate on each drawing an itemized list of components showing type, grade, and class of material used and make and model number of standard component used.
d. Detail and assembly drawings required for manufacturing showing dimensions, tolerances, and clearances of shafts, sleeve journals, bearings, including dimensions of grooving, couplings, and packing gland, and diameter and tip clearance of propeller.
e. Drawings covering erection and installation, which Contractor intends to furnish to erecting engineer.
1.5 DELIVERY, STORAGE, AND HANDLING
1.5.1 General
Furnish major pump components with lifting lugs or eye bolts to facilitate handling. Design and arrange lugs or bolts to allow safe handling of pump components singly or collectively as required during shipping, installation, and maintenance. Submit copies of certified shipping bills, in duplicate, mailed promptly to Owner's Representative or memorandums of all shipments of finished pieces or members to designated site, giving designation mark and weight of each piece, number of pieces, total weight, and if shipped by rail in carload lots, car initial and number.
1.5.2 Processing for Storage
Prepare pumps (and spare parts) for storage indoors. Indoor storage consists of a permanent building that has leak-proof roof, full walls to
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contain stored equipment, and a concrete floor or temporary trailers. A temporary structure may also be built at job site for equipment storage that will contain features of the permanent building above except that provision for ventilation will be provided and floor may be crushed rock. A vapor barrier will be provided below the crushed rock. Crushed rock will be of sufficient thickness so that settlement of equipment will not occur. Equipment stored on crushed rock will have cribbing under each support location so that equipment does not come in contact with crushed rock. A plastic barrier will be placed between equipment and wood cribbing. Submit a list of equipment and materials requiring humidity-controlled storage to Owner's Representative no later than 30 days prior to shipment of pumping units. Long term storage (greater than 6 months) requirements shall be in accordance with pump manufacturers recommendations.
1.6 PROJECT/SITE CONDITIONS
1.6.1 Datum
Elevations shown or referred to in specifications, are above or below mean sea level National Geodetic Vertical Datum (NGVD) .
1.6.2 Static Head
Static head is the difference, in feet, between water surface elevation in sump and top of discharge pipe at highest elevation. Total dynamic head includes static head, friction losses outside of equipment being furnished, plus velocity head loss. A curve showing friction losses plus velocity head for pumped capacities is included at the end of this section.
1.7 MAINTENANCE
1.7.1 Special Tools
Furnish one set of all "special tools" required to completely assemble, disassemble, or maintain pump. "Special tools" refer to oversized or specially dimensioned tools, special attachment or fixtures, or any similar items. If required, provide a device for temporarily supporting pump shaft and impeller during assembly, disassembly, and reassembly of motor reducer when thrust bearing is not in place. Lifting devices required for use in conjunction with overhead crane shall be furnished. Provide portable steel cabinet large enough to accommodate all "special tools" furnished under this paragraph and as required by Section(s) 26 29 01.00 10 ELECTRIC MOTORS, 3-PHASE VERTICAL INDUCTION TYPE. Mount cabinet on four rubber-tired casters. Provide drawers to accommodate tools. Fit front of cabinet with doors hinged to swing horizontally. Furnish doors with necessary stops, catches, and hasps for completely securing cabinet with a padlock. Furnish padlock complete with three keys. Pack "special tools" in wooden boxes if size and weight do not permit storage in tool cabinet. Provide slings if box and tools are heavier than 75 pounds.
PART 2 PRODUCTS
2.1 MATERIALS
If not specified, materials and fabrication shall conform to the requirements of Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS 05 50 14 STRUCTURAL METAL FABRICATIONS. Material selection not specified shall be guided by HI 9.1-9.5 for corrosion, erosion, and abrasion resistance. Submit two copies of purchase orders, deviations from the specified
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materials, mill orders, shop orders for materials, and work orders, including orders placed or extended by each supplier. Furnish list designating materials to be used for each item at time of submittal of drawings. Furnish, within 60 days of notice of award, names of manufacturers of machinery and other equipment which Contractor contemplates incorporating in the work, together with performance capacities and other relevant information pertaining to the equipment. Submit samples of materials as directed. Equipment, materials, and articles installed or used without the approval of the Owner's Representative shall be at risk of subsequent rejection.
a. The pump shall be identified by means of a separate name-plate permanently affixed in a conspicuous location. The plate shall bear the manufacturer's name, model designation, serial number if applicable, and other pertinent information such as horsepower, speed, capacity, type, direction of rotation, etc. The plate shall be made of corrosion-resisting metal with raised or depressed lettering and contrasting background.
b. The pump shall be equipped with suitably located instruction plates, including any warnings and cautions, describing any special and important procedures to be followed in starting, operating, and servicing the equipment. Plates shall be made of corrosion-resisting metal with raised or depressed lettering and contrasting background.
c. Safety guards and/or covers shall be provided wherever necessary to protect the operators from accidental contact with moving parts. Guards and covers shall be of sheet steel, expanded metal, or another acceptable material and removable for disassembly of the pump.
2.2 METALWORK FABRICATION
2.2.1 Designated Materials
Designated materials shall conform to the following specifications, grades, and classifications.
MATERIALS SPECIFICATION GRADE, CLASS
Aluminum-Bronze ASTM B148 Alloy No. C95500 Castings Cast Iron ASTM A48/A48M Class Nos. 150A 150B, and 150C; 30A, 30B, and 30C Cast Steel ASTM A27/A27M Grade 65-35, annealed
Coal Tar Protective AWWA C203 Coatings Cold-Rolled Steel Bars ASTM A108 min, Wt. Strm 65,000 psi Copper Alloy Castings ASTM B584 Alloy No. C93700
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MATERIALS SPECIFICATION GRADE, CLASS
Corrosion-Resistant ASTM A217/A217M Grade CA15 Alloy Casting
ASTM A352/A352M CA6NM
ASTM A351/A351M CF8M
Dimensions for Steel AWWA C208 Water Piping Fittings
Hot-Rolled Stainless ASTM A576 Graded G10200 and G11410
Ring Flanges AWWA C207 Class B
Rubber Products in ASTM D2000 Automotive Applications
Seamless and Welded ASTM A312/A312M Austenitic Stainless Steel Pipe
Stainless Bars and ASTM A276 Grades S30400 and Shapes S41000
Steel Forging ASTM A668/A668M Class F
Steel Pipe AWWA C200 6 inch and Larger
Steel Plates, Pressure ASTM A516/A516M Grade 55 Vessel Steel Plate, ASTM A285/A285M Grade B Structural Quality
Structural Steel ASTM A36/A36M
Surface Texture ASME B46.1 (Surface Roughness, Waviness, and Lay)
2.2.2 Bolted Connections
2.2.2.1 Bolts, Nuts, and Washers
Bolts, nuts, and washers shall conform to requirements of paragraph MATERIALS AND METALWORK FABRICATION, subparagraph DESIGNATED MATERIALS, and paragraph VERTICAL PUMPS, subparagraph PUMP COLUMN AND DISCHARGE ELBOW, subparagraph NUTS AND BOLTS for types required. Use beveled washers where
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bearing faces have a slope of more than 1:20 with respect to a plane normal to bolt axis.
2.2.2.2 Materials Not Specifically Described
Materials not specifically described shall conform to latest ASTM specification or to other listed commercial specifications covering class or kinds of materials to be used.
2.2.3 Metalwork
2.2.3.1 Flame Cutting of Material
Flame cutting of material other than steel shall be subject to approval of Owner's Representative. Shearing shall be accurately done, and all portions of work neatly finished. Steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a smooth surface free from cracks and notches is secured. Surfaces and edges to be welded shall be prepared in accordance with AWS D1.1/D1.1M. Chipping and/or grinding will not be required except where specified and as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Visible or exposed hand-guided cuts shall be chipped, ground, or machined to metal free of voids, discontinuities, and foreign materials.
2.2.3.2 Alignment of Wetted Surfaces
Exercise care to assure that correct alignment of wetted surfaces being joined by a flanged joint is being obtained. Where plates of the water passage change thickness, transition shall occur on the outer surface, leaving inner surface properly aligned. When welding has been completed and welds have been cleaned, but prior to stress relieving, joining of plates shall be carefully checked in the presence of Owner's Representative inspector for misalignment of adjoining parts. Localized misalignment between inside or wetted surfaces of an adjoining flange-connected section of pump or formed suction intake shall not exceed amount shown in Column 4 of Table 1 for the respective radius or normal distance from the theoretical flow centerline. Misalignments greater than allowable amount shall be corrected by grinding away offending metal, providing the maximum depth to which metal is to be removed does not exceed amount shown in Column 5 of Table 1. No metal shall be removed until Contractor has assured himself and Contractor Officer that no excessive stresses will occur in remaining material and that excessive local vibration will not result from removal of the material. Where required correction is greater than the amount in Column 5 of Table 1, pipe shall be rejected for use. Proposed procedure for all corrective work, other than minor grinding, shall be approved by Owner's Representative prior to start of corrective work. Corrective work shall be finished by grinding corrected surface to a smooth taper. Length of the taper along each flow line element shall be 10 times the depth of the offset error at flow line. Wetted surface irregularities that might have existed in an approved model shall not be reason for accepting comparable surface irregularities in prototype pump.
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TABLE 1
(1) (2) (3) (4) (5)
Pipe Diameter Pipe Radius Pipe Thickness Maximum Offset Grind-Not (inches) or Distance (inches) (inches) More Than (inches) (inches) 24 12 3/8 1/16 3/32
30 15 3/8 1/16 3/32
36 18 3/8 3/32 3/32
42 21 1/2 3/32 1/8
48 24 1/2 1/8 1/8
54 27 1/2 1/8 1/8
60 30 3/4 5/32 5/32
72 36 1 5/32 5/32
84 42 1-1/8 3/16 1/4
2.2.3.3 Stress-Relieving Procedure
After all fabrication welding is completed, and prior to any machining, stress-relieve bell by heat treatment. Submit proposed stress-relieving procedure for approval by Owner's Representative.
2.2.4 Examination of Castings
All castings shall be cleaned and carefully examined for surface defects. All defects shall be further examined by nondestructive means. Examination personnel shall be qualified/certified in accordance with applicable ASTM requirements. The examination procedure and qualification of the examiner shall be submitted for approval. Examination tests shall be made in the presence of the Owner's Representative. Choose the examination procedure best suited for the application.
2.2.4.1 Examination Procedures
2.2.4.1.1 Ultrasonic
Conform inspection to the applicable provisions of ASTM A609/A609M.
2.2.4.1.2 Magnetic Particle
Conform inspection to the applicable provisions of ASTM E709.
2.2.4.1.3 Liquid Penetrant
Conform inspection to the applicable provisions of ASTM E165/E165M.
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2.2.4.2 Acceptance and Repair Criteria
Acceptance and repair criteria shall be in accordance with Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.
2.3 VERTICAL PUMPS
2.3.1 Speed
Rotative speed of pump shall be no greater than 900 rpm. Verify that rotative speed of pump at which the NPSH is produced is no less than required.
2.3.2 Reverse Flow
Pump shall withstand, with no damage, the full force exerted on it, with impeller subjected to reverse flow and upper end locked in place by backstop. Calculate head to determine the force developed by this reverse flow from specified highest discharge side water elevation and lowest pump intake side water elevation. Reverse rotative speed shall be 0.0 with instantaneous activation of backstop.
2.3.3 Formed Suction Intake (FSI)
Provide an FSI for each pump to the dimensional requirements and arrangements show on the drawings and in accordance with HI 9.8, Figure 9.8.2.2.2. The FSI will be connected to the inlet of the pump bowl via the 24 inch spool piece/coupling arrangement shown in the drawings . The method of connection shall be a flanged joint as specified in paragraph Fanged Joints. The FSI shall be constructed of fabricated steel. Any stiffeners used shall be on the outside of the FSI to allow smooth flow within. Bolts shall be stainless steel with bronze nuts. The minimum thickness of fabricated material shall be 3/8 inch. Grout holes shall be provided in the floor of the FSI to permit grouting during installation.
2.3.4 Impeller Bowl
Make impeller bowl of cast iron. Provide flanges for mating with suction bell and impeller bowl or two-piece construction of impeller. Flanged connections with FSI diffuser or split construction shall be provided with a rabbet fit or four equally spaced dowels installed in the vertical position for initial alignment purposes and to maintain concentric alignment of pump. Machine finish impeller-swept area in impeller bowl to at least 125 microinch rms and concentric with impeller axis. For mixed-flow impellers, angle in impeller bowl shall equal the outside angle of impeller blade tips. Tolerance for concentricity of impeller with the impeller axis shall not be greater than 20 percent of the operating clearance between impeller and impeller bowl.
2.3.5 Diffuser Bowl
Make diffuser bowl of cast iron. Diffuser shall contain support for upper impeller shaft bearing and have vanes to guide the pumped flow. Equip diffuser bowl with a bypass drain to outside of pump from the diffuser cavity located between the enclosing tube connection and impeller. Furnish throttle bushing located in the cavity immediately above impeller. Bypass drain and throttle bushing should be designed to reduce water pressure on lower seal. Impeller back-wear rings can also be used to reduce water pressure on lower seal.
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2.3.6 Pump Column and Discharge Elbow
2.3.6.1 Column and Discharge Elbow
Make column and discharge elbow of either cast iron, cast steel, or welded steel plate. Steel plate, if used, shall have thickness of not less than 1/2 inch after machining is completed. Elbow shall be of mitered type. Turning vanes shall not be used. Column and discharge elbow shall be designed to withstand internal pressures and external loadings associated with various conditions of pump operation. Provide flanges for mating individual segments together and for mating pump column to diffuser bowl. Flanges shall have rabbeted fits or four equally spaced dowels installed in flanges for initial alignment purposes and to maintain concentric alignment. The elbow shall terminate in a plain-end circular section. Diameter tolerance of plain end shall be 0.10 inch. Diameter of discharge end of elbow shall be as shown and shall allow standard diameter flexible couplings to be used. Adjustable thrust rods and thrust lugs shall be used to transfer the load by bridging the coupling.
2.3.6.2 Column and Discharge Elbow Support
Pump column and discharge elbow shall be designed for suspension from a baseplate assembly specified in paragraph BASE PLATE AND SUPPORTS and located at operating floor level.
2.3.6.3 Flanges
Machine flanges and drill bolt holes concentric with pump shaft vertical centerline, having tolerance of plus or minus one fourth of clearance between bolt and bolt hole. When fabricated from steel plate, flanges shall not be less than 1-1/2 inch thick after machining. Flange thickness after machining shall not vary more than 10 percent of greatest flange thickness. Provide external stiffeners, if needed. Construct fabricated flanges, as a minimum, to the dimensions of AWWA C207, Class B. Flanges on major components of pump casing (suction bell, impeller bowl, diffuser bowl, and column and elbow piping) shall be designed such that blind holes necessitating use of cap screws or stud bolts will not be used. Design flanges for connection to column pipe by at least two continuous fillet welds. One weld shall connect inside diameter of flange to pump column and the other shall connect outside diameter of pump column to flange. Final design of welds rests with manufacturer, and specified welds are the minimum requirement. They shall be parallel machined, when provided on each end of the same component, and mounted parallel to a plane that is normal to pump shaft centerline. Flanges on each end of the same component shall have parallel tolerance of 0.002 inch. Finish machine mating surface on flange to 125 microinch finish or better. Provide flanges with minimum of three jacking bolts to aid in disassembly of pump.
2.3.6.4 Flanged Joints
Design flanged joints to be air-and water-tight, without the use of preformed gaskets, against positive and negative operating pressures that will be experienced, except that "PERMATEX" or equal gasketing compound will be permitted. Provide mating flanges, unless of the male-female rabbet type, with not less than four tapered dowels equally spaced around flange. If rabbeted fit is not used, then Contractor shall provide the method used to determine concentricity of connected pieces.
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2.3.6.5 Nuts and Bolts
Bolts used in assembling pump and its supporting members, including anchor bolts and dowels, shall be of 300 series stainless steel. Use only bronze nuts and hexagonal bolts and nuts. Washers used shall be 300 series of stainless steel.
2.3.6.6 Galvanic Protection
When dissimilar metals are used, use zinc anodes. Provide machined mounting pads and install anodes on carbon steel or cast iron parts. Fasten anodes to bare material on pump so that continuity is obtained between anode and pump. Verify continuity by checking joint with an ohmmeter. Locate anodes on exterior of pump below normal sump level. Total weight of anodes used per pump shall be 80 pounds. Pump joints shall be electrically bonded at the joints.
2.3.6.7 Harnessed Coupling
Provide a flexible mechanical coupling conforming to ASTM F1476, Type II, Class 3, stainless steel as manufactured by Teekay or Straub Couplings or Dresser style 38 or approved equal, to connect pump discharge elbow to discharge piping.
2.3.7 Impeller
Make impeller of aluminum bronze.
2.3.7.1 Removal and Prior To Finishing
After removal from mold, and prior to finishing of surface imperfections, castings shall be inspected by Owner's Representative. Minor surface imperfections shall be filled or ground down as necessary to preserve correct contour and outline of impeller and to restore surface imperfections to the same degree of finish as surrounding surfaces. Correct surface pits, depressions, projections, or overlaps showing greater than 1/16 inch variation from the general contour for that section. Method and procedure for accomplishing repair shall be as required in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS. Castings that exhibit surface imperfections (as defined above) covering an area of more than 10 percent of blade surface will be rejected.
2.3.7.2 Balance
Balance impeller by the two-plane balancing technique. Impeller shall be balanced at rated operating speed. Check balance at 110 percent of balance speed, and make needed corrections. Amount of allowable unbalance shall be in accordance with grade G6.3 of ASA S2.19. Weights needed to obtain required level of balance shall be securely fastened to inside cavity of impeller hub. In no case will portions of the impeller be removed or weights be added to outside of hub, vanes, or water passages. Submit balancing procedure to Owner's Representative for approval at least four weeks prior to date of balancing. Each finished impeller shall be weighted and weight stamped on the bottom of hub. Weight shall be accurate to 0.5 percent of the total weight of impeller. Weighing and balancing shall be witnessed by Owner's Representative.
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2.3.8 Shafting
2.3.8.1 Shaft
Impeller shaft shall be stainless steel and intermediate shaft(s) shall be same material as impeller shaft. Design shafting so that shaft sections shall not exceed 10 feet in length and that any necessary vertical adjustment of impeller can be made from operating room floor without interfering with shaft alignment. Also provide for removal of impeller from below without disassembly of pump above impeller bowl. If pump is multi-staged, design to permit the lower bowls and impeller to be easily removed for in-place inspections of upper propeller and bowl. Design shafts for two different design cases. The first uses a factor of safety of 5 based on ultimate tensile strength of shaft material and rated horsepower of motor. The second uses 75 percent of the yield strength of shaft material and locked rotor torque of motor.
2.3.8.2 Couplings
Pump and motor shafts and pump shaft sections shall be coupled together by manufacturer's standard method and be capable of transmitting the forces and torques involved. Coupling halves shall be maintained concentric with each other, to within 0.002 inch. Shaft coupling nut, if used, shall be retained by fitted bolts, and all tolerances specified for the coupling shall apply. Pump shaft sections shall be joined together with sleeve-type couplings capable of taking rotation in either direction. Threads, except on fasteners, shall not be employed in construction of sleeve-type couplings. Couplings, including keys and fasteners, shall be constructed of stainless steel materials. The finished shaft assembly shall be concentric about shaft centerline to within 0.004 inch. Shop assemble couplings and pump shaft and inspect for compliance with contract requirements. After inspection, matchmark parts, including fitted bolts, to their mating pieces.
2.3.8.3 Journals
Finish the shaft journal at all guide bearing and packing gland locations to at least 32 rms and finish shaft at seal journal locations to 16 rms. The Contractor has the option to install replaceable stainless steel one-piece sleeves at each bearing, packing gland and seal locations with the finishes stated above. Securely fasten sleeves to shaft to prevent movement. Keys and fasteners, if used, shall be made from corrosion resisting steel; fastening by adhesive or welding is not acceptable. The surface hardness at the seal locations shall be as recommended by the seal manufacturer.
2.3.9 Shaft Enclosure
Provide shaft enclosure to cover intermediate shaft and coupling. It shall be rigid enough to be self-supporting. External supports or bracing located in pump water passage shall not be used for support of the enclosing tube unless necessary to support intermediate bearings or indicated to be necessary or advantageous by dynamic analysis required in paragraph DYNAMIC ANALYSIS. Consider effect of external supports, including rubber inserts, in the dynamic analysis required in paragraph TEST, INSPECTIONS, AND VERIFICATIONS, subparagraph DYNAMIC ANALYSIS. Design enclosure to be watertight and for easy assembly and disassembly in the field. Enclosure shall be split longitudinally to permit easy removal without removing or disassembling pump shaft. Enclosing tubes constructed with screw type joints and using tension in tube to hold alignment, shall
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be constructed to prohibit tension tube from unscrewing when packing gland adjustments are made. Provide shaft enclosure for grease-lubricated pumps with a drain having a shut-off valve located outside of the to permit draining enclosure between operation periods. Locate drain at bottom of shaft enclosure. On oil-lubricated pumps, the enclosing tube below lowest bearing and above oil seals shall be fitted with an oil/water drain line to the outside of pump. Drain line shall have a check valve outside of pump to preclude entrance of sump water.
2.3.10 Guide Bearings and Seals
2.3.10.1 Guide Bearings
Provide pump with sleeve-type bearings designed for grease lubrication. Bearing shall have a bronze lining in contact with shaft journal and shall be replaceable type. Arrange bearing liner for maximum distribution of grease for lubrication of journal surface. Bearings shall have a surface finish of 32 microinches rms or better to match journal finish. Since pumped water may contain some fine sand and silt in suspension, give special attention to the design and selection of bearing parts, especially seal rings, to preclude entrance of foreign material between bearing and journal due to differential water pressure.
2.3.10.2 Grease Lubrication Shaft Seals
Pumps designed for grease lubrication shall have a shaft seal consisting of lip seals. Seal system shall consist of a lip-type seal located on each end of bearing. Each seal shall contain a lip element having a stainless steel garter spring back-up and be constructed of TFE (Teflon). Lip element shall face bearing. Lowest bearing shall have an additional grease seat with lip facing away from bearing. Use bullet-shaped assembly tool or other special tools over the end of shaft and shaft grooves to preclude damage to lip element during assembly. Assembly tool used is considered a special tool and shall be furnished to Owner's Representative as part of special tools specified in paragraph MAINTENANCE, subparagraph SPECIAL TOOLS.
2.3.11 Bearing Heat Sensors
Fit impeller shaft bearings with temperature-sensing elements, inserted in bearings to within 1/8 inch of shaft. These temperature-sensing elements shall be provided with temperature readouts mounted on motor. Provide visual and audible alarm system to warn of bearing overheating. Support leads and protect from water and mechanical damage. Terminate leads outside of pump casing in a waterproof connection head, Minco CH 339 or equal, and cap until final connections are made in the field. The connection head shall be rated watertight to 25 psi. Lead protection shall consist of pipes fastened to pump with brackets using bolts and nuts to permit their removal, and shall be constructed with enough unions to be completely disassembled. Leads passing through pump water passage in pump shall either be contained in a guide vane or be protected by Schedule 120 pipe. Protection pipe shall be removable if connected to shaft-enclosing tube. Install bearing heat sensors per pump manufacturer's design. Run leads and wiring to a junction box located on baseplate. Provide terminal strip in junction box for connection of wiring to temperature readouts.
2.3.12 Thrust Bearing
Provide thrust bearing in the motor to carry total thrust load and weight
SECTION 22 10 00.00 10 Page 15 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
of rotating assembly.
2.3.13 Packing Gland
Provide grease-lubricated packing gland split longitudinally to facilitate removal or renewal. Arrange it to permit inspection, repair, removal, or replacement of packing without entering pump from below operating room floor. Provide eye bolts and tapped holes in each half of the split gland if halves weigh over 30 pounds each.
2.4 LUBRICATION SYSTEM
Support grease lines to each bearing and protect from water and mechanical damage. Grease line protection shall consist of channels fastened to pump with brackets, using bolts and nuts to permit removal. Grease lines passing through pump water passage shall either be contained in a guide vane or be protected by Schedule 120 pipe. This protection pipe shall be removable if connected to shaft-enclosing tube. Prefill grease lines before connection to bearings. Terminate grease lines above baseplate for connection to lubricating grease pump.
2.4.1 Centralized Pressure Lubrication System
2.4.1.1 General
Provide one individual electric motor-driven centralized pressure lubrication system for every two pumps, as shown on the Drawings, designed to deliver the proper predetermined or metered quantity of lubricant to each individual bearing and stuffing box. It shall positively indicate proper or improper functioning of any individual metering device. Mount pressure pump, individual metering devices, and any required auxiliary operating accessories suitably on baseplate. System shall be furnished complete and ready for operation, including sufficient lubricant to fill each pressure pump lubricant reservoir. Submit complete centralized pressure lubrication system to Owner's Representative for review and approval. Furnish lubricant recommended by pump manufacturer, subject to approval of Owner's Representative.
2.4.1.2 Pumping Unit
Provide Electric motor-driven pumping unit as a complete assembly, consisting of positive displacement type pump, flow-directing valve (if required), lubricant reservoir, suitable pressure gage to indicate pump discharge pressure, operation counter, pressure protective device, and other auxiliary accessories as required to give a complete and workable unit conforming to requirements specified. Pump shall be of multiple individual piston, positive displacement type utilizing hardened steel pistons closely fitted to cylinder bores to eliminate the need for packing, and spring-actuated check valves shall not be required for its operation. Pump shall deliver not less than 6 cu inches of lubricant per minute against a pressure of not less than 2,000 psi measured at the most remote bearing connection. Lubricant reservoir shall be of suitable metallic construction, shall have a capacity of not less than 24 pounds of lubricant, shall be provided with suitable means that will ensure positive priming of pump at all times (such as an atmospheric or spring-loaded follower plate), an indicator to show quantity of lubricant in reservoir, and a screened fill connection to permit filling reservoir by transfer pump without exposing lubricant to atmosphere. Provide pump unit with a fully automatic control system, capable of suitable or proper scheduling by an
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adjustable synchronous motor-driven timing device, and other required auxiliaries necessary to give a complete and workable system. Provide controller with a "Hand Off-Automatic" selector master switch to permit selection between push button manual and automatic time clock operation, and to deenergize the system. Electric power will be supplied at 115 volts single phase, 60 cycles. Use time clock setting recommended by main pump manufacturer.
2.4.1.3 Metering Valves
Provide metering or measuring valve for each bearing and stuffing box. It shall be fully hydraulic in its operation, requiring no internal springs or check valves. Valve size to be determined by the pump manufacturer.
2.4.1.4 Piping
System piping shall be stainless steel tubing (ASTM A269, Type 410 or equal) using flared or compression-type connectors. Adequately protect and rigidly support piping located below operating room floor in a manner approved by Owner's Representative. Provide each individual grease line with a "Tee" fitting, located immediately below the respective metering valve and accessible from operating room. Also provide with a standard 1/4 inch grease fitting so that each individual line may be fully charged without using pump of lubricating system. Size and strength of pipe and type and strength of fittings shall be as recommended and guaranteed by lubrication system manufacturer, but in no case shall bursting pressure of pipe or tubing used be less than three times the maximum working pressure. Provide check valve located between discharge outlet of the measuring valve and "Tee" fitting specified above in each lubricating line of bearings that is exposed to water pressure to prevent entrance of water into the respective measuring valves.
2.4.2 Lubrication System Accessories
2.4.2.1 Grease Gun
A hand operated, heavy duty lever grease gun for charging lubrication lines and for emergency lubrication shall be provided. Provide grease as recommended by the vertical pump manufacturer.
2.4.2.2 Service Facilities
A service facility consisting of a portable hand operated transfer pump, a hand-towed dolly, and a 120 pound drum of lubricant, all assembled and ready for operation shall be provided. The pump shall be self-contained and designed for mounting on the grease drum to protect the contents from the entrance of foreign matter. The pump shall deliver not less than one pound in not more than eight strokes of the pump handle under normal temperature conditions. Furnish necessary hose and quick disconnect coupling for a complete system. The hand-towed dolly shall have a rigid platform with four anti-friction bearing mounted wheels, a towing handle and a provision for securing the lubricant barrel. The type of lubricant shall be as recommended by the vertical pump manufacturer.
2.5 PAINTING
Provide manufacturer's standard paint system, that at a minimum, meets the requirements of Section 09 90 00 PAINTING: HYDRAULIC STRUCTURES.
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2.6 TESTS, INSPECTIONS, AND VERIFICATIONS
2.6.1 Critical Speeds
Assembled pumping unit, consisting of motor and pump shall be free from critical speeds or harmful torsional vibrations at all speeds encountered within the operating range.
Before pump and motor, furnished under Section 26 29 01.00 10 ELECTRIC MOTORS, 3-PHASE VERTICAL INDUCTION TYPE are released for manufacture, pump/motor structure shall be analyzed by pump manufacturer for harmful natural frequencies in the lateral and torsional directions. A natural frequency that occurs within 25 percent above or below normal operating speed is unacceptable. Dynamic analysis model shall be constructed using a commercially available program such as Ansys, Cosmos/M, or equivalent, which utilize finite element methods. Incorporate effects of column pipes, cover pipes, shafts, bearings, mass concentrations, and other such features as necessary to accurately model pump structure. Analyze structure in the run (wet) condition and consider the effect of water mass in the column and damping effect of water in the sump (vertical units only) at highest and lowest sump water levels. Incorporate Reed critical frequency and mass elastic diagram information provided by motor manufacturer. If motor manufacturer cannot demonstrate to the satisfaction of Owner's Representative (based on impact tests of similar units) that the Reed critical frequency value is accurate, motor manufacturer shall conduct a dynamic analysis using finite element methods as described to determine motor Reed critical frequency for use by pump manufacturer. Submit complete detailed dynamic analysis report including the following information:
a. Computer program used.
b. Schematic diagram of the model depicting nodes and elements.
c. Input data consisting of node coordinates, element types, material properties, element characteristics, element connectivities, and specified displacements.
d. Motor mass elastic and Reed critical information (or dynamic analysis, if required).
e. Analysis results, including significant natural frequencies.
f. Interpretation of results.
Impact test motor furnished before shipment to determine actual Reed critical frequency of motor. Include results of impact tests included in motor test data to be submitted. Pump manufacturer shall address any discrepancy between calculated and actual motor Reed critical frequency values to determine whether design changes are required to prevent harmful natural frequencies in the pump/motor structure. If any design changes are required, these shall be incorporated at no cost to Owner's Representative.
2.6.1.1 Torsional Analysis
Before pump, gear drive, and engine are released for manufacture, engine supplier shall analyze the system for harmful torsional natural frequencies using mass elastic information provided by pump and gear drive manufacturers. A natural frequency that occurs within 25 percent above or
SECTION 22 10 00.00 10 Page 18 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
below any of the operating speeds required for pump operating conditions is considered to be unacceptable.
2.6.2 Lubricating System Tests
Test complete lubricating system for each pumping unit, as deemed necessary by Owner's Representative, to determine that system meets operational requirements specified. At least one valve of each size furnished shall be tested with the lubrication line removed from its bearing and fitted with a pressure relief valve and pressure gage. The pressure relief valve shall be adjusted to discharge it at the operating pressure specified and the system shall be operated through one or more cycles as required to obtain an accurate measurement of the quantity of lubricant delivered, which shall be within plus or minus 20 percent of the theoretical delivery of the respective valve. Any component parts that are damaged as the result of these tests or that fail to meet the requirements of the specification shall be replaced, reinstalled, and retested at the Contractor's expense.
2.6.3 Factory Test
2.6.3.1 General
Performance of the pump to be furnished will be accepted on the basis of the factory test. Conduct this test using first pump produced for this contract. Pumps shall be tested with actual motors provided for this project. All pumps for this project shall be tested prior to shipment. Pump testing shall be continuous between test points (no shutting off the pump).
2.6.3.2 Test Setup
All pumps shall be set with shaft in vertical position. Factory test elbow may be used in lieu of the prototype elbow for testing purposes, providing test results are adjusted to reflect the difference in losses. Tests shall be completed on the first pump prior to assembling and testing the remaining pumps. Testing shall include use of and the evaluation of the Formed Suction Intake detailed on the Drawings.
2.6.3.3 Instrumentation and Procedures
Each instrument shall be described in detail, giving all data applicable, such as manufacturer's name, type, model number, certified accuracy, coefficient, ratios, specific gravity of manometer fluid to be used, and smallest scale division. When necessary for clarity, sketch of instrument or instrument arrangement shall be included. Include fully detailed narrative description of each proposed method of instrumentation, procedures to be used, and a sample set of computations. State the lowest equivalent static head that is obtainable with the testing when operating along the head-capacity curve of proposed pump. Test procedures, except as specified, shall be in accordance with applicable provisions of HI 2.6.
a. Head Measurements - Make head measurements using either a direct reading water column, mercury-air, mercury-water, a Meriam fluid manometer, or a pressure transducer. Measure vacuums with either a mercury-air, a mercury-water manometer, or a pressure transducer. Fluctuations shall be dampened sufficiently to permit column gages or a differential pressure transducer to be read to either closest 0.01 foot of water or Meriam fluid or 0.1 inch of mercury. Manometers shall be used as indicated by ISA RP2.1. When pressure transducers are used,
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their accuracy shall be checked with a manometer.
b. Capacity - Determine capacity by calibrated venturi flowmeter or long-radius ASME flow nozzle. Do not use orifice plates. Connect venturi or nozzle taps to column gages equipped with dampening devices that will permit differential head to be determined to either the closest 0.01 foot of water or Meriam fluid or 0.1 inch of mercury. Magnetic flowmeters and flowmeters utilizing ultrasonic flow measurements will be acceptable if calibration of flowmeter has been completed within the last 6 months.
c. Rotational Speed of Pump - Measure rotational speed of pump in accordance with "Method of Rotary Speed Movement" in HI 2.6, except that revolution counters shall not be used. Non-contacting hand-held electronic tachometers are acceptable. Device used shall permit speed to be determined to 1 rpm.
d. Power Input - Measure power input to pump in accordance with "Power Measurements" in HI 2.6. Use a method to permit pump brake horsepower to be determined to the closest 0.5 horsepower.
2.6.3.4 Pump Test
Test shall demonstrate that proposed pump complies with specified performance. Pump shall be capable of operation without instability over entire range of heads specified in paragraph CAPACITIES. Instability is defined, for this specification, as when one or more of the following conditions occur:
a. Pump has two or more flow rates at the same total head;
b. Head-capacity curve has a dip (region on curve where change in flow rate produces an abnormally low head);
c. When any point in usable range of head-capacity curve cannot be repeated within 3 percent.
Rerun test if this occurs. Compliance with specifications will be determined from curves required by paragraph TEST RESULTS. Test procedures, except as specified, shall be in accordance with applicable provisions of HI 2.6. Temperature of water used for testing shall be approximately the same for all tests run and shall be recorded during test runs.
2.6.3.5 Test Procedure
a. Performance of The Pump - The performance of the pump shall be determined by a series of test points sufficient in number to develop a constant-speed curve over the range of total heads corresponding to the static heads in paragraph CAPACITIES. The performance/test range shall include additional testing at total heads 2 feet higher than the total head determined in paragraph CAPACITIES. The lowest total head for testing shall be, as a minimum, the total head determined from paragraph "CAPACITIES". If the test setup permits testing at lower total heads, the range of total heads shall be extended 2 feet lower. Testing shall be inclusive for each speed(s) involved with the sump at elevations 876 and 884.50 feet. Tests shall be made using prototype total heads. Head differentials between adjacent test points shall not exceed 3 feet, but in no case shall less than 10 points be plotted in
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the pumping range. If the plot of the data indicates a possibility of instability or dip in the head-versus-capacity curve, a sufficient number of additional points on either side of instability shall be made to clearly define the head-capacity characteristics. When a scale model of the pump is tested, the efficiency of the prototype pump shall be considered to be the efficiency of the model. No other computation or adjustment of model efficiency to prototype conditions will be permitted.
b. Sump Elevations - Tests shall be conducted at two different sump elevations (approximately an 8.5 foot differential) to determine the effect of test sump geometry on the performance of the pump. Should the test results indicate that the performance is not the same in all respects for both sump conditions, take whatever corrective action is necessary to produce congruent results. The sump elevations used shall be those specified in paragraph CAPACITIES. The test results with this sump elevation shall meet all specified conditions of capacity, head, and brake horsepower. Submit curves indicating test results.
c. Tests Results - Plot results of tests to show total head, static, brake horsepower and efficiency as ordinates; all plotted against pump discharge as the abscissa. Plot curves showing prototype performance to a scale that will permit reading head directly to 0.5 foot, capacity to 500 gpm efficiency to 1 percent, and power input to 50 horsepower.
d. Demonstration - Demonstrate to Owner's Representative witness that the blade templates fit the tested pump. Demonstration shall be done immediately after testing is completed. Retain all templates for the tested pump, and furnish them to Owner's Representative upon request of Owner's Representative, to permit Owner's Representative to verify geometric similarity with the manufacturer's pump. In addition to providing templates, furnish dimensioned drawings of impeller, which contain all dimensions needed to manufacture it. Tested impeller shall be stamped with identification marks. Provide necessary facilities and instruments needed to permit Owner's Representative to verify that pumps are in complete geometric similarity with the tested pump.
2.6.3.6 Witness Test
When the Contractor is satisfied that the tested pump performs in accordance with the requirements of the specifications and the guaranteed values, notify the Owner's Representative that the witness tests are ready to be run and shall furnish two copies of the curves required in paragraph PUMP TEST AND CAVITATION TESTS along with a set of sample calculations with constants and conversion factors. Four weeks will be required to review this data before the Owner's Representative will be available to visit the Contractor's laboratory for witnessing the test. Should the results of the witness test reveal that the tested pump does not perform in accordance with the requirements of the specification and the guaranteed values, make such changes as are required to make it acceptable before again notifying the Owner's Representative that the witness tests are ready to be run. Immediately upon completion of each witness test, submit copies of all data taken during the test to the Owner's Representative witnessing the test. Computations of test results and plotted preliminary curves shall be furnished to the witness.
2.6.3.7 Test Report
Submit, within 30 days of receipt of approval of the witness test, to
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Owner's Representative 7 bound copies of a report covering completely test setup and performance and cavitation tests. Each test report shall include, as a minimum, the following:
a. Statement of the purpose of test, name of project, contract number, and design conditions should be given. Where guaranteed values differ from specified values, they also should be given.
b. A resume of preliminary studies, if such studies were made.
c. Description of test pump and motor, including serial numbers, if available. Information required under "b" may be included here.
d. Description of test procedure used, including dates, test personnel, any retest events, and witness test data.
e. List of all test instruments with model numbers and serial numbers.
f. Sample computations (complete).
g. A discussion of test results.
h. Conclusions.
i. Photographic evidence in the form of either 24 color photographs of test equipment, test setup and representative test segments, and a VHS videotape, at least 30 minutes in length, covering the same information as photographs. All photographic evidence should be labeled with Contract number, location, date/time, and test activity. Videotape shall be voice annotated with the same information.
j. Copies of instrument calibration.
k. Copies of all recorded test data.
l. Curves required by paragraph TESTS RESULTS.
m. Curves showing the performance of the test pump.
n. Drawings of the test setup showing all pertinent dimensions and elevations and a detailed dimensioned cross section of the pump.
2.7 BASEPLATE AND SUPPORTS
The baseplate shall be proportioned to support the entire pump assembly, the motor and the loads (including the results of the dynamic analysis) to which it may be subjected during operation. It shall be supported and anchored as shown on the drawings. Lifting lugs or eye bolts, special slings, strongbacks, or other devices necessary to handle the pump during loading, unloading, erection, installation, and subsequent disassembly and assembly shall be furnished. A sole plate shall be provided under the baseplate. The sole plate shall be installed, leveled and grouted in accordance with API RP 686, Chapter 5 - Mounting Plate Grouting. Jacking bolts shall be provided for leveling the baseplate assembly. An anchor bolt layout shall be provided to aid in placement of anchor bolts. All leveling jacking bolts shall be backed off after grouting so that they do not support any of the load. The pedestal supporting the motor shall contain a 1-inch lip to contain water leakage from the shaft packing. A threaded drain to the sump shall be provided.
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2.8 FACTORY ASSEMBLY
The pump shall be assembled at the manufacturer's plant to assure proper fitting and alignment of all parts. Tolerances shall not exceed those specified or shown on the the Contractor's manufacturing drawings. Rotating elements shall be checked for binding. The suction bell, impeller housing, diffuser, and the discharge elbow shall be properly match marked and have their centerlines clearly marked on the outside of all flanges to facilitate erection and alignment in the field. Notify the Owner's Representative sufficiently in advance to permit a representative of the Owner's Representative to inspect and witness the pump assembly. All parts disassembled for shipment shall be matchmarked.
PART 3 EXECUTION
3.1 INSTALLATION
a. The installation of the equipment furnished under this section and related drive machinery furnished under other sections of this specification shall be in accordance with the approved Installation and Erection Instructions Manual; submit, no later than time of pump delivery, three copies of typed or printed, and bound, manual describing procedures to be followed by erecting engineer in erecting, assembling, installing, and dry-and wet-testing pump. To the extent necessary or desirable, coordinate and consolidate description of pump with similar descriptions specified for motor.
(1) Description shall be complete, orderly, step-by-step explanation of operations required, and shall also include such things as alignment procedures, bolt torque values, permissible blade/bowl clearances; permissible bowl out-of-roundness; permissible shaft misalignment; recommended instrument setups; recommended gages and instruments; bearing clearances; and similar details.
(2) Description shall be complemented and supplemented by drawings, sketches, photos, and similar materials to whatever extent necessary or desirable, and the overall result shall be a description that may be comprehended by an engineer or mechanic without extensive experience in erecting or installing pumps of this type.
b. The erection engineer(s), familiar with the equipment to be installed, shall supervise the handling, installation, start-up and testing of the equipment as required by paragraph ERECTION ENGINEER(S).
c. Submit 7 copies of Operation and Maintenance Instructions Manual containing complete information on operation, lubrication, adjustment, routine and special maintenance, disassembly, repair, reassembly, and trouble diagnostics of pump and auxiliary units. Operation and maintenance manual and both parts lists shall be printed on good quality ANSI size A 8-1/2 by 11-inch paper, bound separately between flexible, durable covers. Drawings incorporated in manual or parts lists, may be reduced to page size provided they are clear and legible, or may be folded into the manual to page size. Photographs or catalog cuts of components may be included for identification.
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3.2 FIELD TESTS
Prior to proceeding with construction of the test setup but not later than 60 days after date of notice to proceed, submit a description of the test setup and test procedure proposed. Include dimensioned drawings and cross-sectional views of the setup and pump, respectively, with location of instruments and points of their connection shown.
3.2.1 Wet Tests
Each pump unit shall be given a test under load, at or near normal operating conditions, for at least 1 hour or as directed by the Owner's Representative; the test will be witnessed by the Owner's Representative. Provide all supplies and equipment required to conduct the test. During the test the operation of the pumps will be observed and measurements of vibration and bearing temperatures shall be taken and recorded. Without additional costs to the Owner's Representative, make all changes and correct any errors for which the Contractor is responsible. The Owner's Representative may waive or postpone the test if sufficient water is not available. Appropriate changes will then be made to the contract.
-- End of Section --
SECTION 22 10 00.00 10 Page 24 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo 2nd Street Lift Station, Single Stormwater Pump Total Head Loss System Curve, C=120 35.0
30.0
25.0 Design Points
20.0
Head (ft)
15.0
10.0
5.0
Max TDH Curve
Min TDH Curve
0.0 0 5000 10000 15000 20000 Flow (gpm)
Section 22 10 00.00 10A
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 22 12 00
WET WELL PHYSICAL MODEL STUDY 06/14 08/22/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
U.S. ARMY CORPS OF ENGINEERS (USACE)
EM 1110-2-3105 (1999) Mechanical and Electrical Design of Pump Stations
HYDRAULIC INSTITUTE (HI)
ANSI/HI 9.8 (2012) Pump Intake Design
1.2 STUDY OBJECTIVE
The Contractor/Supplier shall complete a physical model study of the proposed pumps, FSIs, and wet well prior to beginning fabrication of the pumps and FSIs. The physical model study shall be completed according to the most recent version of ANSI/HI 9.8 with the purpose of identifying adverse hydraulic conditions in the wet well that can affect pump performance, including pre-rotation and surface and subsurface vortex formations.
1.2.1 Model Description
The 2nd Street Pump Station consists of five (5) vertical storm water pumps withdrawing flow from a wet well approximately 28 FT long by 25 FT wide. Flow enters the wet well through an 8 FT wide trash rack from a 6 FT by 6 FT RCB culvert. Upon entering the wet well, flow passes through two slots in the bottom of the intake trough or flows over a wall into a common chamber. The wet well invert is set at EL 868.0 FT and contains five (5) formed suction intakes, (FSI) one for each pump.
The firm capacity of the pump station is 60,000 GPM with four (4) pumps operating. The total capacity of the station with all pumps are operating is at 75,000 GPM. It is anticipated that the low water level will be at elevation 876.00. There is a small sump pump to dewater the wet well after each use. The pump formed suction intakes are designed in accordance with ANSI/HI 9.8, EM 1110-2-3105 and the United States of America Corps of Engineers Type 10, Formed Suction Intake Design.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
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Detail Drawings; G
SD-05 Design Data
Model Analysis; G
SD-06 Test Reports
Witness Testing Shop Test; G
1.4 QUALITY ASSURANCE
1.4.1 Qualifications
The pump manufacturer shall retain the services of Northwest Hydraulic Consultants, Alden Labs, St. Anthony Fall Laboratory, or approved equal to perform the modeling.
Alden Labs St. Anthony Falls Northwest Hydraulic 30 Shrewbury St. Laboratory Consultants Holden, MA 01520 2 Third Avenue SE 16300 Christensen Rd. St 350 (508) 829-6000 Minneapolis, MN 55455 Seattle, WA 98188 (612) 624-4363 (206) 241-6000
Project Manager shall be responsible for overall direction of the project to ensure all objectives of the study are achieved in a timely manner and will participate in the modeling and review of the study reports. Project Manager shall have a minimum 10 years of experience in physical and numerical modeling with experience in pump intake structures.
Project Engineer shall be responsible for the day-to-day modeling activities, including model design, construction supervision and instrumentation. The Project Engineer shall conduct and supervise all of the testing and data processing for the study and work closely with the Project Manager and Technical Advisors to ensure all study objectives are met.
1.4.2 Detail Drawings
Submit drawings showing model details and dimensions within 30 days of notice of award of contract. Submit information in the English language. Dimensions shall be in English. Remainder of Drawing Submittals shall be as required to meet the Model Schedule.
a. Drawings showing model details and dimensions of pump station as designed and the pump/water surface combinations to be modeled prior to the initial design test.
b Drawings showing possible model modifications correcting performance issues in the initial design test following design development testing.
c. Drawings showing selected model modifications. Select model modifications shall be incorporated into the Pump Station design by the Contractor.
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PART 2 PRODUCTS
Not Used.
PART 3 EXECUTION
3.1 MODEL CONSTRUCTION
The scale of the physical model shall be determined by the firm performing the modeling but shall be in the range of 1/4 to 1/8 scale. Engineer shall approve request to change model scale.
The model will include a portion of the influent trough, the wet well, the inlet baffling, FSI's, and the five pumps. The small dewatering sump shall not be modeled since it may have an impact on the approach flow to the effluent pumps. The back wall of the wet well and portions of the side walls will be fabricated from acrylic plastic for viewing purposes. The pump FSI's will be modeled from acrylic plastic and pump columns will be acrylic tubing. Each modeled pump discharge line will be connected to the suction side of the laboratory pump, individually controlled, and the flow re-circulated back to the inlet.
The model will be constructed to the Hydraulic Institute 2012 Standards. All pumps will have pre-swirl meters and one of the pumps will have a velocity probe to evaluate the distribution of flow entering the pumps. Vortices will be assessed using dye to determine strength and susceptibility of the wet well to vortices. During design and construction of the model, care will be taken to ensure that the model will facilitate evaluation of design modifications as required. Flow will be circulated through the model using a laboratory pump.
3.2 MODEL TESTING
Model testing will be conducted in three phases and shall be completed before pump factory and witness testing is completed and wet well constructions begins.
a. Initial design testing shall be conducted to evaluate the performance of the pump station as designed. A minimum of 7 pump/water surface combinations shall be modeled of the initial design including the folllowing: Water surface elevation 876.00; Pump #1, Pump #2, Pump #3, Pump #4, Pump #5, and Pump #1 + Pump #2 + Pump #3. The remaining test combinations are to be determined based on the judgement of the testing lab. If any adverse hydraulic performance issues are identified, notify Engineer of the nature of the adverse hydraulic conditions. The testing lab shall recommend and test corrective measures to minimize the adverse hydraulic performance issues in the wet well.
b. Design development testing shall be conducted to correct any performance issues identified in the initial design testing. Possible modifications include the addition of flow straightening devices and modifying the distribution weir. The overall layout of the wet well shall not be modified.
c. Final design testing shall be conducted for the selected design over a full range of operating conditions. Nine (9) tests shall be completed for this phase of testing. The pump combinations and water surface combinatins shall be determined jointly between the Engineer and test laboratory.
SECTION 22 12 00 Page 3 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
3.2.1 Witness Testing
A witness test shall be held at the end of Design Development Testing to observe model operation with the iniital design and with the selected modifications. This testing shall be witnessed by two (2) of the Owner's Representative's Representatives. Transportation, lodging, meals and other miscellaneous cost to Witness the testing shall be paid for by the Pump Manufacturer. This meeting shall be a one day event at the lab. At the end of the testing, the preliminary design modifications will be provided.
3.2.2 Draft Report
Test laboratory will prepare a draft report for the physical model study. The report shall summarize the results, provide graphical and tabular data, pertinent photos (physical model), conceptual level drawings of any modifications, conclusions, and recommendations. An electronic copy (PDF format) shall be submitted for review.
3.2.3 Final Report
Upon receipt of comments, test laboratory shall address each comment and provide five (5) copies of the final report. The final report shall be submitted with the details of the physical model study including, results, graphical and tabular data, pertinent photos, conceptual drawings of any modifications, conclusions, and recommendations. Two copies of the unedited phycial model videos of the testing shall accompany the reports.
-- End of Section --
SECTION 22 12 00 Page 4 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 22 13 29
SUBMERSIBLE NON-CLOG PUMP 02/11 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)
ABMA 11 (1990; R 2008) Load Ratings and Fatigue Life for Roller Bearings
ABMA 9 (1990; ERTA 2012; S 2013) Load Ratings and Fatigue Life for Ball Bearings
ASME INTERNATIONAL (ASME)
ASME B40.100 (2013) Pressure Gauges and Gauge Attachments
HYDRAULIC INSTITUTE (HI)
HI 14.6 (2011) Rotodynamic Pumps for Hydraulic Performance Acceptance Tests
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA ICS 1 (2000; R 2008; E 2010) Standard for Industrial Control and Systems: General Requirements
NEMA MG 1 (2011; Errata 2012) Motors and Generators
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 10 (2010; Errata 2012) Standard for Portable Fire Extinguishers
NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013) National Electrical Code
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Equipment Installation
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SD-03 Product Data
Materials and Equipment Framed Instructions Spare Parts
SD-06 Test Reports
Factory Test Reports. Field Testing and Adjusting Equipment
SD-10 Operation and Maintenance Data
Operating and Maintenance Manuals
1.3 DELIVERY, STORAGE, AND HANDLING
Protect from the weather, excessive humidity and excessive temperature variation; and dirt, dust, or other contaminants all equipment delivered and placed in storage.
1.4 EXTRA MATERIALS
Submit spare parts data for each different item of material and equipment specified, after approval of the related submittals, and not later than 1 month after approval date of the related submittals. Include in the data a complete list of parts and supplies, with current unit prices and source of supply
PART 2 PRODUCTS
2.1 MATERIALS AND EQUIPMENT
Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of such products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Equipment shall be supported by a service organization that is, in the opinion of the Owner's Representative, reasonably convenient to the site. Pump casings shall be constructed of cast iron of uniform quality and free from blow holes, porosity, hard spots, shrinkage defects, cracks, and other injurious defects. Impellers shall be cast iron.
2.1.1 Nameplates
Provide each major item of equipment with the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment.
2.1.2 Equipment Guards
Enclose or guard belts, pulleys, chains, gears, projecting setscrews, keys, and other rotating parts so located that any person may come in close proximity thereto.
2.1.3 Special Tools
Provide one set of special tools, calibration devices, and instruments
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required for operation, calibration, and maintenance of the equipment.
2.1.4 Electric Motors
Motors shall conform to NEMA MG 1.
2.1.5 Motor Controls
Controls shall conform to NEMA ICS 1.
2.1.6 Bolts, Nuts, Anchors, and Washers
Bolts, nuts, anchors, and washers shall be stainless steel.
2.1.7 Pressure Gauges
Compound gauges shall be provided on the suction side of pumps and standard pressure gauges on the discharge side of pumps. Gauges shall comply with ASME B40.100. Gauge ranges shall be as appropriate for the particular installation.
2.2 SUBMERSIBLE CENTRIFUGAL PUMPS
Submersible centrifugal pumps shall be centrifugal type pumps designed to pump solids up to 3 inches in diameter and shall be capable of withstanding submergence as required for the particular installation.
2.2.1 Pump Characteristics
Pump number P-6 located in the Underpass Wetwell shall have the following operating characteristics:
Pump Service Stormwater
Design Operating Point 6,000 gpm flow, 33.9 feet head, 81 percent efficiency
Minimum Operating Point 8300 gpm flow, 23.0 feet head, 72 percent efficiency
Impeller Type Non-Clog
Operating Speed Maximum 705 rpm
Depth of Submergence 3 feet
Motor Type Submersible
Electrical Characteristics 480 volts ac, 3 phase, 60 Hz
Size Within rated load driving pump at specified rpm
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Pump Control Constant Speed
Pump number P-7 located in the main wet well shall have the following operating characteristics:
Pump Service Stormwater
Design Operating Point 200 gpm flow, 27.7 feet head, 50% efficiency
Impeller Type Non-Clog
Operating Speed 1800 rpm
Motor Type Submersible
Electrical Characteristics 480 volts ac, 3 phase, 60 Hz
Size Within rated load driving pump at spefificed rpm
Pump Control Constant Speed
2.2.2 Pump Casing
The casing shall be capable of withstanding operating pressures 50 percent greater than the maximum operating pressures. The volute shall have smooth passages which provide unobstructed flow through the pump.
2.2.3 Mating Surfaces
Mating surfaces where watertight seal is required, including seal between discharge connection elbow and pump, shall be machined and fitted with nitrile rubber O-rings. Fitting shall be such that sealing is accomplished by metal-to-metal contact between mating surfaces, resulting in proper compression of the O-rings without the requirement of specific torque limits.
2.2.4 Coatings
See Specification Section 09 90 00, PAINTS AND COATINGS. Protect all metallic surfaces coming in contact with stormwater except stainless steel and bronze.
2.2.5 Impeller
The impeller shall be of the shrouded non-clogging design to minimize clogging of solids, fibrous materials, heavy sludge, or other materials found in sewage. The impeller shall be statically, dynamically, and hydraulically balanced within the operating range and to the first critical speed at 150 percent of the maximum operating speed. The impeller shall be securely keyed to the shaft with a locking arrangement whereby the impeller cannot be loosened by torque from either forward or reverse direction.
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2.2.6 Wearing Rings
Wearing rings, when required, shall be renewable type and shall be provided on the impeller and casing and shall have wearing surfaces normal to the axis of rotation. Material for wear rings shall be standard of pump manufacturer. Wearing rings shall be designed for ease of maintenance and shall be adequately secured to prevent rotation.
2.2.7 Pump Shaft
The pump shaft shall be of stainless steel and shall be of adequate size and strength to transmit the full driver horsepower with a liberal safety factor.
2.2.8 Seals
A tandem mechanical shaft seal system running in an oil bath shall be provided. Seals shall be of tungsten carbide with each interface held in contact by its own spring system. Conventional mechanical seals which require a constant pressure differential to effect sealing will not be allowed.
2.2.9 Bearings
Pump bearings shall be ball or roller type designed to handle all thrust loads in either direction. Pumps depending only on hydraulic balance end thrust will not be acceptable. Bearings shall have an ABEMA L-10 life of 50,000 hours minimum, as specified in ABMA 9 or ABMA 11.
2.2.10 Motor
The pump motor shall have Class F insulation, NEMA B design, in accordance with NEMA MG 1, and shall be watertight. The motor shall be either oil filled, air filled with a water jacket, or air filled with cooling fins which encircles the stator housing.
2.2.11 Temperature Monitor
Furnish each phase of the motor with a temperature monitor embedded in the motor windings. Arrange controls so as to shut the pump down and sound alarm should any one of the monitors detect high temperature and automatically reset once the stator temperature returns to normal. Set temperature of the temperature monitors at not higher than 90 percent of insulation temperature rating.
2.2.12 Leak Sensor
Provide electrical probe as needed for detecting the presence of water in the seal chamber and motor housing. If water enters, the probe shall energize electrical circuit to shut down pump and sound alarm circuit for external alarm.
2.2.13 Pump Protection/Monitoring Module
Provide protective relays to simultaneously monitor pump thermal switches and leak detectors. Thermal switches and leak sensor shall be connected to a control and status monitoring module as provided by pump manufacturer. Mount pump protection/monitoring module in pump control panel.
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2.2.14 Power Cable
The power cable shall comply with NFPA 70, Type SO, and shall be of standard construction for submersible pump applications. The power cable shall enter the pump through a heavy duty entry assembly provided with an internal grommet assembly to prevent leakage. The cable entry junction chamber and motor shall be separated by a stator lead sealing gland or terminal board which shall isolate the motor interior from foreign material gaining access through the pump top. Provide 50 feet of power and control cable. Provide each cable with strain relief, cor grip, and explosion proof seal installed in acordance with NFPA 10, Article 500.
2.2.15 Installation Systems
2.2.15.1 Rail Mounted Systems
Rail mounted installation systems shall consist of guide rails, a sliding bracket, and a discharge connection elbow. Guide rails shall be of stainless steel and the size standard with the manufacturer and shall not support any portion of the weight of the pump. The sliding guide bracket shall be an integral part of the pump unit. The discharge connection elbow shall be permanently installed in the wet well along with the discharge piping. The pump shall be automatically connected to the discharge connection elbow when lowered into place and shall be easily removed for inspection and service without entering the pump well.
2.2.15.2 Lifting Chain
Lifting chain to raise and lower the pump through the limits indicated shall be provided. The chain shall be stainless steel and shall be capable of supporting the pump.
2.2.16 Factory Tests
Performance of the pump to be furnished will be accepted on the basis of the factory tests. All pumps for this project shall be tested prior to the shipment. Pump tests shall be continuous between test points (no shutting off the pump). Conduct factory tests in accordance with HI Standards. At the design conditions; performance tolerance meeting Grade 1U per HI 14.6 shall apply. Hydrostatic test at 150% of shut-off head for a minimum of 5 minutes. Provide tests results certified by a Registerd Professional Engineer for Heat (FT) versus flow (gpm) pump curves with efficiencies and horsepower along each curve.
2.3 ELECTRICAL WORK
Provide electrical motor driven equipment specified complete with motors, motor starters, controls and wiring in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Electrical characteristics shall be as specified or indicated. Motor starters shall be provided complete with thermal overload protection and other appurtenances necessary for the motor control specified. Manual or automatic control and protective or signal devices required for the operation specified, and any control wiring required for controls and devices but not shown, shall be provided.
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PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Owner's Representative of any discrepancy before performing the work.
3.2 EQUIPMENT INSTALLATION
Submit Drawings containing complete wiring and schematic diagrams and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Show on the Drawings proposed layout and anchorage of equipment and appurtenances, and equipment relationship to other parts of the work including clearances for maintenance and operation.
3.2.1 Pump Installation
Install pumping equipment and appurtenances in the position indicated and in accordance with the manufacturer's written instructions. Provide all appurtenances required for a complete and operating pumping system, including such items as piping, conduit, valves, wall sleeves, wall pipes, concrete foundations, anchors, grouting, pumps, drivers, power supply, seal water units, and controls.
3.2.2 Concrete
Concrete shall conform to Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.
3.3 PAINTING
Pumps and motors shall be thoroughly cleaned, primed, and given two finish coats of paint at the factory in accordance with the recommendations of the manufacturer. Field painting required for ferrous surfaces not finished at the factory is specified in Section 09 90 00 PAINTS AND COATINGS.
3.4 FRAMED INSTRUCTIONS
Post, where directed, framed instructions containing wiring and control diagrams under glass or in laminated plastic. Condensed operating instructions, prepared in typed form, shall be framed as specified above and posted beside the diagrams. Post the framed instructions before acceptance testing of the system. Submit pump characteristic curves showing capacity in gpm, net positive suction head (NPSH), head, efficiency, and pumping horsepower from 0 gpm to 110 percent (100 percent for positive displacement pumps) of design capacity. Submit a complete list of equipment and material, including manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions. Diagrams, instructions, and other sheets proposed for posting.
3.5 FIELD TESTING AND ADJUSTING EQUIPMENT
3.5.1 Operational Test
Prior to acceptance, an operational test of all pumps, drivers, and control systems shall be performed to determine if the installed equipment meets the purpose and intent of the specifications. Tests shall demonstrate that the equipment is not electrically, mechanically, structurally, or otherwise
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defective; is in safe and satisfactory operating condition; and conforms with the specified operating characteristics. Prior to applying electrical power to any motor driven equipment, the drive train shall be rotated by hand to demonstrate free operation of all mechanical parts. Tests shall include checks for excessive vibration, leaks in all piping and seals, correct operation of control systems and equipment, proper alignment, excessive noise levels, and power consumption.
3.5.2 Retesting
If any deficiencies are revealed during any test, such deficiencies shall be corrected and the tests shall be reconducted at no cost to Onwer.
3.5.3 Performance Test Reports
Submit performance test reports in booklet form showing all field tests performed to adjust each component and all field tests performed to prove compliance with the specified performance criteria, upon completion and testing of the installed system. In each test report indicate the final position of controls.
3.6 MANUFACTURER'S SERVICES
Provide the services of a manufacturer's representative who is experienced in the installation, adjustment, and operation of the equipment specified. The representative shall supervise the installation, adjustment, and testing of the equipment.
3.7 FIELD TRAINING
Provide a field training course for designated operating and maintenance staff members. Training shall be provided for a total period of 1 hour of normal working time and shall start after the system is functionally complete but prior to final acceptance tests. Field training shall cover all of the items contained in the operating and maintenance manuals. Submit six copies of operation and six copies of maintenance manuals for the equipment furnished. One complete set prior to performance testing and the remainder upon acceptance. Operation manuals shall detail the step-by-step procedures required for system startup, operation, and shutdown. Include in the operation manuals the manufacturer's name, model number, parts list, and brief description of all equipment and their basic operating features. List in the maintenance manuals routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. Maintenance manuals shall include piping and equipment layout and simplified wiring and control diagrams of the system as installed. Manuals shall be approved prior to the field training course.
-- End of Section --
SECTION 22 13 29 Page 8 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 23 HEATING, VENTILATING, AND AIR- CONDITIONING (HVAC)
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 23 00 00
AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS 08/10 08/21/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)
AMCA 201 (2002; R 2011) Fans and Systems
AMCA 210 (2007) Laboratory Methods of Testing Fans for Aerodynamic Performance Rating
AMCA 300 (2008) Reverberant Room Method for Sound Testing of Fans
AMCA 301 (1990; INT 2007) Methods for Calculating Fan Sound Ratings from Laboratory Test Data
AMCA 500-D (2012) Laboratory Methods of Testing Dampers for Rating
AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI)
AHRI Guideline D (1996) Application and Installation of Central Station Air-Handling Units
AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)
ABMA 11 (1990; R 2008) Load Ratings and Fatigue Life for Roller Bearings
ABMA 9 (1990; R 2008) Load Ratings and Fatigue Life for Ball Bearings
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)
ASHRAE 62.1 (2013) Ventilation for Acceptable Indoor Air Quality
ASHRAE 90.1 - IP (2010; INT 1 2010; Errata 1-2 2010) Energy Standard for Buildings Except Low-Rise Residential Buildings
ASME INTERNATIONAL (ASME)
ASME A13.1 (2007; R 2013) Scheme for the Identification of Piping Systems
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ASTM INTERNATIONAL (ASTM)
ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A924/A924M (2013) Standard Specification for General Requirements for Steel Sheet, Metallic-Coated by the Hot-Dip Process
ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM B766 (1986; R 2008) Standard Specification for Electrodeposited Coatings of Cadmium
ASTM C553 (2011) Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications
ASTM D1654 (2008) Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments
ASTM D3359 (2009; E 2010; R 2010) Measuring Adhesion by Tape Test
ASTM D520 (2000; R 2011) Zinc Dust Pigment
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA MG 1 (2011; Errata 2012) Motors and Generators
NEMA MG 10 (2001; R 2007) Energy Management Guide for Selection and Use of Fixed Frequency Medium AC Squirrel-Cage Polyphase Induction Motors
NEMA MG 11 (1977; R 2012) Energy Management Guide for Selection and Use of Single Phase Motors
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 701 (2010) Standard Methods of Fire Tests for Flame Propagation of Textiles and Films
NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems
SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)
SMACNA 1966 (2005) HVAC Duct Construction Standards Metal and Flexible, 3rd Edition
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SMACNA 1972 CD (2012) HVAC Air Duct Leakage Test Manual - 2nd Edition
SMACNA 1981 (2008) Seismic Restraint Manual Guidelines for Mechanical Systems, 3rd Edition
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
40 CFR 82 Protection of Stratospheric Ozone
UNDERWRITERS LABORATORIES (UL)
UL 181 (2013) Factory-Made Air Ducts and Air Connectors
UL 6 (2007; reprint Nov 2010) Electrical Rigid Metal Conduit-Steel
UL 705 (2004; Reprint Mar 2012) Standard for Power Ventilators
UL Bld Mat Dir (2012) Building Materials Directory
1.2 SYSTEM DESCRIPTION
Furnish ductwork, piping offsets, fittings, and accessories as required to provide a complete installation. Coordinate the work of the different trades to avoid interference between piping, equipment, structural, and electrical work. Provide complete, in place, all necessary offsets in piping and ductwork, and all fittings, and other components, required to install the work as indicated and specified.
1.2.1 Mechanical Equipment Identification
The number of charts and diagrams shall be equal to or greater than the number of mechanical equipment rooms. Where more than one chart or diagram per space is required, mount these in edge pivoted, swinging leaf, extruded aluminum frame holders which open to 170 degrees.
1.2.1.1 Charts
Provide chart listing of equipment by designation numbers and capacities such as flow rates, pressure and temperature differences, heating and cooling capacities, horsepower, pipe sizes, and voltage and current characteristics.
1.2.2 Service Labeling
Label equipment, including fans, air handlers, terminal units, etc. with labels made of self-sticking, plastic film designed for permanent installation. Labels shall be in accordance with the typical examples below:
SERVICE LABEL AND TAG DESIGNATION
Motorized Damper MOD - XX
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SERVICE LABEL AND TAG DESIGNATION
Control and instrument air CONTROL AND INSTR.
Exhaust Fan Number EF - XX
Louver LVR - XX
Fan Coil Unit Number FC - XX
Heat Pump Unit HP
Unit Heater UH
Identify similar services with different temperatures or pressures. Where pressures could exceed 125 pounds per square inch, gage, include the maximum system pressure in the label. Label and arrow piping in accordance with the following:
a. Each point of entry and exit of pipe passing through walls.
b. Each change in direction, i.e., elbows, tees.
c. In congested or hidden areas and at all access panels at each point required to clarify service or indicated hazard.
d. In long straight runs, locate labels at distances within eyesight of each other not to exceed 75 feet. All labels shall be visible and legible from the primary service and operating area.
For Bare or Insulated Pipes
for Outside Diameters of Lettering
1/2 thru 1-3/8 inch 1/2 inch
1-1/2 thru 2-3/8 inch 3/4 inch
2-1/2 inch and larger 1-1/4 inch
1.2.3 Color Coding
Color coding of all piping systems shall be in accordance with ASME A13.1.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings; G
SD-03 Product Data
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Metallic Flexible Duct Duct Connectors Duct Access Doors; G Louvers Centrifugal Fans Room Fan-Coil Units; G Test Procedures Diagrams; G
SD-06 Test Reports
Performance Tests; G Damper Acceptance Test; G
SD-07 Certificates
Bolts Certification
SD-08 Manufacturer's Instructions
Manufacturer's Installation Instructions Operation and Maintenance Training
SD-10 Operation and Maintenance Data
Operation and Maintenance Manuals; G Centrifugal Fans; G Room Fan-Coil Units; G
1.4 QUALITY ASSURANCE
Except as otherwise specified, approval of materials and equipment is based on manufacturer's published data.
a. Where materials and equipment are specified to conform to the standards of the Underwriters Laboratories, the label of or listing with reexamination in UL Bld Mat Dir, and UL 6 is acceptable as sufficient evidence that the items conform to Underwriters Laboratories requirements. In lieu of such label or listing, submit a written certificate from any nationally recognized testing agency, adequately equipped and competent to perform such services, stating that the items have been tested and that the units conform to the specified requirements. Outline methods of testing used by the specified agencies.
b. Where materials or equipment are specified to be constructed or tested, or both, in accordance with the standards of the ASTM International (ASTM), the ASME International (ASME), or other standards, a manufacturer's certificate of compliance of each item is acceptable as proof of compliance.
c. Conformance to such agency requirements does not relieve the item from compliance with other requirements of these specifications.
1.4.1 Prevention of Corrosion
Protect metallic materials against corrosion. Manufacturer shall provide rust-inhibiting treatment and standard finish for the equipment
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enclosures. Do not use aluminum in contact with earth, and where connected to dissimilar metal. Protect aluminum by approved fittings, barrier material, or treatment. Ferrous parts such as anchors, bolts, braces, boxes, bodies, clamps, fittings, guards, nuts, pins, rods, shims, thimbles, washers, and miscellaneous parts not of corrosion-resistant steel or nonferrous materials shall be hot-dip galvanized in accordance with ASTM A123/A123M for exterior locations and cadmium-plated in conformance with ASTM B766 for interior locations.
1.4.2 Asbestos Prohibition
Do not use asbestos and asbestos-containing products.
1.4.3 Ozone Depleting Substances Used as Refrigerants
Minimize releases of Ozone Depleting Substances (ODS) during repair, maintenance, servicing or disposal of appliances containing ODS's by complying with all applicable sections of 40 CFR 82 Part 82 Subpart F. Any person conducting repair, maintenance, servicing or disposal of appliances owned by NASA shall comply with the following:
a. Do not knowingly vent or otherwise release into the environment, Class I or Class II substances used as a refrigerant.
b. Do not open appliances without meeting the requirements of 40 CFR 82 Part 82.156 Subpart F, regarding required practices for evacuation and collection of refrigerant, and 40 CFR 82 Part 82.158 Subpart F, regarding standards of recycling and recovery equipment.
c. Only persons who comply with 40 CFR 82 Part 82.161 Subpart F, regarding technician certification, can conduct work on appliances containing refrigerant.
In addition, provide copies of all applicable certifications to the Owner's Representative at least 14 calendar days prior to initiating maintenance, repair, servicing, dismantling or disposal of appliances, including:
a. Proof of Technician Certification
b. Proof of Equipment Certification for recovery or recycling equipment.
c. Proof of availability of certified recovery or recycling equipment.
1.4.4 Test Procedures
Submit proposed test procedures and test schedules for the performance tests of systems, at least 2 weeks prior to the start of related testing.
1.5 DELIVERY, STORAGE, AND HANDLING
Protect stored equipment at the jobsite from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Additionally, cap or plug all pipes until installed.
PART 2 PRODUCTS
2.1 STANDARD PRODUCTS
Provide components and equipment that are "standard products" of a
SECTION 23 00 00 Page 6 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
manufacturer regularly engaged in the manufacturing of products that are of a similar material, design and workmanship. "Standard products" is defined as being in satisfactory commercial or industrial use for 2 years before bid opening, including applications of components and equipment under similar circumstances and of similar size, satisfactorily completed by a product that is sold on the commercial market through advertisements, manufacturers' catalogs, or brochures. Products having less than a 2-year field service record are acceptable if a certified record of satisfactory field operation, for not less than 6000 hours exclusive of the manufacturer's factory tests, can be shown. Provide equipment items that are supported by a service organization. Where applicable, provide equipment that is an ENERGY STAR Qualified product or a Federal Energy Management Program (FEMP) designated product.
2.2 IDENTIFICATION PLATES
In addition to standard manufacturer's identification plates, provide engraved laminated phenolic identification plates for each piece of mechanical equipment. Identification plates are to designate the function of the equipment. Submit designation with the shop drawings. Identification plates shall be three layers, black-white-black, engraved to show white letters on black background. Letters shall be upper case. Identification plates 1-1/2-inches high and smaller shall be 1/16-inch thick, with engraved lettering 1/8-inch high; identification plates larger than 1-1/2-inches high shall be 1/8-inch thick, with engraved lettering of suitable height. Identification plates 1-1/2-inches high and larger shall have beveled edges. Install identification plates using a compatible adhesive.
2.3 EQUIPMENT GUARDS AND ACCESS
Fully enclose or guard belts, pulleys, chains, gears, couplings, projecting setscrews, keys, and other rotating parts exposed to personnel contact according to OSHA requirements. Properly guard or cover with insulation of a type specified, high temperature equipment and piping exposed to contact by personnel or where it creates a potential fire hazard. The requirements for ladders and guardrails are specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.
2.4 ELECTRICAL WORK
a. Provide motors, controllers, integral disconnects, contactors, and controls with their respective pieces of equipment, except controllers indicated as part of motor control centers. Provide electrical equipment, including motors and wiring, as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Provide manual or automatic control and protective or signal devices required for the operation specified and control wiring required for controls and devices specified, but not shown. For packaged equipment, include manufacturer provided controllers with the required monitors and timed restart.
b. For single-phase motors, provide high-efficiency type, fractional-horsepower alternating-current motors, including motors that are part of a system, in accordance with NEMA MG 11. Integral size motors shall be the premium efficiency type in accordance with NEMA MG 1.
c. For polyphase motors, provide squirrel-cage medium induction motors, including motors that are part of a system , and that meet the efficiency ratings for premium efficiency motors in accordance with
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NEMA MG 1. Select premium efficiency polyphase motors in accordance with NEMA MG 10.
d. Provide motors in accordance with NEMA MG 1 and of sufficient size to drive the load at the specified capacity without exceeding the nameplate rating of the motor. Provide motors rated for continuous duty with the enclosure specified. Provide motor duty that allows for maximum frequency start-stop operation and minimum encountered interval between start and stop. Provide motor torque capable of accelerating the connected load within 20 seconds with 80 percent of the rated voltage maintained at motor terminals during one starting period. Provide motor starters complete with thermal overload protection and other necessary appurtenances. Fit motor bearings with grease supply fittings and grease relief to outside of the enclosure.
e. Where two-speed or variable-speed motors are indicated, solid-state variable-speed controllers are allowed to accomplish the same function. Use solid-state variable-speed controllers for motors rated 10 hp or less and adjustable frequency drives for larger motors.
2.5 ANCHOR BOLTS
Provide anchor bolts for equipment placed on concrete equipment pads or on concrete slabs. Bolts to be of the size and number recommended by the equipment manufacturer and located by means of suitable templates. Installation of anchor bolts shall not degrade the surrounding concrete.
2.6 SEISMIC ANCHORAGE
Anchor equipment in accordance with applicable seismic criteria for the area and as defined in SMACNA 1981
2.7 PAINTING
Paint equipment units in accordance with approved equipment manufacturer's standards unless specified otherwise. Field retouch only if approved. Otherwise, return equipment to the factory for refinishing.
2.8 INDOOR AIR QUALITY
Provide equipment and components that comply with the requirements of ASHRAE 62.1 unless more stringent requirements are specified herein.
2.9 DUCT SYSTEMS
2.9.1 Metal Ductwork
Provide metal ductwork construction, including all fittings and components, that complies with SMACNA 1966, as supplemented and modified by this specification .
a. Provide radius type elbows with a centerline radius of 1.5 times the width or diameter of the duct where space permits. Otherwise, elbows having a minimum radius equal to the width or diameter of the duct or square elbows with factory fabricated turning vanes are allowed.
b. Provide ductwork that meets the requirements of Seal Class A.
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2.9.1.1 Metallic Flexible Duct
a. Provide duct that conforms to UL 181 and NFPA 90A with factory-applied insulation, vapor barrier, and end connections. Provide duct assembly that does not exceed 25 for flame spread and 50 for smoke developed. Provide ducts designed for working pressures of 2 inches water gauge positive and 1.5 inches water gauge negative. Provide flexible round duct length that does not exceed 5 feet. Secure connections by applying adhesive for 2 inches over rigid duct, apply flexible duct 2 inches over rigid duct, apply metal clamp, and provide minimum of three No. 8 sheet metal screws through clamp and rigid duct.
b. Inner duct core: Provide interlocking spiral or helically corrugated flexible core constructed of zinc-coated steel, aluminum, or stainless steel; or constructed of inner liner of continuous galvanized spring steel wire helix fused to continuous, fire-retardant, flexible vapor barrier film, inner duct core.
c. Insulation: Provide inner duct core that is insulated with mineral fiber blanket type flexible insulation, minimum of 1 inch thick. Provide insulation covered on exterior with manufacturer's standard fire retardant vapor barrier jacket for flexible round duct.
2.9.1.2 General Service Duct Connectors
Provide a flexible duct connector approximately 6 inches in width where sheet metal connections are made to fans or where ducts of dissimilar metals are connected. For round/oval ducts, secure the flexible material by stainless steel or zinc-coated, iron clinch-type draw bands. For rectangular ducts, install the flexible material locked to metal collars using normal duct construction methods. Provide a composite connector system that complies with NFPA 701 and is classified as "flame-retardent fabrics" in UL Bld Mat Dir.
2.9.1.3 High Temperature Service Duct Connections
Provide material that is approximately 3/32 inch thick, 35 to 40-ounce per square yard weight, plain weave fibrous glass cloth with, nickel/chrome wire reinforcement for service in excess of 1200 degrees F.
2.9.1.4 Aluminum Ducts
ASTM B209, alloy 3003-H14 for aluminum sheet and alloy 6061-T6 or equivalent strength for aluminum connectors and bar stock.
2.9.2 Duct Access Doors
Provide hinged access doors conforming to SMACNA 1966 in ductwork and plenums where indicated and at all air flow measuring primaries, automatic dampers, thermostats, and other apparatus requiring service and inspection in the duct system. Provide access doors upstream and downstream of air flow measuring primaries. Provide doors that are a minimum 15 by 18 inches, unless otherwise shown. Where duct size does not accommodate this size door, make the doors as large as practicable. Equip doors 24 by 24 inches or larger with fasteners operable from inside and outside the duct. Use insulated type doors in insulated ducts.
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2.9.3 Air Supply And Exhaust Air Dampers
Where outdoor air supply and exhaust air dampers are required they shall have a maximum leakage rate when tested in accordance with AMCA 500-D as required by ASHRAE 90.1 - IP, including maximum Damper Leakage for:
a. Climate Zones 1,2,6,7,8 the maximum damper leakage at 1.0 inch w.g. for motorized dampers is 4 cfm per square foot of damper area and non-motorized dampers are not allowed.
Dampers smaller than 24 inches in either direction may have leakage of 40 cfm per square foot.
2.9.4 Plenums and Casings for Field-Fabricated Units
2.9.4.1 Access Doors
Provide access doors in each section of the casing. Weld doorframes in place, gasket each door with neoprene, hinge with minimum of two brass hinges, and fasten with a minimum of two brass tension fasteners operable from inside and outside of the casing. Where possible, make doors 36 by 18 inches and locate them 18 inches above the floor. Where the space available does not accommodate doors of this size, use doors as large as the space accommodates. Swing doors so that fan suction or pressure holds doors in closed position, airtight. Provide a push-button station, located inside the casing, to stop the supply.
2.9.4.2 Duct Liner
Unless otherwise specified, duct liner is not permitted.
2.9.5 Louvers
Provide louvers for installation in exterior walls that are associated with the air supply and distribution system as specified in Section 07 60 00 FLASHING AND SHEET METAL and Section 08 91 00 METAL WALL LOUVERS.
2.10 AIR SYSTEMS EQUIPMENT
2.10.1 Fans
Test and rate fans according to AMCA 210. Calculate system effect on air moving devices in accordance with AMCA 201 where installed ductwork differs from that indicated on drawings. Install air moving devices to minimize fan system effect. Where system effect is unavoidable, determine the most effective way to accommodate the inefficiencies caused by system effect on the installed air moving device. The sound power level of the fans shall not exceed 85 dBA when tested according to AMCA 300 and rated in accordance with AMCA 301. Provide all fans with an AMCA seal. Connect fans to the motors either directly or indirectly with V-belt drive. Use V-belt drives designed for not less than 150 percent of the connected driving capacity. Provide variable pitch motor sheaves for 15 hp and below, and fixed pitch as defined by AHRI Guideline D (A fixed-pitch sheave is provided on both the fan shaft and the motor shaft. This is a non-adjustable speed drive.). Select variable pitch sheaves to drive the fan at a speed which can produce the specified capacity when set at the approximate midpoint of the sheave adjustment. When fixed pitch sheaves are furnished, provide a replaceable sheave when needed to achieve system air balance. Provide motors for V-belt drives with adjustable rails or bases. Provide removable metal
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guards for all exposed V-belt drives, and provide speed-test openings at the center of all rotating shafts. Provide fans with personnel screens or guards on both suction and supply ends, except that the screens need not be provided, unless otherwise indicated, where ducts are connected to the fan. Provide fan and motor assemblies with vibration-isolation supports or mountings as indicated. Use vibration-isolation units that are standard products with published loading ratings. Select each fan to produce the capacity required at the fan static pressure indicated. Provide sound power level as indicated. Obtain the sound power level values according to AMCA 300. Provide standard AMCA arrangement, rotation, and discharge as indicated. Provide power ventilators that conform to UL 705 and have a UL label.
2.10.1.1 Centrifugal Fans
Provide fully enclosed, single-width single-inlet, or double-width double-inlet centrifugal fans, with AMCA Pressure Class I, II, or III as required or indicated for the design system pressure. Provide impeller wheels that are rigidly constructed and accurately balanced both statically and dynamically. Provide forward curved or backward-inclined airfoil design fan blades in wheel sizes up to 30 inches. Provide backward-inclined airfoil design fan blades for wheels over 30 inches in diameter. Provide fan wheels over 36 inches in diameter with overhung pulleys and a bearing on each side of the wheel. Provide fan wheels 36 inches or less in diameter that have one or more extra long bearings between the fan wheel and the drive. Provide sleeve type, self-aligning and self-oiling bearings with oil reservoirs, or precision self-aligning roller or ball-type with accessible grease fittings or permanently lubricated type. Connect grease fittings to tubing for serviceability from a single accessible point. Provide L50 rated bearing life at not less than 200,000 hours as defined by ABMA 9 and ABMA 11. Provide steel, accurately finished fan shafts, with key seats and keys for impeller hubs and fan pulleys. Provide fan outlets of ample proportions, designed for the attachment of angles and bolts for attaching flexible connections. Unless otherwise indicated, provide motors that do not exceed 1800 rpm and have totally enclosed enclosures. Provide manual type motor starters with watertight enclosure.
2.10.2 UNITARY SPLIT SYSTEM HEAT PUMP
A. Outdoor Unit: 1) Casing and frame: a) Material: Heavy gage galvanized steel. b) Insulation: 1 IN thick neoprene-coated glass fiber. c) Installation: Base equipped with lifting brackets with lifting holes. d) Removable end panel for access to components and connections. 2) Compressors: a) Heavy duty, reciprocating, semi-hermetic type. b) Positive displacement oil pump. c) Suction and discharge service valves. d) Crankcase heater. e) Thermal overload protection. 3) Refrigeration circuit: a) Sight glass. b) Filter dryer. c) Manual shut-off valve. d) High pressure relief valve. 4) Compressor isolators.
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5) Condenser coils: a) Nominal 3/8 IN OD seamless copper mechanically bonded to corrugated aluminum fins. b) Factory leak tested at 315 psig under water. 6) Condenser fans: a) Direct drive. b) Propeller type. 7) Condenser fan motors: a) Heavy duty, inherently protected, non-reversing. b) Permanently lubricated bearings. c) Integral rain shield. 8) Defrost control: Defrost cycles at a preselected time interval when the outdoor coil is below a preset initiation temperature. 9) Expansion valve: Designed and sized specifically for heat pump service. 10) Reversing valve: Four-way interchange reversing valve, operates on pressure differential between the outdoor unit and indoor unit. B. Indoor unit: 1) Materials: a) Casing: Heavy gage steel. b) Framework: Steel angle. c) Pan insulation: Foam-in-place insulation. d) Casing insulation: 1 IN, 3/4 LB fiberglass blanket. 2) Casing: a) Removable access panels. b) Insulated weatherproof casing. 3) Evaporated fans: a) Double-width, double-inlet centrifugal type. b) Forward curved or airfoil. c) Solid steel shafts. d) 200,000 HR relubricative ball-bearings. 4) Fan motors: a) Relubricative ball-bearings. b) Variable pitch sheave. 5) Isolated fan assembly. 6) Filter section: a) 4 10.6"x8.75" honeycomb polypropylene filters. b) Access doors for filter removal. 7) Evaporator coil circuiting: a) Adjustable thermal expansion valve per circuit with external equalizer. b) Combination row/split face circuiting. 8) Drain pan: a) Mastic-coated. b) Threaded drain connections. 9) Electric heating coil: a) Built-in static-pressure airflow switch. b) ARI certified. c) 80-percent nickel, 20-percent chromium elements. d) Built-in thermal protection. e) Airflow switch. f) Built-in circuit fusing. g) Control voltage transformer. h) Terminal block. i) Magnetic contactor. j) Fused disconnect switch. k) Step controller as required by instrumentation. l) Single point electrical connection. m) Size and capacity as scheduled on Drawings.
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2.11 FACTORY PAINTING
Factory paint new equipment, which are not of galvanized construction. Paint with a corrosion resisting paint finish according to ASTM A123/A123M or ASTM A924/A924M. Clean, phosphatize and coat internal and external ferrous metal surfaces with a paint finish which has been tested according to ASTM B117, ASTM D1654, and ASTM D3359. Submit evidence of satisfactory paint performance for a minimum of 125 hours for units to be installed indoors and 500 hours for units to be installed outdoors. Provide rating of failure at the scribe mark that is not less than 6, average creepage not greater than 1/8 inch. Provide rating of the inscribed area that is not less than 10, no failure. On units constructed of galvanized steel that have been welded, provide a final shop docket of zinc-rich protective paint on exterior surfaces of welds or welds that have burned through from the interior according to ASTM D520 Type I.
Factory painting that has been damaged prior to acceptance by the Owner's Representative shall be field painted in compliance with the requirements of paragraph FIELD PAINTING OF MECHANICAL EQUIPMENT.
2.12 SUPPLEMENTAL COMPONENTS/SERVICES
2.12.1 Refrigerant Piping
The requirements for refrigerant piping are specified in Section 23 23 00 REFRIGERANT PIPING.
2.12.2 Condensate Drain Lines
Provide and install condensate drainage for each item of equipment that generates condensate in accordance with Section 22 00 00 PLUMBING, GENERAL PURPOSEexcept as modified herein.
2.12.3 Controls
The requirements for controls are specified in Section 23 05 93 TESTING, ADJUSTING, AND BALANCING OF HVAC SYSTEMS.
PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Owner's Representative of any discrepancy before performing the work.
3.2 INSTALLATION
a. Install materials and equipment in accordance with the requirements of the contract drawings and approved manufacturer's installation instructions. Accomplish installation by workers skilled in this type of work. Perform installation so that there is no degradation of the designed fire ratings of walls, partitions, ceilings, and floors.
b. No installation is permitted to block or otherwise impede access to any existing machine or system. Install all hinged doors to swing open a minimum of 120 degrees. Provide an area in front of all access doors that clears a minimum of 3 feet. In front of all access doors to
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electrical circuits, clear the area the minimum distance to energized circuits as specified in OSHA Standards, part 1910.333 (Electrical-Safety Related work practices)and an additional 3 feet.
c. Except as otherwise indicated, install emergency switches and alarms in conspicuous locations. Mount all indicators, to include gauges, meters, and alarms in order to be easily visible by people in the area.
3.2.1 Condensate Drain Lines
Provide water seals in the condensate drain from all fan-coil units. Provide a depth of each seal of 2 inches plus the number of inches, measured in water gauge, of the total static pressure rating of the unit to which the drain is connected. Provide water seals that are constructed of 2 tees and an appropriate U-bend with the open end of each tee plugged. Provide pipe cap or plug cleanouts where indicated. Connect drains indicated to connect to the sanitary waste system using an indirect waste fitting. Insulate air conditioner drain lines as specified in Section 23 23 00 REFRIGERANT PIPING.
3.2.2 Equipment and Installation
Provide frames and supports for tanks, compressors, pumps, valves, air handling units, fans, coils, dampers, and other similar items requiring supports. Floor mount or ceiling hang air handling units as indicated. Anchor and fasten as detailed. Set floor-mounted equipment on not less than 6 inch concrete pads or curbs doweled in place unless otherwise indicated. Make concrete foundations heavy enough to minimize the intensity of the vibrations transmitted to the piping, duct work and the surrounding structure, as recommended in writing by the equipment manufacturer. In lieu of a concrete pad foundation, build a concrete pedestal block with isolators placed between the pedestal block and the floor. Make the concrete foundation or concrete pedestal block a mass not less than three times the weight of the components to be supported. Provide the lines connected to the pump mounted on pedestal blocks with flexible connectors. Submit foundation drawings as specified in paragraph DETAIL DRAWINGS. Provide concrete for foundations as specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.
3.2.3 Access Panels
Install access panels for concealed valves, vents, controls, dampers, and items requiring inspection or maintenance of sufficient size, and locate them so that the concealed items are easily serviced and maintained or completely removed and replaced. Provide access panels as specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.
3.2.4 Flexible Duct
Install pre-insulated flexible duct in accordance with the latest printed instructions of the manufacturer to ensure a vapor tight joint. Provide hangers, when required to suspend the duct, of the type recommended by the duct manufacturer and set at the intervals recommended.
3.2.5 Metal Ductwork
Install according to SMACNA 1966 unless otherwise indicated. Install duct supports for sheet metal ductwork according to SMACNA 1966, unless otherwise specified. Do not use friction beam clamps indicated in
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SMACNA 1966. Anchor risers on high velocity ducts in the center of the vertical run to allow ends of riser to move due to thermal expansion. Erect supports on the risers that allow free vertical movement of the duct. Attach supports only to structural framing members and concrete slabs. Do not anchor supports to metal decking unless a means is provided and approved for preventing the anchor from puncturing the metal decking. Where supports are required between structural framing members, provide suitable intermediate metal framing. Where C-clamps are used, provide retainer clips.
3.2.6 Dust Control
To prevent the accumulation of dust, debris and foreign material during construction, perform temporary dust control protection. Protect the distribution system (supply and return) with temporary seal-offs at all inlets and outlets at the end of each day's work. Keep temporary protection in place until system is ready for startup.
3.2.7 Insulation
Provide thickness and application of insulation materials for ductwork, piping, and equipment according to Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS.
3.2.8 Duct Test Holes
Provide holes with closures or threaded holes with plugs in ducts and plenums as indicated or where necessary for the use of pitot tube in balancing the air system. Plug insulated duct at the duct surface, patched over with insulation and then marked to indicate location of test hole if needed for future use.
3.2.9 Power Transmission Components Adjustment
Test V-belts and sheaves for proper alignment and tension prior to operation and after 72 hours of operation at final speed. Uniformly load belts on drive side to prevent bouncing. Make alignment of direct driven couplings to within 50 percent of manufacturer's maximum allowable range of misalignment.
3.3 EQUIPMENT PADS
Provide equipment pads to the dimensions shown or, if not shown, to conform to the shape of each piece of equipment served with a minimum 3-inch margin around the equipment and supports. Allow equipment bases and foundations, when constructed of concrete or grout, to cure a minimum of 14 calendar days before being loaded.
3.4 PENETRATIONS
Provide sleeves and prepared openings for duct mains, branches, and other penetrating items, and install during the construction of the surface to be penetrated. Cut sleeves flush with each surface. Pack spaces between sleeve or opening and duct or duct insulation with mineral fiber conforming with ASTM C553, Type 1, Class B-2.
3.4.1 Closure Collars
Provide closure collars of a minimum 4 inches wide, unless otherwise
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indicated, for exposed ducts and items on each side of penetrated surface, except where equipment is installed. Install collar tight against the surface and fit snugly around the duct or insulation. Grind sharp edges smooth to prevent damage to penetrating surface. Fabricate collars for square and rectangular ducts, with minimum dimension over 15 inches from 18 gauge galvanized steel. Fabricate collars for square and rectangular ducts with a maximum side of 15 inches or less from 20 gauge galvanized steel. Install collars with fasteners a maximum of 6 inches on center. Attach to collars a minimum of 4 fasteners where the opening is 12 inches in diameter or less, and a minimum of 8 fasteners where the opening is 20 inches in diameter or less.
3.5 IDENTIFICATION SYSTEMS
Provide identification tags made of brass, engraved laminated plastic, or engraved anodized aluminum, indicating service and item number on all valves and dampers. Provide tags that are 1-3/8 inch minimum diameter with stamped or engraved markings. Make indentations black for reading clarity. Attach tags to valves with No. 12 AWG 0.0808-inch diameter corrosion-resistant steel wire, copper wire, chrome-plated beaded chain or plastic straps designed for that purpose.
3.6 DUCTWORK LEAK TEST
Perform ductwork leak test for the entire air distribution and exhaust system, including fans, coils, filters, etc. Provide test procedure, apparatus, and report that conform to SMACNA 1972 CD. The maximum allowable leakage rate is 0 cfm. Complete ductwork leak test with satisfactory results prior to applying insulation to ductwork exterior.
3.7 DAMPER ACCEPTANCE TEST
Submit the proposed schedule, at least 2 weeks prior to the start of test. Operate all fire dampers and smoke dampers under normal operating conditions, prior to the occupancy of a building to determine that they function properly. Test each fire damper equipped with fusible link by having the fusible link cut in place. Test dynamic fire dampers with the air handling and distribution system running. Reset all fire dampers with the fusible links replaced after acceptance testing. To ensure optimum operation and performance, install the damper so it is square and free from racking.
3.8 TESTING, ADJUSTING, AND BALANCING
The requirements for testing, adjusting, and balancing are specified in Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC. Begin testing, adjusting, and balancing only when the air supply and distribution, including controls, has been completed, with the exception of performance tests.
3.9 PERFORMANCE TESTS
After testing, adjusting, and balancing is complete as specified, test each system as a whole to see that all items perform as integral parts of the system and temperatures and conditions are evenly controlled throughout the building. Record the testing during the applicable season. Make corrections and adjustments as necessary to produce the conditions indicated or specified. Conduct capacity tests and general operating tests by an experienced engineer. Provide tests that cover a period of not less
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than 1 day for each system and demonstrate that the entire system is functioning according to the specifications. Make coincidental chart recordings at points indicated on the drawings for the duration of the time period and record the temperature at space thermostats or space sensors, the humidity at space humidistats or space sensors and the ambient temperature and humidity in a shaded and weather protected area.
Submit test reports for the ductwork leak test, and performance tests in booklet form, upon completion of testing. Document phases of tests performed including initial test summary, repairs/adjustments made, and final test results in the reports.
3.10 CLEANING AND ADJUSTING
Inside of room fan-coil unit, thoroughly clean ducts, plenums, and casing of debris and blow free of small particles of rubbish and dust and then vacuum clean before installing outlet faces. Wipe equipment clean, with no traces of oil, dust, dirt, or paint spots. Provide temporary filters prior to startup of all fans that are operated during construction, and install new filters after all construction dirt has been removed from the building, and the ducts, plenums, casings, and other items specified have been vacuum cleaned. Maintain system in this clean condition until final acceptance. Properly lubricate bearings with oil or grease as recommended by the manufacturer. Tighten belts to proper tension. Adjust control valves and other miscellaneous equipment requiring adjustment to setting indicated or directed. Adjust fans to the speed indicated by the manufacturer to meet specified conditions. Maintain all equipment installed under the contract until close out documentation is received, the project is completed and the building has been documented as beneficially occupied.
3.11 OPERATION AND MAINTENANCE
3.11.1 Operation and Maintenance Manuals
Submit six manuals at least 2 weeks prior to field training. Submit data complying with the requirements specified in Division 1 - General Requirements. Submit Data Package 3 for the items/units listed under SD-10 Operation and Maintenance Data
3.11.2 Operation And Maintenance Training
Conduct a training course for the members of the operating staff as designated by the Owner's Representative. Make the training period consist of a total of 2 hours of normal working time and start it after all work specified herein is functionally completed and the Performance Tests have been approved. Conduct field instruction that covers all of the items contained in the Operation and Maintenance Manuals as well as demonstrations of routine maintenance operations. Submit the proposed On-site Training schedule concurrently with the Operation and Maintenance Manuals and at least 14 days prior to conducting the training course.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 23 03 00.00 20
BASIC MECHANICAL MATERIALS AND METHODS 08/10 08/20/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-6 2013) National Electrical Safety Code
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA MG 1 (2011; Errata 2012) Motors and Generators
NEMA MG 10 (2001; R 2007) Energy Management Guide for Selection and Use of Fixed Frequency Medium AC Squirrel-Cage Polyphase Induction Motors
NEMA MG 11 (1977; R 2012) Energy Management Guide for Selection and Use of Single Phase Motors
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Certification
1.3 RELATED REQUIREMENTS
This section applies to all sections of Divisions: 21, FIRE SUPPRESSION; 22, PLUMBING; and 23, HEATING, VENTILATING, AND AIR CONDITIONING of this project specification, unless specified otherwise in the individual section.
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1.4 QUALITY ASSURANCE
1.4.1 Material and Equipment Qualifications
Provide materials and equipment that are standard products of manufacturers regularly engaged in the manufacture of such products, which are of a similar material, design and workmanship. Standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year use shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2 year period.
1.4.2 Alternative Qualifications
Products having less than a two-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, can be shown.
1.4.3 Service Support
The equipment items shall be supported by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
1.4.4 Manufacturer's Nameplate
Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.
1.4.5 Modification of References
In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction", or words of similar meaning, to mean the Owner's Representative.
1.4.5.1 Definitions
For the International Code Council (ICC) Codes referenced in the contract documents, advisory provisions shall be considered mandatory, the word "should" shall be interpreted as "shall." Reference to the "code official" shall be interpreted to mean the "Owner's Representative." For Navy owned property, references to the "owner" shall be interpreted to mean the " Owner's Representative." For leased facilities, references to the "owner" shall be interpreted to mean the "lessor." References to the "permit holder" shall be interpreted to mean the "Contractor."
1.4.5.2 Administrative Interpretations
For ICC Codes referenced in the contract documents, the provisions of Chapter 1, "Administrator," do not apply. These administrative
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requirements are covered by the applicable Federal Acquisition Regulations (FAR) included in this contract and by the authority granted to the Officer in Charge of Construction to administer the construction of this project. References in the ICC Codes to sections of Chapter 1, shall be applied appropriately by the Owner's Representative as authorized by his administrative cognizance and the FAR.
1.5 DELIVERY, STORAGE, AND HANDLING
Handle, store, and protect equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Owner's Representative. Replace damaged or defective items.
1.6 ELECTRICAL REQUIREMENTS
Furnish motors, controllers, disconnects and contactors with their respective pieces of equipment. Motors, controllers, disconnects and contactors shall conform to and have electrical connections provided under Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Furnish internal wiring for components of packaged equipment as an integral part of the equipment. Extended voltage range motors will not be permitted. Controllers and contactors shall have a maximum of 120 volt control circuits, and shall have auxiliary contacts for use with the controls furnished. When motors and equipment furnished are larger than sizes indicated, the cost of additional electrical service and related work shall be included under the section that specified that motor or equipment. Power wiring and conduit for field installed equipment shall be provided under and conform to the requirements of Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
1.7 ELECTRICAL INSTALLATION REQUIREMENTS
Electrical installations shall conform to IEEE C2, NFPA 70, and requirements specified herein.
1.7.1 New Work
Provide electrical components of mechanical equipment, such as motors, motor starters (except starters/controllers which are indicated as part of a motor control center), control or push-button stations, float or pressure switches, solenoid valves, integral disconnects, and other devices functioning to control mechanical equipment, as well as control wiring and conduit for circuits rated 100 volts or less, to conform with the requirements of the section covering the mechanical equipment. Extended voltage range motors shall not be permitted. The interconnecting power wiring and conduit, control wiring rated 120 volts (nominal) and conduit, the motor control equipment forming a part of motor control centers, and the electrical power circuits shall be provided under Division 26, except internal wiring for components of package equipment shall be provided as an integral part of the equipment. When motors and equipment furnished are larger than sizes indicated, provide any required changes to the electrical service as may be necessary and related work as a part of the work for the section specifying that motor or equipment.
1.7.2 High Efficiency Motors
1.7.2.1 High Efficiency Single-Phase Motors
Unless otherwise specified, single-phase fractional-horsepower
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alternating-current motors shall be high efficiency types corresponding to the applications listed in NEMA MG 11.
1.7.2.2 High Efficiency Polyphase Motors
Unless otherwise specified, polyphase motors shall be selected based on high efficiency characteristics relative to the applications as listed in NEMA MG 10. Additionally, polyphase squirrel-cage medium induction motors with continuous ratings shall meet or exceed energy efficient ratings in accordance with Table 12-6C of NEMA MG 1.
1.7.3 Three-Phase Motor Protection
Provide controllers for motors rated one 1 horsepower and larger with electronic phase-voltage monitors designed to protect motors from phase-loss, undervoltage, and overvoltage. Provide protection for motors from immediate restart by a time adjustable restart relay.
1.8 INSTRUCTION TO OWNER'S PERSONNEL
When specified in other sections, furnish the services of competent instructors to give full instruction to the designated Owner's personnel in the adjustment, operation, and maintenance, including pertinent safety requirements, of the specified equipment or system. Instructors shall be thoroughly familiar with all parts of the installation and shall be trained in operating theory as well as practical operation and maintenance work.
Instruction shall be given during the first regular work week after the equipment or system has been accepted and turned over to the Owner's Representative for regular operation. The number of man-days (8 hours per day) of instruction furnished shall be as specified in the individual section. When more than 4 man-days of instruction are specified, use approximately half of the time for classroom instruction. Use other time for instruction with the equipment or system.
When significant changes or modifications in the equipment or system are made under the terms of the contract, provide additional instruction to acquaint the operating personnel with the changes or modifications.
1.9 ACCESSIBILITY
Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors.
PART 2 PRODUCTS
Not Used
PART 3 EXECUTION
3.1 PAINTING OF NEW EQUIPMENT
New equipment painting shall be factory applied or shop applied, and shall be as specified herein, and provided under each individual section.
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3.1.1 Factory Painting Systems
Manufacturer's standard factory painting systems may be provided subject to certification that the factory painting system applied will withstand 125 hours in a salt-spray fog test, except that equipment located outdoors shall withstand 500 hours in a salt-spray fog test. Salt-spray fog test shall be in accordance with ASTM B117, and for that test the acceptance criteria shall be as follows: immediately after completion of the test, the paint shall show no signs of blistering, wrinkling, or cracking, and no loss of adhesion; and the specimen shall show no signs of rust creepage beyond 0.125 inch on either side of the scratch mark.
The film thickness of the factory painting system applied on the equipment shall not be less than the film thickness used on the test specimen. If manufacturer's standard factory painting system is being proposed for use on surfaces subject to temperatures above 120 degrees F, the factory painting system shall be designed for the temperature service.
3.1.2 Shop Painting Systems for Metal Surfaces
Clean, pretreat, prime and paint metal surfaces; except aluminum surfaces need not be painted. Apply coatings to clean dry surfaces. Clean the surfaces to remove dust, dirt, rust, oil and grease by wire brushing and solvent degreasing prior to application of paint, except metal surfaces subject to temperatures in excess of 120 degrees F shall be cleaned to bare metal.
Where more than one coat of paint is specified, apply the second coat after the preceding coat is thoroughly dry. Lightly sand damaged painting and retouch before applying the succeeding coat. Color of finish coat shall be aluminum or light gray.
a. Temperatures Less Than 120 Degrees F: Immediately after cleaning, the metal surfaces subject to temperatures less than 120 degrees F shall receive one coat of pretreatment primer applied to a minimum dry film thickness of 0.3 mil, one coat of primer applied to a minimum dry film thickness of 1 mil; and two coats of enamel applied to a minimum dry film thickness of 1 mil per coat.
b. Temperatures Between 120 and 400 Degrees F: Metal surfaces subject to temperatures between 120 and 400 degrees F shall receive two coats of 400 degrees F heat-resisting enamel applied to a total minimum thickness of 2 mils.
c. Temperatures Greater Than 400 Degrees F: Metal surfaces subject to temperatures greater than 400 degrees F shall receive two coats of 600 degrees F heat-resisting paint applied to a total minimum dry film thickness of 2 mils.
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SECTION 23 05 48.00 40
VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT 02/11 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ACOUSTICAL SOCIETY OF AMERICA (ASA)
ASA S2.71 (1983; R 2006) Guide to the Evaluation of Human Exposure to Vibration in Buildings
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)
ASHRAE HVAC APP IP HDBK (2011) HVAC Applications Handbook, I-P Edition
NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB)
NEBB PROCEDURAL STANDARDS (2005) Procedural Standards for TAB (Testing, Adjusting and Balancing) Environmental Systems
1.2 ADMINISTRATIVE REQUIREMENTS
Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS applies to work specified in this section to the extent applicable.
Ensure all vibration-control apparatus is the product of a single manufacturing source, where possible. Human exposure levels should be considered using ASA S2.71 and NEBB PROCEDURAL STANDARDS.
Scheduled isolation mounting is in inches and is a minimum static deflection.
Spans referred to in Part 2, "Vibration-Isolation Systems Application," means longest bay dimension.
Determine exact mounting sizes and number of isolators by the isolator manufacturer based on equipment that will be installed. Check equipment revolutions per minute (rpm) and spring deflections to verify that resonance cannot occur.
Five working days prior to commencement of installation, submit installation drawings for vibration isolator systems including equipment and performance requirements.
Indicate within outline drawings for vibration isolator systems, overall physical features, dimensions, ratings, service requirements, and weights
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of equipment.
Within ten working days of Contract Award, submit equipment and performance data for vibration isolator systems including equipment base design; inertia-block mass relative to support equipment weight; spring loads and free, operating, and solid heights of spring; spring diameters; nonmetallic isolator loading and deflection; disturbing frequency; natural frequency of mounts; deflection of working member; and anticipated amount of physical movement at the reference points.
Ensure data includes the following:
a. Mountings
b. Bases
c. Isolators
d. Floor-Mounted Piping
e. Vertical Piping
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Installation Drawings; G
Outline Drawings; G
SD-03 Product Data
Equipment and Performance Data; G
Isolators; G
SD-06 Test Reports
Type of Isolator; G
Type of Base; G
Allowable Deflection; G
Measured Deflection; G
PART 2 PRODUCTS
2.1 TYPE OF VIBRATION-ISOLATION PROVISIONS
Design for vibration isolation using ASHRAE HVAC APP IP HDBK, Chapter 48, as applicable to the following sections.
Submit test reports for testing vibration isolation for each type of isolator and each type of base, and meet referenced standards contained within this section. Include in test reports allowable deflection and
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measured deflection also meeting referenced standards within this section.
2.1.1 Materials
Ensure rubber is natural rubber and elastomer is chloroprene. Shore A durometer measurement of both materials and range between 40 and 60.
Inorganic materials such as precompressed, high-density, fibrous glass encased in a resilient moisture-impervious membrane may be used in lieu of specified natural rubber and elastomers. Where this substitution is made, ensure specified deflections are modified by the manufacturing source to accommodate physical characteristics of inorganic materials and to provide equal or better vibration isolation.
Ensure weather-exposed metal vibration-isolator parts are corrosion protected. Chloroprene coat springs.
2.1.2 Mountings
Provide the following mountings:
Type C: Free-standing laterally stable open-spring type for deflections over 0.50 inch, with built-in bearing and leveling provisions, 0.25-inch thick Type A base elastomer pads, and accessories. Ensure outside diameter of each spring is equal to or greater than 0.9 times the operating height of the spring under rated load.
Type D: Partially housed type, containing one or more vertically restrained springs with at least 0.50 inch clearance maintained around springs, with adjustable limit stops, 0.25-inch thick Type A base elastomer pads, and accessories.
Type F: Combination spring and rubber-in-shear steel framed for hanger-rod mounting, with minimum total static deflection of 1 inch.
2.2 VIBRATION-ISOLATION SYSTEMS APPLICATION
Vibration isolation design per ASHRAE HVAC APP IP HDBK, Chapter 37.
2.2.1 Air-Moving Device Locations
Vibration-isolation provisions apply to unhoused free-standing fans of any pressure rating, located in field-erected factory- fabricated central-station units service.
ON\ABOVE ON\ABOVE ON\ABOVE GRADE GRADE GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS*
Through 20 hp 200 to 300 rpm B-U-0.35 C-S-2.5 C-S-2.5 C-S-3.5
300 to 500 rpm B-U-0.35 C-S-1.75 C-S-1.75 C-S-2.5
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ON\ABOVE ON\ABOVE ON\ABOVE GRADE GRADE GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS*
500 rpm and over B-U-0.35 C-S-1.0 C-S-1.5 C-S-1.75
2.3 PIPE AND DUCT VIBRATION ISOLATION
Type G: Provide isolators with in-series contained steel springs and preformed fibrous-glass or chloroprene-elastomer elements for connecting to building-structure attachments. Load devices by supported system during operating conditions to produce a minimum spring and elastomer static deflection of 1 inch and 3/8 inch, respectively.
Type H: Provide isolators with contained chloroprene-elastomer elements for connecting to building-structure attachments. Load devices by supported system during operating conditions to produce a minimum elastomer static deflection of 3/8 inch.
Type J: Provide isolators with elastomers mounted on floor-supported columns or directly on the floor. Load devices by supported system during operating conditions to produce a minimum elastomer static deflection of 3/8 inch.
2.3.1 Vertical Piping
Type L: Provide isolators which are pipe base-support devices with one or more contained steel springs. Load devices by supported system during operating conditions to produce a minimum static deflection of 1 inch. Equip devices with precompression and vertical-limit features, as well as a minimum 1/4-inch thick elastomer sound pad and isolation washers, for mounting to floor.
Type M: Provide isolators which are elastomer mounted baseplate and riser pipe-guide devices, with contained double acting elastomer elements which under rated load have a minimum static deflection of 3/8 inch. Size isolator to accommodate thermal insulation within the stationary guide ring.
PART 3 EXECUTION
3.1 INSTALLATION
Install equipment in accordance with manufacturer's recommendations.
Ensure rails, structural steel bases, and concrete inertia blocks are raised not less than 1 inch above the floor and are level when equipment supported is under operating load.
Ensure vibration-isolation installation and deflection testing after equipment start-up is directed by a competent representative of the manufacturer.
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3.2 TESTS AND REPORTS
Ensure vibration-isolation devices are deflection tested. Submit test reports in accordance with paragraph entitled, "Submittals," substantiating that all equipment has been isolated as specified and that minimum specified deflections have been met. Make all measurements in the presence of the Owner's Representative.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 23 05 93
TESTING, ADJUSTING, AND BALANCING FOR HVAC 08/09 08/20/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ACOUSTICAL SOCIETY OF AMERICA (ASA)
ASA S1.11 (2004; Errata 2005; R 2009) Specification for Octave- Band and Fractional-Octave-Band Analog and Digital Filters (ASA 65)
ASA S1.4 (1983; Amendment 1985; R 2006) Specification for Sound Level Meters (ASA 47)
AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)
AMCA 203 (1990; R 2011) Field Performance Measurements of Fan Systems
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)
ASHRAE 62.1 (2013) Ventilation for Acceptable Indoor Air Quality
ASHRAE HVAC APP IP HDBK (2011) HVAC Applications Handbook, I-P Edition
ASSOCIATED AIR BALANCE COUNCIL (AABC)
AABC MN-1 (2002; 6th ed) National Standards for Total System Balance
NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB)
NEBB MASV (2006) Procedural Standards for Measurements and Assessment of Sound and Vibration
NEBB PROCEDURAL STANDARDS (2005) Procedural Standards for TAB (Testing, Adjusting and Balancing) Environmental Systems
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SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)
SMACNA 1780 (2002) HVAC Systems - Testing, Adjusting and Balancing, 3rd Edition
SMACNA 1858 (2004) HVAC Sound And Vibration Manual - First Edition
SMACNA 1972 CD (2012) HVAC Air Duct Leakage Test Manual - 2nd Edition
1.2 DEFINITIONS
a. AABC: Associated Air Balance Council.
b. COTR: Owner's Representative's Technical Representative.
c. DALT: Duct air leakage test
d. DALT'd: Duct air leakage tested
e. HVAC: Heating, ventilating, and air conditioning; or heating, ventilating, and cooling.
f. NEBB: National Environmental Balancing Bureau
g. Out-of-tolerance data: Pertains only to field acceptance testing of Final DALT or TAB report. When applied to DALT work, this phase means "a leakage rate measured during DALT field acceptance testing which exceeds the leakage rate allowed by SMACNA Leak Test Manual for an indicated duct construction and sealant class." When applied to TAB work this phase means "a measurement taken during TAB field acceptance testing which does not fall within the range of plus 5 to minus 5 percent of the original measurement reported on the TAB Report for a specific parameter."
h. Season of maximum heating load: The time of year when the outdoor temperature at the project site remains within plus or minus 30 degrees Fahrenheit of the project site's winter outdoor design temperature, throughout the period of TAB data recording.
i. Season of maximum cooling load: The time of year when the outdoor temperature at the project site remains within plus or minus 5 degrees Fahrenheit of the project site's summer outdoor design temperature, throughout the period of TAB data recording.
j. Sound measurements terminology: Defined in AABC MN-1, NEBB MASV, or SMACNA 1858 (TABB).
k. TAB: Testing, adjusting, and balancing (of HVAC systems).
l. TAB'd: HVAC Testing/Adjusting/Balancing procedures performed.
m. TAB Agency: TAB Firm
n. TABB: Testing Adjusting and Balancing Bureau.
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1.2.1 Similar Terms
In some instances, terminology differs between the Contract and the TAB Standard primarily because the intent of this Section is to use the industry standards specified, along with additional requirements listed herein to produce optimal results.
The following table of similar terms is provided for clarification only. Contract requirements take precedent over the corresponding AABC, NEBB, or TABB requirements where differences exist.
SIMILAR TERMS
Contract Term AABC Term NEBB Term TABB Term
TAB Standard National Procedural International Standards for Standards for Standards for Testing and Testing, Environmental Balancing Adjusting and Systems Balance Heating, Balancing of Ventilating, and Environmental Air Conditioning Systems Systems Systems Readiness Construction Field Readiness Field Readiness Check Phase Inspection Check & Check & Prelim. Preliminary Field Field Procedures Procedures
1.3 WORK DESCRIPTION
The work includes duct air leakage testing (DALT) and testing, adjusting, and balancing (TAB) of new heating, ventilating, and cooling (HVAC) air distribution systems including equipment and performance data, ducts, and piping which are located within, on, under, between, and adjacent to buildings, including records of existing conditions.
Perform TAB in accordance with the requirements of the TAB procedural standard recommended by the TAB trade association that approved the TAB Firm's qualifications. Comply with requirements of AABC MN-1, NEBB PROCEDURAL STANDARDS, or SMACNA 1780 (TABB) as supplemented and modified by this specification section. All recommendations and suggested practices contained in the TAB procedural standards are considered mandatory.
Conduct DALT and TAB of the indicated existing systems and equipment and submit the specified DALT and TAB reports for approval. Conduct DALT testing in compliance with the requirements specified in SMACNA 1972 CD, except as supplemented and modified by this section. Conduct DALT and TAB work in accordance with the requirements of this section.
1.3.1 Air Distribution Systems
Test, adjust, and balance systems (TAB) in compliance with this section.
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1.3.2 TAB SCHEMATIC DRAWINGS
Show the following information on TAB Schematic Drawings:
1. A unique number or mark for each piece of equipment or terminal.
2. Air quantities at air terminals.
3. Ductwork Construction and Leakage Testing Table that defines the DALT test requirements, including each applicable HVAC duct system ID or mark, duct pressure class, duct seal class, and duct leakage test pressure. This table is included in the file for Graphics for Unified Facilities Guide Specifications: http://www.wbdg.org/ccb/NAVGRAPH/graphtoc.pdf
The Testing, Adjusting, and Balancing (TAB) Specialist must review the Contract Plans and Specifications and advise the Owner's Representative of any deficiencies that would prevent the effective and accurate TAB of the system, including records of existing conditions, and systems readiness check. The TAB Specialist must provide a Design Review Report individually listing each deficiency and the corresponding proposed corrective action necessary for proper system operation.
Submit three copies of the TAB Schematic Drawings and Report Forms to the Owner's Representative, no later than 14 days prior to the start of TAB field measurements.
1.4 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-01 Preconstruction Submittals
TAB Firm; G
SD-02 Shop Drawings
TAB Schematic Drawings and Report Forms; G
SD-03 Product Data
Equipment and Performance Data; G
TAB Related HVAC Submittals; G
A list of the TAB Related HVAC Submittals, no later than 7 days after the approval of the TAB team engineer.
TAB Procedures; G
Proposed procedures for TAB, submitted with the TAB Schematic Drawings and Report Forms.
Calibration; G
Systems Readiness Check; G
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TAB Execution; G
TAB Verification; G
SD-06 Test Reports
TAB Work Execution Schedule; G
TAB Procedures Summary; G
TAB Firm; G
1.5 QUALITY ASSURANCE
1.5.1 Independent TAB Agency and Personnel Qualifications
To secure approval for the proposed agency, submit information certifying that the TAB agency is a first tier subcontractor who is not affiliated with any other company participating in work on this contract, including design, furnishing equipment, or construction. Further, submit the following, for the agency, to Owner's Representative for approval:
a. Independent AABC or NEBB or TABB TAB agency:
TAB agency: AABC registration number and expiration date of current certification; or NEBB certification number and expiration date of current certification; or TABB certification number and expiration date of current certification.
Current certificates: Registrations and certifications are current, and valid for the duration of this contract. Renew Certifications which expire prior to completion of the TAB work, in a timely manner so that there is no lapse in registration or certification. TAB agency or TAB team personnel without a current registration or current certification are not to perform TAB work on this contract.
b. TAB Team Members: TAB team approved to accomplish work on this contract are full-time employees of the TAB agency. No other personnel is allowed to do TAB work on this contract.
c. Replacement of TAB team members: Replacement of members may occur if each new member complies with the applicable personnel qualifications and each is approved by the Owner's Representative.
1.5.2 TAB Standard
Perform TAB in accordance with the requirements of the standard under which the TAB Firm's qualifications are approved, i.e., AABC MN-1, NEBB PROCEDURAL STANDARDS, or SMACNA 1780 unless otherwise specified herein. All recommendations and suggested practices contained in the TAB Standard are considered mandatory. Use the provisions of the TAB Standard, including checklists, report forms, etc., as nearly as practical, to satisfy the Contract requirements. Use the TAB Standard for all aspects of TAB, including qualifications for the TAB Firm and Specialist and calibration of TAB instruments. Where the instrument manufacturer calibration recommendations are more stringent than those listed in the TAB Standard, adhere to the manufacturer's recommendations.
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All quality assurance provisions of the TAB Standard such as performance guarantees are part of this contract. For systems or system components not covered in the TAB Standard, TAB procedures must be developed by the TAB Specialist. Where new procedures, requirements, etc., applicable to the Contract requirements have been published or adopted by the body responsible for the TAB Standard used (AABC, NEBB, or TABB), the requirements and recommendations contained in these procedures and requirements are considered mandatory, including the latest requirements of ASHRAE 62.1.
1.5.3 Qualifications
1.5.3.1 TAB Firm
The TAB Firm must be either a member of AABC or certified by the NEBB or the TABB and certified in all categories and functions where measurements or performance are specified on the plans and specifications, including TAB of environmental systems AND building systems commissioning.
Certification must be maintained for the entire duration of duties specified herein. If, for any reason, the firm loses subject certification during this period, the Contractor must immediately notify the Owner's Representative and submit another TAB Firm for approval. Any firm that has been the subject of disciplinary action by either the AABC, the NEBB, or the TABB within the five years preceding Contract Award is not be eligible to perform any duties related to the HVAC systems, including TAB. All work specified in this Section and in other related Sections to be performed by the TAB Firm will be considered invalid if the TAB Firm loses its certification prior to Contract completion and must be performed by an approved successor.
These TAB services are to assist the prime Contractor in performing the quality oversight for which it is responsible. The TAB Firm must be a prime subcontractor of the Contractor and be financially and corporately independent of the mechanical subcontractor, reporting directly to and paid by the Contractor.
1.5.3.2 TAB Specialist
The TAB Specialist must be either a member of AABC,an experienced technician of the Firm certified by the NEBB, or a Supervisor certified by the TABB. The certification must be maintained for the entire duration of duties specified herein. If, for any reason, the Specialist loses subject certification during this period, immediately notify the Owner's Representative and submit another TAB Specialist for approval. Any individual that has been the subject of disciplinary action by either the AABC, the NEBB, or the TABB within the five years preceding Contract Award is not eligible to perform any duties related to the HVAC systems, including TAB. All work specified in this Section and in other related Sections performed by the TAB Specialist will be considered invalid if the TAB Specialist loses its certification prior to Contract completion and must be performed by the approved successor.
1.5.3.3 TAB Specialist Responsibilities
TAB Specialist responsibilities include all TAB work specified herein and in related sections under his direct guidance. The TAB specialist is required to be onsite on a daily basis to direct TAB efforts. The TAB
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Specialist must participate in the commissioning process specified in Section 23 08 00.00 10 COMMISSIONING OF HVAC SYSTEMS.
1.5.3.4 TAB Related HVAC Submittals
The TAB Specialist must prepare a list of the submittals from the Contract Submittal Register that relate to the successful accomplishment of all HVAC TAB. Accompany the submittals identified on this list with a letter of approval signed and dated by the TAB Specialist when submitted to the Owner's Representative. Ensure that the location and details of ports, terminals, connections, etc., necessary to perform TAB are identified on the submittals.
1.5.4 Responsibilities
The Contractor is responsible for ensuring compliance with the requirements of this section. The following delineation of specific work responsibilities is specified to facilitate TAB execution of the various work efforts by personnel from separate organizations. This breakdown of specific duties is specified to facilitate adherence to the schedule listed in paragraph entitled "TAB Submittal and Work Schedule."
1.5.4.1 Contractor
a. TAB personnel: Ensure that the DALT work and the TAB work is accomplished by a group meeting the requirements specified in paragraph entitled "TAB Personnel Qualification Requirements."
b. HVAC documentation: Furnish one complete set of the following HVAC-related documentation to the TAB agency:
(1) Contract drawings and specifications
(2) Approved submittal data for equipment
(3) Construction work schedule
(4) Up-to-date revisions and change orders for the previously listed items
c. Submittal and work schedules: Ensure that the schedule for submittals and work required by this section and specified in paragraph entitled "TAB Submittal and Work Schedule," is met.
d. Coordination of supporting personnel:
Provide the technical personnel, such as factory representatives or HVAC controls installer required by the TAB field team to support the DALT and the TAB field measurement work.
Provide equipment mechanics to operate HVAC equipment and ductwork mechanics to provide the field designated test ports to enable TAB field team to accomplish the DALT and the TAB field measurement work. Ensure these support personnel are present at the times required by the TAB team, and cause no delay in the DALT and the TAB field work.
e. Deficiencies: Ensure that the TAB Agency submits all Design/Construction deficiency notifications directly to the Owner's Representative within 3 days after the deficiency is encountered.
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Further, ensure that all such notification submittals are complete with explanation, including documentation, detailing deficiencies.
f. Prerequisite HVAC work: Complete check out and debugging of HVAC equipment, ducts, and controls prior to the TAB engineer arriving at the project site to begin the TAB work. Debugging includes searching for and eliminating malfunctioning elements in the HVAC system installations, and verifying all adjustable devices are functioning as designed. Include as prerequisite work items, the deficiencies pointed out by the TAB team in the design review report.
g. Advance notice: Furnish to the Owner's Representative with advance written notice for the commencement of the DALT field work and for the commencement of the TAB field work.
h. Insulation work: For required DALT work , ensure that insulation is not installed on ducts to be DALT'd until DALT work on the subject ducts is complete. Later, ensure that openings in duct and machinery insulation coverings for TAB test ports are marked, closed and sealed.
1.5.4.2 TAB Agency
Provide the services of a TAB team which complies with the requirements of paragraph entitled "Independent TAB Agency Personnel Qualifications". The work to be performed by the TAB agency is limited to testing, adjusting, and balancing of HVAC air and water systems to satisfy the requirements of this specification section.
1.5.5 Test Reports
1.5.5.1 Certified TAB Reports
a. Temperatures: On each TAB report form reporting TAB work accomplished on HVAC thermal energy transfer equipment, include the indoor and outdoor dry bulb temperature range and indoor and outdoor wet bulb temperature range within which the TAB data was recorded. Include in the TAB report continuous time versus temperature recording data of wet and dry bulb temperatures for the rooms, or zones, as designated in the following list:
(1) Measure and compile data on a continuous basis for the period in which TAB work affecting those rooms is being done.
(2) Measure and record data only after the HVAC systems installations are complete, the systems fully balanced and the HVAC systems controls operating in fully automatic mode.
(3) Data may be compiled using direct digital controls trend logging where available. Otherwise, temporarily install calibrated time versus temperature/humidity recorders for this purpose. The HVAC systems and controls must be fully operational a minimum of 24 hours in advance of commencing data compilation.
b. Static Pressure Profiles: Report static pressure profiles for air duct systems. Report static pressure data for all exhaust ducts for the systems listed. Include the following in the static pressure report data, in addition to AABC/NEBB/TABB required data:
(1) Report exhaust fan inlet and discharge static pressures.
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(2) Report static pressure drop across outside air automatic control dampers, both proportional and two-position, installed in unit cabinetry.
(3) Report static pressure drop across air flow measuring stations.
Do not report static pressure drop across duct fittings provided for the sole purpose of conveying air, such as elbows, transitions, offsets, plenums, manual dampers, and branch takes-offs.
(4) Report static pressure drop across outside air and relief/exhaust air louvers.
c. Duct Traverses: Report duct traverses for main exhaust and outside air ducts. This includes all ducts, including those which lack 7 1/2 duct diameters upstream and 2 1/2 duct diameters downstream of straight duct unobstructed by duct fittings/offsets/elbows. The TAB Agency must evaluate and report findings on the duct traverses taken. Evaluate the suitability of the duct traverse measurement based on satisfying the qualifications for a pilot traverse plane as defined by AMCA 203, "Field Measurements", Section 8, paragraph 8.3, "Location of Traverse Plane."
d. Certification: Include the typed name of the TAB specialist and the dated signature of the TAB specialist.
e. Performance Curves: The TAB Specialist must include, in the TAB Reports, factory pump curves and fan curves for pumps and fans TAB'd on the job.
f. Calibration Curves: The TAB Specialist must include, in the TAB Reports, a factory calibration curve for installed flow control balancing valves, flow venturi's and flow orifices TAB'd on the job.
1.6 SEQUENCING AND SCHEDULING
1.6.1 Projects with Phased Construction
This specification section is structured as though the HVAC construction, and thereby the TAB work, will be completed in a single phase. When the construction is completed in phases, the DALT work and TAB work must be planned, completed, and accepted for each construction phase.
1.6.1.1 Phasing of Work
This specification section is structured as though the HVAC construction, and thereby the TAB work, is going to be completed in a single phase in spite of the fact that there will be two seasons. All elements of the TAB work are addressed on this premise. When a contract is to be completed in construction phases, including the TAB work, and the DALT work, the TAB work and DALT work must be planned for, completed and approved by the Owner's Representative with each phase. An example of this case would be one contract that requires the rehabilitation of the HVAC in each of several separated buildings. At the completion of the final phase, compile all approved reports and submit as one document.
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1.6.2 DALT and TAB Submittal and Work Schedule
Submit this schedule,and TAB Schematic Drawings, adapted for this particular contract, to the Owner's Representative (CO) for review and approval. Include with the submittal the planned calendar dates for each submittal or work item. Resubmit an updated version for CO approval every 90 calendar days days. Compliance with the following schedule is the Contractor's responsibility.
Qualify TAB Personnel: Within 45 calendar days after date of contract award, submit TAB agency and personnel qualifications.
Pre-DALT/TAB Meeting: Within 30 calendar days after the date of approval of the TAB agency and personnel, meet with the COTR.
Design Review Report: Within 60 calendar days after the date of the TAB agency personnel qualifications approval, submit design review report.
1.6.2.1 Design Review Report
Submit typed report describing omissions and deficiencies in the HVAC system's design that would preclude the TAB team from accomplishing the duct leakage testing work and the TAB work requirements of this section. Provide a complete explanation including supporting documentation detailing the design deficiency. State that no deficiencies are evident if that is the case.
1.7 WARRANTY
Furnish workmanship and performance warranty for the DALT and TAB system work performed for a period not less than 2 years from the date of Owner's Representative acceptance of the work; issued directly to the Owner's Representative. Include provisions that if within the warranty period the system shows evidence of major performance deterioration, or is significantly out of tolerance, resulting from defective TAB or DALT workmanship, the corrective repair or replacement of the defective materials and correction of the defective workmanship is the responsibility of the TAB firm. Perform corrective action that becomes necessary because of defective materials and workmanship while system TAB and DALT is under warranty 7 days after notification, unless additional time is approved by the Owner's Representative. Failure to perform repairs within the specified period of time constitutes grounds for having the corrective action and repairs performed by others and the cost billed to the TAB firm. The Contractor must also provide a 2 year contractor installation warranty.
PART 2 PRODUCTS
Not Used.
PART 3 EXECUTION
3.1 PRE-DALT/TAB MEETING
Meet with the Owner's Representative's technical representative (COTR)to develop a mutual understanding relative to the details of the DALT work and TAB work requirements. Ensure that the TAB specialist is present at this meeting. Requirements to be discussed include required submittals, work
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schedule, and field quality control.
3.2 TAB PROCEDURES
3.2.1 TAB Field Work
Test, adjust, and balance the HVAC systems until measured flow rates (air and water flow) are within plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents.
That is, comply with the the requirements of AABC MN-1 , or SMACNA 1780 (TABB) and SMACNA 1858 (TABB),except as supplemented and modified by this section.
Provide instruments and consumables required to accomplish the TAB work. Calibrate and maintain instruments in accordance with manufacturer's written procedures.
Test, adjust, and balance the HVAC systems until measured flow rates (air flow) are within plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents. Conduct TAB work, including measurement accuracy, and sound measurement work in conformance with the AABC MN-1 and AABC MN-4, or NEBB TABES and NEBB MASV, or SMACNA 1780 (used by TABB) and SMACNA 1858 sound measurement procedures, except as supplemented and modified by this section.
3.2.2 TAB Air Distribution Systems
3.2.2.1 Fan Coils
Fan coil unit systems including fans, coils, ducts, plenums, and air distribution devices for supply air, return air, and outside air.
3.2.2.2 Exhaust Fans
Exhaust fan systems including fans, ducts, plenums, grilles, and hoods for exhaust air.
3.2.3 Sound Measurement Work
3.2.3.1 Areas To Be Sound Measured
In the following spaces, measure and record the sound power level for each octave band listed in ASHRAE HVAC APP IP HDBK Noise Criteria:
a. All HVAC mechanical rooms, including machinery spaces and other spaces containing HVAC power drivers and power driven equipment.
b. All spaces sharing a common barrier with each mechanical room, including rooms overhead, rooms on the other side of side walls, and rooms beneath the mechanical room floor.
c. EF No. 1 System: Rooms: Pump Room.
d. EF No. 2 System: Rooms: Wet Well.
e. EG-01 System: Rooms: Generator Room.
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3.2.3.2 Procedure
Measure sound levels in each room, when unoccupied except for the TAB team, with all HVAC systems that would cause sound readings in the room operating in their noisiest mode. Record the sound level in each octave band. Attempt to mitigate the sound level and bring the level to within the specified ASHRAE HVAC APP IP HDBK noise criteria goals, if such mitigation is within the TAB team's control. State in the report the ASHRAE HVAC APP IP HDBK noise criteria goals. If sound level cannot be brought into compliance, provide written notice of the deficiency to the Contractor for resolution or correction.
3.2.3.3 Timing
Measure sound levels at times prescribed by AABC or NEBB or TABB.
3.2.3.4 Meters
Measure sound levels with a sound meter complying with ASA S1.4, Type 1 or 2, and an octave band filter set complying with ASA S1.11. Use measurement methods for overall sound levels and for octave band sound levels as prescribed by NEBB.
3.2.3.5 Calibration
Calibrate sound levels as prescribed by AABC or NEBB or TABB, except that calibrators emitting a sound pressure level tone of 94 dB at 1000 hertz (Hz) are also acceptable.
3.2.3.6 Background Noise Correction
Determine background noise component of room sound (noise) levels for each (of eight) octave bands as prescribed by AABC or NEBB or TABB.
3.2.4 TAB Work on Performance Tests Without Seasonal Limitations
3.2.4.1 Performance Tests
In addition to the TAB proportionate balancing work on the air distribution systems and the water distribution systems, accomplish TAB work on the HVAC systems which directly transfer thermal energy. TAB the operational performance of the heating systems and cooling systems.
3.2.4.2 Ambient Temperatures
On each tab report form used for recording data, record the outdoor and indoor ambient dry bulb temperature range and the outdoor and indoor ambient wet bulb temperature range within which the report form's data was recorded. Record these temperatures at beginning and at the end of data taking.
3.2.4.3 Sound Measurements
Comply with paragraph entitled "Sound Measurement Work," specifically, the requirement that a room must be operating in its noisiest mode at the time of sound measurements in the room. The maximum noise level measurements could depend on seasonally related heat or cooling transfer equipment.
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3.2.5 TAB Work on Performance Tests With Seasonal Limitations
3.2.5.1 Performance Tests
Accomplish proportionate balancing TAB work on the air distribution systems and water distribution systems, in other words, accomplish adjusting and balancing of the air flows and water flows, any time during the duration of this contract, subject to the limitations specified elsewhere in this section. However, accomplish, within the following seasonal limitations, TAB work on HVAC systems which directly transfer thermal energy.
3.2.5.2 Season Of Maximum Load
Visit the contract site for at least two TAB work sessions for TAB field measurements. Visit the contract site during the season of maximum heating load and visit the contract site during the season of maximum cooling load, the goal being to TAB the operational performance of the heating systems and cooling systems under their respective maximum outdoor environment-caused loading. During the seasonal limitations, TAB the operational performance of the heating systems and cooling systems.
3.2.5.3 Ambient Temperatures
On each tab report form used for recording data, record the outdoor and indoor ambient dry bulb temperature range and the outdoor and indoor ambient wet bulb temperature range within which the report form's data was recorded. Record these temperatures at beginning and at the end of data taking.
3.2.5.4 Sound Measurements
Comply with paragraph entitled "Sound Measurement Work," specifically, the requirement that a room must be operating in its noisiest mode at the time of sound measurements in the room. The maximum noise level measurements could depend on seasonally related heat or cooling transfer equipment.
3.2.5.5 Refrigeration Units
For refrigeration compressors/condensers/condensing units,report data as required by NEBB Form TAB 15-83, NEBB PROCEDURAL STANDARDS, including refrigeration operational data.
3.2.5.6 Coils
Report heating and cooling performance capacity tests for DX for the purpose of verifying that the coils meet the indicated design capacity. Submit the following data and calculations with the coil test reports:
a. For units with capacities of 7.5 tons (90,000 Btu) or less, such as fan coil units, duct mounted reheat coils associated with VAV terminal units, and unitary units, such as through-the-wall heat pumps:
Determine the apparent coil capacity by calculations using single point measurement of entering and leaving wet and dry bulb temperatures; submit the calculations with the coil reports.
3.2.6 Workmanship
Conduct TAB work on the HVAC systems until measured flow rates are within
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plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents. This TAB work includes adjustment of balancing valves, balancing dampers, and sheaves. Further, this TAB work includes changing out fan sheaves and pump impellers if required to obtain air and water flow rates specified or indicated. If, with these adjustments and equipment changes, the specified or indicated design flow rates cannot be attained, contact the Owner's Representative for direction.
3.2.7 Deficiencies
Strive to meet the intent of this section to maximize the performance of the equipment as designed and installed. However, if deficiencies in equipment design or installation prevent TAB work from being accomplished within the range of design values specified in the paragraph entitled "Workmanship," provide written notice as soon as possible to the Contractor and the Owner's Representative describing the deficiency and recommended correction.
Responsibility for correction of installation deficiencies is the Contractor's. If a deficiency is in equipment design, call the TAB team specialist for technical assistance. Responsibility for reporting design deficiencies to Contractor is the TAB team specialist's.
3.2.8 TAB Reports
Data required by those approved data report forms is to be furnished by the TAB team. Except as approved otherwise in writing by the Owner's Representative, the TAB work and thereby the TAB report is considered incomplete until the TAB work is accomplished to within the accuracy range specified in the paragraph entitled "Workmanship."
3.2.9 Quality Assurance - COTR TAB Field Acceptance Testing
3.2.9.1 TAB Field Acceptance Testing
During the field acceptance testing, verify, in the presence of the COTR, random selections of data (air quantities, air motion, sound level readings ) recorded in the TAB Report. Points and areas for field acceptance testing are to be selected by the COTR. Measurement and test procedures are the same as approved for TAB work for the TAB Report.
Field acceptance testing includes verification of TAB Report data recorded for the following equipment groups:
Group 1: All chillers, boilers, return fans, computer room units, and air handling units (rooftop and central stations).
Group 2: 25 percent of the supply fans, exhaust fans, and pumps.
Further, if any data on the TAB Report for Groups 2 through 5 is found not to fall within the range of plus 5 to minus 5 percent of the TAB Report data, additional group data verification is required in the presence of the COTR. Verify TAB Report data for one additional piece of equipment in that group. Continue this additional group data verification until out-of-tolerance data ceases to be found.
3.2.9.2 Additional COTR TAB Field Acceptance Testing
If any of the acceptance testing measurements for a given equipment group
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is found not to fall within the range of plus 5 to minus 5 percent of the TAB Report data, terminate data verification for all affected data for that group. The affected data for the given group will be disapproved. Make the necessary corrections and prepare a revised TAB Report. Reschedule acceptance testing of the revised report data with the COTR. Further, if any data on the TAB Report for a given field acceptance test group is out-of-tolerance, then field test data for one additional field test group as specified herein. Continue this increase field test work until out-of-tolerance data ceases to to be found. This additional field testing is up and above the original 25 percent of the of reported data entries to be field tested.
If there are no more similar field test groups from which to choose, additional field testing from another, but different, type of field testing group must be tested.
3.2.9.3 Prerequisite for Approval
Compliance with the field acceptance testing requirements of this section is a prerequisite for the final Owner's Representative approval of the TAB Report submitted.
3.3 MARKING OF SETTINGS
Upon the final TAB work approval, permanently mark the settings of HVAC adjustment devices including valves, gauges, splitters, and dampers so that adjustment can be restored if disturbed at any time. Provide permanent markings clearly indicating the settings on the adjustment devices which result in the data reported on the submitted TAB report.
3.4 MARKING OF TEST PORTS
The TAB team is to permanently and legibly mark and identify the location points of the duct test ports. If the ducts have exterior insulation, make these markings on the exterior side of the duct insulation. Show the location of test ports on the as-built mechanical drawings with dimensions given where the test port is covered by exterior insulation.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 23 07 00
THERMAL INSULATION FOR MECHANICAL SYSTEMS 02/13 08/21/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. At the discretion of the Owner's Representative, the manufacturer of any material supplied will be required to furnish test reports pertaining to any of the tests necessary to assure compliance with the standard or standards referenced in this specification.
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)
ASHRAE 90.1 - IP (2010; Errata 1-4 2011; INT 1-12 2011; Addenda A, B, C, G, H, J, K, O, P, S, Y, Z, BZ, CG, CI and DS 2012; Errata 5-9 2012; INT 13-16 2012; Errata 10-12 2013; INT 17-18 2013) Energy Standard for Buildings Except Low-Rise Residential Buildings
ASTM INTERNATIONAL (ASTM)
ASTM A167 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip
ASTM A580/A580M (2013b) Standard Specification for Stainless Steel Wire
ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM C1126 (2013a) Standard Specification for Faced or Unfaced Rigid Cellular Phenolic Thermal Insulation
ASTM C1136 (2012) Standard Specification for Flexible, Low Permeance Vapor Retarders for Thermal Insulation
ASTM C1710 (2011) Standard Guide for Installation of Flexible Closed Cell Preformed Insulation in Tube and Sheet Form
ASTM C195 (2007; R 2013) Standard Specification for Mineral Fiber Thermal Insulating Cement
ASTM C450 (2008) Standard Practice for Fabrication
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of Thermal Insulating Fitting Covers for NPS Piping, and Vessel Lagging
ASTM C533 (2013) Standard Specification for Calcium Silicate Block and Pipe Thermal Insulation
ASTM C534/C534M (2013) Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form
ASTM C547 (2012) Standard Specification for Mineral Fiber Pipe Insulation
ASTM C552 (2013) Standard Specification for Cellular Glass Thermal Insulation
ASTM C610 (2011) Standard Specification for Molded Expanded Perlite Block and Pipe Thermal Insulation
ASTM C647 (2008; R 2013) Properties and Tests of Mastics and Coating Finishes for Thermal Insulation
ASTM C795 (2008; R 2013) Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel
ASTM C920 (2011) Standard Specification for Elastomeric Joint Sealants
ASTM C921 (2010) Standard Practice for Determining the Properties of Jacketing Materials for Thermal Insulation
ASTM D2863 (2013) Measuring the Minimum Oxygen Concentration to Support Candle-Like Combustion of Plastics (Oxygen Index)
ASTM D5590 (2000; R 2010; E 2012) Standard Test Method for Determining the Resistance of Paint Films and Related Coatings to Fungal Defacement by Accelerated Four-Week Agar Plate Assay
ASTM D882 (2012) Tensile Properties of Thin Plastic Sheeting
ASTM E2231 (2009) Specimen Preparation and Mounting of Pipe and Duct Insulation Materials to Assess Surface Burning Characteristics
ASTM E84 (2013a) Standard Test Method for Surface Burning Characteristics of Building Materials
ASTM E96/E96M (2013) Standard Test Methods for Water Vapor Transmission of Materials
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FM GLOBAL (FM)
FM APP GUIDE (updated on-line) Approval Guide http://www.approvalguide.com/
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)
ISO 2758 (2001) Paper - Determination of Bursting Strength
MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)
MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)
MIDWEST INSULATION CONTRACTORS ASSOCIATION (MICA)
MICA Insulation Stds (1999) National Commercial & Industrial Insulation Standards
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems
NFPA 90B (2012) Standard for the Installation of Warm Air Heating and Air Conditioning Systems
U.S. DEPARTMENT OF DEFENSE (DOD)
MIL-A-24179 (1969; Rev A; Am 2 1980; Notice 1 1987) Adhesive, Flexible Unicellular-Plastic Thermal Insulation
MIL-A-3316 (1987; Rev C; Am 2 1990) Adhesives, Fire-Resistant, Thermal Insulation
MIL-PRF-19565 (1988; Rev C) Coating Compounds, Thermal Insulation, Fire- and Water-Resistant, Vapor-Barrier
UNDERWRITERS LABORATORIES (UL)
UL 723 (2008; Reprint Aug 2013) Test for Surface Burning Characteristics of Building Materials
UL 94 (2013) Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances
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1.2 SYSTEM DESCRIPTION
1.2.1 General
Provide field-applied insulation and accessories on mechanical systems as specified herein; factory-applied insulation is specified under the piping, duct or equipment to be insulated. Field applied insulation materials required for use on Owner's Representative-furnished items as listed in the SPECIAL CONTRACT REQUIREMENTS shall be furnished and installed by the Contractor.
1.2.2 Recycled Materials
Provide thermal insulation containing recycled materials to the extent practicable, provided that the materials meet all other requirements of this section. The minimum recycled material content of the following insulation are:
Rock Wool 75 percent slag of weight
Fiberglass 20-25 percent glass cullet by weight
Rigid Foam 9 percent recovered material
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
Submit the three SD types, SD-02 Shop Drawings, SD-03 Product Data, and SD-08 Manufacturer's Instructions at the same time for each system.
SD-02 Shop Drawings
MICA Plates; G Pipe Insulation Systems and Associated Accessories Equipment Insulation Systems and Associated Accessories
SD-03 Product Data
Certification Pipe Insulation Systems; G Equipment Insulation Systems; G
SD-04 Samples
Thermal Insulation; G Display Samples; G
SD-08 Manufacturer's Instructions
Pipe Insulation Systems; G Equipment Insulation Systems; G
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1.4 QUALITY ASSURANCE
1.4.1 Installer Qualification
Qualified installers shall have successfully completed three or more similar type jobs within the last 5 years.
1.5 DELIVERY, STORAGE, AND HANDLING
Materials shall be delivered in the manufacturer's unopened containers. Materials delivered and placed in storage shall be provided with protection from weather, humidity, dirt, dust and other contaminants. The Owner's Representative may reject insulation material and supplies that become dirty, dusty, wet, or contaminated by some other means. Packages or standard containers of insulation, jacket material, cements, adhesives, and coatings delivered for use, and samples required for approval shall have manufacturer's stamp or label attached giving the name of the manufacturer and brand, and a description of the material, date codes, and approximate shelf life (if applicable). Insulation packages and containers shall be asbestos free.
PART 2 PRODUCTS
2.1 STANDARD PRODUCTS
Provide materials which are the standard products of manufacturers regularly engaged in the manufacture of such products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Submit a complete list of materials, including manufacturer's descriptive technical literature, performance data, catalog cuts, and installation instructions. The product number, k-value, thickness and furnished accessories including adhesives, sealants and jackets for each mechanical system requiring insulation shall be included. The product data must be copyrighted, have an identifying or publication number, and shall have been published prior to the issuance date of this solicitation. Materials furnished under this section shall be submitted together in a booklet and in conjunction with the MICA plates booklet (SD-02). Annotate the product data to indicate which MICA plate is applicable.
2.1.1 Insulation System
Provide insulation systems in accordance with the approved MICA National Insulation Standards plates as supplemented by this specification. Provide field-applied insulation for heating, ventilating, and cooling (HVAC) air distribution systems and piping systems that are located within, on, under, and adjacent to buildings; and for plumbing systems. Insulation shall be CFC and HCFC free.
2.1.2 Surface Burning Characteristics
Unless otherwise specified, insulation shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Flame spread, and smoke developed indexes, shall be determined by ASTM E84 or UL 723. Insulation shall be tested in the same density and installed thickness as the material to be used in the actual construction. Test specimens shall be prepared and mounted according to ASTM E2231.
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2.2 MATERIALS
Provide insulation that meets or exceed the requirements of ASHRAE 90.1 - IP. Insulation exterior shall be cleanable, grease resistant, non-flaking and non-peeling. Materials shall be compatible and shall not contribute to corrosion, soften, or otherwise attack surfaces to which applied in either wet or dry state. Materials to be used on stainless steel surfaces shall meet ASTM C795 requirements. Materials shall be asbestos free. Provide product recognized under UL 94 (if containing plastic) and listed in FM APP GUIDE.
2.2.1 Adhesives
2.2.1.1 Mineral Fiber Insulation Cement
Cement shall be in accordance with ASTM C195.
2.2.1.2 Lagging Adhesive
Lagging is the material used for thermal insulation, especially around a cylindrical object. This may include the insulation as well as the cloth/material covering the insulation. To resist mold/mildew, lagging adhesive shall meet ASTM D5590 with 0 growth rating. Lagging adhesives shall be nonflammable and fire-resistant and shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Adhesive shall be MIL-A-3316, Class 1, pigmented white and be suitable for bonding fibrous glass cloth to faced and unfaced fibrous glass insulation board; for bonding cotton brattice cloth to faced and unfaced fibrous glass insulation board; for sealing edges of and bonding glass tape to joints of fibrous glass board; for bonding lagging cloth to thermal insulation; or Class 2 for attaching fibrous glass insulation to metal surfaces. Lagging adhesives shall be applied in strict accordance with the manufacturer's recommendations for pipe and duct insulation.
2.2.1.3 Contact Adhesive
Adhesives may be any of, but not limited to, the neoprene based, rubber based, or elastomeric type that have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. The adhesive shall not adversely affect, initially or in service, the insulation to which it is applied, nor shall it cause any corrosive effect on metal to which it is applied. Any solvent dispersing medium or volatile component of the adhesive shall have no objectionable odor and shall not contain any benzene or carbon tetrachloride. The dried adhesive shall not emit nauseous, irritating, or toxic volatile matters or aerosols when the adhesive is heated to any temperature up to 212 degrees F. The dried adhesive shall be nonflammable and fire resistant. Flexible Elastomeric Adhesive: Comply with MIL-A-24179, Type II, Class I. Provide product listed in FM APP GUIDE.
2.2.2 Caulking
ASTM C920, Type S, Grade NS, Class 25, Use A.
2.2.3 Corner Angles
Nominal 0.016 inch aluminum 1 by 1 inch with factory applied kraft backing. Aluminum shall be ASTM B209, Alloy 3003, 3105, or 5005.
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2.2.4 Fittings
Fabricated Fittings are the prefabricated fittings for flexible elastomeric pipe insulation systems in accordance with ASTM C1710. Flexible elastomeric, fabricated fittings provide thermal protection (0.25 k) and condensation resistance (0.05 Water Vapor Transmission factor). For satisfactory performance, properly installed protective vapor retarder/barriers and vapor stops shall be used on high relative humidity and below ambient temperature applications to reduce movement of moisture through or around the insulation to the colder interior surface.
2.2.5 Finishing Cement
ASTM C450: Mineral fiber hydraulic-setting thermal insulating and finishing cement. All cements that may come in contact with Austenitic stainless steel must comply with ASTM C795.
2.2.6 Fibrous Glass Cloth and Glass Tape
Fibrous glass cloth, with 20X20 maximum mesh size, and glass tape shall have maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Tape shall be 4 inch wide rolls. Class 3 tape shall be 4.5 ounces/square yard. Elastomeric Foam Tape: Black vapor-retarder foam tape with acrylic adhesive containing an anti-microbial additive.
2.2.7 Staples
Outward clinching type ASTM A167, Type 304 or 316 stainless steel.
2.2.8 Jackets
2.2.8.1 Aluminum Jackets
Aluminum jackets shall be corrugated, embossed or smooth sheet, 0.016 inch nominal thickness; ASTM B209, Temper H14, Temper H16, Alloy 3003, 5005, or 3105. Corrugated aluminum jacket shall not be used outdoors. Aluminum jacket securing bands shall be Type 304 stainless steel, 0.015 inch thick, 1/2 inch wide for pipe under 12 inch diameter and 3/4 inch wide for pipe over 12 inch and larger diameter. Aluminum jacket circumferential seam bands shall be 2 by 0.016 inch aluminum matching jacket material. Bands for insulation below ground shall be 3/4 by 0.020 inch thick stainless steel, or fiberglass reinforced tape. The jacket may, at the option of the Contractor, be provided with a factory fabricated Pittsburgh or "Z" type longitudinal joint. When the "Z" joint is used, the bands at the circumferential joints shall be designed by the manufacturer to seal the joints and hold the jacket in place.
2.2.8.2 Polyvinyl Chloride (PVC) Jackets
Polyvinyl chloride (PVC) jacket and fitting covers shall have high impact strength, ultraviolet (UV) resistant rating or treatment and moderate chemical resistance with minimum thickness 0.030 inch.
2.2.8.3 Vapor Barrier/Weatherproofing Jacket
Vapor barrier/weatherproofing jacket shall be laminated self-adhesive, greater than 3 plies standard grade, silver, white, black and embossed or
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greater than 8 ply (minimum 2.9 mils adhesive); with 0.0000 permeability when tested in accordance with ASTM E96/E96M, using the water transmission rate test method; heavy duty, white or natural; and UV resistant. Flexible Elastomeric exterior foam with factory applied, UV Jacket made with a cold weather acrylic adhesive. Construction of laminate designed to provide UV resistance, high puncture, tear resistance and excellent Water Vapor Transmission (WVT) rate.
2.2.8.4 Vapor Barrier/Vapor Retarder
Apply the following criteria to determine which system is required.
a. On ducts, piping and equipment operating below 60 degrees F or located outside shall be equipped with a vapor barrier.
b. Ducts, pipes and equipment that are located inside and that always operate above 60 degrees F shall be installed with a vapor retarder where required as stated in paragraph VAPOR RETARDER REQUIRED.
2.2.9 Vapor Retarder Required
ASTM C921, Type I, minimum puncture resistance 50 Beach units on all surfaces except concealed ductwork, where a minimum puncture resistance of 25 Beach units is acceptable. Minimum tensile strength, 35 pounds/inch width. ASTM C921, Type II, minimum puncture resistance 25 Beach units, tensile strength minimum 20 pounds/inch width. Jackets used on insulation exposed in finished areas shall have white finish suitable for painting without sizing. Based on the application, insulation materials that require manufacturer or fabricator applied pipe insulation jackets are cellular glass, when all joints are sealed with a vapor barrier mastic, and mineral fiber. All non-metallic jackets shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Flexible elastomerics require (in addition to vapor barrier skin) vapor retarder jacketing for high relative humidity and below ambient temperature applications.
2.2.9.1 White Vapor Retarder All Service Jacket (ASJ)
ASJ is for use on hot/cold pipes, ducts, or equipment indoors or outdoors if covered by a suitable protective jacket. The product shall meet all physical property and performance requirements of ASTM C1136, Type I, except the burst strength shall be a minimum of 85 psi. ASTM D2863 Limited Oxygen Index (LOI) shall be a minimum of 31.
In addition, neither the outer exposed surface nor the inner-most surface contacting the insulation shall be paper or other moisture-sensitive material. The outer exposed surface shall be white and have an emittance of not less than 0.80. The outer exposed surface shall be paintable.
2.2.9.2 Vapor Retarder/Vapor Barrier Mastic Coatings
2.2.9.2.1 Vapor Barrier
The vapor barrier shall be self adhesive (minimum 2 mils adhesive, 3 mils embossed) greater than 3 plies standard grade, silver, white, black and embossed white jacket for use on hot/cold pipes. Permeability shall be less than 0.02 when tested in accordance with ASTM E96/E96M. Products shall meet UL 723 or ASTM E84 flame and smoke requirements and shall be UV resistant.
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2.2.9.2.2 Vapor Retarder
The vapor retarder coating shall be fire and water resistant and appropriately selected for either outdoor or indoor service. Color shall be white. The water vapor permeance of the compound shall be 0.013 perms or less at 43 mils dry film thickness as determined according to procedure B of ASTM E96/E96M utilizing apparatus described in ASTM E96/E96M. The coating shall be nonflammable, fire resistant type. To resist mold/mildew, coating shall meet ASTM D5590 with 0 growth rating. Coating shall meet MIL-PRF-19565 Type II (if selected for indoor service) and be Qualified Products Database listed. All other application and service properties shall be in accordance with ASTM C647.
2.2.9.3 Laminated Film Vapor Retarder
ASTM C1136, Type I, maximum moisture vapor transmission 0.02 perms, minimum puncture resistance 50 Beach units on all surfaces except concealed ductwork; where Type II, maximum moisture vapor transmission 0.02 perms, a minimum puncture resistance of 25 Beach units is acceptable. Vapor retarder shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Flexible Elastomeric exterior foam with factory applied UV Jacket. Construction of laminate designed to provide UV resistance, high puncture, tear resistance and an excellent WVT rate.
2.2.9.4 Polyvinylidene Chloride (PVDC) Film Vapor Retarder
The PVDC film vapor retarder shall have a maximum moisture vapor transmission of 0.02 perms, minimum puncture resistance of 150 Beach units, a minimum tensile strength in any direction of 30 lb/inch when tested in accordance with ASTM D882, and a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84.
2.2.9.5 Polyvinylidene Chloride Vapor Retarder Adhesive Tape
Requirements must meet the same as specified for Laminated Film Vapor Retarder above.
2.2.9.6 Vapor Barrier/Weather Barrier
The vapor barrier shall be greater than 3 ply self adhesive laminate -white vapor barrier jacket- superior performance (less than 0.0000 permeability when tested in accordance with ASTM E96/E96M). Vapor barrier shall meet UL 723 or ASTM E84 25 flame and 50 smoke requirements; and UV resistant. Minimum burst strength 185 psi in accordance with ISO 2758. Tensile strength 68 lb/inch width (PSTC-1000). Tape shall be as specified for laminated film vapor barrier above.
2.2.10 Vapor Retarder Not Required
ASTM C921, Type II, Class D, minimum puncture resistance 50 Beach units on all surfaces except ductwork, where Type IV, maximum moisture vapor transmission 0.10, a minimum puncture resistance of 25 Beach units is acceptable. Jacket shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84.
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2.2.11 Wire
Soft annealed ASTM A580/A580M Type 302, 304 or 316 stainless steel, 16 or 18 gauge.
2.2.12 Insulation Bands
Insulation bands shall be 1/2 inch wide; 26 gauge stainless steel.
2.2.13 Sealants
Sealants shall be chosen from the butyl polymer type, the styrene-butadiene rubber type, or the butyl type of sealants. Sealants shall have a maximum permeance of 0.02 perms based on Procedure B for ASTM E96/E96M, and a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84.
2.3 PIPE INSULATION SYSTEMS
Insulation materials shall conform to Table 1. Insulation thickness shall be as listed in Table 2 and meet or exceed the requirements of ASHRAE 90.1 - IP. Insulation thickness shall be 2 inches. Pipe insulation materials shall be limited to those listed herein and shall meet the following requirements:
2.3.1 Aboveground Hot Pipeline (Above 60 deg. F)
Insulation for outdoor, indoor, exposed or concealed applications shall meet the following requirements. Supply the insulation with manufacturer's recommended factory-applied jacket/vapor barrier.
2.3.1.1 Mineral Fiber
ASTM C547, Types I, II or III, supply the insulation with manufacturer's recommended factory-applied jacket.
2.3.1.2 Calcium Silicate
ASTM C533, Type I indoor only, or outdoors above 250 degrees F pipe temperature. Supply insulation with the manufacturer's recommended factory-applied jacket/vapor barrier.
2.3.1.3 Cellular Glass
ASTM C552, Type II and Type III. Supply the insulation with manufacturer's recommended factory-applied jacket.
2.3.1.4 Flexible Elastomeric Cellular Insulation
Closed-cell, foam- or expanded-rubber materials containing anti-microbial additive, complying with ASTM C534/C534M, Grade 1, Type I or II to 220 degrees F service. Type I for tubular materials. Type II for sheet materials.
2.3.1.5 Phenolic Insulation
ASTM C1126 Type III to 250 degrees F service shall comply with ASTM C795. Supply the insulation with manufacturer's recommended factory-applied jacket/vapor barrier.
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2.3.1.6 Perlite Insulation
ASTM C610
PART 3 EXECUTION
3.1 APPLICATION - GENERAL
Insulation shall only be applied to unheated and uncooled piping and equipment. Flexible elastomeric cellular insulation shall not be compressed at joists, studs, columns, ducts, hangers, etc. The insulation shall not pull apart after a one hour period; any insulation found to pull apart after one hour, shall be replaced.
3.1.1 Display Samples
Submit and display, after approval of materials, actual sections of installed systems, properly insulated in accordance with the specification requirements. Such actual sections must remain accessible to inspection throughout the job and will be reviewed from time to time for controlling the quality of the work throughout the construction site. Each material used shall be identified, by indicating on an attached sheet the specification requirement for the material and the material by each manufacturer intended to meet the requirement. The Owner's Representative will inspect display sample sections at the jobsite. Approved display sample sections shall remain on display at the jobsite during the construction period. Upon completion of construction, the display sample sections will be closed and sealed.
3.1.1.1 Pipe Insulation Display Sections
Display sample sections shall include as a minimum an elbow or tee, a valve, dielectric waterways and flanges, a hanger with protection shield and insulation insert, or dowel as required, at support point, method of fastening and sealing insulation at longitudinal lap, circumferential lap, butt joints at fittings and on pipe runs, and terminating points for each type of pipe insulation used on the job, and for hot pipelines and cold pipelines, both interior and exterior, even when the same type of insulation is used for these services.
3.1.2 Installation
Except as otherwise specified, material shall be installed in accordance with the manufacturer's written instructions. Insulation materials shall not be applied until tests specified in other sections of this specification are completed. Material such as rust, scale, dirt and moisture shall be removed from surfaces to receive insulation. Insulation shall be kept clean and dry. Insulation shall not be removed from its shipping containers until the day it is ready to use and shall be returned to like containers or equally protected from dirt and moisture at the end of each workday. Insulation that becomes dirty shall be thoroughly cleaned prior to use. If insulation becomes wet or if cleaning does not restore the surfaces to like new condition, the insulation will be rejected, and shall be immediately removed from the jobsite. Joints shall be staggered on multi layer insulation. Mineral fiber thermal insulating cement shall be mixed with demineralized water when used on stainless steel surfaces. Insulation, jacketing and accessories shall be installed in accordance with MICA Insulation Stds plates except where modified herein or on the drawings.
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3.1.3 Firestopping
Where pipes and ducts pass through fire walls, fire partitions, above grade floors, and fire rated chase walls, the penetration shall be sealed with fire stopping materials. The protection of ducts at point of passage through firewalls must be in accordance with NFPA 90A and/or NFPA 90B. All other penetrations, such as piping, conduit, and wiring, through firewalls must be protected with a material or system of the same hourly rating that is listed by UL, FM, or a NRTL.
3.1.4 Painting and Finishing
Painting shall be as specified in Section 09 90 00 PAINTS AND COATINGS.
3.1.5 Installation of Flexible Elastomeric Cellular Insulation
Install flexible elastomeric cellular insulation with seams and joints sealed with rubberized contact adhesive. Flexible elastomeric cellular insulation shall not be used on surfaces greater than 220 degrees F. Stagger seams when applying multiple layers of insulation. Protect insulation exposed to weather and not shown to have vapor barrier weatherproof jacketing with two coats of UV resistant finish or PVC or metal jacketing as recommended by the manufacturer after the adhesive is dry and cured.
3.1.5.1 Adhesive Application
Apply a brush coating of adhesive to both butt ends to be joined and to both slit surfaces to be sealed. Allow the adhesive to set until dry to touch but tacky under slight pressure before joining the surfaces. Insulation seals at seams and joints shall not be capable of being pulled apart one hour after application. Insulation that can be pulled apart one hour after installation shall be replaced.
3.1.5.2 Adhesive Safety Precautions
Use natural cross-ventilation, local (mechanical) pickup, and/or general area (mechanical) ventilation to prevent an accumulation of solvent vapors, keeping in mind the ventilation pattern must remove any heavier-than-air solvent vapors from lower levels of the workspaces. Gloves and spectacle-type safety glasses are recommended in accordance with safe installation practices.
3.1.6 Pipes That Require Insulation
Insulation is required on all pipes except for omitted items as specified.
3.2 PIPE INSULATION SYSTEMS INSTALLATION
Install pipe insulation systems in accordance with the approved MICA Insulation Stds plates as supplemented by the manufacturer's published installation instructions.
3.2.1 Pipe Insulation
3.2.1.1 General
Pipe insulation shall be installed on aboveground hot and cold pipeline
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systems as specified below to form a continuous thermal retarder/barrier, including straight runs, fittings and appurtenances unless specified otherwise. Installation shall be with full length units of insulation and using a single cut piece to complete a run. Cut pieces or scraps abutting each other shall not be used. Pipe insulation shall be omitted on the following:
a. Storm drain lines.
b. Adjacent insulation.
c. ASME stamps.
d. Cleanouts or handholes.
3.2.1.2 Pipes Passing Through Walls, Roofs, and Floors
Pipe insulation shall be continuous through the sleeve.
An aluminum jacket or vapor barrier/weatherproofingJacket or Vapor Barrier/Weatherproofing - self adhesive jacket (minimum 2 mils adhesive, 3 mils embossed) less than 0.0000 permeability, greater than 3 ply standard grade, silver, white, black and embossed with factory applied moisture retarder shall be provided over the insulation wherever penetrations require sealing.
3.2.1.2.1 Penetrate Interior Walls
The aluminum jacket or vapor barrier/weatherproofing - self adhesive jacket (minimum 2 mils adhesive, 3 mils embossed) less than 0.0000 permeability, greater than 3 plies standard grade, silver, white, black and embossed shall extend 2 inches beyond either side of the wall and shall be secured on each end with a band.
3.2.1.2.2 Penetrating Floors
Extend the aluminum jacket from a point below the backup material to a point 10 inches above the floor with one band at the floor and one not more than 1 inch from the end of the aluminum jacket.
3.2.1.2.3 Penetrating Waterproofed Floors
Extend the aluminum jacket rom below the backup material to a point 2 inches above the flashing with a band 1 inch from the end of the aluminum jacket.
3.2.1.2.4 Penetrating Exterior Walls
Continue the aluminum jacket required for pipe exposed to weather through the sleeve to a point 2 inches beyond the interior surface of the wall.
3.2.1.3 Pipes Passing Through Hangers
Insulation, whether hot or cold application, shall be continuous through hangers. All horizontal pipes 2 inches and smaller shall be supported on hangers with the addition of a Type 40 protection shield to protect the insulation in accordance with MSS SP-69. Whenever insulation shows signs of being compressed, or when the insulation or jacket shows visible signs of distortion at or near the support shield, insulation inserts as specified below for piping larger than 2 inches shall be installed, or
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factory insulated hangers (designed with a load bearing core) can be used.
3.2.1.3.1 Horizontal Pipes Larger Than 2 Inches at 60 Degrees F and Above
Supported on hangers in accordance with MSS SP-69, and Section 22 00 00 PLUMBING, GENERAL PURPOSE.
3.2.1.3.2 Vertical Pipes
Supported with either Type 8 or Type 42 riser clamps with the addition of two Type 40 protection shields in accordance with MSS SP-69 covering the 360-degree arc of the insulation. An insulation insert of cellular glass or calcium silicate shall be installed between each shield and the pipe. The insert shall cover the 360-degree arc of the pipe. Inserts shall be the same thickness as the insulation, and shall extend 2 inches on each end beyond the protection shield. When insulation inserts are required in accordance with the above, and the insulation thickness is less than 1 inch, wooden or cork dowels or blocks may be installed between the pipe and the shield to prevent the hanger from crushing the insulation, as an option instead of installing insulation inserts. The insulation jacket shall be continuous over the wooden dowel, wooden block, or insulation insert. The vertical weight of the pipe shall be supported with hangers located in a horizontal section of the pipe. When the pipe riser is longer than 30 feet, the weight of the pipe shall be additionally supported with hangers in the vertical run of the pipe that are directly clamped to the pipe, penetrating the pipe insulation. These hangers shall be insulated and the insulation jacket sealed as indicated herein for anchors in a similar service.
3.2.1.3.3 Inserts
Covered with a jacket material of the same appearance and quality as the adjoining pipe insulation jacket, overlap the adjoining pipe jacket 1-1/2 inches, and seal as required for the pipe jacket. The jacket material used to cover inserts in flexible elastomeric cellular insulation shall conform to ASTM C1136, Type 1, and is allowed to be of a different material than the adjoining insulation material.
3.2.1.4 Flexible Elastomeric Cellular Pipe Insulation
Flexible elastomeric cellular pipe insulation shall be tubular form for pipe sizes 6 inches and less. Grade 1, Type II sheet insulation used on pipes larger than 6 inches shall not be stretched around the pipe. On pipes larger than 12 inches, the insulation shall be adhered directly to the pipe on the lower 1/3 of the pipe. Seams shall be staggered when applying multiple layers of insulation. Sweat fittings shall be insulated with miter-cut pieces the same size as on adjacent piping. Screwed fittings shall be insulated with sleeved fitting covers fabricated from miter-cut pieces and shall be overlapped and sealed to the adjacent pipe insulation. Type II requires an additional exterior vapor retarder/barrier covering for high relative humidity and below ambient temperature applications.
3.2.1.5 Pipes in high abuse areas.
In high abuse areas such as janitor closets and traffic areas in equipment rooms, and mechanical rooms, stainless steel, aluminum or flexible laminate cladding (comprised of elastomeric, plastic or metal foil laminate) laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket, - less than 0.0000 permeability; (greater
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than 3 ply, standard grade, silver, white, black and embossed) aluminum jackets shall be utilized. Pipe insulation to the 6 foot level shall be protected.
3.2.1.6 Pipe Insulation Material and Thickness
TABLE 1 Insulation Material for Piping
Service Material Specification Type Class VR/VB Req'd Refrigerant Suction Piping (35 degrees F nominal) Flexible Elastomeric ASTM C534/C534M I No Cellular Cellular Glass ASTM C552 II 1 Yes Flexible Elastomeric ASTM C534/C534M I 2 No Cellular Horizontal Roof Drain Leaders (Including Underside of Roof Drain Fittings) Flexible Elastomeric ASTM C534/C534M I No Cellular Faced Phenolic Foam ASTM C1126 III Yes Cellular Glass ASTM C552 III Yes Condensate Drain Located Inside Building Cellular Glass ASTM C552 II 2 No Flexible Elastomeric ASTM C534/C534M I No Cellular Cellular Glass ASTM C552 II 2 No Flexible Elastomeric ASTM C534/C534M I No Cellular Note: VR/VB = Vapor Retarder/Vapor Barrier
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TABLE 2
Piping Insulation Thickness (inch)
Service
Material Tube And Pipe Size (inch)
<1 1-<1.5 1.5-<4 4-<8 > or = >8
Cellular Glass 1.5 1.5 1.5 2 2
Flexible Elastomeric 1 1 1 N/A N/A Cellular Refrigerant Suction Piping (35 degrees F nominal)
Flexible Elastomeric 1 1 1 N/A N/A Cellular Cellular Glass 1.5 1.5 1.5 1.5 1.5
Horizontal Roof Drain Leaders (Including Underside of Roof Drain Fittings) Cellular Glass 1.5 1.5 1.5 1.5 1.5
Flexible Elastomeric 1 1 1 N/A N/A Cellular Faced Phenolic Foam 1 1 1 1 1
Condensate Drain Located Inside Building
Cellular Glass 1.5 1.5 1.5 1.5 1.5
Flexible Elastomeric 1 1 1 N/A N/A Cellular
3.2.2 Aboveground Cold Pipelines
The following cold pipelines for minus 30 to plus 60 degrees F, shall be insulated in accordance with Table 2 except those piping listed in subparagraph Pipe Insulation in PART 3 as to be omitted. This includes but is not limited to the following:
a. Horizontal and vertical portions of interior roof drains.
b. Refrigerant suction lines.
c. Air conditioner condensate drains.
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3.2.2.1 Insulation Material and Thickness
Insulation thickness for cold pipelines shall be determined using Table 2.
3.2.2.2 Factory or Field applied Jacket
Insulation shall be covered with a factory applied vapor retarder jacket/vapor barrier or field applied seal welded PVC jacket or greater than 3 ply laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability, standard grade, sliver, white, black and embossed for use with Mineral Fiber, Cellular Glass, and Phenolic Foam Insulated Pipe. Insulation inside the building, to be protected with an aluminum jacket or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, Embossed Silver, White & Black, shall have the insulation and vapor retarder jacket installed as specified herein. The aluminum jacket or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, embossed silver, White & Black, shall be installed as specified for piping exposed to weather, except sealing of the laps of the aluminum jacket is not required. In high abuse areas such as janitor closets and traffic areas in equipment rooms, and mechanical rooms, aluminum jackets or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, embossed silver, white & black, shall be provided for pipe insulation to the 6 ft level.
3.2.2.3 Installing Insulation for Straight Runs Hot and Cold Pipe
3.2.2.3.1 Longitudinal Laps of the Jacket Material
Overlap not less than 1-1/2 inches. Provide butt strips 3 inches wide for circumferential joints.
3.2.2.3.2 Laps and Butt Strips
Secure with adhesive and staple on 4 inch centers if not factory self-sealing. If staples are used, seal in accordance with paragraph STAPLES below. Note that staples are not required with cellular glass systems.
3.2.2.3.3 Factory Self-Sealing Lap Systems
May be used when the ambient temperature is between 40 and 120 degrees F during installation. Install the lap system in accordance with manufacturer's recommendations. Use a stapler only if specifically recommended by the manufacturer. Where gaps occur, replace the section or repair the gap by applying adhesive under the lap and then stapling.
3.2.2.3.4 Staples coat all staples, including those used to repair factory self-seal lap systems, with a vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. Coat all seams, except those on factory self-seal systems, with vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape.
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3.2.2.3.5 Breaks and Punctures in the Jacket Material
Patch by wrapping a strip of jacket material around the pipe and secure it with adhesive, staple, and coat with vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. Extend the patch not less than 1-1/2 inches past the break.
3.2.2.3.6 Flexible Elastomeric Cellular Pipe Insulation
Install by slitting the tubular sections and applying them onto the piping or tubing. Alternately, whenever possible slide un-slit sections over the open ends of piping or tubing. Secure all seams and butt joints and seal with adhesive. When using self seal products only the butt joints shall be secured with adhesive. Push insulation on the pipe, never pulled. Stretching of insulation may result in open seams and joints. Clean cut all edges. Rough or jagged edges of the insulation are not be permitted. Use proper tools such as sharp knives. Do not stretch Grade 1, Type II sheet insulation around the pipe when used on pipe larger than 6 inches. On pipes larger than 12 inches, adhere sheet insulation directly to the pipe on the lower 1/3 of the pipe.
3.2.2.4 Insulation for Fittings and Accessories
a. Pipe insulation shall be tightly butted to the insulation of the fittings and accessories. The butted joints and ends shall be sealed with joint sealant and sealed with a vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape.
b. Precut or preformed insulation shall be placed around all fittings and accessories and shall conform to MICA plates except as modified herein: 5 for anchors; 10, 11, and 13 for fittings; 14 for valves; and 17 for flanges and unions. Insulation shall be the same insulation as the pipe insulation, including same density, thickness, and thermal conductivity. Where precut/preformed is unavailable, rigid preformed pipe insulation sections may be segmented into the shape required. Insulation of the same thickness and conductivity as the adjoining pipe insulation shall be used. If nesting size insulation is used, the insulation shall be overlapped 2 inches or one pipe diameter. Elbows insulated using segments shall conform to MICA Tables 12.20 "Mitered Insulation Elbow'. Submit a booklet containing completed MICA Insulation Stds plates detailing each insulating system for each pipe, duct, or equipment insulating system, after approval of materials and prior to applying insulation.
(1) The MICA plates shall detail the materials to be installed and the specific insulation application. Submit all MICA plates required showing the entire insulating system, including plates required to show insulation penetrations, vessel bottom and top heads, legs, and skirt insulation as applicable. The MICA plates shall present all variations of insulation systems including locations, materials, vaporproofing, jackets and insulation accessories.
(2) If the Contractor elects to submit detailed drawings instead of edited MICA Plates, the detail drawings shall be technically equivalent to the edited MICA Plate submittal.
c. Upon completion of insulation installation on flanges, unions, valves,
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anchors, fittings and accessories, terminations, seams, joints and insulation not protected by factory vapor retarder jackets or PVC fitting covers shall be protected with PVDC or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape or two coats of vapor retarder coating with a minimum total thickness of 1/16 inch, applied with glass tape embedded between coats. Tape seams shall overlap 1 inch. The coating shall extend out onto the adjoining pipe insulation 2 inches. Fabricated insulation with a factory vapor retarder jacket shall be protected with either greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape, standard grade, silver, white, black and embossed or PVDC adhesive tape or two coats of vapor retarder coating with a minimum thickness of 1/16 inch and with a 2 inch wide glass tape embedded between coats. Where fitting insulation butts to pipe insulation, the joints shall be sealed with a vapor retarder coating and a 4 inch wide ASJ tape which matches the jacket of the pipe insulation.
d. Anchors attached directly to the pipe shall be insulated for a sufficient distance to prevent condensation but not less than 6 inches from the insulation surface.
e. Insulation shall be marked showing the location of unions, strainers, and check valves.
3.2.2.5 Optional PVC Fitting Covers
At the option of the Contractor, premolded, one or two piece PVC fitting covers may be used in lieu of the vapor retarder and embedded glass tape. Factory precut or premolded insulation segments shall be used under the fitting covers for elbows. Insulation segments shall be the same insulation as the pipe insulation including same density, thickness, and thermal conductivity. The covers shall be secured by PVC vapor retarder tape, adhesive, seal welding or with tacks made for securing PVC covers. Seams in the cover, and tacks and laps to adjoining pipe insulation jacket, shall be sealed with vapor retarder tape to ensure that the assembly has a continuous vapor seal.
3.2.3 Aboveground Hot Pipelines
3.2.3.1 General Requirements
All hot pipe lines above 60 degrees F, except those piping listed in subparagraph Pipe Insulation in PART 3 as to be omitted, shall be insulated in accordance with Table 2. This includes but is not limited to the following:
a. Condensate discharge.
b. Heated fuel.
Insulation shall be covered, in accordance with manufacturer's recommendations, with a factory applied Type I jacket or field applied aluminum where required or seal welded PVC.
3.2.3.2 Insulation for Fittings and Accessories
Pipe insulation shall be tightly butted to the insulation of the fittings and accessories. The butted joints and ends shall be sealed with joint sealant. Insulation shall be marked showing the location of unions,
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strainers, check valves and other components that would otherwise be hidden from view by the insulation.
3.2.3.2.1 Precut or Preformed
Place precut or preformed insulation around all fittings and accessories. Insulation shall be the same insulation as the pipe insulation, including same density, thickness, and thermal conductivity.
3.2.3.2.2 Rigid Preformed
Where precut/preformed is unavailable, rigid preformed pipe insulation sections may be segmented into the shape required. Insulation of the same thickness and conductivity as the adjoining pipe insulation shall be used. If nesting size insulation is used, the insulation shall be overlapped 2 inches or one pipe diameter. Elbows insulated using segments shall conform to MICA Tables 12.20 "Mitered Insulation Elbow".
3.2.4 Piping Exposed to Weather
Piping exposed to weather shall be insulated and jacketed as specified for the applicable service inside the building. After this procedure, a laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability (greater than 3 ply, standard grade, silver, white, black and embossed aluminum jacket or PVC jacket shall be applied. PVC jacketing requires no factory-applied jacket beneath it, however an all service jacket shall be applied if factory applied jacketing is not furnished. Flexible elastomeric cellular insulation exposed to weather shall be treated in accordance with paragraph INSTALLATION OF FLEXIBLE ELASTOMERIC CELLULAR INSULATION in PART 3.
3.2.4.1 Aluminum Jacket
The jacket for hot piping may be factory applied. The jacket shall overlap not less than 2 inches at longitudinal and circumferential joints and shall be secured with bands at not more than 12 inch centers. Longitudinal joints shall be overlapped down to shed water and located at 4 or 8 o'clock positions. Joints on piping 60 degrees F and below shall be sealed with metal jacketing/flashing sealant while overlapping to prevent moisture penetration. Where jacketing on piping 60 degrees F and below abuts an un-insulated surface, joints shall be caulked to prevent moisture penetration. Joints on piping above 60 degrees F shall be sealed with a moisture retarder.
3.2.4.2 Insulation for Fittings
Flanges, unions, valves, fittings, and accessories shall be insulated and finished as specified for the applicable service. Two coats of breather emulsion type weatherproof mastic (impermeable to water, permeable to air) recommended by the insulation manufacturer shall be applied with glass tape embedded between coats. Tape overlaps shall be not less than 1 inch and the adjoining aluminum jacket not less than 2 inches. Factory preformed aluminum jackets may be used in lieu of the above. Molded PVC fitting covers shall be provided when PVC jackets are used for straight runs of pipe. PVC fitting covers shall have adhesive welded joints and shall be weatherproof laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability, (greater than 3 ply, standard grade, silver, white, black and
SECTION 23 07 00 Page 20 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
embossed, and UV resistant.
3.2.4.3 PVC Jacket
PVC jacket shall be ultraviolet resistant and adhesive welded weather tight with manufacturer's recommended adhesive. Installation shall include provision for thermal expansion.
3.3 EQUIPMENT INSULATION SYSTEMS INSTALLATION
Install equipment insulation systems in accordance with the approved MICA Insulation Stds plates as supplemented by the manufacturer's published installation instructions.
3.3.1 General
Removable insulation sections shall be provided to cover parts of equipment that must be opened periodically for maintenance including vessel covers, fasteners, flanges and accessories. Equipment insulation shall be omitted on the following:
a. ASME stamps.
b. Manufacturer's nameplates.
c. Duct Test/Balance Test Holes.
3.3.2 Insulation for Cold Equipment
Cold equipment below 60 degrees F: Insulation shall be furnished on equipment handling media below 60 degrees F including the following:
a. Refrigeration equipment parts that are not factory insulated.
b. Roof drain bodies.
3.3.2.1 Insulation Type
Insulation shall be suitable for the temperature encountered. Material and thicknesses shall be as shown in Table 5:
TABLE 5
Insulation Thickness for Cold Equipment (inches)
Equipment handling media at indicated temperature
Material Thickness (inches) 35 to 60 degrees F
Cellular Glass 1.5
Flexible Elastomeric Cellular 1
1 to 34 degrees F
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TABLE 5
Insulation Thickness for Cold Equipment (inches)
Equipment handling media at indicated temperature
Material Thickness (inches) Cellular Glass 3
Flexible Elastomeric Cellular 1.5
Minus 30 to 0 degrees F
Cellular Glass 3.5
Flexible Elastomeric Cellular 1.75
3.3.2.2 Other Equipment
a. Insulation shall be formed or fabricated to fit the equipment. To ensure a tight fit on round equipment, edges shall be beveled and joints shall be tightly butted and staggered.
b. Insulation shall be secured in place with bands or wires at intervals as recommended by the manufacturer but not more than 12 inch centers except flexible elastomeric cellular which shall be adhered with contact adhesive. Insulation corners shall be protected under wires and bands with suitable corner angles.
c. Cellular glass shall be installed in accordance with manufacturer's instructions. Joints and ends shall be sealed with joint sealant, and sealed with a vapor retarder coating.
d. Insulation on heads of heat exchangers shall be removable. Removable section joints shall be fabricated using a male-female shiplap type joint. The entire surface of the removable section shall be finished by applying two coats of vapor retarder coating with a layer of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1/16 inch.
e. Exposed insulation corners shall be protected with corner angles.
f. Insulation on equipment with ribs shall be applied over 6 by 6 inches by 12 gauge welded wire fabric which has been cinched in place, or if approved by the Owner's Representative, spot welded to the equipment over the ribs. Insulation shall be secured to the fabric with J-hooks and 2 by 2 inches washers or shall be securely banded or wired in place on 12 inch centers.
3.3.2.3 Vapor Retarder/Vapor Barrier
Upon completion of installation of insulation, penetrations shall be caulked. Two coats of vapor retarder coating or vapor barrier jacket shall be applied over insulation, including removable sections, with a layer of open mesh synthetic fabric embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. Flashing sealant or vapor
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barrier tape shall be applied to parting line between equipment and removable section insulation.
3.3.3 Insulation for Hot Equipment
Insulation shall be furnished on equipment handling media above 60 degrees F including the following:
l. Unjacketed generators or parts of generators.
m. Generator flue gas connection from generator to stack (if inside).
n. Generator.
3.3.3.1 Insulation
Insulation shall be suitable for the temperature encountered. Shell and tube-type heat exchangers shall be insulated for the temperature of the shell medium.
Insulation thickness for hot equipment shall be determined using Table 6:
TABLE 6
Insulation Thickness for Hot Equipment (inches)
Equipment handling steam or media at indicated pressure or temperature limit Material Thickness (inches) 15 psig or 250 degrees F
Rigid Mineral Fiber 2
Flexible Mineral Fiber 2
Calcium Silicate/Perlite 4
Cellular Glass 3
Faced Phenolic Foam 1.5
Flexible Elastomeric Cellular (<200 F) 1
200psig or 400 degrees F Rigid Mineral Fiber 3
Flexible Mineral Fiber 3
Calcium Silicate/Perlite 4
Cellular Glass 4
600 degrees F
Rigid Mineral Fiber 5
Flexible Mineral Fiber 6
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TABLE 6
Insulation Thickness for Hot Equipment (inches)
Equipment handling steam or media at indicated pressure or temperature limit Material Thickness (inches) Calcium Silicate/Perlite 6
Cellular Glass 6
600 degrees F: Thickness necessary to limit the external temperature of the insulation to 120 F. Heat transfer calculations shall be submitted to substantiate insulation and thickness selection.
3.3.3.2 Insulation of Boiler Stack and Diesel Engine Exhaust Pipe
Inside Generator Room, bevel insulation neatly around openings and provide sheet metal insulation stop strips around such openings. Apply a skim coat of hydraulic setting cement directly to insulation. Apply a flooding coat of adhesive over hydraulic setting cement, and while still wet, press a layer of glass cloth or tape into adhesive and seal laps and edges with adhesive. Coat glass cloth with adhesive. When dry, apply a finish coat of adhesive at can-consistency so that when dry no glass weave shall be observed. Provide metal jackets for exhaust pipes that are located above finished floor and spaces outside generator room. Apply metal jackets directly over insulation and secure with 3/4 inch wide metal bands spaced on 18 inch centers. Do not insulate name plates. Insulation type and thickness shall be in accordance with the following Table 7.
TABLE 7
Insulation and Thickness for Boiler Stack and Diesel Engine Exhaust Pipe
Service & Surface Temperature Range (Degrees F)
Material Outside Diameter (Inches)
0.25 - 1 - 3.5-5 6 - 10 > or = 11 - 36 1.25 1.67
Diesel Engine Exhaust (Up to 700 degrees F)
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TABLE 7
Insulation and Thickness for Boiler Stack and Diesel Engine Exhaust Pipe
Service & Surface Temperature Range (Degrees F)
Material Outside Diameter (Inches)
0.25 - 1 - 3.5-5 6 - 10 > or = 11 - 36 1.25 1.67
Calcium Silicate 3 3.5 4 4 4 ASTM C533, Type I or II
Cellular Glass 2.5* 3.5 4 4.5 6 ASTM C552, Type II
3.3.3.3 Other Equipment
a. Insulation shall be formed or fabricated to fit the equipment. To ensure a tight fit on round equipment, edges shall be beveled and joints shall be tightly butted and staggered.
b. Insulation shall be secured in place with bands or wires at intervals as recommended by the manufacturer but not greater than 12 inch centers except flexible elastomeric cellular which shall be adhered. Insulation corners shall be protected under wires and bands with suitable corner angles.
c. Upon completion of installation of insulation, penetrations shall be caulked. Two coats of adhesive shall be applied over insulation, including removable sections, with a layer of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. Caulking shall be applied to parting line between equipment and removable section insulation.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 23 08 00.00 10
COMMISSIONING OF HVAC SYSTEMS 01/08 08/20/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASSOCIATED AIR BALANCE COUNCIL (AABC)
ACG Commissioning Guideline (2005) Commissioning Guideline
NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB)
NEBB Commissioning Standard (2009) Procedural Standards for Whole Building Systems Commissioning of New Construction; 3rd Edition
SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)
SMACNA 1429 (1994) HVAC Systems Commissioning Manual, 1st Edition
U.S. GREEN BUILDING COUNCIL (USGBC)
LEED NC (2009) Leadership in Energy and Environmental Design(tm) New Construction Rating System
1.2 DEFINITIONS
In some instances, terminology differs between the Contract and the Commissioning Standard primarily because the intent of this Section is to use the industry standards specified, along with additional requirements listed herein to produce optimal results. The following table of similar terms is provided for clarification only. Contract requirements take precedent over the corresponding ACG, NEBB, or TABB requirements where differences exist.
SIMILAR TERMS
Contract Term ACG NEBB TABB
Commissioning ACG Commissioning Procedural SMACNA HVAC Standard Guideline Standards for Commissioning Building Systems Guidelines Commissioning
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SIMILAR TERMS
Contract Term ACG NEBB TABB
Commissioning ACG Certified NEBB Qualified TABB Certified Specialist Commissioning Commissioning Commissioning Agent Administrator Supervisor
1.3 SYSTEM DESCRIPTION
1.3.1 General
Perform Commissioning in accordance with the requirements of the standard under which the Commissioning Firm's qualifications are approved, i.e., ACG Commissioning Guideline, NEBB Commissioning Standard, or SMACNA 1429 unless otherwise stated herein. Consider mandatory all recommendations and suggested practices contained in the Commissioning Standard. Use the Commissioning Standard for all aspects of Commissioning, including qualifications for the Commissioning Firm and Specialist and calibration of Commissioning instruments. Where the instrument manufacturer calibration recommendations are more stringent than those listed in the Commissioning Standard, the manufacturer's recommendations shall be adhered to. All quality assurance provisions of the Commissioning Standard such as performance guarantees shall be part of this contract. For systems or system components not covered in the Commissioning Standard, Commissioning procedures shall be developed by the Commissioning Specialist. Where new procedures, requirements, etc., applicable to the Contract requirements have been published or adopted by the body responsible for the Commissioning Standard used (ACG, NEBB, or TABB), the requirements and recommendations contained in these procedures and requirements shall be considered mandatory.
1.3.2 Energy
Formal LEED NC certification is not required; however, the Contractor is required to provide documentation that meets the LEED NC Energy & Atmosphere (EA) Prerequisite 1, Fundamental Commissioning. For New Construction and Major Revisions provide, also, documentation that meets EA Credit 3; Enhanced Commissioning. Provide documentation for as many LEED credits as possible to support LEED Silver certification of the project.
1.4 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Commissioning Plan; G,
SD-03 Product Data
Functional Performance Tests; G,
SD-06 Test Reports
Commissioning Report; G
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SD-07 Certificates
Commissioning Firm; G Commissioning Specialist; G
1.5 QUALITY ASSURANCE
1.5.1 Commissioning Firm
Submit certification of the proposed Commissioning Firm's qualifications to perform the duties specified herein and in other related Sections, no later than 21 days after the Notice to Proceed. Include in the documentation the date that the Certification was initially granted and the date when the current Certification expires. The firm is either a member of ACG or certified by the NEBB or the TABB and certified in all categories and functions where measurements or performance are specified on the plans and specifications. Any lapses in Certification of the proposed Commissioning Firm or disciplinary action taken by ACG, NEBB, or TABB against the proposed Commissioning Firm shall be described in detail. The certification shall be maintained for the entire duration of duties specified herein. If, for any reason, the firm loses subject certification during this period, immediately notify the Owner's Representative and submit another Commissioning Firm for approval. Any firm that has been the subject of disciplinary action by the ACG, the NEBB, or the TABB within the five years preceding Contract Award is not eligible to perform any duties related to the HVAC systems, including Commissioning. All work specified in this Section and in other related Sections to be performed by the Commissioning Firm shall be considered invalid if the Commissioning Firm loses its certification prior to Contract completion and must be performed by an approved successor. These Commissioning services are to assist the prime Contractor in performing the quality oversight for which it is responsible. The Commissioning Firm shall be a subcontractor of the prime Contractor and shall be financially and corporately independent of all other subContractors. The Commissioning Firm shall report to and be paid by the prime Contractor.
1.5.2 Commissioning Specialist
1.5.2.1 General
Submit certification of the proposed Commissioning Specialist's qualifications to perform the duties specified herein and in other related Sections, no later than 21 days after the Notice to Proceed. The documentation shall include the date that the Certification was initially granted and the date when the current Certification expires. The Commissioning Specialist shall be an ACG Certified Commissioning Agent, a NEBB Qualified Commissioning Administrator, or a TABB Certified Commissioning Supervisor and shall be an employee of the approved Commissioning Firm. Any lapses in Certification of the proposed Commissioning Specialist or disciplinary action taken by ACG, NEBB, or TABB against the proposed Commissioning Specialist shall be described in detail. The certification shall be maintained for the entire duration of duties specified herein. If, for any reason, the Commissioning Specialist loses subject certification during this period, immediately notify the Owner's representative and submit another Commissioning Specialist for approval. Any individual that has been the subject of disciplinary action by the ACG, the NEBB, or the TABB within the five years preceding Contract Award is not eligible to perform any duties related to the HVAC systems,
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including Commissioning. All work specified in this Section and in other related Sections performed by the Commissioning Specialist shall be considered invalid if the Commissioning Specialist loses certification prior to Contract completion and must be performed by the approved successor.
1.5.2.2 Responsibilities
Perform all Commissioning work specified herein and in related sections under the direct guidance of the Commissioning Specialist. The Commissioning Specialist shall prepare, no later than 28 days after the approval of the Commissioning Specialist, the Commissioning Plan which will be a comprehensive schedule and will include all submittal requirements for procedures, notifications, reports and the Commissioning Report. After approval of the Commissioning Plan, revise the Contract NAS schedule to reflect the schedule requirements in the Commissioning Plan.
1.6 SEQUENCING AND SCHEDULING
Begin the work described in this Section only after all work required in related Sections has been successfully completed, and all test and inspection reports and operation and maintenance manuals required in these Sections have been submitted and approved. Pre-Functional Performance Test Checklists shall be performed at appropriate times during the construction phase of the Contract.
PART 2 PRODUCTS
Not Used
PART 3 EXECUTION
3.1 COMMISSIONING TEAM AND TEST FORMS AND CHECKLISTS
Designate Contractor team members to participate in the Pre- Functional Performance Test Checklists and the Functional Performance Tests specified herein. In addition, the Owner's Representative team members will include a representative of the Owner's Representative, the Design Agent's Representative, and the Using Agency's Representative. The team members shall be as follows:
Designation Function
A Contractor's Commissioning Specialist
M Contractor's Mechanical Representative
E Contractor's Electrical Representative
T Contractor's Testing, Adjusting, and Balancing (TAB) Specialist C Contractor's Controls Representative
D Design Agency Representative
O Owner's Representative
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Designation Function
U Using Agency's Representative
Appendices A and B shall be completed by the commissioning team. Acceptance by each commissioning team member of each Pre- Functional Performance Test Checklist item shall be indicated by initials and date unless an "X" is shown indicating that participation by that individual is not required. Acceptance by each commissioning team member of each functional performance test item shall be indicated by signature and date.
3.2 TESTS
Perform the pre-functional performance test checklists and functional performance tests in a manner that essentially duplicates the checking, testing, and inspection methods established in the related Sections. Where checking, testing, and inspection methods are not specified in other Sections, establish methods which will provide the information required. Testing and verification required by this section shall be performed during the Commissioning phase. Requirements in related Sections are independent from the requirements of this Section and shall not be used to satisfy any of the requirements specified in this Section. Provide all materials, services, and labor required to perform the pre- functional performance tests checks and functional performance tests. A functional performance test shall be aborted if any system deficiency prevents the successful completion of the test or if any participating non-Owner commissioning team member of which participation is specified is not present for the test.
3.2.1 Pre-Functional Performance Test Checklists
Perform Pre-Functional Performance Test Checklists, for the items indicated in Appendix A, at least 28 days prior to the start of Pre-Functional Performance Test Checks.. Correct and re-inspect deficiencies discovered during these checks in accordance with the applicable contract requirements. Submit the schedule for the test checks at least 14 days prior to the start of Pre-Functional Performance Test Checks.
3.2.2 Functional Performance Tests
Submit test procedures at least 28 days prior to the start of Functional Performance Tests. Submit the schedule for the tests at least 14 days prior to the start of Functional Performance Tests. Perform Functional Performance Tests for the items indicated in Appendix B. Begin Functional Performance Tests only after all Pre-Functional Performance Test Checklists have been successfully completed. Tests shall prove all modes of the sequences of operation, and shall verify all other relevant contract requirements. Begin Tests with equipment or components and progress through subsystems to complete systems. Upon failure of any Functional Performance Test item, correct all deficiencies in accordance with the applicable contract requirements. The item shall then be retested until it has been completed with no errors.
3.3 COMMISSIONING REPORT
Submit the Commissioning Report, no later than 14 days after completion of Functional Performance Tests, consisting of completed Pre- Functional Performance Test Checklists and completed Functional Performance Tests organized by system and by subsystem and submitted as one package. The
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Commissioning Report shall also include all HVAC systems test reports, inspection reports (Preparatory, Initial and Follow-up inspections), start-up reports, TAB report, TAB verification report, Controls start-up test reports and Controls Performance Verification Test (PVT) report. The results of failed tests shall be included along with a description of the corrective action taken.
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APPENDIX A
PRE-FUNCTIONAL PERFORMANCE TEST CHECKLISTS
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Pre-Functional Performance Test Checklist - DX Air Cooled Condensing Unit
For Heat Pump Unit: HP-01
Checklist Item A M E T C O
Installation
a. Check condenser fans for proper rotation. ______X ___ X ___
Electrical A M E T C O
a. Power available to unit disconnect. ___ X ___ X X ___
b. Power available to unit control panel. ___ X ___ X ______
c. Verify that power disconnect is located within sight of the unit it controls ___ X ___ X ______
Controls A M E T C O
a. Unit safety/protection devices tested. ______X X ______
b. Control system and interlocks installed. ______X X ______
c. Control system and interlocks operational. ______X X ______
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Pre-Functional Performance Test Checklist - Pumps
Pre-Functional Performance Test Checklist - Fan Coil Unit
For Fan Coil Unit: FC-01
Checklist Item
Installation A M E T C O
a. Access doors/removable panels are operable and sealed. ______X ___ X ___
b. Condensate drainage is unobstructed. ______X X X ___
c. Fan belt adjusted. ______X ___ X ___
Electrical A M E T C O
a. Power available to unit disconnect. ______X ______
b. Power available to unit control panel. ______X ______
c. Proper motor rotation verified. ______X ___
d. Verify that power disconnect is located within sight of the unit it controls. ______X ______
e. Power available to electric heating coil. ______X X ___
Controls A M E T C O
a. Control valves/actuators properly installed. ______X ______
b. Control valves/actuators operable. ______X X ______
c. Verify proper location and installation of thermostat. ______X ______
Testing, Adjusting, and Balancing (TAB) A M E T C O
a. TAB Report approved. ______X ___ X ___
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Pre-Functional Performance Test Checklist - Unit Heater
For Unit Heater: UH-01, UH-02
Checklist Item
Installation A M E T C O
Electrical A M E T C O
a. Power available to unit disconnect. ______X ______
b. Proper motor rotation verified. ______X X ___
c. Verify that power disconnect is located within sight of the unit it controls. ______X ______
d. Power available to electric heating coil. ______X ______
Controls A M E T C O
a. Control valves properly installed. ______X ______
b. Control valves operable. ______X X ______
c. Verify proper location and installation of thermostat. ______X ______
Testing, Adjusting, and Balancing (TAB) A M E T C O
a. TAB Report approved. ______X ___ X ___
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Pre-Functional Performance Test Checklist - Exhaust Fan
For Exhaust Fan: EF-01, EF-02
Checklist Item
Installation A M E T C O
a. Fan belt adjusted. ______X ___ X ___
Electrical A M E T C O
a. Power available to fan disconnect. ______X ______
b. Proper motor rotation verified. ______X ___
c. Verify that power disconnect is located within sight of the unit it controls. ______X ______
Controls A M E T C O
a. Control interlocks properly installed. ______X ______
b. Control interlocks operable. ______X ______
c. Dampers/actuators properly installed. ______X ______
d. Dampers/actuators operable. ______X ______
e. Verify proper location and installation of thermostat. ______X ______
Testing, Adjusting, and Balancing (TAB) A M E T C O
a. TAB Report approved. ______X ___ X ___
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- End of Appendix A -
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APPENDIX B
FUNCTIONAL PERFORMANCE TESTS CHECKLISTS
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Functional Performance Test Checklist - Fan Coil Units
The Owner's Representative will select fan coil units to be spot-checked during the functional performance test. The number of terminals shall not exceed 10 percent. Hot water and chilled water systems must be in operation providing design water temperatures.
1. Functional Performance Test: Contractor shall demonstrate operation of selected fan coils in accordance with specifications including the following:
a. Cooling only fan coils:
(1) Verify fan coil unit response to room temp set point adjustment. 1. Check blower fan airflow. _____ cfm 2. Check cooling coil water flow. _____ gpm 3. Verify proper operation of cooling water control valve.______4. Cooling mode inlet air temperature ______deg F 5. Cooling mode outlet air temperature______deg F 6. Calculate coil sensible capacity and compare to design: Calculated ______BTU/hr Design______BTU/hr
b. Cooling/heating fan coils:
(1) Verify fan coil unit response to room temp set point adjustment. 1. Check blower fan airflow. _____ cfm 2. Check cooling coil water flow. _____ gpm 3. Verify proper operation of cooling water control valve. ____ 4. Check cooling mode inlet air temperature. _____deg F 5. Check cooling mode outlet air temperature. _____deg F 6. Calculate cooling coil sensible capacity and compare to design: 7. Calculated ______BTU/hr Design_____BTU/hr 8. Check heating coil water flow. _____ gpm 9. Verify proper operation of heating water control valve. _____ 10. Check heating mode inlet air temperature. _____ deg F 11. Check heating mode outlet air temperature. _____deg F 12. Calculate heating coil capacity and compare to design: Calculated______BTU/hr design______BTU/hr
2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date
Contractor's Commissioning Specialist ______
Contractor's Mechanical Representative ______
Contractor's Electrical Representative ______
Contractor's TAB Representative ______
Contractor's Controls Representative ______
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Design Agency Representative ______
Owner's Representative's Representative ______
Using Agency's Representative ______
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Functional Performance Test Checklist - Unit Heaters
The Owner's Representative will select unit heaters to be spot-checked during the functional performance test. The number of terminals shall not exceed 10 percent. Hot water systems (for hot water unit heaters) must be in operation and supplying design hot water supply temperature water.
1. Functional Performance Test: Contractor shall demonstrate operation of selected unit heaters:
a. Verify unit heater response to room temperature set point adjustment.______b. Check heating mode inlet air temperature. _____ deg F c. Check heating mode outlet air temperature. _____ deg F d. Record manufacturer's submitted fan capacity _____cfm e. Calculate unit heater capacity using manufacturer's fan capacity and recorded temperatures and compare to design. f. Calculated_____BTU/hr Design______BTU/hr
2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.
Signature and Date
Contractor's Commissioning Specialist ______
Contractor's Mechanical Representative ______
Contractor's Electrical Representative ______
Contractor's TAB Representative ______
Contractor's Controls Representative ______
Design Agency Representative ______
Owner's Representative's Representative ______
Using Agency's Representative ______
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Functional Performance Test Checklist - HVAC Controls
For HVAC System:
The Owner's Representative will select HVAC control systems to undergo functional performance testing. The number of systems shall not exceed 10 percent. Perform this test simultaneously with FPT for AHU or other controlled equipment.
1. Functional Performance Test: Contractor shall verify operation of HVAC controls by performing the Performance Verification Test (PVT) test for that system. Contractor to provide blank PVT test procedures previously done by the controls Contractor.
2. Verify interlock with UMCS system______.
3. Verify all required I/O points function from the UMCS system_____.
4. Certification: We the undersigned have witnessed the Performance Verification Test and certify that the item tested has met the performance requirements in this section of the specifications.
Signature and Date
Contractor's Commissioning Specialist ______
Contractor's Mechanical Representative ______
Contractor's Electrical Representative ______
Contractor's TAB Representative ______
Contractor's Controls Representative ______
Design Agency Representative ______
Owner's Representative ______
Using Agency's Representative ______
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- End of Appendix B -
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-End of document -- End of Section --
SECTION 23 08 00.00 10 Page 19 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 23 09 33.00 40
ELECTRIC AND ELECTRONIC CONTROL SYSTEM FOR HVAC 08/10 08/20/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus
NATIONAL AERONAUTICS AND SPACE ADMINISTRATION (NASA)
RCBEA GUIDE (2004) NASA Reliability Centered Building and Equipment Acceptance Guide
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA DC 3 (2008) Residential Controls - Electrical Wall-Mounted Room Thermostats
1.2 SYSTEM DESCRIPTION
1.2.1 General Requirements
Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS applies to work specified in this section.
Submit Material, Equipment, and Fixture Lists for control and instrumentation systems including manufacturer's style or catalog numbers, specification and drawing reference numbers, warranty information, and fabrication site information.
Submit Records of Existing Conditions consisting of the results of survey of work area conditions and features of existing structures and facilities within and adjacent to the jobsite. Commencement of work constitutes acceptance of existing conditions.
1.2.2 System Requirements
Provide automatic temperature control systems that are complete in all details and that include all necessary accessories to maintain conditions indicated or specified.
Provide electronic electric/electronic low-voltage electric automatic temperature control systems. As far as practical, provide control equipment that is the product of a single automatic control systems manufacturer. Provide automatic control systems components not the product of the control system manufacturer that are approved for use with the
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control system as indicated.
Provide automatically controlled valves to control environment that are furnished by the automatic control systems manufacturer.
Provide automatically controlled dampers, independent of dampers integral with manufactured air-handling units, furnished by the automatic control systems manufacturer. Use a damper manufacturer that is licensed to display the AMCA seal.
Provide dual-duct system mixing boxes and air-mixing valve operators that are furnished by the automatic control systems manufacturer.
Submit Fabrication Drawings for control and instrumentation systems consisting of fabrication and assembly details to be performed in the factory.
Submit Operating Instructions for control and instrumentation consisting of standard operating procedures including startup, shutdown, and emergency operation.
1.3 QUALITY ASSURANCE
1.3.1 Predictive Testing And Inspection Technology Requirements
This section contains systems and/or equipment components regulated by NASA's Reliability Centered Building and Equipment Acceptance Program. This program requires the use of Predictive Testing and Inspection (PT&I) technologies in conformance with RCBEA GUIDE to ensure building equipment and systems installed by the Contractor have been installed properly and contain no identifiable defects that shorten the design life of a system and/or its components. Satisfactory completion of all acceptance requirements is required to obtain Owner's Representative approval and acceptance of the Contractor's work.
1.3.2 Material and Equipment Qualifications
Provide materials and equipment that are standard products of manufacturers regularly engaged in the manufacture of such products, which are of similar material, design and workmanship. Provide standard products that have been in satisfactory commercial or industrial use for 2 years prior to bid opening that includes applications of equipment and materials under similar circumstances and of similar size. Provide a product that has been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period.
1.3.3 Alternative Qualifications
Products having less than a two-year field service record are acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, are shown.
1.3.4 Service Support
Support the equipment items by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. Provide service organizations that are reasonably convenient to the equipment
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installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of contract.
1.3.5 Manufacturer's Nameplate
Provide each item of equipment with a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent is not acceptable.
1.3.6 Modifications of References
In each of the publications referred to herein, consider the advisory provisions to be mandatory, wherever the words shall, should, will, would, or may appear. Interpret references in these publications to the "authority having jurisdiction," or words of similar meaning, to mean the " Owner's Representative."
1.4 SUBMITTALS
Owner's Representative approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that reviews the submittal for the Owner's Representative. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-01 Preconstruction Submittals
Material, Equipment, and Fixture Lists; G
SD-02 Shop Drawings
Fabrication Drawings; G
Installation Drawings; G
SD-03 Product Data
Control Components; G
Thermometers; G
Pressure Gages; G
Valves; G
Dampers; G
Operators; G
SD-06 Test Reports
Set Points And Final Adjustments Of Controls; G
Test Reports; G
SD-07 Certificates
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Listing of Product Installations; G
Qualified Permanent Service Organizations; G
Manufacturer's Standard Factory Finishing; G
SD-08 Manufacturer's Instructions
Operating Instructions; G
SD-10 Operation and Maintenance Data
Operation and Maintenance Manuals; G
Scheduled Instructional Services; G
Electric Operators; G
1.5 STORAGE AND HANDLING
Seal openings after manufacturing and inspection, until ready for installation.
Carefully handle instruments and equipment, do not subject to shock, and protect from weather, dust, construction materials, and damage.
1.6 ACCESSIBILITY
Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors.
1.7 ELECTRICAL REQUIREMENTS
Furnish motors, controllers, disconnects and contactors with their respective pieces of equipment. Provide motors, controllers, disconnects and contactors that conform to and have electrical connections provided under Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Furnish internal wiring for components of packaged equipment as an integral part of the equipment. Extended voltage range motors are not permitted. Provide controllers and contactors that have a maximum of 120 volt control circuits, and have auxiliary contacts for use with the controls furnished. When motors and equipment furnished are larger than sizes indicated, include the cost of additional electrical service and related work under the section that specified that motor or equipment. Provide power wiring and conduit for field installed equipment under and conforming to the requirements of Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
PART 2 PRODUCTS
Submit Equipment and performance data for the following items consisting of use life, system functional flows, safety features, and mechanical automated details. Submit curves indicating tested and certified equipment response and performance characteristics.
a. Control Components
b. Thermometers
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c. Pressure Gages
d. Dampers
e. Operators
2.1 CONTROL COMPONENTS
2.1.1 Temperature Sensors
Provide temperature sensors, sensor transmitters, and controller output signals that are directly proportional to the variations in the measured variable. Provide linearity that is within plus or minus 1/2 percent for a 200 degrees F span, and plus or minus 1 percent for a 50 degrees F span, throughout the scale range.
Where extremely accurate temperature sensing is required or the transmitter is a considerable distance from the receiver controller, use a two-pipe relay-type transmitter. Provide instrument that has feedback incorporated into the design and 200 degrees F temperature range. Provide capillary that is compensated and is available in 8 and 16-foot averaging lengths. Provide unit that operates on 20 pounds per square inch (psi)input pressure, and has a 3 to 15-psi output over the specified range.
2.1.2 Humidity Sensors
Provide humidity sensors, sensor transmitters, and controller output signals that are directly proportional to the variations in the measured variable. Provide linearity that is within plus or minus 1 percent for a 70 -percent relative humidity span. Provide element that is capable of withstanding 98 percent relative humidity without loss of calibration when humidity sensor is duct-mounted downstream from a cooling coil.
2.1.3 Receiver Controllers
Provide receiver controllers that have a calibrated set point adjustment, minimum calibrated scale with no greater than 2 degrees F degrees divisions for duct and immersion application and 1 degrees F divisions for room control application. Provide set point indication and an adjustable proportional band covering the complete range necessary for the specific application. Provide controller range that matches that of the temperature sensor. Provide devices that incorporate authority and remote set point calibrated adjustments, as required.
2.1.4 Receiver Indicators
Provide receiver indicators that have visual readout for temperature and humidity, using the transmitted signal from the sensor device to the receiver-controller device. Provide readout and accuracy of the receiver indicator that has the indicated value within plus or minus 1/2 percent of the span of the measured variable, as transmitted by the sensor. Mark factory calibration on back of instrument. Provide range that matches that of the temperature or humidity sensor.
Provide a combined accuracy of the sensor and the receiver indicator that is within 2 degrees F and 5 percent relative humidity of the span.
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2.1.5 Space Thermostats
2.1.5.1 Electrical Control
Provide low-voltage type space thermostat with setback/setup temperature control for cooling and heating only. Provide thermostat that conforms to NEMA DC 3, and is as indicated.
2.1.5.2 Space Thermostat Accessories
Provide brushed aluminum Thermostat covers.
Provide insulating bases for thermostats located on exterior walls.
Provide cast-metal Thermostat guards in unfinished spaces.
Mount guards and thermostats on separate bases.
Submit Manufacturer's standard color charts showing the manufacturer's recommended color and finish selections.
2.1.6 Line-Voltage Thermostats
Provide line-voltage thermostats that have integral "MANUAL ON/OFF/AUTO" selector switch, a maximum differential of 2 degrees F, concealed temperature adjustment, and a locking cover. Provide line-voltage thermostats that are rated for the load, single-pole as required.
Provide insulating bases for thermostats located on exterior walls.
Provide cast metal type thermostat guards in unfinished spaces.
Mount guards and thermostats on separate bases, unless otherwise approved.
Provide line-voltage thermostats that are furnished and mounted under this section, and wired in accordance with applicable sections of DIVISION 26 ELECTRICAL unless otherwise specified.
2.1.7 Building Static-Pressure Transmitter
Provide a double-bell, differential type building static-pressure transmitter with temperature compensation. Provide scale range of minus 0.5 to plus 0.5 inch water gage (wg), and sensitivity within plus or minus 0.0005 inch wg. Provide transmitter that transmits an electronic signal to an indicating receiver with a matched scale range.
Provide a total system accuracy of not less than 0.05 inch wg.
2.1.8 Remote Pressure Transmitter
Provide pressure sensors for gas, liquid, or steam service remote indication that are pressure-to-current type. Provide direct current output and power supply that is compatible with the remote readout indicator.
2.1.9 Remote Element Instruments
Provide remote element instruments that have sufficient length of capillary to mount the instrument on the control panel in an accessible location.
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Provide excess capillary that is coiled and concealed. Provide armored capillary where indicated.
2.1.10 Airflow Switches
Provide UL approved airflow switches, with pressure range of 0.12 to 10 inches wg, and electrical rating of 120 volts ac and 3/4 horsepower ac pilot duty.
2.1.11 Switches
Provide switches as indicated.
Provide adjustable switches with indicating plates and accessible adjustment. Calibrate and mark minimum-positioning switches that control dampers in percent of maximum airflow determined by airflow test.
2.2 POWER-OPERATED DAMPERS
2.2.1 Frame and Blade Assembly
Provide frames and blades that are constructed of extruded aluminum.
Provide mechanically attached, field replaceable resilient seals. Attachment by adhesive is not acceptable. Provide neoprene seals.
Provide frames that have corner reinforcement and stay rods, where necessary. Provide frames that are fabricated by welding or riveting. Repair damaged galvanized surfaces by coating with an equal weight of zinc.
Provide minimum shaft size of 1/2 inch, round.
Where linkage is such that operator torque is applied to a master blade and transmitted therefrom, provide a master blade that is reinforced and a shaft that is full length. This type construction is limited to 2 inch wg, static pressure.
Provide blades that are attached to round shafts by hardened cup-point setscrews, or by being pinned. Provide a minimum three-thread engagement. Where setscrews are used, provide two setscrews, 90 degrees apart, to secure master blade. Secure shaft end retainers by pins or spring washers in grooved shaft or by similar construction.
Caulk frames with elastomer compounds to prevent bypass leakage.
Provide maximum leakage of dampers of 15 cfm/ft2.
2.2.2 Bearings
Provide graphite-impregnated nylon sleeve type shaft bearings, except as otherwise indicated. Provide thrust washers at bearings, when necessary to maintain blade alignment.
2.2.3 Installation
Install dampers in accordance with the manufacturer's instructions.
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2.3 CONTROL SYSTEM VALVE AND DAMPER OPERATORS
2.3.1 Operators
Provide motor operators that provide smooth proportional control under operating conditions normal to the system.
Provide spring-return operators for two-position control.
Provide spring returns on reversible operators where required for fail-safe operation.
For operators operating in sequence with other operators, provide operators that have adjustable operating ranges and set points.
Provide operators that have sufficient power on closeoff to provide tight sealing against maximum system pressures.
Provide operators that close valves and dampers to fail-safe position indicated.
2.3.2 Dampers
Provide dampers that are equipped with operators of sufficient power to control dampers, without flutter or hunting, through the entire operating range at air velocities at least 20 percent greater than maximum design velocity.
2.3.3 Electric Operators
Provide reversible type electric motor operators for modulating control.
Provide split-phase type electric motor operators with oil-immersed gear train. Provide motor that has ample capacity to handle applied loads under operating conditions normal to the system. Heat locations where temperatures fall below minimum operating temperature of operator.
2.4 INDIVIDUAL SYSTEM CONTROL PANELS
Provide each air handling system with an individual control panel mounted adjacent to and vibration isolated from the air handling unit.
Provide manufacturer's standard steel construction control panel of adequate gage and sufficient reinforcement to be completely rigid. Provide manufacturer's color finish approved by the Owner's Representative. Provide mechanically attached, engraved, 1/8 inch thick, laminated, black and white plastic identification plates. Locate panel as indicated.
Provide panel that contains a thermometer for each duct or immersion thermostat, as indicated, and for pilot lights for fan air filters, pump motors, filter runout pilot lights, air switches, or other accessories, as indicated. Provide panel that contains all controllers, recorders, and other instruments, and 1-1/2 inch gages showing pressures of controlled air from each controller, other than room controllers.
2.5 FACTORY FINISHING
Manufacturer's standard factory finishing systems is acceptable with certification that the factory painting system applied withstands 125 hours
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in a salt-spray fog test, and equipment located outdoors withstands 500 hours in salt-spray fog test. Perform salt-spray fog test in accordance with ASTM B117, and for that test the acceptance criteria are the following: immediately after completion of the test, the paint shows no signs of blistering, wrinkling, or cracking, and no loss of adhesion; and the specimen shows no signs of rust creepage beyond 0.125 inch on either side of the scratch mark.
Provide a film thickness of not less than the film thickness used on the test specimen for the factory finishing system applied on the equipment. If manufacturer's standard factory finishing system is being proposed for use on surfaces subject to temperatures above 120 degrees F, provide a factory finishing system designed for the temperature service.
PART 3 EXECUTION
3.1 INSTALLATION
Install in accordance with the manufacturer's instructions and as indicated.
Submit Installation Drawings and include details of equipment room layout and design.
3.2 VIBRATION ISOLATION
To prevent vibration, isolate controllers by location or by mounting devices supplied by the equipment manufacturer.
Install tubing and conduit to prevent the transmission of equipment vibration. Mount single tube runs in aircraft-type clamps containing an elastomer insert, preventing contact with ducting or air handling unit housing, casing, or enclosure. Provide multiple runs that conform to the same isolation requirements, but submit mounting details for approval. Refer to Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT for vibration isolation considerations.
3.3 FIELD QUALITY CONTROL Provide equipment to check the calibration of instruments. Recalibrate or replace instruments not in calibration.
Perform tests in accordance with referenced standards in this section.
After the inspection has been completed, check systems for continuity.
After completion of control and instrument piping, test and adjust control equipment in terms of design, function, systems balance, and performance, and otherwise make ready for air handling systems acceptance tests. Provide data showing set points and final adjustments of controls.
After air handling system acceptance and after the systems have operated in normal service for 2 weeks, check the adjustment on instruments and devices. Correct items found to be out of order. When air handling systems are in specified operating condition and when all other pertinent specifications requirements have been met, automatic temperature-control systems are acceptable.
Submit test reports to the Owner's Representative.
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3.4 OPERATOR TRAINING
Provide written operating instructions and not less than 8 hours of operator training.
Provide classroom and field instructions in operation and maintenance of systems equipment where required by the technical provisions. Direct these services using the manufacturer's factory trained personnel or qualified representative. Give the Owner's Representative seven calendar days written notice of scheduled instructional services. Make instructional materials belonging to the manufacturer or vendor available to the Owner's Representative.
3.5 SPECIAL TOOLS
Provide special tools as required for the operation and adjustment of controllers, instruments, or other control system devices.
3.6 OPERATION AND MAINTENANCE
Provide Operation and Maintenance Manuals that are consistent with manufacturer's standard brochures, schematics, printed instructions, general operating procedures and safety precautions.
-- End of Section --
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SECTION 23 23 00
REFRIGERANT PIPING 10/07 08/21/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI)
AHRI 710 I-P (2009) Performance Rating of Liquid-Line Driers
AHRI 720 (2002) Refrigerant Access Valves and Hose Connectors
ANSI/AHRI 750 (2007) Thermostatic Refrigerant Expansion Valves
ANSI/AHRI 760 (2007) Performance Rating of Solenoid Valves for Use With Volatile Refrigerants
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)
ANSI/ASHRAE 15 & 34 (2013) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants
ASHRAE 17 (2008) Method of Testing Capacity of Thermostatic Refrigerant Expansion Valves
AMERICAN WELDING SOCIETY (AWS)
AWS A5.8/A5.8M (2011; Amendment 2012) Specification for Filler Metals for Brazing and Braze Welding
AWS BRH (2007; 5th Ed) Brazing Handbook
AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel
AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes
ASME INTERNATIONAL (ASME)
ASME B1.20.1 (2013) Pipe Threads, General Purpose (Inch)
ASME B16.11 (2011) Forged Fittings, Socket-Welding and
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Threaded
ASME B16.21 (2011) Nonmetallic Flat Gaskets for Pipe Flanges
ASME B16.22 (2013) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings
ASME B16.26 (2013) Standard for Cast Copper Alloy Fittings for Flared Copper Tubes
ASME B16.3 (2011) Malleable Iron Threaded Fittings, Classes 150 and 300
ASME B16.5 (2013) Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24 Metric/Inch Standard
ASME B16.9 (2012) Standard for Factory-Made Wrought Steel Buttwelding Fittings
ASME B31.1 (2012; INT 2-6, 8-10, 13, 15, 17-25, 27-31 and 42-46) Power Piping
ASME B31.5 (2013) Refrigeration Piping and Heat Transfer Components
ASME B31.9 (2011) Building Services Piping
ASME B40.100 (2013) Pressure Gauges and Gauge Attachments
ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications
ASTM INTERNATIONAL (ASTM)
ASTM A193/A193M (2012a) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications
ASTM A334/A334M (2004a; R 2010) Standard Specification for Seamless and Welded Carbon and Alloy-Steel Tubes for Low-Temperature Service
ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
ASTM A653/A653M (2013) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process
ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM B280 (2013) Standard Specification for Seamless Copper Tube for Air Conditioning and
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Refrigeration Field Service
ASTM B32 (2008) Standard Specification for Solder Metal
ASTM B62 (2009) Standard Specification for Composition Bronze or Ounce Metal Castings
ASTM B75/B75M (2011) Standard Specification for Seamless Copper Tube
ASTM B813 (2010) Standard Specification for Liquid and Paste Fluxes for Soldering of Copper and Copper Alloy Tube
ASTM D3308 (2012) PTFE Resin Skived Tape
ASTM D520 (2000; R 2011) Zinc Dust Pigment
ASTM E84 (2013a) Standard Test Method for Surface Burning Characteristics of Building Materials
MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)
MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation
MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)
U.S. DEPARTMENT OF DEFENSE (DOD)
UFC 3-310-04 (2013) Seismic Design for Buildings
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Refrigerant Piping System; G
SD-03 Product Data
Refrigerant Piping System Spare Parts Qualifications; G Refrigerant Piping Tests; G Verification of Dimensions
SD-06 Test Reports
Refrigerant Piping Tests
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SD-07 Certificates
Service Organization; G
SD-10 Operation and Maintenance Data
Maintenance Operation and Maintenance Manuals
1.3 QUALITY ASSURANCE
1.3.1 Qualifications
Submit 3 copies of qualified procedures, and list of names and identification symbols of qualified welders and welding operators, prior to non-factory welding operations. Piping shall be welded in accordance with the qualified procedures using performance qualified welders and welding operators. Procedures and welders shall be qualified in accordance with ASME BPVC SEC IX. Welding procedures qualified by others, and welders and welding operators qualified by another employer may be accepted as permitted by ASME B31.1. Notify the Owner's Representative 24 hours in advance of tests to be performed at the work site, if practical. The welder or welding operator shall apply the personally assigned symbol near each weld made, as a permanent record. Structural members shall be welded in accordance with Section 05 12 00 STRUCTURAL STEEL.
1.3.2 Contract Drawings
Because of the small scale of the drawings, it is not possible to indicate all offsets, fittings, and accessories that may be required. Carefully investigate the plumbing, fire protection, electrical, structural and finish conditions that would affect the work to be performed and arrange such work accordingly, furnishing required offsets, fittings, and accessories to meet such conditions.
1.4 DELIVERY, STORAGE, AND HANDLING
Protect stored items from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Proper protection and care of all material both before and during installation is the Contractor's responsibility. Replace any materials found to be damaged at the Contractor's expense. During installation, cap piping and similar openings to keep out dirt and other foreign matter.
1.5 MAINTENANCE
1.5.1 General
Submit Data Package 2 plus operation and maintenance data complying with the requirements of Division 1 - General Requirements and as specified herein.
1.5.2 Extra Materials
Submit spare parts data for each different item of equipment specified, after approval of detail drawings and not later than 1 month prior to the date of beneficial occupancy. The data shall include a complete list of parts and supplies, with current unit prices and source of supply, a recommended spare parts list for 1 year of operation, and a list of the
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parts recommended by the manufacturer to be replaced on a routine basis.
PART 2 PRODUCTS
2.1 STANDARD COMMERCIAL PRODUCTS
a. Provide materials and equipment which are standard products of a manufacturer regularly engaged in the manufacturing of such products, that are of a similar material, design and workmanship and that have been in satisfactory commercial or industrial use for 2 years prior to bid opening.
b. The 2 year use shall include applications of equipment and materials under similar circumstances and of similar size. The 2 years experience shall be satisfactorily completed by a product which has been sold or is offered for sale on the commercial market through advertisements, manufacturer's catalogs, or brochures. Products having less than a 2 year field service record will be acceptable if a certified record of satisfactory field operation, for not less than 6000 hours exclusive of the manufacturer's factory tests, can be shown.
c. Products shall be supported by a service organization. System components shall be environmentally suitable for the indicated locations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. The service organizations shall be reasonably convenient to the equipment installation and be able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
d. Exposed equipment moving parts, parts that produce high operating temperature, parts which may be electrically energized, and parts that may be a hazard to operating personnel shall be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Install safety devices so that proper operation of equipment is not impaired. Welding and cutting safety requirements shall be in accordance with AWS Z49.1.
e. Manufacturer's standard catalog data, at least 5 weeks prior to the purchase or installation of a particular component, highlighted to show material, size, options, performance charts and curves, etc. in adequate detail to demonstrate compliance with contract requirements. Include in the data manufacturer's recommended installation instructions and procedures. Provide data for the following components as a minimum:
(1) Piping and Fittings (2) Valves (3) Piping Accessories (4) Pipe Hangers, Inserts, and Supports
2.2 ELECTRICAL WORK
Electrical equipment and wiring shall be in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Field wiring shall be in accordance with manufacturer's instructions. Manual or automatic control and protective or signal devices required for the operation specified and any control wiring required for controls and devices specified, but not shown, shall be provided.
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2.3 REFRIGERANT PIPING SYSTEM
Refrigerant piping, valves, fittings, and accessories shall be in accordance with ANSI/ASHRAE 15 & 34 and ASME B31.5, except as specified herein. Refrigerant piping, valves, fittings, and accessories shall be compatible with the fluids used and capable of withstanding the pressures and temperatures of the service. Refrigerant piping, valves, and accessories used for refrigerant service shall be cleaned, dehydrated, and sealed (capped or plugged) prior to shipment from the manufacturer's plant. Submit drawings, at least 5 weeks prior to beginning construction, provided in adequate detail to demonstrate compliance with contract requirements. Drawings shall consist of:
a. Piping layouts which identify all valves and fittings.
b. Plans and elevations which identify clearances required for maintenance and operation.
2.4 PIPE, FITTINGS AND END CONNECTIONS (JOINTS)
2.4.1 Steel Pipe
Steel pipe for refrigerant service shall conform to ASTM A53/A53M, Schedule 40, Type E or S, Grades A or B. Type F pipe shall not be used.
2.4.1.1 Welded Fittings and Connections
Butt-welded fittings shall conform to ASME B16.9. Socket-welded fittings shall conform to ASME B16.11. Welded fittings shall be identified with the appropriate grade and marking symbol. Welded valves and pipe connections (both butt-welds and socket-welds types) shall conform to ASME B31.9.
2.4.1.2 Threaded Fittings and Connections
Threaded fitting shall conform to ASME B16.3. Threaded valves and pipe connections shall conform to ASME B1.20.1.
2.4.1.3 Flanged Fittings and Connections
Flanges shall conform to ASME B16.5, Class 150. Gaskets shall be nonasbestos compressed material in accordance with ASME B16.21, 1/16 inch thickness, full face or self-centering flat ring type. This gaskets shall contain aramid fibers bonded with styrene butadeine rubber (SBR) or nitrile butadeine rubber (NBR). Bolts, nuts, and bolt patterns shall conform to ASME B16.5. Bolts shall be high or intermediate strength material conforming to ASTM A193/A193M.
2.4.2 Steel Tubing
Tubing shall be cold-rolled, electric-forged, welded-steel in accordance with ASTM A334/A334M, Grade 1. Joints and fittings shall be socket type provided by the steel tubing manufacturer.
2.4.3 Copper Tubing
Copper tubing shall conform to ASTM B280 annealed or hard drawn as required. Copper tubing shall be soft annealed where bending is required and hard drawn where no bending is required. Soft annealed copper tubing
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shall not be used in sizes larger than 1-3/8 inches. Joints shall be brazed except that joints on lines 7/8 inchand smaller may be flared. Cast copper alloy fittings for flared copper tube shall conform to ASME B16.26 and ASTM B62. Wrought copper and bronze solder-joint pressure fittings shall conform to ASME B16.22 and ASTM B75/B75M. Joints and fittings for brazed joint shall be wrought-copper or forged-brass sweat fittings. Cast sweat-type joints and fittings shall not be allowed for brazed joints. Brass or bronze adapters for brazed tubing may be used for connecting tubing to flanges and to threaded ends of valves and equipment.
2.4.4 Solder
Solder shall conform to ASTM B32, grade Sb5, tin-antimony alloy for service pressures up to 150 psig. Solder flux shall be liquid or paste form, non-corrosive and conform to ASTM B813.
2.4.5 Brazing Filler Metal
Filler metal shall conform to AWS A5.8/A5.8M, Type BAg-5 with AWS Type 3 flux, except Type BCuP-5 or BCuP-6 may be used for brazing copper-to-copper joints.
2.5 VALVES
Valves shall be designed, manufactured, and tested specifically for refrigerant service. Valve bodies shall be of brass, bronze, steel, or ductile iron construction. Valves 1 inch and smaller shall have brazed or socket welded connections. Valves larger than 1 inch shall have tongue-and-groove flanged end connections. Threaded end connections shall not be used, except in pilot pressure or gauge lines where maintenance disassembly is required and welded flanges cannot be used. Internal parts shall be removable for inspection or replacement without applying heat or breaking pipe connections. Valve stems exposed to the atmosphere shall be stainless steel or corrosion resistant metal plated carbon steel. Direction of flow shall be legibly and permanently indicated on the valve body. Control valve inlets shall be fitted with integral or adapted strainer or filter where recommended or required by the manufacturer. Purge, charge and receiver valves shall be of manufacturer's standard configuration.
2.5.1 Refrigerant Stop Valves
Valve shall be the globe or full-port ball type with a back-seating stem especially packed for refrigerant service. Valve packing shall be replaceable under line pressure. Valve shall be provided with a handwheel or wrench operator and a seal cap. Valve shall be the straight or angle pattern design as indicated.
2.5.2 Check Valves
Valve shall be the swing or lift type as required to provide positive shutoff at the differential pressure indicated. Valve shall be provide with resilient seat.
2.5.3 Liquid Solenoid Valves
Valves shall comply with ANSI/AHRI 760 and be suitable for continuous duty with applied voltages 15 percent under and 5 percent over nominal rated voltage at maximum and minimum encountered pressure and temperature service
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conditions. Valves shall be direct-acting or pilot-operating type, packless, except that packed stem, seal capped, manual lifting provisions shall be furnished. Solenoid coils shall be moisture-proof, UL approved, totally encapsulated or encapsulated and metal jacketed as required. Valves shall have safe working pressure of 400 psi and a maximum operating pressure differential of at least 200 psi at 85 percent rated voltage. Valves shall have an operating pressure differential suitable for the refrigerant used.
2.5.4 Expansion Valves
Valve shall conform to ANSI/AHRI 750 and ASHRAE 17. Valve shall be the diaphragm and spring-loaded type with internal or external equalizers, and bulb and capillary tubing. Valve shall be provided with an external superheat adjustment along with a seal cap. Internal equalizers may be utilized where flowing refrigerant pressure drop between outlet of the valve and inlet to the evaporator coil is negligible and pressure drop across the evaporator is less than the pressure difference corresponding to 2 degrees F of saturated suction temperature at evaporator conditions. Bulb charge shall be determined by the manufacturer for the application and such that liquid will remain in the bulb at all operating conditions. Gas limited liquid charged valves and other valve devices for limiting evaporator pressure shall not be used without a distributor or discharge tube or effective means to prevent loss of control when bulb becomes warmer than valve body. Pilot-operated valves shall have a characterized plug to provide required modulating control. A de-energized solenoid valve may be used in the pilot line to close the main valve in lieu of a solenoid valve in the main liquid line. An isolatable pressure gauge shall be provided in the pilot line, at the main valve. Automatic pressure reducing or constant pressure regulating expansion valves may be used only where indicted or for constant evaporator loads.
2.5.5 Safety Relief Valves
Valve shall be the two-way type, unless indicated otherwise. Valve shall bear the ASME code symbol. Valve capacity shall be certified by the National Board of Boiler and Pressure Vessel Inspectors. Valve shall be of an automatically reseating design after activation.
2.5.6 Evaporator Pressure Regulators, Direct-Acting
Valve shall include a diaphragm/spring assembly, external pressure adjustment with seal cap, and pressure gauge port. Valve shall maintain a constant inlet pressure by balancing inlet pressure on diaphragm against an adjustable spring load. Pressure drop at system design load shall not exceed the pressure difference corresponding to a 2 degrees F change in saturated refrigerant temperature at evaporator operating suction temperature. Spring shall be selected for indicated maximum allowable suction pressure range.
2.5.7 Refrigerant Access Valves
Refrigerant access valves and hose connections shall be in accordance with AHRI 720.
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2.6 PIPING ACCESSORIES
2.6.1 Filter Driers
Driers shall conform to AHRI 710 I-P. Sizes 5/8 inch and larger shall be the full flow, replaceable core type. Sizes 1/2 inch and smaller shall be the sealed type. Cores shall be of suitable desiccant that will not plug, cake, dust, channel, or break down, and shall remove water, acid, and foreign material from the refrigerant. Filter driers shall be constructed so that none of the desiccant will pass into the refrigerant lines. Minimum bursting pressure shall be 1,500 psi.
2.6.2 Sight Glass and Liquid Level Indicator
2.6.2.1 Assembly and Components
Assembly shall be pressure- and temperature-rated and constructed of materials suitable for the service. Glass shall be borosilicate type. Ferrous components subject to condensation shall be electro-galvanized.
2.6.2.2 Gauge Glass
Gauge glass shall include top and bottom isolation valves fitted with automatic checks, and packing followers; red-line or green-line gauge glass; elastomer or polymer packing to suit the service; and gauge glass guard.
2.6.2.3 Bull's-Eye and Inline Sight Glass Reflex Lens
Bull's-eye and inline sight glass reflex lens shall be provided for dead-end liquid service. For pipe line mounting, two plain lenses in one body suitable for backlighted viewing shall be provided.
2.6.2.4 Moisture Indicator
Indicator shall be a self-reversible action, moisture reactive, color changing media. Indicator shall be furnished with full-color-printing tag containing color, moisture and temperature criteria. Unless otherwise indicated, the moisture indicator shall be an integral part of each corresponding sight glass.
2.6.3 Vibration Dampeners
Dampeners shall be of the all-metallic bellows and woven-wire type.
2.6.4 Flexible Pipe Connectors
Connector shall be a composite of interior corrugated phosphor bronze or Type 300 Series stainless steel, as required for fluid service, with exterior reinforcement of bronze, stainless steel or monel wire braid. Assembly shall be constructed with a safety factor of not less than 4 at300 degrees F. Unless otherwise indicated, the length of a flexible connector shall be as recommended by the manufacturer for the service intended.
2.6.5 Strainers
Strainers used in refrigerant service shall have brass or cast iron body, Y-or angle-pattern, cleanable, not less than 60-mesh noncorroding screen of an area to provide net free area not less than ten times the pipe diameter
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with pressure rating compatible with the refrigerant service. Screens shall be stainless steel or monel and reinforced spring-loaded where necessary for bypass-proof construction.
2.6.6 Pressure and Vacuum Gauges
Gauges shall conform to ASME B40.100 and shall be provided with throttling type needle valve or a pulsation dampener and shut-off valve. Gauge shall be a minimum of 3-1/2 inches in diameter with a range from 0 psig to approximately 1.5 times the maximum system working pressure. Each gauge range shall be selected so that at normal operating pressure, the needle is within the middle-third of the range.
2.6.7 Temperature Gauges
Temperature gauges shall be the industrial duty type and be provided for the required temperature range. Gauges shall have Fahrenheit scale in 2 degrees graduations scale (black numbers) on a white face. The pointer shall be adjustable. Rigid stem type temperature gauges shall be provided in thermal wells located within 5 feet of the finished floor. Universal adjustable angle type or remote element type temperature gauges shall be provided in thermal wells located 5 to 7 feet above the finished floor. Remote element type temperature gauges shall be provided in thermal wells located 7 feet above the finished floor.
2.6.7.1 Stem Cased-Glass
Stem cased-glass case shall be polished stainless steel or cast aluminum, 9 inches long, with clear acrylic lens, and non-mercury filled glass tube with indicating-fluid column.
2.6.7.2 Bimetallic Dial
Bimetallic dial type case shall be not less than 3-1/2 inches, stainless steel, and shall be hermetically sealed with clear acrylic lens. Bimetallic element shall be silicone dampened and unit fitted with external calibrator adjustment. Accuracy shall be one percent of dial range.
2.6.7.3 Liquid-, Solid-, and Vapor-Filled Dial
Liquid-, solid-, and vapor-filled dial type cases shall be not less than 3-1/2 inches, stainless steel or cast aluminum with clear acrylic lens. Fill shall be nonmercury, suitable for encountered cross-ambients, and connecting capillary tubing shall be double-braided bronze.
2.6.7.4 Thermal Well
Thermal well shall be identical size, 1/2 or 3/4 inch NPT connection, brass or stainless steel. Where test wells are indicated, provide captive plug-fitted type 1/2 inch NPT connection suitable for use with either engraved stem or standard separable socket thermometer or thermostat. Mercury shall not be used in thermometers. Extended neck thermal wells shall be of sufficient length to clear insulation thickness by 1 inch.
2.6.8 Pipe Hangers, Inserts, and Supports
Pipe hangers, inserts, guides, and supports shall conform to MSS SP-58 and MSS SP-69.
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2.6.9 Escutcheons
Escutcheons shall be chromium-plated iron or chromium-plated brass, either one piece or split pattern, held in place by internal spring tension or set screws.
2.7 FABRICATION
2.7.1 Factory Coating
Unless otherwise specified, equipment and component items, when fabricated from ferrous metal, shall be factory finished with the manufacturer's standard finish, except that items located outside of buildings shall have weather resistant finishes that will withstand 125 hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride solution. Immediately after completion of the test, the specimen shall show no signs of blistering, wrinkling, cracking, or loss of adhesion and no sign of rust creepage beyond 1/8 inch on either side of the scratch mark. Cut edges of galvanized surfaces where hot-dip galvanized sheet steel is used shall be coated with a zinc-rich coating conforming to ASTM D520, Type I.
2.7.2 Factory Applied Insulation
Refrigerant suction lines between the cooler and each compressor and cold gas inlet connections to gas cooled motors shall be insulated with not less than 3/4 inch thick unicellular plastic foam. Factory insulated items installed outdoors are not required to be fire-rated. As a minimum, factory insulated items installed indoors shall have a flame spread index no higher than 75 and a smoke developed index no higher than 150. Factory insulated items (no jacket) installed indoors and which are located in air plenums, in ceiling spaces, and in attic spaces shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50. Flame spread and smoke developed indexes shall be determined by ASTM E84. Insulation shall be tested in the same density and installed thickness as the material to be used in the actual construction. Material supplied by a manufacturer with a jacket shall be tested as a composite material. Jackets, facings, and adhesives shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50 when tested in accordance with ASTM E84.
PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, perform a verification of dimensions in the field. Submit a letter, at least 2 weeks prior to beginning construction, including the date the site was visited, conformation of existing conditions, and any discrepancies found before performing any work.
3.2 INSTALLATION
Pipe and fitting installation shall conform to the requirements of ASME B31.1. Cut pipe accurately to measurements established at the jobsite, and work into place without springing or forcing, completely clearing all windows, doors, and other openings. Cutting or other weakening of the building structure to facilitate piping installation are not permitted without written approval. Cut pipe or tubing square,
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removeremoved by reaming, and permit free expansion and contraction without causing damage to the building structure, pipe, joints, or hangers.
3.2.1 Directional Changes
Make changes in direction with fittings, except that bending of pipe 4 inches and smalleris permitted, provided a pipe bender is used and wide weep bends are formed. Mitering or notching pipe or other similar construction to form elbows or tees is not permitted. The centerline radius of bends shall not be less than 6 diameters of the pipe. Bent pipe showing kinks, wrinkles, flattening, or other malformations will not be accepted.
3.2.2 Functional Requirements
Piping shall be installed 1/2 inch/10 feet of pipe in the direction of flow to ensure adequate oil drainage. Open ends of refrigerant lines or equipment shall be properly capped or plugged during installation to keep moisture, dirt, or other foreign material out of the system. Piping shall remain capped until installation. Equipment piping shall be in accordance with the equipment manufacturer's recommendations and the contract drawings. Equipment and piping arrangements shall fit into space allotted and allow adequate acceptable clearances for installation, replacement, entry, servicing, and maintenance.
3.2.3 Fittings and End Connections
3.2.3.1 Threaded Connections
Make threaded connections with tapered threads and make tight with PTFE tape complying with ASTM D3308 or equivalent thread-joint compound applied to the male threads only. Show not more than three threads after the joint is made.
3.2.3.2 Brazed Connections
Perform brazing in accordance with AWS BRH, except as modified herein. During brazing, fill the pipe and fittings with a pressure regulated inert gas, such as nitrogen, to prevent the formation of scale. Before brazing copper joints, clean both the outside of the tube and the inside of the fitting with a wire fitting brush until the entire joint surface is bright and clean. Do not use brazing flux. Remove surplus brazing material at all joints. Make steel tubing joints in accordance with the manufacturer's recommendations. Paint joints in steel tubing with the same material as the baked-on coating within 8 hours after joints are made. Protect tubing against oxidation during brazing by continuous purging of the inside of the piping using nitrogen. Support piping prior to brazing and do not spring or force.
3.2.3.3 Welded Connections
Welded joints in steel refrigerant piping shall be fusion-welded. Branch connections shall be made with welding tees or forged welding branch outlets. Pipe shall be thoroughly cleaned of all scale and foreign matter before the piping is assembled. During welding the pipe and fittings shall be filled with an inert gas, such as nitrogen, to prevent the formation of scale. Beveling, alignment, heat treatment, and inspection of weld shall conform to ASME B31.1. Weld defects shall be removed and rewelded at no additional cost to the Owner's Representative. Electrodes shall be stored
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and dried in accordance with AWS D1.1/D1.1M or as recommended by the manufacturer. Electrodes that have been wetted or that have lost any of their coating shall not be used.
3.2.3.4 Flared Connections
When flared connections are used, a suitable lubricant shall be used between the back of the flare and the nut in order to avoid tearing the flare while tightening the nut.
3.2.3.5 Flanged Connections
When steel refrigerant piping is used, union or flange joints shall be provided in each line immediately preceding the connection to each piece of equipment requiring maintenance, such as compressors, coils, chillers, control valves, and other similar items. Flanged joints shall be assembled square end tight with matched flanges, gaskets, and bolts. Gaskets shall be suitable for use with the refrigerants to be handled.
3.2.4 Valves
3.2.4.1 General
Refrigerant stop valves shall be installed on each side of each piece of equipment such as compressors condensers, evaporators, receivers, and other similar items in multiple-unit installation, to provide partial system isolation as required for maintenance or repair. Stop valves shall be installed with stems horizontal unless otherwise indicated. Ball valves shall be installed with stems positioned to facilitate operation and maintenance. Isolating valves for pressure gauges and switches shall be external to thermal insulation. Safety switches shall not be fitted with isolation valves. Filter dryers having access ports may be considered a point of isolation. Purge valves shall be provided at all points of systems where accumulated noncondensable gases would prevent proper system operation. Valves shall be furnished to match line size, unless otherwise indicated or approved.
3.2.4.2 Expansion Valves
Expansion valves shall be installed with the thermostatic expansion valve bulb located on top of the suction line when the suction line is less than 2-1/8 inches in diameter and at the 4 o'clock or 8 o'clock position on lines larger than 2-1/8 inches. The bulb shall be securely fastened with two clamps. The bulb shall be insulated. The bulb shall installed in a horizontal portion of the suction line, if possible, with the pigtail on the bottom. If the bulb must be installed in a vertical line, the bulb tubing shall be facing up.
3.2.4.3 Valve Identification
Each system valve, including those which are part of a factory assembly, shall be tagged. Tags shall be in alphanumeric sequence, progressing in direction of fluid flow. Tags shall be embossed, engraved, or stamped plastic or nonferrous metal of various shapes, sized approximately 1-3/8 inch diameter, or equivalent dimension, substantially attached to a component or immediately adjacent thereto. Tags shall be attached with nonferrous, heavy duty, bead or link chain, 14 gauge annealed wire, nylon cable bands or as approved. Tag numbers shall be referenced in Operation and Maintenance Manuals and system diagrams.
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3.2.5 Vibration Dampers
Vibration damper shall be provided in the suction and discharge lines on spring mounted compressors. Vibration dampers shall be installed parallel with the shaft of the compressor and shall be anchored firmly at the upstream end on the suction line and the downstream end in the discharge line.
3.2.6 Strainers
Strainers shall be provided immediately ahead of solenoid valves and expansion devices. Strainers may be an integral part of an expansion valve.
3.2.7 Filter Dryer
A liquid line filter dryer shall be provided on each refrigerant circuit located such that all liquid refrigerant passes through a filter dryer. Dryers shall be sized in accordance with the manufacturer's recommendations for the system in which it is installed. Dryers shall be installed such that it can be isolated from the system, the isolated portion of the system evacuated, and the filter dryer replaced. Dryers shall be installed in the horizontal position except replaceable core filter dryers may be installed in the vertical position with the access flange on the bottom.
3.2.8 Sight Glass
A moisture indicating sight glass shall be installed in all refrigerant circuits down stream of all filter dryers and where indicated. Site glasses shall be full line size.
3.2.9 Discharge Line Oil Separator
Discharge line oil separator shall be provided in the discharge line from each compressor. Oil return line shall be connected to the compressor as recommended by the compressor manufacturer.
3.2.10 Accumulator
Accumulators shall be provided in the suction line to each compressor.
3.2.11 Flexible Pipe Connectors
Connectors shall be installed perpendicular to line of motion being isolated. Piping for equipment with bidirectional motion shall be fitted with two flexible connectors, in perpendicular planes. Reinforced elastomer flexible connectors shall be installed in accordance with manufacturer's instructions. Piping guides and restraints related to flexible connectors shall be provided as required.
3.2.12 Temperature Gauges
Temperature gauges shall be located specifically on, but not limited to the following: the sensing element of each automatic temperature control device where a thermometer is not an integral part thereof the liquid line leaving a receiver and the suction line at each evaporator or liquid cooler. Thermal wells for insertion thermometers and thermostats shall extend beyond thermal insulation surface not less than 1 inch.
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3.2.13 Pipe Hangers, Inserts, and Supports
Pipe hangers, inserts, and supports shall conform to MSS SP-58 and MSS SP-69, except as modified herein. Pipe hanger types 5, 12, and 26 shall not be used. Hangers used to support piping 2 inches and larger shall be fabricated to permit adequate adjustment after erection while still supporting the load. Piping subjected to vertical movement, when operating temperatures exceed ambient temperatures, shall be supported by variable spring hangers and supports or by constant support hangers.
3.2.13.1 Hangers
Do not use Type 3 on insulated piping. Type 24 may be used only on trapeze hanger systems or on fabricated frames.
3.2.13.2 Inserts
Secure Type 18 inserts to concrete forms before concrete is placed. Continuous inserts which allow more adjustments may be used if they otherwise meet the requirements for Type 18 inserts.
3.2.13.3 C-Clamps
Torque Type 19 and 23 C-clamps in accordance with MSS SP-69 and have both locknuts and retaining devices, furnished by the manufacturer. Field-fabricated C-clamp bodies or retaining devices are not acceptable.
3.2.13.4 Angle Attachments
Type 20 attachments used on angles and channels shall be furnished with an added malleable-iron heel plate or adapter.
3.2.13.5 Saddles and Shields
Where Type 39 saddle or Type 40 shield are permitted for a particular pipe attachment application, the Type 39 saddle, connected to the pipe, shall be used on all pipe 4 inches and larger when the temperature of the medium is 60 degrees F or higher. Type 40 shields shall be used on all piping less than 4 inches and all piping 4 inches and larger carrying medium less than 60 degrees F. A high density insulation insert of cellular glass shall be used under the Type 40 shield for piping 2 inches and larger.
3.2.13.6 Horizontal Pipe Supports
Horizontal pipe supports shall be spaced as specified in MSS SP-69 and a support shall be installed not over 1 foot from the pipe fitting joint at each change in direction of the piping. Pipe supports shall be spaced not over 5 feet apart at valves. Pipe hanger loads suspended from steel joist with hanger loads between panel points in excess of 50 pounds shall have the excess hanger loads suspended from panel points.
3.2.13.7 Vertical Pipe Supports
Vertical pipe shall be supported at each floor, except at slab-on-grade, and at intervals of not more than 15 feet not more than 8 feet from end of risers, and at vent terminations.
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3.2.13.8 Pipe Guides
Type 35 guides using, steel, reinforced polytetrafluoroethylene (PTFE) or graphite slides shall be provided where required to allow longitudinal pipe movement. Lateral restraints shall be provided as required. Slide materials shall be suitable for the system operating temperatures, atmospheric conditions, and bearing loads encountered.
3.2.13.9 Steel Slides
Where steel slides do not require provisions for restraint of lateral movement, an alternate guide method may be used. On piping 4 inches and larger, a Type 39 saddle shall be used. On piping under 4 inches, a Type 40 protection shield may be attached to the pipe or insulation and freely rest on a steel slide plate.
3.2.13.10 High Temperature Guides with Cradles
Where there are high system temperatures and welding to piping is not desirable, then the Type 35 guide shall include a pipe cradle, welded to the guide structure and strapped securely to the pipe. The pipe shall be separated from the slide material by at least 4 inches, or by an amount adequate for the insulation, whichever is greater.
3.2.13.11 Multiple Pipe Runs
In the support of multiple pipe runs on a common base member, a clip or clamp shall be used where each pipe crosses the base support member. Spacing of the base support members shall not exceed the hanger and support spacing required for an individual pipe in the multiple pipe run.
3.2.13.12 Seismic Requirements
Piping and attached valves shall be supported and braced to resist seismic loads as specified under UFC 3-310-04. Structural steel required for reinforcement to properly support piping, headers, and equipment but not shown shall be provided under this section. Material used for support shall be as specified under Section 05 12 00 STRUCTURAL STEEL.
3.2.13.13 Structural Attachments
Attachment to building structure concrete and masonry shall be by cast-in concrete inserts, built-in anchors, or masonry anchor devices. Inserts and anchors shall be applied with a safety factor not less than 5. Supports shall not be attached to metal decking. Masonry anchors for overhead applications shall be constructed of ferrous materials only. Structural steel brackets required to support piping, headers, and equipment, but not shown, shall be provided under this section. Material used for support shall be as specified under Section 05 12 00 STRUCTURAL STEEL.
3.2.14 Pipe Alignment Guides
Pipe alignment guides shall be provided where indicated for expansion loops, offsets, and bends and as recommended by the manufacturer for expansion joints, not to exceed 5 feet on each side of each expansion joint, and in lines 4 inches or smaller not more than 2 feet on each side of the joint.
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3.2.15 Pipe Anchors
Anchors shall be provided wherever necessary or indicated to localize expansion or to prevent undue strain on piping. Anchors shall consist of heavy steel collars with lugs and bolts for clamping and attaching anchor braces, unless otherwise indicated. Anchor braces shall be installed in the most effective manner to secure the desired results using turnbuckles where required. Supports, anchors, or stays shall not be attached where they will injure the structure or adjacent construction during installation or by the weight of expansion of the pipeline. Where pipe and conduit penetrations of vapor barrier sealed surfaces occur, these items shall be anchored immediately adjacent to each penetrated surface, to provide essentially zero movement within penetration seal. Detailed drawings of pipe anchors shall be submitted for approval before installation.
3.2.16 Building Surface Penetrations
Sleeves shall not be installed in structural members except where indicated or approved. Sleeves in nonload bearing surfaces shall be galvanized sheet metal, conforming to ASTM A653/A653M, Coating Class G-90, 20 gauge. Sleeves in load bearing surfaces shall be uncoated carbon steel pipe, conforming to ASTM A53/A53M, Standard weight. Sealants shall be applied to moisture and oil-free surfaces and elastomers to not less than 1/2 inch depth. Sleeves shall not be installed in structural members.
3.2.16.1 Refrigerated Space
Refrigerated space building surface penetrations shall be fitted with sleeves fabricated from hand-lay-up or helically wound, fibrous glass reinforced polyester or epoxy resin with a minimum thickness equal to equivalent size Schedule 40 steel pipe. Sleeves shall be constructed with integral collar or cold side shall be fitted with a bonded slip-on flange or extended collar. In the case of masonry penetrations where sleeve is not cast-in, voids shall be filled with latex mixed mortar cast to shape of sleeve and flange/external collar type sleeve shall be assembled with butyl elastomer vapor barrier sealant through penetration to cold side surface vapor barrier overlap and fastened to surface with masonry anchors. Integral cast-in collar type sleeve shall be flashed as indicated with not less than 4 inches of cold side vapor barrier overlap of sleeve surface. Normally noninsulated penetrating round surfaces shall be sealed to sleeve bore with mechanically expandable seals in vapor tight manner and remaining warm and cold side sleeve depth shall be insulated with not less than 4 inches of foamed-in-place rigid polyurethane or foamed-in-place silicone elastomer. Vapor barrier sealant shall be applied to finish warm side insulation surface. Warm side of penetrating surface shall be insulated beyond vapor barrier sealed sleeve insulation for a distance which prevents condensation. Wires in refrigerated space surface penetrating conduit shall be sealed with vapor barrier plugs or compound to prevent moisture migration through conduit and condensation therein.
3.2.16.2 General Service Areas
Each sleeve shall extend through its respective wall, floor, or roof, and shall be cut flush with each surface. Pipes passing through concrete or masonry wall or concrete floors or roofs shall be provided with pipe sleeves fitted into place at the time of construction. Sleeves shall be of such size as to provide a minimum of 1/4 inch all-around clearance between bare pipe and sleeves or between jacketed-insulation and sleeves. Except in pipe chases or interior walls, the annular space between pipe and sleeve
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or between jacket over-insulation and sleeve shall be sealed in accordance with Section 07 92 00 JOINT SEALANTS.
3.2.16.3 Waterproof Penetrations
Pipes passing through roof or floor waterproofing membrane shall be installed through a 17 ounce copper sleeve, or a 0.032 inch thick aluminum sleeve, each within an integral skirt or flange. Flashing sleeve shall be suitably formed, and skirt or flange shall extend not less than 8 inches from the pipe and be set over the roof or floor membrane in a troweled coating of bituminous cement. The flashing sleeve shall extend up the pipe a minimum of 2 inches above the roof or floor penetration. The annular space between the flashing sleeve and the bare pipe or between the flashing sleeve and the metal-jacket-covered insulation shall be sealed as indicated. Penetrations shall be sealed by either one of the following methods.
3.2.16.3.1 Waterproofing Clamping Flange
Pipes up to and including 10 inches in diameter passing through roof or floor waterproofing membrane may be installed through a cast iron sleeve with caulking recess, anchor lugs, flashing clamp device, and pressure ring with brass bolts. Waterproofing membrane shall be clamped into place and sealant shall be placed in the caulking recess.
3.2.16.3.2 Modular Mechanical Type Sealing Assembly
In lieu of a waterproofing clamping flange and caulking and sealing of annular space between pipe and sleeve or conduit and sleeve, a modular mechanical type sealing assembly may be installed. Seals shall consist of interlocking synthetic rubber links shaped to continuously fill the annular space between the pipe/conduit and sleeve with corrosion protected carbon steel bolts, nuts, and pressure plates. Links shall be loosely assembled with bolts to form a continuous rubber belt around the pipe with a pressure plate under each bolt head and each nut. After the seal assembly is properly positioned in the sleeve, tightening of the bolt shall cause the rubber sealing elements to expand and provide a watertight seal rubber sealing elements to expand and provide a watertight seal between the pipe/conduit seal between the pipe/conduit and the sleeve. Each seal assembly shall be sized as recommended by the manufacturer to fit the pipe/conduit and sleeve involved. The Contractor electing to use the modular mechanical type seals shall provide sleeves of the proper diameters.
3.2.16.4 Escutcheons
Finished surfaces where exposed piping, bare or insulated, pass through floors, walls, or ceilings, except in boiler, utility, or equipment rooms, shall be provided with escutcheons. Where sleeves project slightly from floors, special deep-type escutcheons shall be used. Escutcheon shall be secured to pipe or pipe covering.
3.2.17 Access Panels
Access panels shall be provided for all concealed valves, vents, controls, and items requiring inspection or maintenance. Access panels shall be of sufficient size and located so that the concealed items may be serviced and maintained or completely removed and replaced. Access panels shall be as specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS.
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3.2.18 Field Applied Insulation
Field installed insulation shall be as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS, except as defined differently herein.
3.2.19 Field Painting
Painting required for surfaces not otherwise specified, and finish painting of items only primed at the factory are specified in Section 09 90 00 PAINTS AND COATINGS.
3.2.19.1 Color Coding
Color coding for piping identification is specified in Section 09 90 00 PAINTS AND COATINGS.
3.2.19.2 Color Coding Scheme
A color coding scheme for locating hidden piping shall be in accordance with Section 22 00 00 PLUMBING, GENERAL PURPOSE.
3.2.20 Identification Tags
Provide identification tags made of brass, engraved laminated plastic or engraved anodized aluminum indicating service and item number on all valves and dampers. Tags shall be 1-3/8 inch minimum diameter and marking shall be stamped or engraved. Indentations shall be black for reading clarity. Tags shall be attached to valves with No. 12 AWG copper wire, chrome-plated beaded chain or plastic straps designed for that purpose.
3.3 CLEANING AND ADJUSTING
Clean uncontaminated system(s) by evacuation and purging procedures currently recommended by refrigerant and refrigerant equipment manufacturers, and as specified herein, to remove small amounts of air and moisture. Systems containing moderate amounts of air, moisture, contaminated refrigerant, or any foreign matter shall be considered contaminated systems. Restoring contaminated systems to clean condition including disassembly, component replacement, evacuation, flushing, purging, and re-charging, shall be performed using currently approved refrigerant and refrigeration manufacturer's procedures. Restoring contaminated systems shall be at no additional cost to the Owner as determined by the Owner's Representative. Water shall not be used in any procedure or test.
3.4 TRAINING COURSE
a. Submit a schedule, at least 2 weeks prior to the date of the proposed training course, which identifies the date, time, and location for the training. Conduct a training course for all members of the operating staff as designated by the Owner's Representative. The training period shall consist of a total 2 hours of normal working time and start after the system is functionally completed but prior to final acceptance tests.
b. The field posted instructions shall cover all of the items contained in the approved operation and maintenance manuals as well as demonstrations of routine maintenance operations.
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c. Submit 6 complete copies of an operation manual in bound 8 1/2 by 11 inch booklets listing step-by-step procedures required for system startup, operation, abnormal shutdown, emergency shutdown, and normal shutdown at least 4 weeks prior to the first training course. The booklets shall include the manufacturer's name, model number, and parts list. The manuals shall include the manufacturer's name, model number, service manual, and a brief description of all equipment and their basic operating features.
d. Submit 6 complete copies of maintenance manual in bound 8 1/2 x 11 inch booklets listing routine maintenance procedures, possible breakdowns and repairs, and a trouble shooting guide. The manuals shall include piping layouts and simplified wiring and control diagrams of the system as installed.
3.5 REFRIGERANT PIPING TESTS
After all components of the refrigerant system have been installed and connected, subject the entire refrigeration system to pneumatic, evacuation, and startup tests as described herein. Submit a schedule, at least 2 weeks prior to the start of related testing, for each test. Identify the proposed date, time, and location for each test. Conduct tests in the presence of the Owner's Representative. Water and electricity required for the tests will be furnished by the Owner's Representative. Provide all material, equipment, instruments, and personnel required for the test. Provide the services of a qualified technician, as required, to perform all tests and procedures indicated herein. Field tests shall be coordinated with Section 23 05 93 TESTING, ADJUSTING, AND BALANCING OF HVAC SYSTEMS. Submit 6 copies of the tests report in bound 8 1/2 by 11 inch booklets documenting all phases of the tests performed. The report shall include initial test summaries, all repairs/adjustments made, and the final test results.
3.5.1 Preliminary Procedures
Prior to pneumatic testing, equipment which has been factory tested and refrigerant charged as well as equipment which could be damaged or cause personnel injury by imposed test pressure, positive or negative, shall be isolated from the test pressure or removed from the system. Safety relief valves and rupture discs, where not part of factory sealed systems, shall be removed and openings capped or plugged.
3.5.2 Pneumatic Test
Pressure control and excess pressure protection shall be provided at the source of test pressure. Valves shall be wide open, except those leading to the atmosphere. Test gas shall be dry nitrogen, with minus 70 degree F dewpoint and less than 5 ppm oil. Test pressure shall be applied in two stages before any refrigerant pipe is insulated or covered. First stage test shall be at 10 psi with every joint being tested with a thick soap or color indicating solution. Second stage tests shall raise the system to the minimum refrigerant leakage test pressure specified in ANSI/ASHRAE 15 & 34 with a maximum test pressure 25 percent greater. Pressure above 100 psig shall be raised in 10 percent increments with a pressure acclimatizing period between increments. The initial test pressure shall be recorded along with the ambient temperature to which the system is exposed. Final test pressures of the second stage shall be maintained on the system for a minimum of 24 hours. At the end of the 24
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hour period, the system pressure will be recorded along with the ambient temperature to which the system is exposed. A correction factor of 0.3 psi will be allowed for each degree F change between test space initial and final ambient temperature, plus for increase and minus for a decrease. If the corrected system pressure is not exactly equal to the initial system test pressure, then the system shall be investigated for leaking joints. To repair leaks, the joint shall be taken apart, thoroughly cleaned, and reconstructed as a new joint. Joints repaired by caulking, remelting, or back-welding/brazing shall not be acceptable. Following repair, the entire system shall be retested using the pneumatic tests described above. The entire system shall be reassembled once the pneumatic tests are satisfactorily completed.
3.5.3 Evacuation Test
Following satisfactory completion of the pneumatic tests, the pressure shall be relieved and the entire system shall be evacuated to an absolute pressure of 300 micrometers. During evacuation of the system, the ambient temperature shall be higher than 35 degrees F. No more than one system shall be evacuated at one time by one vacuum pump. Once the desired vacuum has been reached, the vacuum line shall be closed and the system shall stand for 1 hour. If the pressure rises over 500 micrometers after the 1 hour period, then the system shall be evacuated again down to 300 micrometers and let set for another 1 hour period. The system shall not be charged until a vacuum of at least 500 micrometers is maintained for a period of 1 hour without the assistance of a vacuum line. If during the testing the pressure continues to rise, check the system for leaks, repair as required, and repeat the evacuation procedure. During evacuation, pressures shall be recorded by a thermocouple-type, electronic-type, or a calibrated-micrometer type gauge.
3.5.4 System Charging and Startup Test
Following satisfactory completion of the evacuation tests, the system shall be charged with the required amount of refrigerant by raising pressure to normal operating pressure and in accordance with manufacturer's procedures. Following charging, the system shall operate with high-side and low-side pressures and corresponding refrigerant temperatures, at design or improved values. The entire system shall be tested for leaks. Fluorocarbon systems shall be tested with halide torch or electronic leak detectors.
3.5.5 Refrigerant Leakage
If a refrigerant leak is discovered after the system has been charged, the leaking portion of the system shall immediately be isolated from the remainder of the system and the refrigerant pumped into the system receiver or other suitable container. Under no circumstances shall the refrigerant be discharged into the atmosphere.
3.5.6 Contractor's Responsibility
At all times during the installation and testing of the refrigeration system, take steps to prevent the release of refrigerants into the atmosphere. The steps shall include, but not be limited to, procedures which will minimize the release of refrigerants to the atmosphere and the use of refrigerant recovery devices to remove refrigerant from the system and store the refrigerant for reuse or reclaim. At no time shall more than 3 ounces of refrigerant be released to the atmosphere in any one
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occurrence. Any system leaks within the first year shall be repaired in accordance with the requirements herein at no cost to the Owner including material, labor, and refrigerant if the leak is the result of defective equipment, material, or installation.
-- End of Section --
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SECTION 23 31 13.00 40
METAL DUCTS 11/12 08/06/2014
PART 1 GENERAL
Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS apply to work specified in this section.
Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT applies to work in this section.
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)
AISC 325 (2011) Steel Construction Manual
AISC 360 (2010) Specification for Structural Steel Buildings
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)
ASHRAE EQUIP IP HDBK (2012) Handbook, HVAC Systems and Equipment (IP Edition)
ASHRAE FUN IP (2013) Fundamentals Handbook, I-P Edition
AMERICAN WELDING SOCIETY (AWS)
AWS A5.8/A5.8M (2011; Amendment 2012) Specification for Filler Metals for Brazing and Braze Welding
ASTM INTERNATIONAL (ASTM)
ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel
ASTM A653/A653M (2011) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process
ASTM A924/A924M (2013) Standard Specification for General Requirements for Steel Sheet, Metallic-Coated by the Hot-Dip Process
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NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 90A (2012) Standard for the Installation of Air Conditioning and Ventilating Systems
SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA)
SMACNA 1966 (2005) HVAC Duct Construction Standards Metal and Flexible, 3rd Edition
SMACNA 1987 (2006) HVAC Duct Systems Inspection Guide, 3rd Edition
SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)
SAE AMS 2480 (2009; Rev H) Phosphate Treatment, Paint, Base
UNDERWRITERS LABORATORIES (UL)
UL 181 (2013) Factory-Made Air Ducts and Air Connectors
1.2 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Equipment and Performance Data; G
Galvanized Steel Ductwork Materials; G
Mill-Rolled Reinforcing and Supporting Materials; G
Round Sheet Metal Duct Fittings; G
Power Operated Dampers; G
SD-06 Test Reports
Operational Tests; G
SD-07 Certificates
Listing of Product Installations; G
Galvanized Steel Ductwork Materials; G
Mill-Rolled Reinforcing and Supporting Materials; G
Round Sheet Metal Duct Fittings; G
Dampers; G
Flexible Connectors; G
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SD-10 Operation and Maintenance Data
Operation and Maintenance Manuals; G
Power Operated Dampers; G
1.3 RECORD DRAWINGS
Provide record drawings with current factual information. Include deviations from, and amendments to, the drawings and concealed or visible changes in the work, for medium/high pressure ductwork systems. Label drawings "As-Built".
PART 2 PRODUCTS
Include the manufacturer's style or catalog numbers, specification and drawing reference numbers, warranty information, and fabrication site information within material, equipment, and fixture lists.
2.1 SYSTEM DESCRIPTION
Provide low-pressure systems ductwork and plenums where maximum air velocity is 2,000 feet per minute(fpm) and maximum static pressure is 2 inches water gage (wg), positive or negative.
Submit connection diagrams for low pressure ductwork systems indicating the relation and connection of devices and apparatus by showing the general physical layout of all controls, the interconnection of one system (or portion of system) with another, and internal tubing, wiring, and other devices.
Submit design analysis and calculations for low pressure ductwork systems indicating the manufacturer's recommended air velocities, maximum static pressures, temperature calculations and acoustic levels.
Encompass high velocity systems ductwork where:
a. Minimum air velocity exceeds 2,000 feet per minute (fpm) or static pressure exceeds 2 inches water gage (wg).
b. Do not use rigid fibrous-glass ductwork.
2.1.1 Design Requirements
Submit records of existing conditions including the results of a survey consisting of work area conditions, and features of existing structures and facilities within and adjacent to the jobsite.
Submit equipment and performance data for medium/high pressure ductwork systems consisting of use life, system functional flows, safety features, and mechanical automated details. Submit test response and performance characteristics curves for certified equipment.
Submit design analysis and calculations for medium/high pressure ductwork systems indicating the manufacturer's recommended air velocities, maximum static pressure, and temperature calculations.
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2.2 MATERIALS
2.2.1 Galvanized Steel Ductwork Materials
Provide hot-dip galvanized carbon steel ductwork sheet metal of lock-forming quality, with regular spangle-type zinc coating, conforming to ASTM A924/A924M and ASTM A653/A653M, Designation G90. Treat duct surfaces to be painted by apostatizing.
Conform to ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966 for sheet metal gages and reinforcement thickness.
Low pressure ductwork minimum standards are:
MINIMUM SHEET METAL GAGE
DUCT WIDTH INCHES GAGE
0 - 12 26 13 - 30 24 31 - 60 22
2.2.2 Brazing Materials
Provide silicon bronze brazing materials conforming to AWS A5.8/A5.8M.
2.2.3 Mill-Rolled Reinforcing And Supporting Materials
Conform to ASTM A36/A36Mfor mill-rolled structural steel and, wherever in contact with sheet metal ducting galvanize to commercial weight of zinc or coated with materials conforming to ASTM A123/A123M.
In lieu of mill-rolled structural steel, submit for approval equivalent strength, proprietary design, rolled-steel structural support systems.
2.3 COMPONENTS
2.3.1 Round Sheet Metal Duct Fittings
Submit offset fitting configurations for approval. Shop fabricate fittings.
2.3.1.1 Fittings Construction
Manufacture as separate fittings, not as tap collars welded or brazed into duct sections.
Provide two-piece type miter elbows for angles less than 31 degrees, three-piece type for angles 31 through 60 degrees, and five-piece type for angles 61 through 90 degrees. Ensure centerline radius of elbows is 1-1/2 times fitting cross section diameter.
Provide conical type crosses, increasers, reducers, reducing tees, and 90-degree tees.
Ensure cutouts in fitting body are equal to branch tap dimension or, where smaller, excess material is flared and rolled into smooth radius nozzle configuration.
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2.3.2 Reinforcement
Support inner liners of both duct and fittings by metal spacers welded in position to maintain spacing and concentricity.
2.3.3 Fittings
Submit offset fitting configurations for approval.
Make divided flow fittings as separate fittings, not tap collars into duct sections, with the following construction requirements:
a. Sound, airtight, continuous welds at intersection of fitting body and tap
B. Tap liner securely welded to inner liner, with weld spacing not to exceed 3 inches
c. Pack insulation around the branch tap area for complete cavity filling.
d. Carefully fit branch connection to cutout openings in inner liner without spaces for air erosion of insulation and without sharp projections that cause noise and airflow disturbance.
Continuously braze seams in the pressure shell of fittings. Protect galvanized areas that have been damaged by welding with manufacturer's standard corrosion-resistant coating.
Construct two-piece type elbows for angles through 35 degrees, three-piece type for angles 36 through 71 degrees, and five-piece type for angles 72 through 90 degrees.
2.3.4 Dampers
Construct low pressure drop, high-velocity manual volume dampers, and high-velocity fire dampers in accordance with ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966.
2.3.5 Flexible Connectors For Sheet Metal
Use UL listed connectors, 30-ounce per square yard, waterproof, fire-retardant, airtight, woven fibrous-glass cloth, double coated with chloroprene. Clear width, not including clamping section, is 6 to 8 inches.
2.3.6 Duct Hangers
For duct hangers in contact with galvanized duct surfaces, provide galvanized steel painted with inorganic zinc.
2.3.7 Mill-Rolled Reinforcing And Supporting Materials
Provide mill-rolled structural steel conforming to ASTM A36/A36M. Whenever in contact with sheet metal ducting, provide galvanized steel in accordance with ASTM A123/A123M.
In lieu of mill-rolled structural steel, submit equivalent strength, proprietary-design, rolled-steel structural support systems for approval.
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2.3.8 Flexible Duct Materials
Ensure flexible duct connectors comply with NFPA 90A, and conform with UL 181, Class 1 material.
Provide wire-reinforced cloth duct consisting of a vinyl-impregnated and coated fibrous-glass cloth bonded to and supported by a corrosion-protected spring steel helix. Fabric may be a laminate of metallic film and fibrous glass. Ensure working pressure rating of ducting is not less than three times maximum system pressure, and the temperature range is minus 20 to plus 175 degrees F.
2.3.9 Power-Operated Dampers
Ensure dampers conform to applicable requirements specified under Section 23 09 33.00 40 ELECTRIC AND ELECTRONIC CONTROL SYSTEM FOR HVAC.
PART 3 EXECUTION
3.1 PREPARATION
For sheet metal surfaces to be painted, and surfaces to which adhesives are to be applied, clean surface of oil, grease, and deleterious substances.
Ensure strength is adequate to prevent failure under service pressure or vacuum created by fast closure of duct devices. Provide leaktight, automatic relief devices.
3.1.1 Construction Standards
Provide sheet metal construction in accordance with the recommendations for best practices in ASHRAE EQUIP IP HDBK, Chapter 16, SMACNA 1966, NFPA 90A, and ASHRAE FUN IP, Chapter 32.
Design and fabricate supplementary steel in accordance with AISC 360 and AISC 325.
Where construction methods for certain items are not described in the referenced standards or herein, perform the work in accordance with recommendations for best practice defined in ASHRAE EQUIP IP HDBK.
3.2 INSTALLATION
When furnishing the listing of product installations for medium/high pressure ductwork systems include identification of at least 5 units, similar to those proposed for use, that have been in successful service for a minimum period of 5 years. Include purchaser, address of installation, service organization, and date of installation.
Fabricate airtight and include reinforcements, bracing, supports, framing, gasketing, sealing, and fastening to provide rigid construction and freedom from vibration, airflow-induced motion and noise, and excessive deflection at specified maximum system air pressure and velocity.
Provide offsets and transformations as required to avoid interference with the building construction, piping, or equipment.
Make plenum anchorage provisions, sheet metal joints, and other areas airtight and watertight by caulking mating galvanized steel and concrete
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surfaces with a two-component elastomer.
3.2.1 Jointing
Enclose dampers located behind architectural intake or exhaust louvers by a rigid sheet metal collar and sealed to building construction with elastomers for complete air tightness.
Provide outside air-intake ducts and plenums made from sheet metal with soldered watertight joints.
3.2.2 Ducts
Wherever ducts pass through firewalls or through walls or floors dividing conditioned spaces from unconditioned spaces, provide a flanged segment in that surface during surface construction.
Where interiors of ducting may be viewed through air diffusion devices, construct the viewed interior with sheet metal and paint flat black.
3.3 APPLICATION
3.3.1 Low Pressure Sheet Metal Ducts
Weld angle iron frames at corners and ends, whenever possible. Rivet or weld angle iron reinforcements to ducts not more than 6 inches on center, with not less than two points of attachment. Spot welding, where used, is 3 inches on center.
Seal standard seam joints with an elastomer compound to comply with SMACNA 1966 Seal Class A, B or C as applicable.
Limit crossbreaking to 4 feet and provide on all ducts 8 inches wide and wider. Provide bead reinforcement in lieu of crossbreaking where panel popping may occur. Where rigid insulation is applied, crossbreaking is not required.
3.3.1.1 Joints and Gaskets
Bolt companion angle flanges together with 1/4 inch diameter bolts and nuts spaced 6 inches on center. Gasket flanged joints with chloroprene full-face gaskets 1/8 inch thick, with Shore A 40 durometer hardness. Use one piece gaskets, dovetailed at joints.
3.3.1.2 Flexible Duct Joints
Between flexible duct without sheet metal collars and round metal ductwork connections make joints by trimming the ends, coating the inside of the flexible duct for a distance equal to depth of insertion with elastomer caulk, and by securing with sheet metal screws or binding with a strap clamp.
3.3.1.3 Radius Elbows
Conform to SMACNA 1966 for radius elbows. Provide an inside radius equal to the width of the duct. Where installation conditions preclude use of standard elbows, the inside radius may be reduced to a minimum of 0.25 times duct width and install turning vanes in accordance with the following schedule.
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RADIUS OF TURNING WIDTH OF ELBOWS VANES IN PERCENT OF DUCT WIDTH INCHES VANE NO. 1 VANE NO. 2 VANE NO. 3
Up to 16 56 -- --
17 to 48 43 73 --
49 and over 37 55 83
Where two elbows are placed together in the same plane in ducts 30 inches wide and larger, continue the guide vanes through both elbows rather than spaced in accordance with above schedule.
3.3.1.4 Outlets, Inlets, And Duct Branches
Install branches, inlets, and outlets so that air turbulence is reduced to a minimum and air volume properly apportioned. Install adjustable splitter dampers at all supply junctions to permit adjustment of the amount of air entering the branch. Wherever an air-diffusion device is shown as being installed on the side, top, or bottom of a duct, and whenever a branch takeoff is not of the splitter type; provide a commercially manufactured 45 degree side-take-off (STO) fitting with manual volume damper to allow adjustment of the air quantity and to provide an even flow of air across the device or duct it services.
Where a duct branch is to handle more than 25 percent of the air handled by the duct main, use a complete 90-degree increasing elbow with an inside radius of 0.75 times branch duct width. Size of the leading end of the increasing elbow within the main duct with the same ratio to the main duct size as the ratio of the related air quantities handled.
Where a duct branch is to handle 25 percent or less of the air handled by the duct main, construct the branch connection with a 45 degree side take-off entry in accordance with SMACNA 1966.
3.3.1.5 Duct Transitions
Where the shape of a duct changes, ensure the angle of the side of the transition piece does not exceed 15 degrees from the straight run of duct connected thereto.
Where equipment is installed in ductwork, ensure the angle of the side of the transition piece from the straight run of duct connected thereto does not exceed 15 degrees on the upstream side of the equipment and 22-1/2 degrees on the downstream side of the equipment.
3.3.1.6 Branch Connections
Construct radius tap-ins in accordance with SMACNA 1966.
3.3.1.7 Access Openings
Construct access door in accordance with SMACNA 1966, except that sliding doors may be used only for special conditions upon prior approval. Provide double-panel type doors.
Install access doors and panels in ductwork at controls or at any item
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requiring periodic inspection, adjustment, maintenance, or cleaning, and every 20 feet for indoor air quality housekeeping purposes.
Minimum access opening size is 12 by 18 inches, unless precluded by duct dimensions or otherwise indicated.
Make airtight access doors that leak by adding or replacing hinges and latches or by construction of new doors adequately reinforced, hinged, and latched.
3.3.1.8 Flexible Connectors For Sheet Metal
Connect air handling equipment, ducts crossing building expansion joints, and fan inlets and outlets to upstream and downstream components by treated woven-cloth connectors.
Install connectors only after system fans are operative, and vibration isolation mountings have been adjusted. When system fans are operating, ensure connectors are free of wrinkle caused by misalignment or fan reaction. Width of surface is curvilinear.
3.3.2 Rectangular Sheet Metal Ducts
3.3.2.1 Medium-Pressure Gages, Joints, And Reinforcement
Ensure minimum sheet metal gages, joints, and reinforcements between joints are in accordance with ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966.
Ensure sheet metal minimum thickness, transverse reinforcement between joints, and joints of ducts are in accordance with the following:
SHEET LONGEST METAL REINFORCEMENT ANGLES SIDE GAGE COMPANION ANGLE INCHES, 24 INCHES ON INCHES ALL SIDES INCHES CENTER MAXIMUM
(BACK TO BACK) ______
97 to 108 16 2 by 2 by 1/8, Two 2 by 2 by 1/8, two tie rods two tie rods along along angle angle
109 to 132 16 2 by 2 by 3/16, Two 2 by 2 by 3/16, two tie rods two tie rods along along angle angle
133 and 14 2 by 2 by 3/16, Two 2 by 2 by 3/16, longer with tie rods with tie rods every every 48 inches 48 inches
3.3.2.2 Medium- And High-Pressure Branches, Inlets, Outlets
Install branches, inlets, and outlets to minimize air turbulence and to ensure proper airflow.
Install dampers so that the amount of air entering duct mains is adjustable.
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Provide commercially manufactured air extractors to allow adjustment of the air quantity and to provide an even flow of air across the device or duct served.
3.3.2.3 Duct Branch Transition
Where a duct branch handles over 25 percent of the air transported by the duct main, use a complete 90-degree increasing, with an inside radius of 0.75 times duct branch width. Ensure the size of the trailing end of the increasing elbow within the main duct is in the same ratio to the main duct size as the ratio of the relative air quantities handled.
Where a duct branch is to handle 25 percent or less of the air handled by the duct main, provide a branch connection with an inside radius of 0.75 times branch duct width, a minimum arc length of 45 degrees, and an outside radius of 1.75 times duct branch width. Place arc tangent to duct main.
3.3.2.4 High-Pressure Gages, Joints, And Reinforcement
Ensure sheet metal minimum thickness, joints, and reinforcement between joints are in accordance with ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966.
Use the following types of ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966 transverse joints:
a. Welded flange joint with angle
b. Companion angle flanged joint
Use the following types of longitudinal seams:
a. Approved lock seams, back brazed, or continuously brazed seams for ducts with largest dimension up to 72 inches
b. Continuously welded or brazed seams for ducts with largest dimension greater than 72 inches
Sheet metal minimum thickness, transverse reinforcement between joints, and companion angle joints of ducts with longest side greater than 96 inches are in accordance with the following:
SHEET LONGEST METAL REINFORCEMENT ANGLES SIDE GAGE COMPANION ANGLE INCHES, 24 INCHES ON INCHES ALL SIDES INCHES CENTER MAXIMUM
(BACK TO BACK) ______
97 to 108 16 2 by 2 by 1/8, *Two 2 by 2 by 1/8, two tie rods two tie rods along along angle angle
109 to 132 16 2 by 2 by 3/16, *Two 2 by 2 by 3/16, two tie rods two tie rods along along angle angle
133 and 14 2-1/2 by 2-1/2 *Two 2-1/2 by 2-1/2
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SHEET LONGEST METAL REINFORCEMENT ANGLES SIDE GAGE COMPANION ANGLE INCHES, 24 INCHES ON INCHES ALL SIDES INCHES CENTER MAXIMUM
(BACK TO BACK) ______longer by 3/16, with by 3/16, with tie tie rods every rods every 24 inches 24 inches
3.3.3 Round Sheet Metal Ducts
3.3.3.1 Duct Gages And Reinforcement
Sheet metal minimum thickness, joints, and reinforcement between joints shall be in accordance with ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966.
Provide ducts with supplemental girth angle supports, riveted with solid rivets 6 inches on center to duct. Locate girth angles as follows:
DIAMETER, INCHES REINFORCEMENT-MAXIMUM SPACING, INCHES
25 to 36 1-1/4 by 1-1/4, 1/8 thick, 72 inches on center
37 to 50 1-1/4 by 1-1/4, 1/8 thick, 60 inches on center
51 to 60 1-1/2 by 1-1/2, 1/8 thick, 48 inches on center
Bolt heads and nuts shall be hex-shaped, 5/16 inch diameter for ducts up to 50 inch diameter, and 3/8 inch diameter for 51 inch diameter ducts and larger.
Continuously weld flanges to duct on outside of duct and intermittently welded with 1 inch welds every4 inches on inside joint face. Remove excess filler metal from inside face. Protect galvanized areas that have been damaged by welding with manufacturer's standard corrosion-resistant coating.
3.3.3.2 Duct Joints
Provide continuously welded duct joints manufactured by machine, with spiral locksets to and including 60 inch diameters, and to dimensional tolerances compatible with fittings provided. Draw band girth joints are not acceptable.
3.3.3.3 Duct Transitions
Where the shape of a duct changes, ensure the angle of the side of the transition piece does not exceed 15 degrees from the straight run of duct connected thereto.
Where equipment is installed in ductwork, ensure the angle of the side of the transition piece from the straight run of duct connected thereto does
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not exceed 15 degrees on the upstream side of the equipment and 22-1/2 degrees on the downstream side of the equipment.
3.3.4 Transverse Reinforcement Joints
Provide transverse reinforcements that are continuously welded. Weld transverse reinforcement at all corners to form continuous frames.
3.3.5 Joint Gaskets
Gasket flanged joints with chloroprene full-face gaskets 1/8 inch thick, Shore A 40 durometer hardness. Use one-piece gaskets, dovetailed at joints.
3.3.6 Radius Elbows
Fabricate elbow proportions and radius elbows in accordance with ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966.
3.3.7 Access Openings
Install access panels in ductwork adjacent to fire dampers.
Minimum size of access opening is 12 by 18 inches, unless precluded by duct dimension.
Frame access openings with welded and ground miter joints, 1/8 inch thick angle iron, with 1/4 inch studs welded to frame. Ensure cover plates are not less than 16-gage, reinforced as necessary for larger sizes.
In lieu of access doors, use readily accessible flanged duct sections upon approval. Provide stable hanger supports for disconnected duct terminal.
3.3.8 Duct Supports
Install duct support in accordance with ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966. Meet the minimum size for duct hangers as specified in ASHRAE EQUIP IP HDBK, Chapter 16, ASHRAE FUN IP, Chapter 32 and SMACNA 1966. Provide two hangers where necessary to eliminate sway. Support attachment to duct surfaces by bolt 4 inches on center.
Take the following into account in selection of a hanging system:
a. Location and precedence of work under other sections
b. Interferences of various piping and electrical conduit
c. Equipment,and building configuration
d. Structural and safety factor requirements
e. Vibration, and imposed loads under normal and abnormal service conditions
Support sizes, configurations, and spacing are given to show the minimal type of supporting components required. If installed loads are excessive for the specified hanger spacing, hangers, and accessories provide heavier-duty components. After system startup, replace any duct support device which, due to length, configuration, or size, vibrates or causes
SECTION 23 31 13.00 40 Page 12 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
possible failure of a member, or the condition otherwise be alleviated. Exercise special care to preclude cascade-type failures.
Do not hang ductwork and equipment from roof deck, piping, or other ducts or equipment. Maximum span between any two points is 10 feet, with lesser spans as required by duct assemblies, interferences, and permitted loads imposed.
3.3.8.1 Hangars
Attach hanger rods, angles, and straps to beam clamps. Receive approval from the Owner's Representative for concrete inserts, masonry anchors, and fasteners for the application.
Hardened high-carbon spring-steel fasteners fitted onto beams and miscellaneous structural steel are acceptable upon prior approval of each proposed application and upon field demonstration of conformance to specification requirements. Make fasteners from steel conforming to AISI Type 1070, treated and finished in conformance with SAE AMS 2480, Type Z (zinc phosphate base), Class 2 (supplementary treatment). Verify a 72-hour load-carrying capacity by a certified independent laboratory.
Where ductwork system contains heavy equipment, excluding air-diffusion devices and single-leaf dampers, hang such equipment independently of the ductwork by means of rods or angles of sizes adequate to support the load.
Sufficiently cross-brace hangers to eliminate swaying both vertically and laterally.
3.3.8.2 Installation
Ensure hanger spacing gives a 20-to-1 safety factor for supported load.
Maximum load supported by any two fasteners is 100 pounds.
Install hangers on both sides of all duct turns, branch fittings, and transitions.
Friction rod assemblies are not acceptable.
3.3.8.3 Strap-type Hangars
Support rectangular ducts up to 36 inches by strap-type hangers attached at not less than three places to not less than two duct surfaces in different planes.
Perforated strap hangers are not acceptable.
3.3.8.4 Trapeze Hangars
Support rectangular ducting, 36 inches and larger, by trapeze hangers. Support ducts situated in unconditioned areas and required to have insulation with a vapor-sealed facing on trapeze hangers. Space hangers far enough out from the side of the duct to permit the duct insulation to be placed on the duct inside the trapeze. Do not penetrate the vapor-sealed facing with duct hangers.
Where trapeze hangers are used, support the bottom of the duct on angles sized as follows:
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WIDTH OF DUCT, INCHES MINIMUM BOTTOM ANGLE SIZE, INCHES
30 and smaller 1-1/4 by 1-1/4 by 1/8
31 to 48 1-1/2 by 1-1/2 by 1/8
49 to 72 1-1/2 by 1-1/2 by 3/16
73 to 96 2 by 2 by 1/4
97 and wider 3 by 3 by 1/4
3.3.8.5 Purlins
Do not support ducting, when supported from roof purlins, at points greater than one-sixth of the purlin span from the roof truss. Do not exceed 400 pounds load per hanger when support is from a single purlin or 800 pounds when hanger load is applied halfway between purlins by means of auxiliary support steel provided under this section. When support is not halfway between purlins, the allowable hanger load is the product of 400 times the inverse ratio of the longest distance of purlin-to-purlin spacing.
When the hanger load exceeds the above limits, provide reinforcing of purlin(s) or additional support beam(s). When an additional beam is used, have the beam bear on the top chord of the roof trusses, and also bear over the gusset plates of top chord. Stabilize the beam by connection to roof purlin along bottom flange.
Purlins used for supporting fire-protection sprinkler mains, electrical lighting fixtures, electrical power ducts, or cable trays are considered fully loaded. Provide supplemental reinforcing or auxiliary support steel for these purlins.
3.3.8.6 Vibration Isolation
Isolate from vibration duct supports from structure at points indicated. Refer to Section 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT.
3.3.9 Flexible Connectors For Steel Metal
Connect air-handling equipment, ducts crossing building expansion joints, and fan inlets and outlets to upstream and downstream components by treated woven-cloth connectors.
Install connectors only after system fans are operative and all vibration isolation mountings have been adjusted. When system fans are operating, ensure connectors are free of wrinkles caused by misalignment or fan reaction. Width of surface is curvilinear.
3.3.10 Insulation Protection Angles
Provide galvanized 20-gage sheet, formed into an angle with a 2 inch exposed long leg with a 3/8 inchstiffening break at outer edge, and with a variable concealed leg, depending upon insulation thickness.
Install angles over all insulation edges terminating by butting against a wall, floor foundation, frame, and similar construction. Fasten angles in
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place with blind rivets through the protection angle, insulation, and sheet metal duct or plenum. Install angles after final insulation covering has been applied.
3.3.11 Duct Probe Access
Provide holes with neat patches, threaded plugs, or threaded or twist-on caps for air-balancing pitot tube access. Provide extended-neck fittings where probe access area is insulated.
3.3.12 Openings In Roofs And Walls
Building openings are fixed and provide equipment to suit.
3.4 FIELD QUALITY CONTROL
3.4.1 Ductwork Leakage Tests
Conduct complete leakage test of new ductwork in accordance with Section 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC. Perform tests prior to installing ductwork insulation.
3.4.2 Inspection
Inspect ductwork in accordance with SMACNA 1987.
3.5 DUCTWORK CLEANING PROVISIONS
Protect open ducting from construction dust and debris in a manner approved by the Owner's Representative. Clean dirty assembled ducting by subjecting all main and branch interior surfaces to airstreams moving at velocities two times specified working velocities, at static pressures within maximum ratings. This may be accomplished by: filter-equipped portable blowers which remain the Contractor's property; wheel-mounted, compressed-air operated perimeter lances which direct the compressed air and which are pulled in the direction of normal airflow; or other means approved by the Owner's Representative. Use water- and oil- free compressed air for cleaning ducting. After construction is complete, and prior to acceptance of the work, remove construction dust and debris from exterior surfaces. Clean in conformance with SMACNA 1987.
3.6 OPERATION AND MAINTENANCE
Submit 6 copies of the operation and maintenance manuals 30 calendar days prior to testing the medium/high pressure ductwork systems. Update data and resubmit for final approval no later than 30 calendar days prior to contract completion.
Ensure Operation and Maintenance Manuals are consistent with manufacturer's standard brochures, schematics, printed instructions, general operating procedures and safety precautions.
-- End of Section --
SECTION 23 31 13.00 40 Page 15 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 23 82 46.00 40
ELECTRIC UNIT HEATERS 08/11 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
UNDERWRITERS LABORATORIES (UL)
UL 1996 (2009; Reprint Nov 2011) Electric Duct Heaters
1.2 ADMINISTRATIVE REQUIREMENTS
Section 26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS applies to work specified in this section.
1.2.1 Pre-Installation Meetings
The Owner's Representative will schedule a pre-installation meeting within 30 days of Contract Award. Provide the following for review and approval:
a. Submit Fabrication Drawings for electric heaters indicating the of fabrication and assembly details to be performed in the factory.
b. Submit Equipment and Performance Data for electric heaters life, test, system functional flows, safety features, and mechanical automated details.
c. Submit Manufacturer's Instructions for electric heaters stating the special provisions required to install equipment components and system packages. Detail impedances, hazards and safety precautions within the special notices.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-03 Product Data
Equipment and Performance Data; G
Electric Unit Heaters; G
Controls; G
Propellers and Motors; G
SD-08 Manufacturer's Instructions
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Manufacturer's Instructions; G
PART 2 PRODUCTS
2.1 PRODUCT STANDARDS
Provide products conforming to the requirements of UL 1996 for electric unit heaters.
2.2 DESCRIPTION
Provide suspended electric unit heaters and arrange for discharge of air as indicated.
Provide electric unit heaters with not less than the indicated capacity and conform to requirements specified herein. Ensure electric unit heaters are factory prewired, ready for field terminal connections.
2.3 CASINGS
Construct casings with smoothly contoured propeller orifice rings of not less than 20-gage cold-rolled carbon steel. Provide casing surface finish with phosphate pretreatment, prime coating, and baked-enamel finish.
2.4 AIR DISTRIBUTION
Provide horizontal units with adjustable single- or double-deflection louvers.
2.5 HEATING ELEMENT
Construct heating element of a resistance wire insulated by highly compacted refractory insulation protected by a sealed metallic-finned sheath. Component materials are as follows:
a. Provide resistance wire not less than 20-helix wound alloy approximately 80-percent nickel and 20-percent chromium.
b. Provide refractory insulation of magnesium oxide with a resistance of not less than 50,000-ohms after exposure to an ambient temperature and humidity of 90 degrees F and 85 plus or minus 5-percent relative humidity, respectively, for not less than 24 hours.
c. Provide sheathing consisting of aluminum fins cast around an internal steel sheath containing refractory insulation and resistance wire or carbon-steel fins permanently attached to a tubular carbon-steel sheath containing refractory insulation and resistance wire and with external surfaces porcelainized.
2.6 CONTROLS
Fit units up to and including 5 kilowatts with integral controls including thermal overload cutout switches, necessary transformers, liquid-vapor system, and low-mass bimetal thermostat as required. Provide automatically resettable cutout switch.
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2.7 PROPELLERS AND MOTORS
Provide propellers with galvanized-steel statically and dynamically balanced to within 0.5 percent. Provide units with fan-inlet safety guards.
AMCA certify propellers and motors for air performance and noise level.
Protect motors against damage by the heating element and resilient mount.
Subfractional and fractional custom-designed or applied motors may deviate from the preceding motor requirements as follows:
a. Shaded-pole motors rated less than 1/6-horsepower may be used for direct-drive service.
b. Permanent split-capacitor, split-phase, and capacitor-start motors rated 1/4-horsepower and less may be used for direct-drive service.
c. Split-phase and capacitor-start motors, rated 1/4-horsepower and less, may be used for belt-drive service.
d. Motor bearings may be manufacturer's standard prelubricated sleeve type except provide motor with antifriction thrust bearings, when specified. Ensure lubricant provisions are extended service type, requiring replenishment not more than twice per year of continuous operation.
Provide motor identification plate per manufacturer's standard.
Provide motor speed and control per unit-heater manufacturer's standard.
PART 3 EXECUTION
3.1 INSTALLATION
Install unit heaters in accordance with the manufacturer's instructions at the mounting heights indicated.
3.2 FIELD TESTING
Demonstrate in the presence of the Owner's Representative that the unit heaters operate satisfactorily.
Cycle unit heaters five times, from start to operating thermal conditions to off, to verify adequacy of construction, system controls, and component performance.
Conduct an operational test for a minimum of 6 hours.
-- End of Section --
SECTION 23 82 46.00 40 Page 3 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 26 ELECTRICAL
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 26 00 00.00 20
BASIC ELECTRICAL MATERIALS AND METHODS 07/06 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM D709 (2013) Laminated Thermosetting Materials
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 100 (2000; Archived) The Authoritative Dictionary of IEEE Standards Terms
IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-6 2013) National Electrical Safety Code
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA 250 (2008) Enclosures for Electrical Equipment (1000 Volts Maximum)
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
1.2 RELATED REQUIREMENTS
This section applies to certain sections of Division 40, PROCESS INTEGRATION, and Divisions 22 and 23, PLUMBING and HEATING VENTILATING AND AIR CONDITIONING. This section applies to all sections of Division 26 and 33, ELECTRICAL and UTILITIES, of this project specification unless specified otherwise in the individual sections. This section has been incorporated into, and thus, does not apply to, and is not referenced in the following sections.
Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM Section 26 51 00 INTERIOR LIGHTING Section 26 56 00 EXTERIOR LIGHTING Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION
1.3 DEFINITIONS
a. Unless otherwise specified or indicated, electrical and electronics terms used in these specifications, and on the drawings, shall be as defined in IEEE 100.
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b. The technical sections referred to herein are those specification sections that describe products, installation procedures, and equipment operations and that refer to this section for detailed description of submittal types.
c. The technical paragraphs referred to herein are those paragraphs in PART 2 - PRODUCTS and PART 3 - EXECUTION of the technical sections that describe products, systems, installation procedures, equipment, and test methods.
1.4 ELECTRICAL CHARACTERISTICS
Electrical characteristics for this project shall be 23.9kV kV primary three phase, three wire, 60 Hz, and 480Y/277 volts secondary, three phase, four wire. Final connections to the power distribution system at the existing utility transformer shall be made by the Contractor as directed by the Power Company.
1.5 ADDITIONAL SUBMITTALS INFORMATION
Submittals required in other sections that refer to this section must conform to the following additional requirements as applicable.
1.5.1 Shop Drawings (SD-02)
Include wiring diagrams and installation details of equipment indicating proposed location, layout and arrangement, control panels, accessories, piping, ductwork, and other items that must be shown to ensure a coordinated installation. Wiring diagrams shall identify circuit terminals and indicate the internal wiring for each item of equipment and the interconnection between each item of equipment. Drawings shall indicate adequate clearance for operation, maintenance, and replacement of operating equipment devices.
1.5.2 Product Data (SD-03)
Submittal shall include performance and characteristic curves.
1.6 QUALITY ASSURANCE
1.6.1 Regulatory Requirements
In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction," or words of similar meaning, to mean the Owner's Representative. Equipment, materials, installation, and workmanship shall be in accordance with the mandatory and advisory provisions of NFPA 70 unless more stringent requirements are specified or indicated.
1.6.2 Standard Products
Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship. Products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year period shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been on sale on
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the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period. Where two or more items of the same class of equipment are required, these items shall be products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in the technical section.
1.6.2.1 Alternative Qualifications
Products having less than a 2-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturers' factory or laboratory tests, is furnished.
1.6.2.2 Material and Equipment Manufacturing Date
Products manufactured more than 3 years prior to date of delivery to site shall not be used, unless specified otherwise.
1.7 WARRANTY
The equipment items shall be supported by service organizations which are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
1.8 POSTED OPERATING INSTRUCTIONS
Provide for each system and principal item of equipment as specified in the technical sections for use by operation and maintenance personnel. The operating instructions shall include the following:
a. Wiring diagrams, control diagrams, and control sequence for each principal system and item of equipment.
b. Start up, proper adjustment, operating, lubrication, and shutdown procedures.
c. Safety precautions.
d. The procedure in the event of equipment failure.
e. Other items of instruction as recommended by the manufacturer of each system or item of equipment.
Print or engrave operating instructions and frame under glass or in approved laminated plastic. Post instructions where directed. For operating instructions exposed to the weather, provide weather-resistant materials or weatherproof enclosures. Operating instructions shall not fade when exposed to sunlight and shall be secured to prevent easy removal or peeling.
1.9 MANUFACTURER'S NAMEPLATE
Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.
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1.10 FIELD FABRICATED NAMEPLATES
ASTM D709. Provide laminated plastic nameplates for each equipment enclosure, relay, switch, and device; as specified in the technical sections or as indicated on the drawings. Each nameplate inscription shall identify the function and, when applicable, the position. Nameplates shall be melamine plastic, 0.125 inch thick, white with black center core. Surface shall be matte finish. Corners shall be square. Accurately align lettering and engrave into the core. Minimum size of nameplates shall be one by 2.5 inches. Lettering shall be a minimum of 0.25 inch high normal block style.
1.11 ELECTRICAL REQUIREMENTS
Electrical installations shall conform to IEEE C2, NFPA 70, and requirements specified herein.
1.12 INSTRUCTION TO PERSONNEL
Where specified in the technical sections, furnish the services of competent instructors to give full instruction to designated personnel in the adjustment, operation, and maintenance of the specified systems and equipment, including pertinent safety requirements as required. Instructors shall be thoroughly familiar with all parts of the installation and shall be trained in operating theory as well as practical operation and maintenance work. Instruction shall be given during the first regular work week after the equipment or system has been accepted and turned over to the Owner's Representative for regular operation. The number of man-days (8 hours per day) of instruction furnished shall be as specified in the individual section.
PART 2 PRODUCTS
2.1 FACTORY APPLIED FINISH
Electrical equipment shall have factory-applied painting systems which shall, as a minimum, meet the requirements of NEMA 250 corrosion-resistance test.
PART 3 EXECUTION
3.1 FIELD FABRICATED NAMEPLATE MOUNTING
Provide number, location, and letter designation of nameplates as indicated. Fasten nameplates to the device with a minimum of two sheet-metal screws or two rivets.
-- End of Section --
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SECTION 26 20 00
INTERIOR DISTRIBUTION SYSTEM 02/14 08/20/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM B1 (2013) Standard Specification for Hard-Drawn Copper Wire
ASTM B8 (2011) Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft
ASTM D709 (2013) Laminated Thermosetting Materials
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 100 (2000; Archived) The Authoritative Dictionary of IEEE Standards Terms
IEEE 81 (2012) Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System
IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-6 2013) National Electrical Safety Code
INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)
NETA ATS (2013) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
ANSI C80.1 (2005) American National Standard for Electrical Rigid Steel Conduit (ERSC)
ANSI C80.5 (2005) American National Standard for Electrical Rigid Aluminum Conduit
NEMA 250 (2008) Enclosures for Electrical Equipment (1000 Volts Maximum)
NEMA ICS 1 (2000; R 2008; E 2010) Standard for Industrial Control and Systems: General Requirements
SECTION 26 20 00 Page 1 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V
NEMA ICS 4 (2010) Terminal Blocks
NEMA ICS 6 (1993; R 2011) Enclosures
NEMA KS 1 (2001; R 2006) Enclosed and Miscellaneous Distribution Equipment Switches (600 V Maximum)
NEMA MG 1 (2011; Errata 2012) Motors and Generators
NEMA MG 10 (2001; R 2007) Energy Management Guide for Selection and Use of Fixed Frequency Medium AC Squirrel-Cage Polyphase Induction Motors
NEMA MG 11 (1977; R 2012) Energy Management Guide for Selection and Use of Single Phase Motors
NEMA RN 1 (2005; R 2013) Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit
NEMA ST 20 (1992; R 1997) Standard for Dry-Type Transformers for General Applications
NEMA TC 2 (2013) Standard for Electrical Polyvinyl Chloride (PVC) Conduit
NEMA TC 3 (2013) Standard for Polyvinyl Chloride (PVC) Fittings for Use With Rigid PVC Conduit and Tubing
NEMA WD 1 (1999; R 2005; R 2010) Standard for General Color Requirements for Wiring Devices
NEMA WD 6 (2012) Wiring Devices Dimensions Specifications
NEMA Z535.4 (2011) American National Standard for Product Safety Signs and Labels
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
NFPA 70E (2012; Errata 2012) Standard for Electrical Safety in the Workplace
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
29 CFR 1910.147 Control of Hazardous Energy (Lock Out/Tag Out)
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UNDERWRITERS LABORATORIES (UL)
UL 1 (2005; Reprint Jul 2012) Standard for Flexible Metal Conduit
UL 1063 (2006; Reprint Jul 2012) Machine-Tool Wires and Cables
UL 1449 (2006; Reprint Sep 2013) Surge Protective Devices
UL 1660 (2004; Reprint Apr 2013) Liquid-Tight Flexible Nonmetallic Conduit
UL 20 (2010; Reprint Feb 2012) General-Use Snap Switches
UL 360 (2013; Reprint May 2013) Liquid-Tight Flexible Steel Conduit
UL 44 (2010) Thermoset-Insulated Wires and Cables
UL 467 (2007) Grounding and Bonding Equipment
UL 486A-486B (2013) Wire Connectors
UL 486C (2013) Splicing Wire Connectors
UL 489 (2013) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures
UL 498 (2012; Reprint Aug 2013) Attachment Plugs and Receptacles
UL 50 (2007; Reprint Apr 2012) Enclosures for Electrical Equipment, Non-environmental Considerations
UL 506 (2008; Reprint Oct 2013) Specialty Transformers
UL 508 (1999; Reprint Oct 2013) Industrial Control Equipment
UL 510 (2005; Reprint Jul 2013) Polyvinyl Chloride, Polyethylene and Rubber Insulating Tape
UL 514A (2013) Metallic Outlet Boxes
UL 514B (2012) Conduit, Tubing and Cable Fittings
UL 514C (1996; Reprint Nov 2011) Nonmetallic Outlet Boxes, Flush-Device Boxes, and Covers
UL 6 (2007; reprint Nov 2010) Electrical Rigid
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Metal Conduit-Steel
UL 651 (2011; Reprint Mar 2012) Standard for Schedule 40 and 80 Rigid PVC Conduit and Fittings
UL 67 (2009; Reprint Jan 2013) Standard for Panelboards
UL 6A (2008; Reprint May 2013) Electrical Rigid Metal Conduit - Aluminum, Red Brass, and Stainless Steel
UL 83 (2008) Thermoplastic-Insulated Wires and Cables
UL 869A (2006) Reference Standard for Service Equipment
UL 943 (2006; Reprint Jun 2012) Ground-Fault Circuit-Interrupters
UL 984 (1996; Reprint Sep 2005) Hermetic Refrigerant Motor-Compressors
1.2 DEFINITIONS
Unless otherwise specified or indicated, electrical and electronics terms used in these specifications, and on the drawings, are as defined in IEEE 100.
1.3 SUBMITTALS
Submit in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Panelboards; G
Transformers; G
Include wiring diagrams and installation details of equipment indicating proposed location, layout and arrangement, control panels, accessories, piping, ductwork, and other items that must be shown to ensure a coordinated installation. Identify circuit terminals on wiring diagrams and indicate the internal wiring for each item of equipment and the interconnection between each item of equipment. Indicate on the drawings adequate clearance for operation, maintenance, and replacement of operating equipment devices.
SD-03 Product Data
Receptacles; G
Circuit breakers; G
Switches; G
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Transformers; G
Enclosed circuit breakers; G
Motor controllers; G
Combination motor controllers; G
Manual motor starters; G
Include performance and characteristic curves.
SD-06 Test Reports
600-volt wiring test; G
Grounding system test; G
Ground-fault receptacle test; G
SD-09 Manufacturer's Field Reports
Transformer factory tests
SD-10 Operation and Maintenance Data
Electrical Systems, Data Package 5; G
Metering, Data Package 5; G
Submit operation and maintenance data in accordance with Division 1 - General Requirements and as specified herein.
1.4 QUALITY ASSURANCE
1.4.1 Regulatory Requirements
In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" or "must" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction," or words of similar meaning, to mean the Owner's Representative. Provide equipment, materials, installation, and workmanship in accordance with the mandatory and advisory provisions of NFPA 70 unless more stringent requirements are specified or indicated.
1.4.2 Standard Products
Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship and:
a. Have been in satisfactory commercial or industrial use for 2 years prior to bid opening including applications of equipment and materials under similar circumstances and of similar size.
b. Have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period.
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c. Where two or more items of the same class of equipment are required, provide products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in this section.
1.4.2.1 Alternative Qualifications
Products having less than a 2-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturers' factory or laboratory tests, is furnished.
1.4.2.2 Material and Equipment Manufacturing Date
Products manufactured more than 3 years prior to date of delivery to site are not acceptable.
1.5 MAINTENANCE
1.5.1 Electrical Systems
Submit operation and maintenance manuals for electrical systems that provide basic data relating to the design, operation, and maintenance of the electrical distribution system for the building. Include the following:
a. Single line diagram of the "as-built" building electrical system.
b. Schematic diagram of electrical control system (other than HVAC, covered elsewhere).
c. Manufacturers' operating and maintenance manuals on active electrical equipment.
1.6 WARRANTY
Provide equipment items supported by service organizations that are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
PART 2 PRODUCTS
2.1 MATERIALS AND EQUIPMENT
As a minimum, meet requirements of UL, where UL standards are established for those items, and requirements of NFPA 70 for all materials, equipment, and devices.
2.2 CONDUIT AND FITTINGS
Conform to the following:
2.2.1 Rigid Metallic Conduit
2.2.1.1 Rigid, Threaded Zinc-Coated Steel Conduit
ANSI C80.1, UL 6.
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2.2.1.2 Rigid Aluminum Conduit
ANSI C80.5, UL 6A.
2.2.2 Rigid Nonmetallic Conduit
PVC Type EPC-40 in accordance with NEMA TC 2,UL 651.
2.2.3 Plastic-Coated Rigid Steel and IMC Conduit
NEMA RN 1, Type 40( 40 mils thick).
2.2.4 Flexible Metal Conduit
UL 1.
2.2.4.1 Liquid-Tight Flexible Metal Conduit, Steel
UL 360.
2.2.5 Fittings for Metal Conduit and Flexible Metal Conduit
UL 514B. Ferrous fittings: cadmium- or zinc-coated in accordance with UL 514B.
2.2.5.1 Fittings for Rigid Metal Conduit and IMC
Threaded-type. Split couplings unacceptable.
2.2.6 Fittings for Rigid Nonmetallic Conduit
NEMA TC 3 for PVC, and UL 514B.
2.2.7 Liquid-Tight Flexible Nonmetallic Conduit
UL 1660.
2.3 OUTLET BOXES AND COVERS
UL 514A, cadmium- or zinc-coated, if ferrous metal. UL 514C, if nonmetallic.
2.4 CABINETS, JUNCTION BOXES, AND PULL BOXES
Volume greater than 100 cubic inches, UL 50, hot-dip, zinc-coated, if sheet steel.
2.5 WIRES AND CABLES
Provide wires and cables in accordance applicable requirements of NFPA 70 and UL for type of insulation, jacket, and conductor specified or indicated. Do not use wires and cables manufactured more than 12 months prior to date of delivery to site.
2.5.1 Conductors
Provide the following:
a. Conductor sizes and capacities shown are based on copper, unless
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indicated otherwise.
b. Conductors No. 8 AWG and larger diameter: stranded.
c. Conductors No. 10 AWG and smaller diameter: solid.
d. Conductors for remote control, alarm, and signal circuits, classes 1, 2, and 3: stranded unless specifically indicated otherwise.
e. All conductors: copper.
2.5.1.1 Minimum Conductor Sizes
Provide minimum conductor size in accordance with the following:
a. Branch circuits: No. 12 AWG.
b. Class 1 remote-control and signal circuits: No. 14 AWG.
c. Class 2 low-energy, remote-control and signal circuits: No. 16 AWG.
d. Class 3 low-energy, remote-control, alarm and signal circuits: No. 22 AWG.
2.5.2 Color Coding
Provide color coding for service, feeder, branch, control, and signaling circuit conductors.
2.5.2.1 Ground and Neutral Conductors
Provide color coding of ground and neutral conductors as follows:
a. Grounding conductors: Green.
b. Neutral conductors: White.
c. Exception, where neutrals of more than one system are installed in same raceway or box, other neutrals color coding: white with a different colored (not green) stripe for each.
2.5.2.2 Ungrounded Conductors
Provide color coding of ungrounded conductors in different voltage systems as follows:
a. 208/120 volt, three-phase
(1) Phase A - black
(2) Phase B - red
(3) Phase C - blue
b. 480/277 volt, three-phase
(1) Phase A - brown
(2) Phase B - orange
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(3) Phase C - yellow
c. 120/240 volt, single phase: Black and red
2.5.3 Insulation
Unless specified or indicated otherwise or required by NFPA 70, provide power and lighting wires rated for 600-volts, Type THWN/THHN-2 conforming to UL 83 Type XHHW-2 conforming to UL 44. Conductor sized No. 6 AWG and larger shall be Type XHHW-2, conductors No. 8 AWG shall be Type THHN/THWN-2.
2.5.4 Bonding Conductors
ASTM B1, solid bare copper wire for sizes No. 8 AWG and smaller diameter; ASTM B8, Class B, stranded bare copper wire for sizes No. 6 AWG and larger diameter.
2.6 SPLICES AND TERMINATION COMPONENTS
UL 486A-486B for wire connectors and UL 510 for insulating tapes. Connectors for No. 10 AWG and smaller diameter wires: insulated, pressure-type in accordance with UL 486A-486B or UL 486C (twist-on splicing connector). Provide solderless terminal lugs on stranded conductors.
2.7 DEVICE PLATES
Provide the following:
a. UL listed, one-piece device plates for outlets to suit the devices installed.
b. For metal outlet boxes, plates on unfinished walls: zinc-coated sheet steel or cast metal having round or beveled edges.
c. For nonmetallic boxes and fittings, other suitable plates may be provided.
e. Screws: machine-type with countersunk heads in color to match finish of plate.
f. Sectional type device plates are not be permitted.
g. Plates installed in wet locations: gasketed and UL listed for "wet locations."
2.8 SWITCHES
2.8.1 Toggle Switches
NEMA WD 1, UL 20, single pole, double pole, three-way, and four-way, totally enclosed with bodies of thermoplastic or thermoset plastic and mounting strap with grounding screw. Include the following:
a. Handles: ivory thermoplastic.
b. Wiring terminals: screw-type, side-wired.
c. Contacts: silver-cadmium and contact arm - one-piece copper alloy.
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d. Switches: rated quiet-type ac only, 120/277 volts, with current rating and number of poles indicated.
2.8.2 Disconnect Switches
NEMA KS 1. Provide heavy duty-type switches where indicated, where switches are rated higher than 240 volts, and for double-throw switches. Utilize Class R fuseholders and fuses for fused switches, unless indicated otherwise. Provide horsepower rated for switches serving as the motor-disconnect means. Provide switches in NEMA 1, 4X, or 7 based on the area classification indicated on the drawings.
2.9 RECEPTACLES
Provide the following:
a. UL 498, hard use (also designated heavy-duty), grounding-type.
b. Ratings and configurations: as indicated.
c. Bodies: ivory as per NEMA WD 1.
d. Face and body: thermoplastic supported on a metal mounting strap.
e. Dimensional requirements: per NEMA WD 6.
f. Screw-type, side-wired wiring terminals or of the solderless pressure type having suitable conductor-release arrangement.
g. Grounding pole connected to mounting strap.
h. The receptacle: containing triple-wipe power contacts and double or triple-wipe ground contacts.
2.9.1 Weatherproof Receptacles
Provide receptacles, UL listed for use in "wet locations". Include cast metal box with gasketed, hinged, lockable and weatherproof while-in-use, die-cast metal/aluminum cover plate.
2.9.2 Ground-Fault Circuit Interrupter Receptacles
UL 943, duplex type for mounting in standard outlet box. Provide device capable of detecting current leak of 6 milliamperes or greater and tripping per requirements of UL 943 for Class A ground-fault circuit interrupter devices. Provide screw-type, side-wired wiring terminals or pre-wired (pigtail) leads.
2.10 PANELBOARDS
Provide panelboards in accordance with the following:
a. UL 67 and UL 50 having a short-circuit current rating as indicatedor 10,000 amperes symmetrical minimum.
b. Panelboards for use as service disconnecting means: additionally conform to UL 869A.
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c. Panelboards: circuit breaker-equipped.
d. Designed such that individual breakers can be removed without disturbing adjacent units or without loosening or removing supplemental insulation supplied as means of obtaining clearances as required by UL.
e. Use of "Subfeed Breakers" is not acceptable unless specifically indicated otherwise.
f. Main breaker: "separately" mounted "above" or "below" branch breakers.
g. Where "space only" is indicated, make provisions for future installation of breakers.
h. Directories: indicate load served by each circuit in panelboard.
i. Directories: indicate source of service to panelboard (e.g., Panel PA served from Panel MDP).
j. Type directories and mount in holder behind transparent protective covering.
k. Panelboard nameplates: provided in accordance with paragraph FIELD FABRICATED NAMEPLATES.
2.10.1 Enclosure
Provide panelboard enclosure in accordance with the following:
a. UL 50.
b. Cabinets mounted outdoors or flush-mounted: hot-dipped galvanized after fabrication.
c. Cabinets: painted in accordance with paragraph PAINTING.
d. Front edges of cabinets: form-flanged or fitted with structural shapes welded or riveted to the sheet steel, for supporting the panelboard front.
e. All cabinets: fabricated such that no part of any surface on the finished cabinet deviates from a true plane by more than 1/8 inch.
f. Holes: provided in the back of indoor surface-mounted cabinets, with outside spacers and inside stiffeners, for mounting the cabinets with a 1/2 inch clear space between the back of the cabinet and the wall surface.
g. Flush doors: mounted on hinges that expose only the hinge roll to view when the door is closed.
h. Each door: fitted with a combined catch and lock, except that doors over 24 inches long provided with a three-point latch having a knob with a T-handle, and a cylinder lock.
i. Keys: two provided with each lock, with all locks keyed alike.
j. Finished-head cap screws: provided for mounting the panelboard fronts
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on the cabinets.
2.10.2 Panelboard Buses
Support bus bars on bases independent of circuit breakers. Design main buses and back pans so that breakers may be changed without machining, drilling, or tapping. Provide isolated neutral bus in each panel for connection of circuit neutral conductors. Provide separate ground bus identified as equipment grounding bus per UL 67 for connecting grounding conductors; bond to steel cabinet.
2.10.3 Circuit Breakers
UL 489, thermal magnetic-type having a minimum short-circuit current rating equal to the short-circuit current rating of the panelboard in which the circuit breaker will be mounted. Breaker terminals: UL listed as suitable for type of conductor provided. Series rated circuit breakers and plug-in circuit breakers are unacceptable.
2.10.3.1 Multipole Breakers
Provide common trip-type with single operating handle. Design breaker such that overload in one pole automatically causes all poles to open. Maintain phase sequence throughout each panel so that any three adjacent breaker poles are connected to Phases A, B, and C, respectively.
2.10.3.2 Circuit Breaker With Ground-Fault Circuit Interrupter
UL 943 and NFPA 70. Provide with "push-to-test" button, visible indication of tripped condition, and ability to detect and trip on current imbalance of 6 milliamperes or greater per requirements of UL 943 for Class A ground-fault circuit interrupter.
2.11 MOTOR SHORT-CIRCUIT PROTECTOR (MSCP)
Motor short-circuit protectors, also called motor circuit protectors (MCPs): UL 508 and UL 489, and provided as shown. Provide MSCPs that consist of an adjustable instantaneous trip circuit breaker used only in conjunction with a combination motor controller which provides coordinated motor branch-circuit overload and short-circuit protection. Rate MSCPs in accordance with the requirements of NFPA 70.
2.12 TRANSFORMERS
Provide transformers in accordance with the following:
a. NEMA ST 20, general purpose, dry-type, self-cooled, ventilated.
b. Provide transformers in NEMA 1 enclosure.
c. Transformer insulation system:
(1) 220 degrees C insulation system for transformers 15 kVA and greater, with temperature rise not exceeding 150 degrees C under full-rated load in maximum ambient of 40 degrees C.
d. Transformer of 150 degrees C temperature rise: capable of carrying continuously 100 percent of nameplate kVA without exceeding insulation rating.
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2.13 MOTORS
Provide motors in accordance with the following:
a. NEMA MG 1.
b. Hermetic-type sealed motor compressors: Also comply with UL 984.
c. Provide the size in terms of HP, or kVA, or full-load current, or a combination of these characteristics, and other characteristics, of each motor as indicated or specified.
d. Determine specific motor characteristics to ensure provision of correctly sized starters and overload heaters.
e. Rate motors for operation on 208-volt, 3-phase circuits with a terminal voltage rating of 200 volts, and those for operation on 480-volt, 3-phase circuits with a terminal voltage rating of 460 volts.
f. Use motors designed to operate at full capacity with voltage variation of plus or minus 10 percent of motor voltage rating.
g. Unless otherwise indicated, use continuous duty type motors if rated 1 HP and above.
h. Where fuse protection is specifically recommended by the equipment manufacturer, provide fused switches in lieu of non-fused switches indicated.
2.13.1 High Efficiency Single-Phase Motors
Single-phase fractional-horsepower alternating-current motors: high efficiency types corresponding to the applications listed in NEMA MG 11. In exception, for motor-driven equipment with a minimum seasonal or overall efficiency rating, such as a SEER rating, provide equipment with motor to meet the overall system rating indicated.
2.13.2 Premium Efficiency Polyphase Motors
Select polyphase motors based on high efficiency characteristics relative to typical characteristics and applications as listed in NEMA MG 10. In addition, continuous rated, polyphase squirrel-cage medium induction motors must meet the requirements for premium efficiency electric motors in accordance with NEMA MG 1, including the NEMA full load efficiency ratings. In exception, for motor-driven equipment with a minimum seasonal or overall efficiency rating, such as a SEER rating, provide equipment with motor to meet the overall system rating indicated.
2.13.3 Motor Sizes
Provide size for duty to be performed, not exceeding the full-load nameplate current rating when driven equipment is operated at specified capacity under most severe conditions likely to be encountered. When motor size provided differs from size indicated or specified, make adjustments to wiring, disconnect devices, and branch circuit protection to accommodate equipment actually provided. Provide controllers for motors rated 1-hp and above with electronic phase-voltage monitors designed to protect motors from phase-loss, undervoltage, and overvoltage. Provide protection for
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motors from immediate restart by a time adjustable restart relay.
2.13.4 Wiring and Conduit
Provide internal wiring for components of packaged equipment as an integral part of the equipment. Provide power wiring and conduit for field-installed equipment, and motor control equipment forming part switchgear assemblies, the conduit and wiring connecting such centers, assemblies, or other power sources to equipment as specified herein. Power wiring and conduit: conform to the requirements specified herein. Control wiring: provided under, and conform to, the requirements of the section specifying the associated equipment.
2.14 MOTOR CONTROLLERS
Provide motor controllers in accordance with the following:
a. UL 508, NEMA ICS 1, and NEMA ICS 2.
b. Provide controllers with thermal overload protection in each phase, and one spare normally open auxiliary contact, and one spare normally closed auxiliary contact.
c. Provide controllers for motors rated 1-hp and above with electronic phase-voltage monitors designed to protect motors from phase-loss, undervoltage, and overvoltage.
d. Provide protection for motors from immediate restart by a time adjustable restart relay.
e. When used with pressure, float, or similar automatic-type or maintained-contact switch, provide a hand/off/automatic selector switch with the controller.
f. Connections to selector switch: wired such that only normal automatic regulatory control devices are bypassed when switch is in "hand" position.
g. Safety control devices, such as low and high pressure cutouts, high temperature cutouts, and motor overload protective devices: connected in motor control circuit in "hand" and "automatic" positions.
h. Control circuit connections to hand/off/automatic selector switch or to more than one automatic regulatory control device: made in accordance with indicated or manufacturer's approved wiring diagram.
i. Provide a disconnecting means, capable of being locked in the open position, for the motor that is located in sight from the motor location and the driven machinery location. For pump motors greater than 100 HP, provide a motor controller disconnect, capable of being locked in the open position, to serve as the disconnecting means for the motor.
j. Overload protective devices: provide adequate protection to motor windings; be thermal inverse-time-limit type; and include manual reset-type pushbutton on outside of motor controller case.
k. Cover of combination motor controller and manual switch or circuit breaker: interlocked with operating handle of switch or circuit
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breaker so that cover cannot be opened unless handle of switch or circuit breaker is in "off" position.
l. Minimum short circuit withstand rating of combination motor controller: 65,000 rms symmetrical amperes.
2.14.1 Control Wiring
Provide control wiring in accordance with the following:
a. All control wire: stranded tinned copper switchboard wire with 600-volt flame-retardant insulation Type SIS meeting UL 44, or Type MTW meeting UL 1063, and passing the VW-1 flame tests included in those standards.
b. Hinge wire: Class K stranding.
c. Current transformer secondary leads: not smaller than No. 10 AWG.
d. Control wire minimum size: No. 14 AWG.
e. Power wiring for 480-volt circuits and below: the same type as control wiring with No. 12 AWG minimum size.
f. Provide wiring and terminal arrangement on the terminal blocks to permit the individual conductors of each external cable to be terminated on adjacent terminal points.
2.14.2 Control Circuit Terminal Blocks
Provide control circuit terminal blocks in accordance with the following:
a. NEMA ICS 4.
b. Control circuit terminal blocks for control wiring: molded or fabricated type with barriers, rated not less than 600 volts.
c. Provide terminals with removable binding, fillister or washer head screw type, or of the stud type with contact and locking nuts.
d. Terminals: not less than No. 10 in size with sufficient length and space for connecting at least two indented terminals for 10 AWG conductors to each terminal.
e. Terminal arrangement: subject to the approval of the Owner's Representative with not less than four (4) spare terminals or 10 percent, whichever is greater, provided on each block or group of blocks.
f. Modular, pull apart, terminal blocks are acceptable provided they are of the channel or rail-mounted type.
g. Submit data showing that any proposed alternate will accommodate the specified number of wires, are of adequate current-carrying capacity, and are constructed to assure positive contact between current-carrying parts.
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2.14.2.1 Types of Terminal Blocks
a. Short-Circuiting Type: Short-circuiting type terminal blocks: furnished for all current transformer secondary leads with provision for shorting together all leads from each current transformer without first opening any circuit. Terminal blocks: comply with the requirements of paragraph CONTROL CIRCUIT TERMINAL BLOCKS above.
b. Load Type: Load terminal blocks rated not less than 600 volts and of adequate capacity: provided for the conductors for NEMA Size 3 and smaller motor controllers and for other power circuits, except those for feeder tap units. Provide terminals of either the stud type with contact nuts and locking nuts or of the removable screw type, having length and space for at least two indented terminals of the size required on the conductors to be terminated. For conductors rated more than 50 amperes, provide screws with hexagonal heads. Conducting parts between connected terminals must have adequate contact surface and cross-section to operate without overheating. Provide eEach connected terminal with the circuit designation or wire number placed on or near the terminal in permanent contrasting color.
2.14.3 Control Circuits
Control circuits: maximum voltage of 120 volts derived from control transformer in same enclosure. Transformers: conform to UL 506, as applicable. Transformers, other than transformers in bridge circuits: provide primaries wound for voltage available and secondaries wound for correct control circuit voltage. Size transformers so that 80 percent of rated capacity equals connected load. Provide disconnect switch on primary side. Provide fuses in each ungrounded primary feeder. Provide one fused secondary lead with the other lead grounded.
2.14.4 Enclosures for Motor Controllers
NEMA ICS 6.
2.14.5 Pilot and Indicating Lights
Provide LED cluster lamps.
2.14.6 Reduced-Voltage Controllers
Provide for poly-phase motors 50 horsepower and larger.
The RVSS shall consist of a six (6) SCR power section with two (2) SCRs per phase connected inverse parallel for variable AC output voltage with minimal motor and starter heating.
The RVSS power section shall be capable of providing maximum torque per amp throughout the motor's speed-torque curve.
The logic control shall consist of a power section for gating the drive SCRs and a control section for performing all the necessary starter functions.
A snubber circuit shall be used to prevent false firing of SCRs due to dV/dt effects.
The RVSS shall be provided with a by-pass contactor that will effectively
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"short" the SCR power section to the incoming line to the motor load without the SCR voltage drop.
a. The contractor shall be a thermal rated contact to bypass the soft starter. b. A horsepower rated across-the-line starter use to start the motor on a failure of the soft starter is not required.
RVSS's shall constitute complete combination motor controllers per NEC Article 430 and shall provide the following per the requirements of that article without the addition of any external components or devices.
a. Motor control. b. Motor overload protection. c. Motor and motor branch circuit short circuit and ground fault protection. d. Motor and controller disconnecting means.
RVSS's shall be "engineered" or "configured" drive packages in which the RVSS chassis, all input, output and bypass power devices, RVSS accessories, ancillary switches, contactors, relays, and related control devices are selected, furnished, factory assembled and tested by the RVSS manufacturer in a single enclosure requiring only connection of the power supply circuit, motor branch circuit, and external control wiring in the field.
Elevation: 900 FT above MSL.
480V, 3 PH, 3-wire, (+/- 10 percent).
Effectively grounded.
Available short circuit current: 65,000 A RMS SYM.
Voltage imbalance tolerance for full load operation: 3 percent minimum.
Operational Features:
a. Pump control functions. b. Insensitive to input phase sequence. c. Continued operation with momentary voltage dips of 25 percent of rated voltage, or single phase condition: 3 sec, minimum. d. Controls power loss ride-through: 500 msec, minimum. e. Anti-windmilling; ability to safely start into turning motor, forward or reverse.
The RVSS shall be provided with the following minimum user-programmable parameters:
a. Selectable torque ramp start or current limit start. b. Starts per hour. c. Time between starts. d. Initial current, maximum current and ramp time. e. Kick current and time. f. Torque ramp. g. Motor deceleration time. h. Relay outputs.
The RVSS shall be designed such that the power circuit components are fully protected from line side disturbances and load side faults:
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a. General:
1. Shutdown conditions associated with supply circuit conditions which can be corrected external to the RVSS motor system shall be provided with automatic reset, with shutdown cause logged in memory:
a) Input under/over voltage. b) Input under/over frequency. c) Input phase loss.
2. Shutdown conditions which indicate overload or fault within the RVSS, the output circuit, or the motor shall require local manual reset at the RVSS, requiring operator intervention.
a) Shorted SCR. b) Component failure. c) Under/over current. d) Overload. e) Short circuit f) Ground fault. g) Logic fault.
3. When automatic shutdown occurs, RVSS shall restart only when remote run signal is removed and reapplied, whether the drive is in automatic or manual mode. 4. RVSS shall hold cause of trip data for a minimum of four shutdowns in memory. 5. Data to be accessible through the keypad, local communication link and remotely. 6. Common alarm contact.
b. Input protection:
1. Input circuit breaker or current-limiting fuses with externally operable disconnect:
a) Fault current interrupting rating equal to or greater than the specified withstand rating of the RVSS. b) Handle padlockable in the OFF position.
2. Incoming line transient suppression:
a) 6000 V peak per IEEE C62.41.1. b) Phase-to-phase and phase-to-ground protection.
3. Internal protection:
a) Surge suppression and power device snubbers. b) SCR peak inverse voltage (PIV): 2.5 times line voltage. c) Instantaneous overcurrent trip. d) Power device overtemperature trip. e) Control logic circuit malfunction trip.
4. Output protection:
a) Inverse-time overload trip: b) UL Class 10 characteristic.
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c) Overvoltage trip. d) Overfrequency trip. e) Short circuit trip: f) Line to line and line to ground. g) Ground fault trip.
Drive controls shall be microprocessor-based with on-board human machine interface and both local and remote digital communications capability.
All monitoring and control functions, other than those shutdowns specified to be manual reset only, shall be available both locally and remotely.
Control circuits shall be 115 Vac or 24 Vdc:
a. 115 Vac supplied by CPT in the RVSS. b. CPT shall have minimum additional capacity of 60 VA greater than that required by control devices. c. CPT shall have two (2) fuses on the primary side and one fuse on the secondary side. d. CPT shall have surge protection on the primary side independent of any other surge protection in the VFD. e. 24 Vdc supplied by Class 2 power supply in the RVSS. f. Power supply shall have minimum additional capacity of 33 percent greater than that required by control devices. g. Provide two (2) current-limiting fuses on the AC supply to the power supply. h. Power supply shall have surge protection on the primary side independent of any other surge protection in the RVSS.
Operator Interface:
a. Door mounted sealed keypad, membrane type with LED or LCD display.
1. Messages shall be in English and engineering units. 2. Drive operating parameters shall be programmable. 3. Menu driven. 4. Password security. 5. Display fault and diagnostic data. 6. Operating parameters, fault and diagnostic data maintained in non-volatile memory with historic log of fault and diagnostic data.
a) Fault descriptions shall be in plain text. b) Fault codes are not acceptable.
9. Gold plated plug-in contacts.
b. HAND-OFF-REMOTE selector switch. c. Status indication:
1. POWER ON. 2. RUN STATUS. 3. RVSS FAULT.
d. Metering indications (minimum):
1. Amperes. 2. Voltage. 3. Frequency.
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e. Diagnostic indicators located externally on the face of the drive shall show the type of fault responsible for drive warning, shutdown or failure. f. On occurrence of more than one condition each shall be recorded or indicated by the diagnostics. g. Remote Control Interface:
1. Contacts:
a) Contacts shall be rated 2 A inductive at 120 Vac. b) All contacts shall be wired to field wiring terminal boards.
2. Network communications capability:
a) Provide RVSS with communication card, protocol and required programming for digital communication of all RVSS program and operational parameters to plant control system via:
1) Ethernet compatible with suppled pump station control system. Refer to Section 40 95 00 PROCESS CONTROL SYSTEM.
Fabrication and Assembly:
a. Each RVSS system shall be factory-assembled in an enclosure for remote mounting, and shall utilize interchangeable plug-in printed circuit boards and power conversion components wherever possible.
1. Factory assembly shall be performed by the RVSS manufacturer or authorized agent. 2. Systems fabricated or assembled in whole or in part by parties other than the RVSS manufacturer or authorized agent will not be acceptable.
b. Cooling fans shall be provided, as required, to run when drive is running.
1. Enclosures for separately mounted RVSS's:
a) NEMA Type 1 for installation in Electrical Rooms.
c. Wiring:
1. The wiring in the RVSS shall be neatly installed in wire ways or with wire ties where wire ways are not practical. 2. Where wire ties are used, the wire bundles are to be held at the back panel with a screw-mounted wire tie mounting base. 3. Bases with a self-sticking back will not be allowed.
d. All plug-in contacts shall be gold-plated. e. Provide terminal boards for all field wiring and inter-unit connections. f. Terminal blocks shall be complete with marking strip, covers and pressure connectors.
1. They shall be non-brittle, interlocking, track-mounted type. 2. Screw terminals will not be allowed. 3. A terminal shall be provided for each conductor of external circuits plus one ground for each shielded cable. 4. For free-standing panels, 8 IN of clearance shall be provided between terminals and the panel base for conduit and wiring space.
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5. Not less than 25 percent spare terminals shall be provided. 6. Terminals shall be labeled to agree with identification indicated on the supplier's submittal drawings. 7. Each control loop or system shall be individually fused, and all fuses or circuit breakers shall be clearly labeled and located for easy maintenance.
g. All grounding wires shall be attached to the enclosure sheet metal with a ring tongue terminal. h. The surface of the sheet metal shall be prepared to assure good conductivity and corrosion protection. i. Wiring shall not be kinked or spliced and shall have markings on both ends or be color coded. j. Markings or color code shall match the manufacturer's drawings. k. With the exception of electronic circuits, all interconnecting wiring and wiring to terminals for external connection shall be stranded copper, type MTW or SIS, insulated for not less than 600 V, with a moisture-resistant and flame-retardant covering rated for not less than 90 DegC. l. Nameplates:
1. RVSS enclosure shall be provided with a phenolic nameplate. 2. Push buttons, selector switches, and pilot lights shall have the device manufacturer's standard legend plate. 3. Relays, terminals and special devices inside the control enclosure shall have permanent markings to match identification used on manufacturer's wiring diagrams. 4. Use stainless steel screws to attach nameplates.
m. Factory Painting: Enclosure, after being phosphate washed, shall be thoroughly cleaned and given at least one coat of rust-inhibiting primer on all inner surfaces prior to fabrication.
2.15 MANUAL MOTOR STARTERS (MOTOR RATED SWITCHES)
Single pole designed for surface mounting with overload protection.
2.15.1 Pilot Lights
Provide yoke-mounted, seven element LED cluster light module. Color: green, red, amber, or white, in accordance with NEMA ICS 2.
2.16 LOCKOUT REQUIREMENTS
Provide disconnecting means capable of being locked out for machines and other equipment to prevent unexpected startup or release of stored energy in accordance with 29 CFR 1910.147. Comply with requirements of Division 23, "Mechanical" for mechanical isolation of machines and other equipment.
2.17 GROUNDING AND BONDING EQUIPMENT
2.17.1 Ground Rods
UL 467. Ground rods: solid copper, with minimum diameter of 3/4 inch and minimum length 10 feet. Sectional ground rods are permitted.
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2.17.2 Ground Bus
Copper ground bus: provided in the electrical equipment rooms as indicated.
2.18 MANUFACTURER'S NAMEPLATE
Provide on each item of equipment a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.
2.19 FIELD FABRICATED NAMEPLATES
Provide field fabricated nameplates in accordance with the following:
a. ASTM D709.
b. Provide laminated plastic nameplates for each equipment enclosure, relay, switch, and device; as specified or as indicated on the drawings.
c. Each nameplate inscription: identify the function and, when applicable, the position.
d. Nameplates: melamine plastic, 0.125 inch thick, white with black center core.
e. Surface: matte finish. Corners: square. Accurately align lettering and engrave into the core.
f. Minimum size of nameplates: one by 2.5 inches.
g. Lettering size and style: a minimum of 0.25 inch high normal block style.
2.20 WARNING SIGNS
Provide warning signs for flash protection in accordance with NFPA 70E and NEMA Z535.4 for switchboards and panelboards that are in other than dwelling occupancies and are likely to require examination, adjustment, servicing, or maintenance while energized. Provide field installed signs to warn qualified persons of potential electric arc flash hazards when warning signs are not provided by the manufacturer. Provide marking that is clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment.
2.21 SURGE PROTECTIVE DEVICES
Provide parallel type surge protective devices (SPD) which comply with UL 1449 at the service entrance switchboard. Provide surge protectors in the switchboard enclosure. Use Type 1 or Type 2 SPD and connect on the load side of a dedicated circuit breaker.
Provide the following modes of protection:
FOR SINGLE PHASE AND THREE PHASE WYE CONNECTED SYSTEMS- Phase to phase ( L-L ) Each phase to neutral ( L-N ) Neutral to ground ( N-G ) Phase to ground ( L-G )
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SPDs at the service entrance: provide with a minimum surge current rating of 80,000 amperes for L-L mode minimum and 40,000 amperes for other modes (L-N, L-G, and N-G).
The minimum MCOV (Maximum Continuous Operating Voltage) rating for L-N and L-G modes of operation: 120% of nominal voltage for 240 volts and below; 115% of nominal voltage above 240 volts to 480 volts.
2.22 FACTORY APPLIED FINISH
Provide factory-applied finish on electrical equipment in accordance with the following:
a. NEMA 250 corrosion-resistance test and the additional requirements as specified herein.
b. Interior and exterior steel surfaces of equipment enclosures: thoroughly cleaned followed by a rust-inhibitive phosphatizing or equivalent treatment prior to painting.
c. Exterior surfaces: free from holes, seams, dents, weld marks, loose scale or other imperfections.
d. Interior surfaces: receive not less than one coat of corrosion-resisting paint in accordance with the manufacturer's standard practice.
e. Exterior surfaces: primed, filled where necessary, and given not less than two coats baked enamel with semigloss finish.
f. Equipment located indoors: ANSI Light Gray.
g. Provide manufacturer's coatings for touch-up work and as specified in paragraph FIELD APPLIED PAINTING.
2.23 SOURCE QUALITY CONTROL
2.23.1 Transformer Factory Tests
Submittal: include routine NEMA ST 20 transformer test results on each transformer and also provide the results of NEMA "design" and "prototype" tests that were made on transformers electrically and mechanically equal to those specified.
PART 3 EXECUTION
3.1 INSTALLATION
Electrical installations, including weatherproof and hazardous locations and ducts, plenums and other air-handling spaces: conform to requirements of NFPA 70 and IEEE C2 and to requirements specified herein.
3.1.1 Underground Service
Underground service conductors and associated conduit: continuous from service entrance equipment to outdoor power system connection.
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3.1.2 Hazardous Locations
Perform work in hazardous locations, as defined by NFPA 70, in strict accordance with NFPA 70 for particular "Class," "Division," and "Group" of hazardous locations involved. Provide conduit and cable seals where required by NFPA 70. Provide conduit with tapered threads.
3.1.3 Service Entrance Identification
Service entrance disconnect devices, switches, and enclosures: labeled and identified as such.
3.1.4 Wiring Methods
Provide insulated conductors installed in rigid steel conduit, PVC coated rigid steel conduit, or rigid nonmetallic conduit, except where specifically indicated or specified otherwise or required by NFPA 70 to be installed otherwise. Grounding conductor: separate from electrical system neutral conductor. Provide insulated green equipment grounding conductor for circuit(s) installed in conduit and raceways. Minimum conduit size: 3/4 inch in diameter for low voltage lighting and power circuits.
3.1.4.1 Pull Wire
Install pull wires in empty conduits. Pull wire: plastic having minimum 200-pound force tensile strength. Leave minimum 36 inches of slack at each end of pull wire.
3.1.5 Conduit Installation
Unless indicated otherwise, conduits shall be exposed. Install conduit parallel with or at right angles to ceilings, walls, and structural members where conduit will be visible after completion of project.
3.1.5.1 Restrictions Applicable to Aluminum Conduit
a. Do not install underground or encase in concrete or masonry.
b. Do not use brass or bronze fittings.
3.1.5.2 Restrictions Applicable to EMT
EMT is not allowed on this project.
3.1.5.3 Restrictions Applicable to Nonmetallic Conduit
a. PVC Schedule 40 and PVC Schedule 80
(1) Use only for underground conduits and where conduit is encased in concrete..
3.1.5.4 Restrictions Applicable to Flexible Conduit
Use only as specified in paragraph FLEXIBLE CONNECTIONS.
3.1.5.5 Underground Conduit
Plastic-coated rigid steel; PVC. Convert nonmetallic conduit, other than PVC Schedule 40 or 80, to plastic-coated rigid steel conduit before rising
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through floor slab. Plastic coating: extend minimum 6 inches above floor.
3.1.5.6 Conduit Installed Under Floor Slabs
Conduit run under floor slab: located a minimum of 12 inches below the vapor barrier. Seal around conduits at penetrations thru vapor barrier.
3.1.5.7 Conduit Through Floor Slabs
Where conduits rise through floor slabs, do not allow curved portion of bends to be visible above finished slab.
3.1.5.8 Conduit Support
Support conduit by pipe straps, wall brackets, threaded rod conduit hangers, or ceiling trapeze. Fasten by wood screws to wood; by toggle bolts on hollow masonry units; by concrete inserts or expansion bolts on concrete or brick; and by machine screws, welded threaded studs, or spring-tension clamps on steel work. Threaded C-clamps may be used on rigid steel conduit only. Do not weld conduits or pipe straps to steel structures. Do not exceed one-fourth proof test load for load applied to fasteners. Provide vibration resistant and shock-resistant fasteners attached to concrete ceiling. Do not cut main reinforcing bars for any holes cut to depth of more than 1 1/2 inches in reinforced concrete beams or to depth of more than 3/4 inch in concrete joints. Fill unused holes. In partitions of light steel construction, use sheet metal screws. Do not share supporting means between electrical raceways and mechanical piping or ducts. Coordinate installation with mechanical systems to assure maximum accessibility to all systems.
3.1.5.9 Directional Changes in Conduit Runs
Make changes in direction of runs with symmetrical bends or cast-metal fittings. Make field-made bends and offsets with hickey or conduit-bending machine. Do not install crushed or deformed conduits. Avoid trapped conduits. Prevent plaster, dirt, or trash from lodging in conduits, boxes, fittings, and equipment during construction. Free clogged conduits of obstructions.
3.1.5.10 Locknuts and Bushings
Fasten conduits to sheet metal boxes and cabinets with two locknuts where required by NFPA 70, where insulated bushings are used, and where bushings cannot be brought into firm contact with the box; otherwise, use at least minimum single locknut and bushing. Provide locknuts with sharp edges for digging into wall of metal enclosures. Install bushings on ends of conduits, and provide insulating type where required by NFPA 70.
3.1.5.11 Flexible Connections
Provide flexible steel conduit between 3 and 6 feet in length for equipment subject to vibration, noise transmission, or movement; and for motors. Install flexible conduit to allow 20 percent slack. Minimum flexible steel conduit size: 1/2 inch diameter. Provide liquidtight flexible conduit in wet and damp locations and in pump rooms for equipment subject to vibration, noise transmission, movement or motors. Provide separate ground conductor across flexible connections.
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3.1.6 Boxes, Outlets, and Supports
Provide boxes in wiring and raceway systems wherever required for pulling of wires, making connections, and mounting of devices or fixtures. Boxes for metallic raceways: cast-metal, hub-type when located in wet locations, when surface mounted on outside of exterior surfaces, when surface mounted on interior walls exposed up to 7 feet above floors and walkways, or when installed in hazardous areas and when specifically indicated. Boxes in other locations: sheet steel, except that aluminum boxes may be used with aluminum conduit system. Provide each box with volume required by NFPA 70 for number of conductors enclosed in box. Boxes for mounting lighting fixtures: minimum 4 inches square, or octagonal, except that smaller boxes may be installed as required by fixture configurations, as approved. Boxes for use in masonry-block or tile walls: square-cornered, tile-type, or standard boxes having square-cornered, tile-type covers. Provide gaskets for cast-metal boxes installed in wet locations and boxes installed flush with outside of exterior surfaces. Support boxes and pendants for surface-mounted fixtures on suspended ceilings independently of ceiling supports. Fasten boxes and supports with bolts and expansion shields on concrete or brick, with toggle bolts on hollow masonry units, and with machine screws or welded studs on steel. When penetrating reinforced concrete members, avoid cutting reinforcing steel.
3.1.6.1 Boxes
Boxes for use with raceway systems: minimum 1 1/2 inches deep, except where shallower boxes required by structural conditions are approved. Boxes for other than lighting fixture outlets: minimum 4 inches square, except that 4 by 2 inch boxes may be used where only one raceway enters outlet.
3.1.6.2 Pull Boxes
Construct of at least minimum size required by NFPA 70 of code-gauge aluminum or galvanized sheet steel, except where cast-metal boxes are required in locations specified herein. Provide boxes with screw-fastened covers. Where several feeders pass through common pull box, tag feeders to indicate clearly electrical characteristics, circuit number, and panel designation.
3.1.7 Mounting Heights
Mount panelboards, enclosed circuit breakers, motor controllers and disconnecting switches so height of operating handle at its highest position is maximum 78 inches above floor. Mount lighting switches 48 inches above finished floor. Mount receptacles 18 inches above finished floor, unless otherwise indicated. Mount other devices as indicated. Measure mounting heights of wiring devices and outlets in non-hazardous areas to center of device or outlet.
3.1.8 Conductor Identification
Provide conductor identification within each enclosure where tap, splice, or termination is made. For conductors No. 6 AWG and smaller diameter, provide color coding by factory-applied, color-impregnated insulation. For conductors No. 4 AWG and larger diameter, provide color coding by plastic-coated, self-sticking markers; colored nylon cable ties and plates; or heat shrink-type sleeves.
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3.1.9 Splices
Make splices in accessible locations. Make splices in conductors No. 10 AWG and smaller diameter with insulated, pressure-type connector. Make splices in conductors No. 8 AWG and larger diameter with solderless connector, and cover with insulation material equivalent to conductor insulation.
3.1.10 Covers and Device Plates
Install plates with alignment tolerance of 1/16 inch. Use of sectional-type device plates are not permitted. Provide gasket for plates installed in wet locations.
3.1.11 Grounding and Bonding
Provide in accordance with NFPA 70. Ground exposed, non-current-carrying metallic parts of electrical equipment, metallic raceway systems, grounding conductor in metallic and nonmetallic raceways, and telecommunications system grounds. Make ground connection to driven ground rods and grounding ring on exterior of building. Interconnect all grounding media in or on the structure to provide a common ground potential. This includes electrical service, telecommunications system grounds, as well as underground process piping systems. Where ground fault protection is employed, ensure that connection of ground and neutral does not interfere with correct operation of fault protection.
3.1.11.1 Ground Rods
Provide cone pointed ground rods. Measure the resistance to ground using the fall-of-potential method described in IEEE 81. Do not exceed 10 ohms under normally dry conditions for the maximum resistance of a driven ground. If the resultant resistance exceeds 10 ohms measured not less than 48 hours after rainfall, notify the Owner's Representative who will decide on the number of ground rods to add.
3.1.11.2 Grounding Connections
Make grounding connections which are buried or otherwise normally inaccessible, by exothermic weld or compression connector.
a. Make exothermic welds strictly in accordance with the weld manufacturer's written recommendations. Welds which are "puffed up" or which show convex surfaces indicating improper cleaning are not acceptable. Mechanical connectors are not required at exothermic welds.
b. Make compression connections using a hydraulic compression tool to provide the correct circumferential pressure. Provide tools and dies as recommended by the manufacturer. Use an embossing die code or other standard method to provide visible indication that a connector has been adequately compressed on the ground wire.
3.1.11.3 Ground Bus
Provide a copper ground bus in the electrical equipment rooms as indicated. Noncurrent-carrying metal parts of transformer neutrals and other electrical equipment: effectively grounded by bonding to the ground bus. Bond the ground bus to both the entrance ground. Make connections and splices of the brazed, welded, bolted, or pressure-connector type, except use pressure
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connectors or bolted connections for connections to removable equipment.
3.1.11.4 Resistance
Maximum resistance-to-ground of grounding system: do not exceed 10 ohms under dry conditions. Where resistance obtained exceeds10 ohms, contact Owner's Representative for further instructions.
3.1.12 Equipment Connections
Provide power wiring for the connection of motors and control equipment under this section of the specification. Except as otherwise specifically noted or specified, automatic control wiring, control devices, and protective devices within the control circuitry are not included in this section of the specifications and are provided under the section specifying the associated equipment.
3.1.13 Surge Protective Devices
Install surge protective devices in accordance with manufacturer's instruction for the device.
3.2 FIELD FABRICATED NAMEPLATE MOUNTING
Provide number, location, and letter designation of nameplates as indicated. Fasten nameplates to the device with a minimum of two sheet-metal screws or two rivets.
3.3 FIELD APPLIED PAINTING
Where field painting of enclosures for panelboards, load centers or the like to correct damage to the manufacturer's factory applied coatings, provide manufacturer's recommended coatings and apply in accordance to manufacturer's instructions.
3.4 FIELD QUALITY CONTROL
Furnish test equipment and personnel and submit written copies of test results. Give Owner's Representative 5 working days notice prior to test.
3.4.1 Devices Subject to Manual Operation
Operate each device subject to manual operation at least five times, demonstrating satisfactory operation each time.
3.4.2 600-Volt Wiring Test
Test wiring rated 600 volt and less to verify that no short circuits or accidental grounds exist. Perform insulation resistance tests on wiring No. 6 AWG and larger diameter using instrument which applies voltage of approximately 500 volts to provide direct reading of resistance. Minimum resistance: 250,000 ohms.
3.4.3 Transformer Tests
Perform the standard, not optional, tests in accordance with the Inspection and Test Procedures for transformers, dry type, air-cooled, 600 volt and below; as specified in NETA ATS. Measure primary and secondary voltages for proper tap settings. Tests need not be performed by a recognized
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independent testing firm or independent electrical consulting firm.
3.4.4 Ground-Fault Receptacle Test
Test ground-fault receptacles with a "load" (such as a plug in light) to verify that the "line" and "load" leads are not reversed.
3.4.5 Grounding System Test
Test grounding system to ensure continuity, and that resistance to ground is not excessive. Test each ground rod for resistance to ground before making connections to rod; tie grounding system together and test for resistance to ground. Make resistance measurements in dry weather, not earlier than 48 hours after rainfall. Submit written results of each test to Owner's Representative, and indicate location of rods as well as resistance and soil conditions at time measurements were made.
-- End of Section --
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SECTION 26 23 00.00 40
SWITCHBOARDS 02/11 08/21/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
ASTM D149 (2009; R 2013) Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies
ASTM D1535 (2013) Specifying Color by the Munsell System
ASTM D709 (2013) Laminated Thermosetting Materials
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 81 (2012) Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System
IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-6 2013) National Electrical Safety Code
IEEE C37.90.1 (2012) Standard for Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus
IEEE C57.12.28 (2005; INT 3 2011) Standard for Pad-Mounted Equipment - Enclosure Integrity
IEEE Stds Dictionary (2009) IEEE Standards Dictionary: Glossary of Terms & Definitions
INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)
NETA ATS (2013) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems
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NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
ANSI C12.1 (2008) Electric Meters Code for Electricity Metering
ANSI/NEMA PB 2.1 (2007) General Instructions for Proper Handling, Installation, Operation and Maintenance of Deadfront Distribution Switchboards Rated 600 V or Less
NEMA ICS 6 (1993; R 2011) Enclosures
NEMA LI 1 (1998; R 2011) Industrial Laminating Thermosetting Products
NEMA PB 2 (2011) Deadfront Distribution Switchboards
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
UNDERWRITERS LABORATORIES (UL)
UL 467 (2007) Grounding and Bonding Equipment
UL 489 (2013) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures
UL 891 (2005; Reprint Oct 2012) Switchboards
1.2 DEFINITIONS
Unless otherwise specified or indicated, electrical and electronics terms used in these specifications, and on the drawings, use as defined in IEEE Stds Dictionary.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Switchboard Drawings; G
Include wiring diagrams and installation details of equipment indicating proposed location, layout and arrangement, control panels, accessories, piping, ductwork, and other items that must be shown to ensure a coordinated installation. Wiring diagrams shall identify circuit terminals and indicate the internal wiring for each item of equipment and the interconnection between each item of equipment. Indicate within the drawings adequate clearance for operation, maintenance, and replacement of operating equipment devices. Include submittals for the nameplate data, size, and capacity. Also include submittals for applicable federal, military, industry, and technical society publication references.
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SD-03 Product Data
Switchboard; G
Digital Metering; G
Surge Protective Devices; G
SD-06 Test Reports
Switchboard Design Tests; G
Switchboard Production Tests; G
Acceptance Checks And Tests; G
SD-10 Operation and Maintenance Data
Switchboard Operation and Maintenance, Data Package 5; G
SD-11 Closeout Submittals
Assembled Operation and Maintenance Manuals; G
Equipment Test Schedule; G
Request for Settings; G
1.4 QUALITY ASSURANCE
1.4.1 Switchboard Product Data
Each submittal shall include manufacturer's information for each component, device and accessory provided with the switchboard including:
a. Circuit breaker type, interrupting rating, and trip devices, including available settings
b. Manufacturer's instruction manuals and published time-current curves (on full size logarithmic paper) of the main secondary breaker and largest secondary feeder device.
c. Digital metering data sheets.
d. Surge protective devices data sheets.
1.4.2 Switchboard Drawings
Drawings shall include, but are not limited to the following:
a. One-line diagram including breakers and meters
b. Outline drawings including front elevation, section views, footprint, and overall dimensions
c. Bus configuration including dimensions and ampere ratings of bus bars
d. Markings and NEMA nameplate data
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e. Circuit breaker type, interrupting rating, and trip devices, including available settings
f. Three-line diagrams and elementary diagrams and wiring diagrams with terminals identified, and indicating prewired interconnections between items of equipment and the interconnection between the items.
g. Manufacturer's instruction manuals and published time-current curves (on full size logarithmic paper) of the main secondary breaker and largest secondary feeder device. These shall be used by the designer of record to provide breaker settings that will ensure protection and coordination are achieved.
h. Provisions for future extension.
1.4.3 Regulatory Requirements
In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction," or words of similar meaning, to mean the Owner's Representative. Equipment, materials, installation, and workmanship shall be in accordance with the mandatory and advisory provisions of NFPA 70 unless more stringent requirements are specified or indicated.
1.4.4 Standard Products
Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship. Products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year period shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period. Where two or more items of the same class of equipment are required, these items shall be products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in this section.
1.4.4.1 Alternative Qualifications
Products having less than a 2-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturers' factory or laboratory tests, is furnished.
1.4.4.2 Material and Equipment Manufacturing Date
Do not use products manufactured more than 3 years prior to date of delivery to site, unless specified otherwise.
1.5 MAINTENANCE
1.5.1 Switchboard Operation and Maintenance Data
Submit Operation and Maintenance Manuals in accordance with Division 1 - General Requirements.
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1.5.2 Assembled Operation and Maintenance Manuals
Assemble and bind manuals securely in durable, hard covered, water resistant binders. Assemble and index the manuals in the following order with a table of contents. The contents of the assembled operation and maintenance manuals shall be as follows:
a. Manufacturer's O&M information required by the paragraph entitled "SD-10, Operation and Maintenance Data".
b. Catalog data required by the paragraph entitled, "SD-03, Product Data".
c. Drawings required by the paragraph entitled, "SD-02, Shop Drawings".
d. Prices for spare parts and supply list.
e. Information on metering
f. Design test reports
g. Production test reports
1.6 WARRANTY
The equipment items shall be supported by service organizations which are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
PART 2 PRODUCTS
2.1 PRODUCT COORDINATION
Products and materials not considered to be switchboards and related accessories are specified in Section 26 36 00.00 10 AUTOMATIC TRANSFER SWITCH, Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION, and Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
2.2 SWITCHBOARD
NEMA PB 2 and UL 891.
2.2.1 Ratings
The voltage rating of the switchboard shall be 480Y/277 volts AC, 4-wire 3 phase. The continuous current rating of the main bus shall be 1600 amperes. The short-circuit current rating shall be 65,000 rms symmetrical amperes. The switchboard shall be UL listed and labeled as service entrance equipment.
2.2.2 Construction
The switchboards shall be dead-front switchboards conforming to NEMA PB 2 and labeled under UL 891. The switchboards shall be completely enclosed self-supporting metal structures with the required number of vertical panel sections, buses, molded-case circuit breakers, and other devices as shown on the drawings. Switchboards shall be fully rated for a short-circuit current of 65,000 symmetrical amperes RMS AC.
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Switchboard shall consist of vertical sections bolted together to form a rigid assembly and shall be rear aligned. All circuit breakers are to be front accessible. Rear aligned switchboards are to have front accessible load connections. Compartmentalized switchboards shall have vertical insulating barriers between the front device section, the main bus section, and the cable compartment with full front to rear vertical insulating barriers between adjacent sections. Where indicated, "space for future" or "space" shall mean to include bus, device supports, and connections. Provide insulating barriers in accordance with NEMA LI 1, Type GPO-3, 0.25 inch minimum thickness. Apply moisture resistant coating to all rough-cut edges of barriers. Switchboard shall be completely factory engineered and assembled, including protective devices and equipment indicated with necessary interconnections, instrumentation, and control wiring.
2.2.2.1 Enclosure
The switchboard enclosure shall be a NEMA ICS 6 Type 1. Enclosure shall be bolted together with removable bolt-on side covers.. Base shall include any part of enclosure that is within 3 inches of concrete pad. Paint enclosure, including bases, ASTM D1535 light gray No. 61 or No. 49. Paint coating system shall comply with IEEE C57.12.28 for galvanized steel and stainless steel.
2.2.2.2 Bus Bars
Bus bars shall be copper with silver-plated contact surfaces or aluminum with tin-plated contact surfaces. Plating shall be a minimum of 0.0002 inch thick. Make bus connections and joints with hardened steel bolts. The through-bus shall be rated at the full ampacity of the main throughout the switchboard. Provide minimum one-quarter by 2 inch copper ground bus secured to each vertical section along the entire length of the switchboard. The neutral bus shall be rated 100 percent of the main bus continuous current rating. Phase bus bars shall be insulated with an epoxy finish coating powder providing a minimum breakdown voltage of 16,000 volts per ASTM D149.
2.2.2.3 Main Section
The main section shall consist of an individually mounted drawout insulated-case circuit breaker.
2.2.2.4 Distribution Sections
The distribution sections shall consist of molded-case circuit breakers as indicated.
2.2.2.5 Handles
Handles for individually mounted devices shall be of the same design and method of external operation. Label handles prominently to indicate device ampere rating, color coded for device type. Identify ON-OFF indication by handle position and by prominent marking.
2.2.3 Protective Device
Provide main and branch protective devices as indicated.
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2.2.3.1 Insulated-Case Breaker
UL listed, 100 percent rated, drawoutmanually operated, low voltage, insulated-case circuit breaker, with a short-circuit current rating of 65,000 rms symmetrical amperes at 480 volts. Breaker frame size is to be as indicated.
2.2.3.2 Molded-Case Circuit Breaker
UL 489. UL listed and labeled, 100 percent rated, stationary manually operated, low voltage molded-case circuit breaker, with a short-circuit current rating of 65,000 rms symmetrical amperes at 480 volts. Breaker frame size is to be as indicated. Series rated circuit breakers are unacceptable.
Equip each switchboard with molded-case circuit breakers with trip ratings and terminal connectors for attachment of outgoing power cables as shown on the drawings. The circuit breakers shall be operable and removable from the front. Where shown on the drawings, enclose circuit breakers in individual compartments.
2.2.4 Drawout Breakers
Equip drawout breakers with disconnecting contacts, wheels, and interlocks for drawout application. The main, auxiliary, and control disconnecting contacts are to be silver-plated, multifinger, positive pressure, self-aligning type. Provide each drawout breaker with four-position operation. Clearly identify each position by an indicator on the circuit breaker front panel.
a. Connected Position: Primary and secondary contacts are fully engaged. Breaker must be tripped before racking into or out of position.
b. Test Position: Primary contacts are disconnected but secondary contacts remain fully engaged. Position shall allow complete test and operation of the breaker without energizing the primary circuit.
c. Disconnected Position: Primary and secondary contacts are disconnected.
d. Withdrawn (Removed) Position: Places breaker completely out of compartment, ready for removal. Removal of the breaker shall actuate assembly that isolates the primary stabs.
2.2.5 Electronic Trip Units
Equip main and distribution breakers as indicated with a solid-state tripping system consisting of three current sensors and a microprocessor-based trip unit that will provide true rms sensing adjustable time-current circuit protection. The ampere rating of the current sensors are to be as indicated. The trip unit ampere rating shall be as indicated. Ground fault protection shall be zero sequence sensing. The electronic trip units shall have the following features as indicated.
a. Indicated Breakers shall have long delay pick-up and time settings, and LED indication of cause of circuit breaker trip.
b. Main and generator breakers shall have short delay pick-up and time settings and, instantaneous settings and ground fault settings as indicated. Refer to Section 26 36 00.00 10 AUTOMATIC TRANSFER SWITCH
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for additional requirements.
c. Distribution breakers shall have short delay pick-up and time settings, instantaneous settings, and ground fault settings as indicated.
2.2.6 Surge Protective Detective Devices (SPD)
2.2.6.1 Provide SPD in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
2.2.7 Watthour and Digital Meters
2.2.7.1 Digital Meters
IEEE C37.90.1 for surge withstand. Provide true rms, plus/minus one percent accuracy, programmable, microprocessor-based meter enclosed in sealed cases with a simultaneous three line, twelve value LED display. Meters shall have 0.56 inch, minimum, LEDs. The meters shall accept input from standard 5A secondary instrument transformers and direct voltage monitoring range to 600 volts, phase to phase. Programming shall be via a front panel display and a communication interface with a computer. Password secured programming shall be stored in non-volatile EEPROM memory. Digital communications shall be Modbus ASCII protocol via a RS232C serial port. The meter shall calculate and store average max/min demand values for all readings based on a user selectable sliding window averaging period. The meter shall have programmable hi/low set limits with two Form C dry contact relays when exceeding alarm conditions. Meter shall provide Total Harmonic Distortion (THD) measurement to the thirty-first order. Historical trend logging capability shall include ability to store up to 100,000 data points with intervals of 1 second to 180 minutes. The unit shall also store and time stamp up to 100 programmable triggered conditions. Event waveform recording shall be triggered by the rms of 2 cycles of voltage or current exceeding programmable set points. Waveforms shall be stored for all 6 channels of voltage and current for a minimum of 10 cycles prior to the event and 50 cycles past the event.
a. Multi-Function Meter: Meter shall simultaneously display a selected phase to neutral voltage, phase to phase voltage, percent phase to neutral voltage THD, percent phase to phase voltage THD; a selected phase current, neutral current, percent phase current THD, percent neutral current; selected total PF, kW, KVA, kVAR, FREQ, kVAh, kWh. Detected alarm conditions include over/under current, over/under voltage, over/under KVA, over/under frequency, over/under selected PF/kVAR, voltage phase reversal, voltage imbalance, reverse power, over percent THD. The meter shall have a Form C KYZ pulse output relay.
2.2.8 Meter Fusing
Provide a fuse block mounted in the metering compartment containing one fuse per phase to protect the voltage input to voltage sensing meters. Size fuses as recommended by the meter manufacturer.
2.2.9 Wire Marking
Mark control and metering conductors at each end. Provide factory-installed, white, plastic tubing, heat stamped with black block type letters on factory-installed wiring. On field-installed wiring, provide white, preprinted, polyvinyl chloride (PVC) sleeves, heat stamped with black block type letters. Each sleeve shall contain a single letter
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or number, shall be elliptically shaped to securely grip the wire, and shall be keyed in such a manner to ensure alignment with adjacent sleeves. Provide specific wire markings using the appropriate combination of individual sleeves. Each wire marker shall indicate the device or equipment, including specific terminal number to which the remote end of the wire is attached.
2.3 MANUFACTURER'S NAMEPLATE
Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable. This nameplate and method of attachment may be the manufacturer's standard if it contains the required information.
2.4 FIELD FABRICATED NAMEPLATES
ASTM D709. Provide laminated plastic nameplates for each switchboard, equipment enclosure, relay, switch, and device; as specified in this section or as indicated on the drawings. Each nameplate inscription shall identify the function and, when applicable, the position. Nameplates shall be melamine plastic, 0.125 inch thick, white with black center core. Surface shall be matte finish. Corners shall be square. Accurately align lettering and engrave into the core. Minimum size of nameplates shall be one by 2.5 inches. Lettering shall be a minimum of 0.25 inch high normal block style.
2.5 SOURCE QUALITY CONTROL
2.5.1 Equipment Test Schedule
The Owner's Representative reserves the right to witness tests. Provide equipment test schedules for tests to be performed at the manufacturer's test facility. Submit required test schedule and location, and notify the Owner's Representative 30 calendar days before scheduled test date. Notify Owner's Representative 15 calendar days in advance of changes to scheduled date.
a. Test Instrument Calibration
(1) The manufacturer shall have a calibration program which assures that all applicable test instruments are maintained within rated accuracy.
(2) The accuracy shall be directly traceable to the National Institute of Standards and Technology.
(3) Instrument calibration frequency schedule shall not exceed 12 months for both test floor instruments and leased specialty equipment.
(4) Dated calibration labels shall be visible on all test equipment.
(5) Calibrating standard shall be of higher accuracy than that of the instrument tested.
(6) Keep up-to-date records that indicate dates and test results of instruments calibrated or tested. For instruments calibrated by the manufacturer on a routine basis, in lieu of third party
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calibration, include the following:
(a) Maintain up-to-date instrument calibration instructions and procedures for each test instrument.
(b) Identify the third party/laboratory calibrated instrument to verify that calibrating standard is met.
2.5.2 Switchboard Design Tests
NEMA PB 2 and UL 891.
2.5.2.1 Design Tests
Furnish documentation showing the results of design tests on a product of the same series and rating as that provided by this specification.
a. Short-circuit current test
b. Enclosure tests
c. Dielectric test
2.5.3 Switchboard Production Tests
NEMA PB 2 and UL 891. Furnish reports which include results of production tests performed on the actual equipment for this project. These tests include:
a. 60-hertz dielectric tests
b. Mechanical operation tests
c. Electrical operation and control wiring tests
d. Ground fault sensing equipment test
PART 3 EXECUTION
3.1 INSTALLATION
Electrical installations shall conform to IEEE C2, NFPA 70, and to the requirements specified herein.
3.2 GROUNDING
NFPA 70 and IEEE C2, except that grounds and grounding systems shall have a resistance to solid earth ground not exceeding 5 ohms.
3.2.1 Grounding Electrodes
Provide driven ground rods as specified in Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION. Connect ground conductors to the upper end of the ground rods by exothermic weld or compression connector. Provide compression connectors at equipment end of ground conductors.
3.2.2 Equipment Grounding
Provide bare copper cableas indicated connecting to the indicated ground
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ring. When work in addition to that indicated or specified is directed to obtain the specified ground resistance, the provision of the contract covering "Changes" shall apply.
3.2.3 Connections
Make joints in grounding conductors and loops by exothermic weld or compression connector. Exothermic welds and compression connectors shall be installed as specified in Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION, paragraph entitled, "Grounding Connections."
3.2.4 Grounding and Bonding Equipment
UL 467, except as indicated or specified otherwise.
3.3 INSTALLATION OF EQUIPMENT AND ASSEMBLIES
Install and connect equipment furnished under this section as indicated on project drawings, the approved shop drawings, and as specified herein.
3.3.1 Switchboard
ANSI/NEMA PB 2.1.
3.3.2 Meters and Instrument Transformers
ANSI C12.1.
3.3.3 Field Applied Painting
Where field painting of enclosures is required to correct damage to the manufacturer's factory applied coatings, provide manufacturer's recommended coatings and apply in accordance with manufacturer's instructions.
3.3.4 Galvanizing Repair
Repair damage to galvanized coatings using ASTM A780/A780M, zinc rich paint, for galvanizing damaged by handling, transporting, cutting, welding, or bolting. Do not heat surfaces that repair paint has been applied to.
3.3.5 Field Fabricated Nameplate Mounting
Provide number, location, and letter designation of nameplates as indicated. Fasten nameplates to the device with a minimum of two sheet-metal screws or two rivets.
3.4 FOUNDATION FOR EQUIPMENT AND ASSEMBLIES
3.4.1 Interior Location
Mount switchboard on concrete slab. Unless otherwise indicated, the slab shall be at least 4 inches thick. The top of the concrete slab shall be approximately 4 inches above finished floor. Edges above floor shall have 1/2 inch chamfer. The slab shall be of adequate size to project at least 2 inches beyond the equipment. Provide conduit turnups and cable entrance space required by the equipment to be mounted. Seal voids around conduit openings in slab with water- and oil-resistant caulking or sealant. Cut off and bush conduits 3 inches above slab surface. Concrete work shall be as specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.
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3.5 FIELD QUALITY CONTROL
Contractor shall submit request for settings of breakers to the Owner's Representative after approval of switchboard and at least 30 days in advance of their requirement.
3.5.1 Performance of Acceptance Checks and Tests
Perform in accordance with the manufacturer's recommendations and include the following visual and mechanical inspections and electrical tests, performed in accordance with NETA ATS.
3.5.1.1 Switchboard Assemblies
a. Visual and Mechanical Inspection
(1) Compare equipment nameplate data with specifications and approved shop drawings.
(2) Inspect physical, electrical, and mechanical condition.
(3) Confirm correct application of manufacturer's recommended lubricants.
(4) Verify appropriate anchorage, required area clearances, and correct alignment.
(5) Inspect all doors, panels, and sections for paint, dents, scratches, fit, and missing hardware.
(6) Verify that circuit breaker sizes and types correspond to approved shop drawings.
(7) Verify that current transformer ratios correspond to approved shop drawings.
(8) Inspect all bolted electrical connections for high resistance using low-resistance ohmmeter, verifying tightness of accessible bolted electrical connections by calibrated torque-wrench method, or performing thermographic survey.
(9) Confirm correct operation and sequencing of electrical and mechanical interlock systems.
(10) Clean switchboard.
(11) Inspect insulators for evidence of physical damage or contaminated surfaces.
(12) Verify correct barrier and shutter installation and operation.
(13) Exercise all active components.
(14) Inspect all mechanical indicating devices for correct operation.
(15) Verify that vents are clear.
(16) Test operation, alignment, and penetration of instrument
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transformer withdrawal disconnects.
(17) Inspect control power transformers.
b. Electrical Tests
(1) Perform insulation-resistance tests on each bus section.
(2) Perform overpotential tests.
(3) Perform insulation-resistance test on control wiring; Do not perform this test on wiring connected to solid-state components.
(4) Perform control wiring performance test.
(5) Perform primary current injection tests on the entire current circuit in each section of assembly.
3.5.1.2 Circuit Breakers
Low Voltage - Insulated-Case and Low Voltage Molded Case with Solid State Trips
a. Visual and Mechanical Inspection
(1) Compare nameplate data with specifications and approved shop drawings.
(2) Inspect circuit breaker for correct mounting.
(3) Operate circuit breaker to ensure smooth operation.
(4) Inspect case for cracks or other defects.
(5) Inspect all bolted electrical connections for high resistance using low resistance ohmmeter, verifying tightness of accessible bolted connections and/or cable connections by calibrated torque-wrench method, or performing thermographic survey.
(6) Inspect mechanism contacts and arc chutes in unsealed units.
b. Electrical Tests
(1) Perform contact-resistance tests.
(2) Perform insulation-resistance tests.
(3) Perform Breaker adjustments for final settings in accordance with Owner's Representative provided settings.
(4) Perform long-time delay time-current characteristic tests.
3.5.1.3 Current Transformers
a. Visual and Mechanical Inspection
(1) Compare equipment nameplate data with specifications and approved shop drawings.
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(2) Inspect physical and mechanical condition.
(3) Verify correct connection.
(4) Verify that adequate clearances exist between primary and secondary circuit.
(5) Inspect all bolted electrical connections for high resistance using low-resistance ohmmeter, verifying tightness of accessible bolted electrical connections by calibrated torque-wrench method, or performing thermographic survey.
(6) Verify that all required grounding and shorting connections provide good contact.
b. Electrical Tests
(1) Perform resistance measurements through all bolted connections with low-resistance ohmmeter, if applicable.
(2) Perform insulation-resistance tests.
(3) Perform polarity tests.
(4) Perform ratio-verification tests.
3.5.1.4 Metering and Instrumentation
a. Visual and Mechanical Inspection
(1) Compare equipment nameplate data with specifications and approved shop drawings.
(2) Inspect physical and mechanical condition.
(3) Verify tightness of electrical connections.
b. Electrical Tests
(1) Determine accuracy of meters at 25, 50, 75, and 100 percent of full scale.
(2) Calibrate watthour meters according to manufacturer's published data.
(3) Verify all instrument multipliers.
(4) Electrically confirm that current transformer and voltage transformer secondary circuits are intact.
3.5.1.5 Grounding System
a. Visual and Mechanical Inspection
(1) Inspect ground system for compliance with contract plans and specifications.
b. Electrical Tests
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(1) IEEE 81. Perform ground-impedance measurements utilizing the fall-of-potential method. On systems consisting of interconnected ground rods, perform tests after interconnections are complete.
3.5.2 Follow-Up Verification
Upon completion of acceptance checks, settings, and tests, the Contractor shall show by demonstration in service that circuits and devices are in good operating condition and properly performing the intended function. Circuit breakers shall be tripped by operation of each protective device. Test shall require each item to perform its function not less than three times. As an exception to requirements stated elsewhere in the contract, the Owner's Representative shall be given 5 working days advance notice of the dates and times for checks, settings, and tests.
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 26 29 01.00 10
ELECTRIC MOTORS, 3-PHASE VERTICAL INDUCTION TYPE 11/08 09/25/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)
ABMA 11 (1990; R 2008) Load Ratings and Fatigue Life for Roller Bearings
ABMA 9 (1990; R 2008) Load Ratings and Fatigue Life for Ball Bearings
ASTM INTERNATIONAL (ASTM)
ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ASTM B344 (2011) Standard Specification for Drawn or Rolled Nickel-Chromium and Nickel-Chromium-Iron Alloys for Electrical Heating Elements
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA MG 1 (2011; Errata 2012) Motors and Generators
1.2 SUMMARY
The work under this section includes providing all labor, equipment, and material and performing all operations required to design, manufacture, assemble, test, and package and deliver the vertical induction motors for driving pumps specified under Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER TYPE.
a. These motors shall be supplied complete with all accessories, spare parts, tools, and manufacturer's data and instructions as specified herein.
b. Submit 6 copies of complete instructions for the proper installation, inspection, and maintenance of the machines provided for this particular service. Instruction manuals shall be submitted to the
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Owner's Representative not later than the date the equipment is shipped from the manufacturer's plant. The instructions shall include a cross-sectional drawing indicating the major component parts of the motor and the procedure for disassembly.
c. Submit 6 copies of a complete list of renewal parts with prices for each different rating of motor. This list shall accompany the instruction manual.
1.3 SUBMITTALS
Owner's Representative approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Owner's Representative. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Motors; G
SD-03 Product Data
Insulated Windings; G Duty Cycle; G Motors; G Spare Parts
SD-06 Test Reports
Starting Capabilities Factory Tests
SD-07 Certificates
Factory Tests
SD-10 Operation and Maintenance Data
Instructions
1.4 QUALITY ASSURANCE
1.4.1 Corrosion Prevention and Finish Painting
The equipment provided under these specifications will be subjected to severe moisture conditions and shall be designed to render it resistant to corrosion from such exposure. The general requirements to be followed to mitigate corrosion are specified below. Any additional special treatment or requirement considered necessary for any individual items is specified under the respective item. However, other corrosion-resisting treatments that are the equivalent of those specified herein may, with the approval of the Owner's Representative, be used.
1.4.1.1 Fastenings and Fittings
Where practicable, all screws, bolts, nuts, pins, studs, springs, washers, and other similar fittings shall be of corrosion-resisting material or
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shall be treated in an approved manner to render them resistant to corrosion.
1.4.1.2 Corrosion-Resisting Materials
Corrosion-resisting steel, copper, brass, bronze, copper-nickel, and nickel-copper alloys are acceptable corrosion-resisting materials.
1.4.1.3 Corrosion-Resisting Treatments
Hot-dip galvanizing shall be in accordance with ASTM A123/A123M or ASTM A153/A153M as applicable. Other corrosion-resisting treatments may be used if approved by the Owner's Representative.
1.4.1.4 Frames
Motor frames, end bells, covers, conduit boxes, and any other parts, if of steel, and if they will be coated during the process of insulating the windings, shall be cleaned of rust, grease, millscale, and dirt, and then treated and rinsed in accordance with manufacturer's standard process. If any of the above-listed parts are not coated during the process of insulating the windings then, in addition to the above, they shall be given one coat of primer and then two coats of manufacturer's standard moisture-resistant coating, processed as required.
1.4.1.5 Cores
The assembled motor core shall be thoroughly cleaned and then immediately primed by applying a minimum of two coats of a moisture-resisting and oil-resisting insulating compound. Air gap surfaces shall be given a minimum of one coat.
1.4.1.6 Shafts
Exposed surfaces of motor shafts shall be cleaned of rust, grease, and dirt and, except for bearing surfaces, given one coat of a zinc molybdate or equivalent primer and two coats of a moisture-proof coating, each cured as required. Shafts of a corrosion-resisting steel may be used in lieu of the above treatment.
1.4.1.7 Finish Painting
Finish painting of all equipment shall be in accordance with the standard practice or recommendation of the manufacturer, as approved by the Owner's Representative.
PART 2 PRODUCTS
2.1 NAMEPLATES
Nameplate data shall include rated voltage, rated full-load amperes, rated horsepower, service factor, number of phases, RPM at rated load, frequency, code letter, locked-rotor amperes, duty rating, insulation system designation, and maximum ambient design temperature.
2.2 MOTORS
The motors to be supplied under these specifications shall be of the vertical shaft type as required by the pump manufacturer, normal or low
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starting torque, low starting current, squirrel-cage induction type, designed for full voltage starting, of Totally Enclosed Fan Cooled (TEFC) construction, rated for installation in Class I, Division 2 locations, and shall conform to the applicable requirements of NEMA MG 1, except as hereinafter specified.
a. Submit 6 copies of equipment foundation dimensions; outline drawings with weights, nameplate data, and details showing method of mounting and anchoring the motor. Owner's Representative's approval shall be obtained in writing prior to the commencement of manufacture of motors.
b. Six copies of complete descriptive specification of each type and size motor provided, with necessary cuts, photographs, and drawings to clearly indicate the construction of the motor, the materials and treatments used to prevent corrosion of parts, bearing construction, and type of insulation used on all windings.
c. Submittal shall include all information required for selection of protective and control equipment and for operational setting, such as, but not limited to, normal and maximum operation temperature for windings and bearings, overload trip setting for motor at pump maximum head condition and starting times for starting at rated and 90 percent starter voltage.
2.2.1 Rating
Each motor shall be wound for 3-phase, 60-Hz, alternating current, and for the respective operating voltage listed below:
PLANT PUMP HORSEPOWER MOTOR OPERATING (Maximum) VOLTAGE
2nd Street Pump P-1 150 480V Station
2nd Street Pump P-2 150 480V Station
2nd Street Pump P-3 150 480V Station
2nd Street Pump P-4 150 480V Station
2nd Street Pump P-5 150 480V Station
The actual motor horsepower shall be determined by the Pump Supplier and coordinated with the Electrical Equipment Supplier for sizing of electrical equipment .The motor shall be designed for operation in a 105 degrees F ambient temperature and all temperature rises shall be above this ambient temperature. The rated horsepower of the motor shall be not less than 110 percent of the determined maximum load requirement of the pump. Motors shall have a service factor of 1.15 or shall be applied using a service factor of 1.15 if standard service factor is greater than 1.15. The temperature rise above the ambient temperature for continuous rated full-load conditions and for the class of insulation used shall not exceed
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the values given in NEMA MG 1, paragraph 12.42 or paragraph 20.8.
The motors shall be certified for use in Class I, Division 2 hazardous locations. The lowest autoignition temperature of any flammable liquid expected to be present in the pump station is 210 degrees C (410 degrees F).
2.2.2 Operating Characteristics
2.2.2.1 Torques
Starting torque shall be sufficient to start the pump to which the motor will be connected under the maximum conditions specified, but in no case shall the starting torque be less than 60 percent of full-load torque. Breakdown torque shall be not less than 150 percent of full-load torque.
2.2.2.2 Locked-Rotor Current
The locked-rotor current shall not exceed 600 percent of normal full-load running current.
2.2.2.3 Balance
The balance for each motor when measured in accordance with NEMA MG 1, paragraph 12.06 or paragraph 20.53, shall not exceed the values specified. Each motor's characteristics shall be such that the provisions of Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE paragraph are met.
2.2.3 Frames and Brackets
Frames and end brackets shall be of cast iron, cast steel, or welded steel. The mounting ring, unless otherwise approved, shall be built integral with the frame or lower end bracket and arranged for direct mounting on the pump, or station floor, or as required by the installation conditions. Treatment against corrosion shall be as specified in paragraph GENERAL REQUIREMENTS.
2.2.3.1 Stator Frame
The stator frame shall be rigid and sufficiently strong to support the weight of the upper bearing bracket load, the weight of the stator core and windings, and to sustain the operating torques without perceptible distortion. The stator frame, if not direct mounted on the pump, shall be supported on a motor base or drive pedestal which in turn will be supported on sole plates or other suitable structure installed in the concrete foundation constructed as part of the pumping station structure. The motor base or drive pedestal shall be provided with bolts and dowels for fastening to the sole plates or supporting structure for preserving the alignment.
2.2.3.2 Supporting Bracket
The upper bracket supporting the thrust bearing and upper guide bearings shall have sufficient strength and rigidity to support the weight of the entire rotating element of the motor, together with the pump impeller and shaft, and the hydraulic thrust of the pump impeller.
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2.2.3.3 Eyebolts
Eyebolts, lugs, or other approved means shall be provided for assembling, dismantling, and removing the motor, if required, from above using an overhead crane. All lifting devices required for use in conjunction with the crane shall be provided with the motor.
2.2.4 Cores
The cores for the stators and rotors shall be built up of separately punched thin laminations of low-hysteresis loss, nonaging, annealed, electrical silicon steel, assembled under heavy pressure, and clamped in such a manner as to insure that the assembled core is tight at the top of the teeth of the laminated core. Laminations shall be properly insulated from each other. Only laminations free from burrs shall be used, and care shall be taken to remove all burrs or projecting laminations from the slots of the assembled cores. Cores shall be keyed, dovetailed, or otherwise secured to the shaft or frame in an approved manner. Treatment against corrosion shall be as specified in paragraph GENERAL REQUIREMENTS.
2.2.5 Insulated Windings
All motors shall have a nonhygroscopic, sealed, fungus-resisting insulation of a type designed and constructed to withstand severe moisture conditions, and insofar as practicable, to operate after long periods of idleness without previous drying out. All windings and connections shall be of the sealed type as defined in NEMA MG 1 paragraph 1.27.2. Submit a detailed description of and specification for the manufacturing process, the materials and the insulating varnish or compound used in insulating the windings shall be submitted to the Owner's Representative for approval before manufacture of the motors is commenced. If, in the opinion of the Owner's Representative, the insulation proposed is not of the quality specified and if the methods of manufacture are not considered to be in accordance with best modern practice, the motors will not be accepted. Submit 6 copies of motor design curves and 6 copies of motor speed-torque curves, as specified. Insulated windings, unless otherwise approved, shall be completely assembled in the motor core before impregnating with the insulating compound. The compound shall consist of 100 percent solid resin.
a. Impregnation of the windings with the insulating compound shall be by vacuum impregnation method followed by baking. The procedure shall be repeated as often as necessary to fill in and seal over the interstices of the winding, but in no case shall the number of dips and bakes be less than two dips and bakes when the vacuum method of impregnation is used. The completed stator shall be of a type that is capable of passing the submerged or sprayed water test, as applicable, required by NEMA MG 1 paragraph 20.49.
b. Random wound coils may be used on motors supplied in NEMA frame size 445 TP and smaller. The components of the insulation system and the conductor insulation of the coils shall be Class F insulation with a 110 percent continuous overload factor as defined in NEMA MG 1 paragraph 1.66. After winding, the completely wound stator shall be encapsulated with an insulating resin as defined in NEMA MG 1 paragraph 1.27.1.
c. Form wound coils shall be used on motors supplied in NEMA frames larger than 445 TP. The components of the insulation system and the coil insulation of the rectangular conductors shall conform to Class F
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insulation with a 110 percent continuous overload factor as defined in NEMA MG 1, paragraph 1.66. The completed stator windings and connections shall be of the sealed type as defined in NEMA MG 1 paragraph 1.27.2.
d. Insulation to ground shall be processed on the coil. Slot tubes or cells are not acceptable. The insulation shall be of adequate thickness and breakdown strength throughout the length of the coil. Mica shall be used in the slot portion and shall be of adequate thickness to withstand the dielectric tests specified in paragraph FACTORY TESTS. Form wound coils shall be of such uniformity that the stator windings on motors of equal ratings shall be alike, in shape and size, and be interchangeable.
e. Submit motor design (characteristic) curves or tabulated data (test or calculated), indicating the speed, power factor, efficiency, current, and kilowatt input, all plotted or tabulated against torque or percent load as abscissa. The base value shall be given whether ANSI or IEEE standard system is used. The maximum allowable reverse rotation speed for the motor shall also be provided.
f. Coils of all windings shall be fully braced so that vibration is virtually eliminated during repeated starts as required by the duty cycle specified as well as during normal operation. If a tied system is used it shall be such that no tie depends upon the integrity of any other tie within the system.
2.2.6 Thermal Protection
For motors 100 HP and above, provide integral thermal detectors with normally closed contacts that will open on overtemperature. Two (2) thermal sensing devices per phase in each phase hot-spot location.
2.2.7 Winding Heaters
Heaters shall be wrapped around the winding end turns. They shall be designated for operation on 120 volts, 1-phase, 60 Hz, alternating current and of sufficient capacity or wattage that, when energized, they will hold the temperature of the motor windings approximately 10 degrees C above the ambient temperature. They shall be designed for continuous operation and to withstand at least 10 percent overvoltage continuously. The rate of heat dissipation shall be uniform throughout the effective length of the heater. Heaters installed around the winding end turns shall consist of the required turns of heating cable wrapped around the end turns and secured in place before the winding is impregnated.
2.2.7.1 Heating Element
Heating element shall conform to the requirements of ASTM B344 for an 80 percent nickel and 20 percent chromium alloy.
2.2.7.2 Sheath
Sheath shall be of a corrosion-resisting, nonoxidizing metal and shall have a wall thickness not less than 0.025 inch.
2.2.7.3 Insulation
Insulation shall be a granular mineral refractory material, highly
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resistant to heat, and shall have a minimum specific resistance of 1,000 megohms per inch cubed at 1,000 degrees F. Insulation for the heating cable (winding wraparound type) type heaters shall be suitable for a conductor temperature of 356 degrees F.
2.2.7.4 Terminals
Terminals of the heater, including the leads, shall be watertight and shall be provided with leads suitable for making connections to the drip-proof terminal box provided in paragraph MOTOR TERMINALS AND BOXES.
2.2.8 Shafts
Shafts shall be made of high grade steel, finished all over, and of ample size to drive the pumps under maximum load conditions. Shafts shall be of hollow types as required by the pump manufacturer. See paragraph GENERAL REQUIREMENTS for treatment against corrosion.
2.2.9 Bearings
2.2.9.1 Loading
Bearings shall be capable of withstanding all stresses incidental to the normal operation of the unit.
2.2.9.2 Thrust Bearings
Thrust bearings shall be of the antifriction type of either the ball or roller type. Tandem or series bearing assemblies shall not be used. Antifriction bearings shall conform to the requirements of ABMA 9 an d ABMA 11.
2.2.9.3 Guide Bearings
Guide bearings shall be of the sleeve or antifriction type of either the ball or roller type or a combination of sleeve and antifriction bearings.
2.2.9.4 Lubrication
Bearings shall be either oil or grease lubricated and the lubricant used shall contain a corrosion inhibitor. Type and grade of lubricant used shall be shown on a special nameplate which shall be attached to the frame of the motor adjacent to the bearing lubricant filling device. In addition to the quantity of lubricant required to fill the system initially, spare lubricant shall be provided in sufficient quantity to purge and refill the system.
2.2.9.5 Housings
Bearing housings shall be of a design and method of assembly that will permit ready removal of the bearings, prevent escape of lubricant and entrance of foreign matter, and protected by the lubricant when the motor is idle. Except for prelubricated antifriction bearings of an approved type, suitable means shall be provided to apply and drain the lubricant. Oil-lubricated bearing housings shall be provided with oil-level indicator gauges that will be readily visible.
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2.2.9.6 Cooling
All bearings shall be self-cooling unless otherwise specifically approved by the Owner's Representative.
2.2.9.7 Rating
Antifriction bearings shall be rated on the basis of a minimum life factor of 8,800 hours, based on the life expectancy of 90 percent of the group, unless otherwise approved by the Owner's Representative.
2.3 Non-Reversing Ratchets
Provide non-reveresing ratchets for all motors.
2.4 MOTOR TERMINALS AND BOXES
2.4.1 Stator Terminal Box
Drip-proof cast iron or steel conduit terminal boxes, treated as specified for frames in paragraph GENERAL REQUIREMENTS, shall be supplied for housing the stator lead connections and shall have adequate space to facilitate the installation and maintenance of cables and equipment. Boxes shall have a bolted cover providing unrestricted access, be mounted on the motor frame, and shall have an auxiliary floor supporting structure, when required, supplied by the motor manufacturer. Conduit entrance shall be from the top. The boxes shall be designed to permit removal of motor supply leads when the motor is removed.
2.4.2 Stator Terminals
Insulated terminal leads shall receive a treatment equal to that of the motor winding. Leads shall be brought out of the stator frame and shall be provided with terminal lugs for connection to the motor supply wiring.
2.4.3 Grounding
A ground bus and means for external connection to the station grounding system shall be provided in the stator terminal box when surge protection is provided.
2.4.4 Accessory Leads and Boxes
Terminal leads for motor winding space heaters, and any other auxiliary equipment shall be brought into conveniently located terminal boxes provided with terminal blocks for extension by others. The terminal boxes shall be drip-proof and treated as specified for frames in paragraph GENERAL REQUIREMENTS. All auxiliary wiring shall be stranded copper conductors with 600-volt flame-retardant insulation, except temperature detector leads may be in accordance with the manufacturer's standard practice. All wiring and terminals shall be properly identified.
2.5 WRENCHES, TOOLS, AND SPECIAL EQUIPMENT
Provide all nonstandard and special equipment required for dismantling, reassembly, and general maintenance of the motor units. Provide one complete set of lifting attachments such as detachable eyebolts or special slings for handling various parts with a hoist.
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2.6 FACTORY TESTS
One motor of each rating type, selected at random by the Owner's Representative, shall be given a complete test. The remainder of the motors shall be given a check test.
a. Submit 6 copies of test reports recording all data obtained during the tests specified to the Owner's Representative for each motor used. Test reports shall include performance curves indicating the results of subparagraph COMPLETE TEST below.
b. Submit 6 certified copies of the results of a "Complete Test" for duplicate equipment. It will be accepted in lieu of the "Complete Test" as specified in subparagraph COMPLETE TEST below for equipment of the respective rating and type.
c. No substitute will be accepted for the "Check Test." The base value shall be given whether ANSI or IEEE standard system is used. All complete tests shall be waived in writing.
2.6.1 Complete Test
A complete test of a motor shall include the following:
2.6.1.1 Excitation Test
Including a plot of volts as abscissa versus amperes and watts as ordinates.
2.6.1.2 Impedance Test
Including a plot of volts as abscissa versus amperes and watts as ordinates.
2.6.1.3 Performance Test
Including a plot of torque or percent load as abscissa versus efficiency, power factor, amperes, watts, and RPM or percent slip as ordinates.
2.6.1.4 Speed-Torque Test
Prony brake or other equivalent method. Including a plot of torque in foot-pounds as abscissa versus speed in RPM as ordinate.
2.6.1.5 Temperature Test
Made on completion of paragraph c above. (If screens are provided over openings, test will be made with screens removed and by thermometer).
2.6.1.6 Insulation Resistance-Temperature Test
Shall be taken following heat run, readings being taken at approximately 10 degrees C intervals. Temperature shall be determined by the resistance method. Test result values shall be plotted on semilogarithmic graphs, the insulation resistance values as logarithmic ordinates and the temperature values as uniform abscissas. For comparison purposes, a curve indicating the safe operating value of insulation resistance shall be plotted on the same sheet with the insulation resistance-temperature test curve.
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2.6.1.7 Cold and Hot Resistance Measurement
2.6.1.8 Dielectric Test
2.6.1.9 Vibration Measurement
In accordance with NEMA MG 1 paragraph 20.54.
2.6.1.10 Conformance Tests
In accordance with NEMA MG 1 paragraph 20.47.
2.6.2 Check Test
A check test of a motor shall include the following:
2.6.2.1 Routine Test
Test in accordance with NEMA MG 1 paragraph 12.51 or NEMA MG 1 paragraph 20.47.
2.6.2.2 Cold Resistance Measurement
2.6.2.3 Insulation Resistance and Winding Temperature
Insulation resistance and winding temperature at time the insulation resistance was measured.
2.6.2.4 Conformance Test
In accordance with NEMA MG 1 paragraph 20.47.
2.6.2.5 Vibration
Vibration measurement in accordance with NEMA MG 1 paragraph 12.07 or NEMA MG 1 paragraph 20.54.
2.6.3 Form Wound Coil Test
All form wound coils, either before or after they are placed in the slots, shall be tested for short circuits between turns of the individual coils by applying a high frequency voltage of not less than 75 percent of the voltage for which the machine is insulated, or by applying a surge test voltage of equivalent value to the terminals of each coil. Equivalent surge voltage shall be a wave whose peak value is equal to 1.06 times the voltage for which the motor is insulated.
2.6.4 Winding Space Heater Test
Each winding space heater unit shall be tested at the factory for successful operation and dielectric strength.
PART 3 EXECUTION
Refer to Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL FLOW AND MIXED FLOW IMPELLER TYPE. Install motors in acordance with manufacturer's instructions.
... -- End of Section --
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SECTION 26 36 00.00 10
AUTOMATIC TRANSFER SWITCH 10/07 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 602 (2007) Recommended Practice for Electric Systems in Health Care Facilities - White Book
IEEE C37.13 (2008; INT 1 2009; AMD 1 2012) Standard for Low-Voltage AC Power Circuit Breakers Used in Enclosures
IEEE C37.90.1 (2012) Standard for Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus
IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits
IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA ICS 1 (2000; R 2008; E 2010) Standard for Industrial Control and Systems: General Requirements
NEMA ICS 10 Part 2 (2005) AC Transfer Equipment, Part 2: Static AC Transfer Equipment
NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V
NEMA ICS 4 (2010) Terminal Blocks
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NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 110 (2013) Standard for Emergency and Standby Power Systems
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
UNDERWRITERS LABORATORIES (UL)
UL 1008 (2012; Reprint Apr 2013) Transfer Switch Equipment
UL 1066 (2012; Reprint Jul 2013) Low-Voltage AC and DC Power Circuit Breakers Used in Enclosures
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings Equipment Installation
SD-03 Product Data
Material Equipment
SD-06 Test Reports
Testing; G
SD-07 Certificates
Equipment Material Switching Equipment
SD-10 Operation and Maintenance Data
Switching Equipment Instructions
1.3 QUALITY ASSURANCE
1.3.1 Detail Drawings
Submit interface equipment connection diagram showing conduit, busswork, and wiring between ATS and related equipment. Submit schematic, external connection, one-line schematic and wiring diagram of each ATS assembly. Device, nameplate, and item numbers shown in list of equipment and material shall appear on drawings wherever that item appears. Diagrams shall show interlocking provisions and cautionary notes, if any. Operating instructions shall be shown either on one-line diagram or separately.
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Unless otherwise approved, one-line and elementary or schematic diagrams shall appear on same drawing.
1.3.2 Switching Equipment
Upon request, manufacturer shall provide notarized letter certifying compliance with requirements of this specification, including withstand current rating (WCR). Submit evidence that ATS withstand current rating (WCR) has been coordinated with upstream protective devices as required by UL 1008. Submit an operating manual outlining step-by-step procedures for system startup, operation, and shutdown. Manual shall include manufacturer's name, model number, service manual, parts list, and brief description of equipment and basic operating features. Manufacturer's spare parts data shall be included with supply source and current cost of recommended spare parts. Manual shall include simplified wiring and control diagrams for system as installed.
PART 2 PRODUCTS
2.1 STANDARD PRODUCTS
Provide material and equipment which are standard products of a manufacturer regularly engaged in manufacturing the products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Submit list of proposed equipment and material, containing a description of each separate item, and certificates of compliance showing evidence of UL listing and conformance with applicable NEMA standards. Such certificates are not required if manufacturer's published data, submitted and approved, reflect UL listing or conformance with applicable NEMA standards. The experience use shall include applications in similar circumstances and of same design and rating as specified ATS. Equipment shall be capable of being serviced by a manufacturer-authorized and trained organization that is, in the Owner's Representative's opinion, reasonably convenient to the site.
2.2 NAMEPLATE
Nameplate showing manufacturer's name and equipment ratings shall be made of corrosion-resistant material with not less than 1/8 inch tall characters. Nameplate shall be mounted to front of enclosure and shall comply with nameplate requirements of NEMA ICS 2.
2.3 AUTOMATIC TRANSFER SWITCH (ATS)
ATS shall consist of two electrically operated insulated case circuit breakers with an integral transfer controller. ATS shall be of switchboard type construction and bussed together with distribution switchboard SWBDA. ATS shall be suitable for use in standby systems described in NFPA 70. ATS shall be UL listed. ATS shall be manufactured and tested in accordance with applicable requirements of IEEE C37.90.1, IEEE C37.13, IEEE C62.41.1, IEEE C62.41.2, IEEE 602, NEMA ICS 1, NEMA ICS 2, NEMA ICS 10 Part 2, and UL 1008. ATS shall conform to NFPA 110. ATS shall be rated for continuous duty at specified continuous current rating.
Voltage 480/277 volts ac
Number of Phases Three
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Number of Wires Four
Frequency 60 Hz
Poles Four switched
ATS WCR Rated to withstand short-circuit current of 65,000 amperes, RMS symmetrical.
2.3.1 Override Time Delay
Provide adjustable time delay to override monitored source deviation from 0.5 to 6 seconds and factory set at 1 second. ATS shall monitor phase conductors to detect and respond to sustained voltage drop of 25 percent of nominal between any two normal source conductors and initiate transfer action to emergency source and start engine driven generator after set time period. Pickup voltage shall be adjustable from 85 to 100 percent of nominal and factory set at 90 percent. Dropout voltage shall be adjustable from 75 to 98 percent of pickup value and factory set at 85 percent of nominal.
2.3.2 Transfer Time Delay
Time delay before transfer to emergency power source shall be adjustable from 0 to 5 minutes and factory set at 0 minutes. ATS shall monitor frequency and voltage of emergency power source and transfer when frequency and voltage are stabilized. Pickup voltage shall be adjustable from 85 to 100 percent of nominal and factory set at 90 percent. Pickup frequency shall be adjustable from 90 to 100 percent of nominal and factory set at 90 percent.
2.3.3 Return Time Delay
Time delay before return transfer to normal power source shall be adjustable from 0 to 30 minutes and factory set at 5 minutes. Time delay shall be automatically defeated upon loss or sustained undervoltage of emergency power source, provided that normal supply has been restored.
2.3.4 Engine Shutdown Time Delay
Time delay shall be adjustable from 0 to 30 minutes and shall be factory set at 10 minutes.
2.3.5 Exerciser
Provide a generator exerciser timer. Run times shall be user programmable. The generator exerciser shall be selectable between load transfer and engine run only, and shall have a fail-safe feature that will retransfer the ATS to normal during the exercise period.
2.3.6 Auxiliary Contacts
Two normally open and two normally closed auxiliary contacts rated at 10 amperes at 120 volts shall operate when ATS is connected to normal power source, and two normally open and two normally closed contacts shall operate when ATS is connected to emergency source.
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2.3.7 Supplemental Features
ATS shall be furnished with the following:
a. Engine start contact.
b. Emergency source monitor.
c. Test switch to simulate normal power outage.
d. Voltage sensing. Pickup voltage adjustable from 85 to 100 percent of nominal; dropout adjustable from 75 to 98 percent of pickup.
e. Time delay bypass switch to override return time delay to normal.
f. Manual return-to-normal switch.
g. Means shall be provided in the ATS to insure that motor/transformer load inrush currents do not exceed normal starting currents. This shall be accomplished with either in-phase monitoring, time-delay transition, or load voltage decay sensing methods. If manufacturer supplies an in-phase monitoring system, the manufacturer shall indicate under what conditions a transfer cannot be accomplished. If the manufacturer supplies a time-delay transition system, the manufacturer shall supply recommendations for establishing time delay. If load voltage decay sensing is supplied, the load voltage setting shall be user programmable.
2.3.8 Override Switch
Override switch shall bypass automatic transfer controls so ATS will transfer and remain connected to emergency power source, regardless of condition of normal source. If emergency source fails and normal source is available, ATS shall automatically retransfer to normal.
2.3.9 Green Indicating Light
A green indicating light shall supervise/provide normal power source switch position indication and shall have a nameplate engraved NORMAL.
2.3.10 Red Indicating Light
A red indicating light shall supervise/provide emergency power source switch position indication and shall have a nameplate engraved EMERGENCY.
2.4 ENCLOSURE
ATS and accessories shall be installed in switchboard SWBDA, in accordance with applicable requirements of UL 1066 and/or UL 1008. Enclosure shall be equipped with at least two approved grounding lugs for grounding enclosure to facility ground system using No. 3 AWG copper conductors. Factory wiring within enclosure and field wiring terminating within enclosure shall comply with NFPA 70. If wiring is not color coded, wire shall be permanently tagged or marked near terminal at each end with wire number shown on approved detail drawing. Terminal block shall conform to NEMA ICS 4. Terminals shall be arranged for entrance of external conductors from top and bottom of enclosure as shown. Main switch terminals, including neutral terminal if used, shall be pressure type
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suitable for termination of external copper conductors shown.
2.4.1 Cleaning and Painting
Both the inside and outside surfaces of an enclosure, including means for fastening, shall be protected against corrosion by enameling, galvanizing, plating, powder coating, or other equivalent means. Protection is not required for metal parts that are inherently resistant to corrosion, bearings, sliding surfaces of hinges, or other parts where such protection is impractical. Finish shall be manufacturer's standard material, process, and color and shall be free from runs, sags, peeling, or other defects. An enclosure marked Type 1 shall be acceptable if there is no visible rust at the conclusion of a salt spray (fog) test using the test method in ASTM B117, employing a 5 percent by weight, salt solution for 24 hours.
2.5 TESTING
Submit a description of proposed field test procedures, including proposed date and steps describing each test, its duration and expected results, not less than two weeks prior to test date. Submit certified factory and field test reports, within 14 days following completion of tests. Reports shall be certified and dated and shall demonstrate that tests were successfully completed prior to shipment of equipment.
2.5.1 Factory Testing
A prototype of specified ATS shall be factory tested in accordance with UL 1008. In addition, factory tests shall be performed on each ATS as follows:
a. Insulation resistance test to ensure integrity and continuity of entire system.
b. Visual inspection to verify that each ATS is as specified.
c. Electrical tests to verify complete system electrical operation and to set up time delays and voltage sensing settings.
2.5.2 Factory Test Reports
Manufacturer shall provide three certified copies of factory test reports.
PART 3 EXECUTION
3.1 INSTALLATION
ATS shall be installed as shown and in accordance with approved manufacturer's instructions. Submit dimensioned plans, sections and elevations showing minimum clearances, weights, and conduit entry provisions for each ATS.
3.2 INSTRUCTIONS
Manufacturer's approved operating instructions shall be permanently secured to cabinet where operator can see them. One-line and elementary or schematic diagram shall be permanently secured to inside of front enclosure door. Submit 6 copies of operating and 6 copies of maintenance manuals listing routine maintenance, possible breakdowns, repairs, and troubleshooting guide.
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3.3 SITE TESTING
Following completion of ATS installation and after making proper adjustments and settings, site tests shall be performed in accordance with manufacturer's written instructions to demonstrate that each ATS functions satisfactorily and as specified. Advise Owner's Representative not less than 5 working days prior to scheduled date for site testing, and provide certified field test reports within 2 calendar weeks following successful completion of site tests. Test reports shall describe adjustments and settings made and site tests performed. Minimum operational tests shall include the following:
3.3.1 Insulation Resistance
Insulation resistance shall be tested, both phase-to-phase and phase-to-ground.
3.3.2 Power Failure of Normal Source
Power failure of normal source shall be simulated by opening upstream protective device. This test shall be performed a minimum of five times.
3.3.3 Power Failure of Emergency Source
Power failure of emergency source with normal source available shall be simulated by opening upstream protective device for emergency source. This test shall be performed a minimum of five times.
3.3.4 Low Phase-to-Ground Voltage
Simulate low phase-to-ground voltage for each phase of normal source.
3.3.5 Operation and Settings
Verify operation and settings for specified ATS features, such as override time delay, transfer time delay, return time delay, engine shutdown time delay, exerciser, auxiliary contacts, and supplemental features.
3.3.6 ATS Functions
Verify mannual and automatic ATS functions.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 26 41 00
LIGHTNING PROTECTION SYSTEM 11/13 08/18/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 81 (2012) Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
NFPA 780 (2014) Standard for the Installation of Lightning Protection Systems
UNDERWRITERS LABORATORIES (UL)
UL 467 (2007) Grounding and Bonding Equipment
UL 96 (2005; Reprint Sep 2013) Standard for Lightning Protection Components
UL Electrical Constructn (2012) Electrical Construction Equipment Directory
1.2 RELATED REQUIREMENTS
1.2.1 Verification of Dimensions
Confirm all details of work, verify all dimensions in field, and advise Owner's Representative of any discrepancy before performing work. Obtain prior approval of Owner's Representative before making any departures from the design.
1.2.2 System Requirements
Provide a system furnished under this specification consisting of the latest UL Listed products of a manufacturer regularly engaged in production of lightning protection system components. Comply with NFPA 70, NFPA 780, and UL 96. Lightning Protection System shall be provided for the Pump Building.
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1.2.3 Lightning Protection System Installers Documentation
Provide documentation showing that the installer is certified with a commercial third-party inspection company whose sole work is lightning protection, or is a UL Listed Lightning Protection Installer. In either case, the documentation must show that they have completed and passed the requirements for certification or listing, and have a minimum of 2 years documented experience installing lightning protection systems for projects of similar scope and complexity.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Overall lightning protection system; G
Each major component; G
SD-06 Test Reports
Lightning Protection and Grounding System Test Plan; G
Lightning Protection and Grounding System Test; G
SD-07 Certificates
Lightning Protection System Installers Documentation; G
Component UL Listed and Labeled; G
Lightning protection system inspection certificate; G
Roof manufacturer's warranty; G
1.4 QUALITY ASSURANCE
In each standard referred to herein, consider the advisory provisions to be mandatory, as though the word "shall" or "must" has been substituted for "should" wherever it appears. Interpret references in these standards to "authority having jurisdiction," or words of similar meaning, to mean Owner's Representative.
1.4.1 Installation Drawings
1.4.1.1 Overall System Drawing
Submit installation shop drawing for the overall lightning protection system. Include on the drawings the physical layout of the equipment (plan view and elevations), mounting details, relationship to other parts of the work, and wiring diagrams.
1.4.1.2 Major Components
Submit detail drawings for each major component including manufacturer's descriptive and technical literature, catalog cuts, and installation instructions.
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1.4.2 Component UL Listed and Labeled
Submit proof of compliance that components are UL Listed and Labeled. Listing alone in UL Electrical Constructn, which is the UL Electrical Construction Directory, is not acceptable evidence. In lieu of Listed and Labeled, submit written certificate from an approved, nationally recognized testing organization equipped to perform such services, stating that items have been tested and conform to requirements and testing methods of Underwriters Laboratories.
1.4.3 Lightning Protection and Grounding System Test Plan
Provide a lightning protection and grounding system test plan. Detail both the visual inspection and electrical testing of the system and components in the test plan. Identify (number) the system test points/locations along with a listing or description of the item to be tested and the type of test to be conducted. As a minimum, include a sketch of the facility and surrounding lightning protection system as part of the specific test plan for each structure. Include the requirements specified in paragraph, "Testing of Integral Lightning Protection System" in the test plan.
1.4.4 Lightning Protection System Inspection Certificate
Provide certification from a commercial third-party inspection company whose sole work is lightning protection, stating that the lightning protection system complies with NFPA 780. Third party inspection company cannot be the system installer or the system designer. Alternatively, provide a UL Lightning Protection Inspection Master Label Certificate for each facility indicating compliance to NFPA 780.
1.5 SITE CONDITIONS
Confirm all details of work, verify all dimensions in field, and advise Owner's Representative of any discrepancy before performing work. Obtain prior approval of Owner's Representative before changing the design.
PART 2 PRODUCTS
2.1 MATERIALS
Do not use a combination of materials that forms an electrolytic couple of such nature that corrosion is accelerated in the presence of moisture unless moisture is permanently excluded from the junction of such metals. Where unusual conditions exist which would cause corrosion of conductors, provide conductors with protective coatings, such as tin or lead, or oversize conductors. Where a mechanical hazard is involved, increase conductor size to compensate for the hazard or protect conductors. When metallic conduit or tubing is provided, electrically bond conductor to conduit or tubing at the upper and lower ends by clamp type connectors or welds (including exothermic). All lightning protection components, such as bonding plates, air terminals, air terminal supports and braces, chimney bands, clips, connector fittings, and fasteners are to comply with the requirements of UL 96 classes as applicable.
2.1.1 Main and Bonding Conductors
NFPA 780 and UL 96 Class I, Class II, or Class II modified materials as applicable.
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2.2 COMPONENTS
2.2.1 Air Terminals
Provide solid air terminals with a blunt tip. Tubular air terminals are not permitted. Support air terminals more than 24 inches in length by suitable brace, supported at not less than one-half the height of the terminal.
2.2.2 Ground Rods
Provide ground rods made of copper-clad steel conforming to conform to UL 467. Provide ground rods that are not less than 3/4 inch in diameter and 10 feet in length. Do not mix ground rods of copper-clad steel or solid copper on the job.
2.2.3 Connections and Terminations
Provide connectors for splicing conductors that conform to UL 96, class as applicable. Conductor connections can be made by clamps or welds (including exothermic). Provide style and size connectors required for the installation.
2.2.4 Connector Fittings
Provide connector fittings for "end-to-end", "Tee", or "Y" splices that conform to NFPA 780 and UL 96.
PART 3 EXECUTION
3.1 INTEGRAL SYSTEM
Provide a lightning protection system that meets the requirements of NFPA 780. Lightning protection system consists of air terminals, roof conductors, down conductors, ground connections, and grounding electrodes. Expose conductors on the structures except where conductors are required to be in protective sleeves. Bond secondary conductors with grounded metallic parts within the building. Make interconnections within side-flash distances at or below the level of the grounded metallic parts.
3.1.1 Roof-Mounted Components
Coordinate with the roofing manufacturer and provide certification that the roof manufacturer's warranty is not violated by the installation methods for air terminals and roof conductors.
3.1.1.1 Air Terminals
Use adhesive shoes with adhesive approved by the roof manufacturer when installing air terminals on "rubber" (EPDM) type roofs. In areas of snow or constant wind, ensure that a section of roofing material (minimum dimensional area of 1 square foot) is first glued to the roof and then the air terminal is glued to it unless the roof manufacturer recommends another solution.
3.1.1.2 Roof Conductors
Use adhesive shoes with adhesive approved by the roof manufacturer when installing roof conductors on "rubber" (EPDM) type roofs.
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3.1.2 Down Conductors
Protect exposed down conductors from physical damage as required by NFPA 780. Use Schedule 80 PVC to protect down conductors. Paint the Schedule 80 PVC to match the surrounding surface with paint that is approved for use on PVC.
3.1.3 Ground Connections
Attach each down conductor to ground rods by welding (including exothermic), brazing, or compression. All connections to ground rods below ground level must be by exothermic weld connection or with a high compression connection using a hydraulic or electric compression tool to provide the correct circumferential pressure. Accessible connections above ground level and in test wells can be accomplished by mechanical clamping.
3.1.4 Grounding Electrodes
Extend driven ground rods vertically into the existing undisturbed earth for a distance of not less 10 feet. Set ground rods not less than 3 feet nor more than 8 feet, from the structure foundation, and at least beyond the drip line for the facility. After the completed installation, measure the total resistance to ground using the fall-of-potential method described in IEEE 81. Maximum allowed resistance of a driven ground rod is 25 ohms, under normally dry conditions. Contact the Owner's Representative for direction on how to proceed when two of any three ground rods, driven not less than 10 feet into the ground, a minimum of 10 feet apart, and equally spaced around the perimeter, give a combined value exceeding 50 ohms immediately after having driven.
Connect ground rods to building grounding electrode system grounding.
3.2 FIELD QUALITY CONTROL
3.2.1 Lightning Protection and Grounding System Test
Test the lightning protection and grounding system to ensure continuity is not in excess of 1 ohm and that resistance to ground is not in excess of 10 ohms. Provide documentation for the measured values at each test point. Test the ground rod for resistance to ground before making connections to the rod. Tie the grounding system together and test for resistance to ground. Make resistance measurements in dry weather, not earlier than 48 hours after rainfall. Include in the written report: locations of test points, measured values for continuity and ground resistances, and soil conditions at the time that measurements were made. Submit results of each test to the Owner's Representative.
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 26 51 00
INTERIOR LIGHTING 07/07 08/06/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.
CALIFORNIA ENERGY COMMISSION (CEC)
CEC Title 24 (2008; Effective Jan 2010) California's Energy Efficiency Standards for Residential and Nonresidential Buildings
ILLUMINATING ENGINEERING SOCIETY OF NORTH AMERICA (IES)
IES HB-10 (2011) IES Lighting Handbook
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 100 (2000; Archived) The Authoritative Dictionary of IEEE Standards Terms
IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-6 2013) National Electrical Safety Code
IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits
IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
ANSI C78.901 (2005) American National Standard for Electric Lamps - Single Base Fluorescent Lamps--Dimensional and Electrical Characteristics
NEMA 250 (2008) Enclosures for Electrical Equipment (1000 Volts Maximum)
NEMA ANSLG C78.81 (2010) American National Standard for Electric Lamps--Double-Capped Fluorescent Lamps--Dimensional and Electrical Characteristics
NEMA ANSLG C82.11 (2011) Lamp Ballasts - High-Frequency Fluorescent Lamp Ballasts
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NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 101 (2012; Amendment 1 2012) Life Safety Code
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
UNDERWRITERS LABORATORIES (UL)
UL 1598 (2008; Reprint Oct 2012) Luminaires
UL 773 (1995; Reprint Mar 2002) Standard for Plug-In, Locking Type Photocontrols for Use with Area Lighting
UL 773A (2006; Reprint Nov 2013) Standard for Nonindustrial Photoelectric Switches for Lighting Control
UL 924 (2006; Reprint Feb 2011) Standard for Emergency Lighting and Power Equipment
UL 935 (2001; Reprint Nov 2011) Standard for Fluorescent-Lamp Ballasts
1.2 RELATED REQUIREMENTS
Materials not considered to be lighting equipment or lighting fixture accessories are specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Lighting fixtures and accessories mounted on exterior surfaces of buildings are specified in this section.
1.3 DEFINITIONS
a. Unless otherwise specified or indicated, electrical and electronics terms used in these specifications, and on the drawings, shall be as defined in IEEE 100.
b. Average life is the time after which 50 percent will have failed and 50 percent will have survived under normal conditions.
c. Total harmonic distortion (THD) is the root mean square (RMS) of all the harmonic components divided by the total fundamental current.
1.4 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
Data, drawings, and reports shall employ the terminology, classifications, and methods prescribed by the IES HB-10, as applicable, for the lighting system specified.
SD-03 Product Data
Fluorescent lighting fixtures; G
Fluorescent electronic ballasts; G
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Fluorescent lamps; G
Lighting contactor; G
Photocell switch; G
Exit signs; G
Emergency lighting equipment; G
1.5 QUALITY ASSURANCE
1.5.1 Fluorescent Electronic Ballasts
Submit ballast catalog data as required in the paragraph entitled "Fluorescent Lamp Electronic Ballasts" contained herein. As an option, submit the fluorescent fixture manufacturer's electronic ballast specification information in lieu of the actual ballast manufacturer's catalog data. This information shall include published specifications and sketches, which covers the information required by the paragraph entitled "Fluorescent Lamp Electronic Ballasts" herein. This information may be supplemented by catalog data if required, and shall contain a list of vendors with vendor part numbers.
1.5.2 Standard Products
Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship. Products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year period shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period. Where two or more items of the same class of equipment are required, these items shall be products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in this section.
1.5.2.1 Alternative Qualifications
Products having less than a 2-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturers' factory or laboratory tests, is furnished.
1.5.2.2 Material and Equipment Manufacturing Date
Products manufactured more than 3 years prior to date of delivery to site shall not be used, unless specified otherwise.
1.6 WARRANTY
The equipment items shall be supported by service organizations which are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
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1.6.1 Electronic Ballast Warranty
Furnish the electronic ballast manufacturer's warranty. The warranty period shall not be less than 5 years from the date of manufacture of the electronic ballast. Ballast assembly in the lighting fixture, transportation, and on-site storage shall not exceed 12 months, thereby permitting 4 years of the ballast 5 year warranty to be in service and energized. The warranty shall state that the malfunctioning ballast shall be exchanged by the manufacturer and promptly shipped to the using Owner's Representative facility. The replacement ballast shall be identical to, or an improvement upon, the original design of the malfunctioning ballast.
PART 2 PRODUCTS
2.1 FLUORESCENT LIGHTING FIXTURES
UL 1598. Fluorescent fixtures shall have electronic ballasts.
2.1.1 Fluorescent Lamp Electronic Ballasts
The electronic ballast shall as a minimum meet the following characteristics:
a. Ballast shall comply with UL 935, NEMA ANSLG C82.11, NFPA 70, and CEC Title 24 unless specified otherwise. Ballast shall be 100 percent electronic high frequency type with no magnetic core and coil components. Ballast shall provide transient immunity as recommended by IEEE C62.41.1 and IEEE C62.41.2. Ballast shall be designed for the wattage of the lamps used in the indicated application. Ballasts shall be designed to operate on the voltage system to which they are connected.
b. Power factor shall be 0.95 (minimum).
c. Ballast shall operate at a frequency of 20,000 Hertz (minimum). Ballast shall be compatible with and not cause interference with the operation of occupancy sensors or other infrared control systems. Provide ballasts operating at or above 40,000 Hertz where available.
d. Ballast shall have light regulation of plus or minus 10 percent lumen output with a plus or minus 10 percent input voltage regulation. Ballast shall have 10 percent flicker (maximum) using any compatible lamp.
e. Ballast factor shall be between 0.85 (minimum) and 1.00 (maximum). Current crest factor shall be 1.7 (maximum).
f. Ballast shall be UL listed Class P with a sound rating of "A."
g. Ballast shall have circuit diagrams and lamp connections displayed on the ballast.
h. Ballasts shall be instant start unless otherwise indicated. Ballasts shall be programmed start where indicated. Instant start ballasts shall operate lamps in a parallel circuit configuration that permits the operation of remaining lamps if one or more lamps fail or are removed. Programmed start ballasts may operate lamps in a series circuit configuration. Provide series/parallel wiring for programmed start ballasts where available.
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i. Ballasts for T-5 and smaller lamps shall have end-of-life protection circuits as required by NEMA ANSLG C78.81 and ANSI C78.901 as applicable.
j. Ballast shall be capable of starting and maintaining operation at a minimum of 0 degrees F unless otherwise indicated.
k. Electronic ballast shall have a full replacement warranty of 5 years from date of manufacture as specified in paragraph entitled "Electronic Ballast Warranty" herein.
2.1.1.1 T-8 Lamp Ballast
a. Total harmonic distortion (THD): Shall be 20 percent (maximum).
b. Input wattage.
1. 32 watts (maximum) when operating one F32T8 lamp
2. 62 watts (maximum) when operating two F32T8 lamps
3. 92 watts (maximum) when operating three F32T8 lamps
4. 114 watts (maximum) when operating four F32T8 lamps
c. A single ballast may be used to serve multiple fixtures if they are continuously mounted and factory manufactured for that installation with an integral wireway.
2.1.2 Open-Tube Fluorescent Fixtures
Provide with self-locking sockets, or lamp retainers (two per lamp). Provide a clear polycarbonate protective sleeve with end caps, over lamp, with 95 percent (minimum) light transmission. The sleeve shall be rated to withstand the thermal profile of the lamp and ballast.
2.2 SUSPENDED FIXTURES
Provide hangers capable of supporting twice the combined weight of fixtures supported by hangers. Provide with swivel hangers to ensure a plumb installation. Hangers shall be cadmium-plated steel with a swivel-ball tapped for the conduit size indicated. Hangers shall allow fixtures to swing within an angle of 45 degrees. Brace pendants 4 feet or longer to limit swinging. Multiple-unit or continuous row fluorescent fixtures shall have a tubing or stem for wiring at one point and a tubing or rod suspension provided for each unit length of chassis, including one at each end. Rods shall be a minimum 0.18 inch diameter.
2.3 SWITCHES
2.3.1 Toggle Switches
Provide toggle switches as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
2.4 PHOTOCELL SWITCH
UL 773 or UL 773A, hermetically sealed cadmium-sulfide or silicon diode
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type cell rated 120/277 volts ac, 60 Hz with single-throw contacts. Switch shall turn on at or below 3 footcandles and off at 2 to 10 footcandles. A time delay shall prevent accidental switching from transient light sources. Provide switch:
a. In a cast weatherproof aluminum housing with adjustable window slide, rated 1800 VA, minimum.
2.5 EXIT SIGNS
UL 924, NFPA 70, and NFPA 101. Exit signs shall be self-powered type. Exit signs shall use no more than 5 watts.
2.5.1 Self-Powered LED Type Exit Signs (Battery Backup)
Provide with automatic power failure device, test switch, pilot light, integral self-testing module and fully automatic high/low trickle charger in a self-contained power pack. Battery shall be sealed electrolyte type, shall operate unattended, and require no maintenance, including no additional water, for a period of not less than 5 years. LED exit sign shall have emergency run time of 1 1/2 hours (minimum). The light emitting diodes shall have rated lamp life of 70,000 hours (minimum).
2.6 EMERGENCY LIGHTING EQUIPMENT
UL 924, NFPA 70, and NFPA 101. Provide lamps in wattage indicated.
2.6.1 Emergency Lighting Unit
Provide as indicated. Equip units with brown-out sensitive circuit to activate battery when ac input falls to 75 percent of normal voltage and 15 minute time delay feature for areas with HID lighting. Provide integral self-testing module.
2.6.2 Fluorescent Emergency System
Each system shall consist of an automatic power failure device, test switch operable from outside of the fixture, pilot light visible from outside the fixture, and fully automatic solid-state charger in a self-contained power pack. Provide self-testing module integral to the fixture. Charger shall be either trickle, float, constant current or constant potential type, or a combination of these. Battery shall be sealed electrolyte type with capacity as required to supply power to the number of lamps shown for each system for 90 minutes at a minimum of 1100 lumens per lamp output. Battery shall operate unattended and require no maintenance, including no additional water, for a period of not less than 5 years. Emergency ballasts provided with fixtures containing solid-state ballasts shall be fully compatible with the solid-state ballasts.
2.7 EQUIPMENT IDENTIFICATION
2.7.1 Manufacturer's Nameplate
Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.
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2.7.2 Labels
Provide labeled luminaires in accordance with UL 1598 requirements. All luminaires shall be clearly marked for operation of specific lamps and ballasts according to proper lamp type. The following lamp characteristics shall be noted in the format "Use Only _____":
a. Lamp diameter code (T-4, T-5, T-8, T-12), tube configuration (twin, quad, triple), base type, and nominal wattage for fluorescent and compact fluorescent luminaires.
b. Lamp type, wattage, bulb type (ED17, BD56, etc.) and coating (clear or coated) for HID luminaires.
c. Start type (preheat, rapid start, instant start) for fluorescent and compact fluorescent luminaires.
d. ANSI ballast type (M98, M57, etc.) for HID luminaires.
e. Correlated color temperature (CCT) and color rendering index (CRI) for all luminaires.
All markings related to lamp type shall be clear and located to be readily visible to service personnel, but unseen from normal viewing angles when lamps are in place. Ballasts shall have clear markings indicating multi-level outputs and indicate proper terminals for the various outputs.
2.8 FACTORY APPLIED FINISH
Electrical equipment shall have factory-applied painting systems which shall, as a minimum, meet the requirements of NEMA 250 corrosion-resistance test.
PART 3 EXECUTION
3.1 INSTALLATION
Electrical installations shall conform to IEEE C2, NFPA 70, and to the requirements specified herein.
3.1.1 Lamps
Lamps of the type, wattage, and voltage rating indicated shall be delivered to the project in the original cartons and installed just prior to project completion. Lamps installed and used for working light during construction shall be replaced prior to turnover to the Owner's Representative if more than 15 percent of their rated life has been used. Lamps shall be tested for proper operation prior to turn-over and shall be replaced if necessary with new lamps from the original manufacturer. Provide 10 percent spare lamps of each type from the original manufacturer.
3.1.2 Lighting Fixtures
Set lighting fixtures plumb, square, and level with ceiling and walls, in alignment with adjacent lighting fixtures, and secure in accordance with manufacturers' directions and approved drawings. Installation shall meet requirements of NFPA 70. Mounting heights specified or indicated shall be to the bottom of fixture. Obtain approval of the exact mounting for lighting fixtures on the job before commencing installation and, where
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applicable, after coordinating with the type, style, and pattern of the ceiling being installed.
3.1.3 Suspended Fixtures
Suspended fixtures shall be provided with 45 degree swivel hangers so that they hang plumb and shall be located with no obstructions within the 45 degree range in all directions. The stem, canopy and fixture shall be capable of 45 degree swing. Pendants, rods, or chains 4 feet or longer excluding fixture shall be braced to prevent swaying using three cables at 120 degree separation. Suspended fixtures in continuous rows shall have internal wireway systems for end to end wiring and shall be properly aligned to provide a straight and continuous row without bends, gaps, light leaks or filler pieces. Aligning splines shall be used on extruded aluminum fixtures to assure hairline joints. Steel fixtures shall be supported to prevent "oil-canning" effects. Fixture finishes shall be free of scratches, nicks, dents, and warps, and shall match the color and gloss specified. Pendants shall be finished to match fixtures. Aircraft cable shall be stainless steel. Canopies shall be finished to match the ceiling and shall be low profile unless otherwise shown. Maximum distance between suspension points shall be 10 feet or as recommended by the manufacturer, whichever is less.
3.1.4 Exit Signs and Emergency Lighting Units
Wire exit signs and emergency lighting units ahead of the switch to the normal lighting circuit located in the same room or area.
3.2 FIELD QUALITY CONTROL
Upon completion of installation, verify that equipment is properly installed, connected, and adjusted. Conduct an operating test to show that equipment operates in accordance with requirements of this section.
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SECTION 26 56 00
EXTERIOR LIGHTING 05/13 08/18/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM B117 (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus
ILLUMINATING ENGINEERING SOCIETY OF NORTH AMERICA (IES)
IES HB-10 (2011) IES Lighting Handbook
IES LM-79 (2008) Electrical and Photometric Measurements of Solid-State Lighting Products
IES LM-80 (2008) Measuring Lumen Maintenance of LED Light Sources
IES RP-16 (2010; Addendum A 2008; Addenda B & C 2009) Nomenclature and Definitions for Illuminating Engineering
IES TM-15 (2011) Luminaire Classification System for Outdoor Luminaires
IES TM-21 (2011) Projecting Long Term Lumen Maintenance of LED Light Sources
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 100 (2000; Archived) The Authoritative Dictionary of IEEE Standards Terms
IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-6 2013) National Electrical Safety Code
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA 250 (2008) Enclosures for Electrical Equipment (1000 Volts Maximum)
NEMA ANSLG C78.377 (2011) American National Standard for Electric Lamps— Specifications for the Chromaticity of Solid State Lighting Products
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NEMA C136.31 (2010) American National for Roadway and Area Lighting Equipment - Luminaire Vibration
NEMA C82.77 (2002) Harmonic Emission Limits - Related Power Quality Requirements for Lighting Equipment
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
UNDERWRITERS LABORATORIES (UL)
UL 1310 (2011; Reprint Oct 2013) UL Standard for Safety Class 2 Power Units
UL 1598 (2008; Reprint Oct 2012) Luminaires
UL 8750 (2009; Reprint Sep 2013) UL Standard for Safety Light Emitting Diode (LED) Equipment for Use in Lighting Products
1.2 RELATED REQUIREMENTS
Materials not considered to be luminaires or lighting equipment are specified in Section(s) 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION. Luminaires and accessories installed in interior of buildings are specified in Section 26 51 00 INTERIOR LIGHTING.
1.3 DEFINITIONS
a. Unless otherwise specified or indicated, electrical and electronics terms used in these specifications, and on the drawings shall be as defined in IEEE 100 and IES RP-16.
b. For LED luminaire light sources, "Useful Life" is the operating hours before reaching 70 percent of the initial rated lumen output (L70) with no catastrophic failures under normal operating conditions. This is also known as 70 percent "Rated Lumen Maintenance Life" as defined in IES LM-80.
1.4 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-01 Preconstruction Submittals
LED Luminaire Warranty; G
SD-02 Shop Drawings
Luminaire drawings; G
SD-03 Product Data
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LED Luminaires; G
Luminaire Power Supply Units (Drivers); G
SD-07 Certificates
Luminaire Useful Life Certificate; G
Submit certification from the manufacturer indicating the expected useful life of the luminaires provided. The useful life shall be directly correlated from the IES LM-80 test data using procedures outlined in IES TM-21. Thermal properties of the specific luminaire and local ambient operating temperature and conditions shall be taken into consideration.
SD-10 Operation and Maintenance Data
Operational Service
Submit documentation that includes contact information, summary of procedures, and the limitations and conditions applicable to the project. Indicate manufacturer's commitment to reclaim materials for recycling and/or reuse.
1.5 QUALITY ASSURANCE
1.5.1 Drawing Requirements
1.5.2 Design Data for Luminaires
a. Provide long term lumen maintenance projections for each LED luminaire in accordance with IES TM-21. Data used for projections shall be obtained from testing in accordance with IES LM-80.
b. Provide wind loading calculations for luminaires mounted on poles. Weight and effective projected area (EPA) of luminaires and mounting brackets shall not exceed maximum rating of pole as installed in particular wind zone area.
1.5.3 LED Luminaire - IES LM-79 Test Report
Submit test report on manufacturer's standard production model luminaire. Submittal shall include all photometric and electrical measurements, as well as all other pertinent data outlined under "14.0 Test Report" in IES LM-79.
1.5.4 LED Light Source - IES LM-80 Test Report
Submit report on manufacturer's standard production LED package, array, or module. Submittal shall include:
a. Testing agency, report number, date, type of equipment, and LED light source being tested.
b. All data required by IES LM-80.
1.5.4.1 Test Laboratories
Test laboratories for the IES LM-79 and IES LM-80 test reports shall be one
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of the following:
a. National Voluntary Laboratory Accreditation Program (NVLAP) accredited for solid-state lighting testing as part of the Energy-Efficient Lighting Products laboratory accreditation program.
b. One of the qualified labs listed on the Department of Energy - Energy Efficiency & Renewable Energy, Solid-State Lighting web site.
c. A manufacturer's in-house lab that meets the following criteria:
1. Manufacturer has been regularly engaged in the design and production of high intensity discharge roadway and area luminaires and the manufacturer's lab has been successfully certifying these fixtures for a minimum of 15 years.
2. Annual equipment calibration including photometer calibration in accordance with National Institute of Standards and Technology.
1.5.5 Standard Products
Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship. Products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year period shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period. Where two or more items of the same class of equipment are required, these items shall be products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in this section.
1.5.5.1 Alternative Qualifications
Products having less than a 2-year field service record will be acceptable if the manufacturer has been regularly engaged in the design and production of high intensity discharge roadway and area luminaires for a minimum of 15 years. Products shall have been in satisfactory commercial or industrial use for 15 years prior to bid opening. The product shall have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 15-year period.
1.5.5.2 Material and Equipment Manufacturing Date
Products manufactured more than 1 year prior to date of delivery to site shall not be used, unless specified otherwise.
1.6 WARRANTY
The equipment items shall be supported by service organizations which are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
1.6.1 LED Luminaire Warranty
Provide Luminaire Useful Life Certificate.
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The equipment items shall be supported by service organizations which are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.
a. Provide a written five year on-site replacement warranty for material, fixture finish, and workmanship. On-site replacement includes transportation, removal, and installation of new products.
1. Finish warranty shall include warranty against failure and against substantial deterioration such as blistering, cracking, peeling, chalking, or fading.
2. Material warranty shall include:
(a) All power supply units (drivers).
(b) Replacement when more than 10 percent of LED sources in any lightbar or subassembly(s) are defective or non-starting.
b. Warranty period must begin on date of beneficial occupancy. Contractor shall provide the Owner's Representative signed warranty certificates prior to final payment.
1.7 OPERATIONAL SERVICE
Coordinate with manufacturer for maintenance agreement. Collect information from the manufacturer about maintenance agreement options, and submit to Owner's Representative. Services shall reclaim materials for recycling and/or reuse. Services shall not deposit materials in landfills or burn reclaimed materials. Indicate procedures for compliance with regulations governing disposal of mercury. When such a service is not available, local recyclers shall be sought after to reclaim the materials.
PART 2 PRODUCTS
2.1 PRODUCT COORDINATION
Products and materials not considered to be luminaires, equipment or accessories are specified in Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION, and and Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Luminaires and associated equipment and accessories for interior applications are specified in Section 26 51 00 INTERIOR LIGHTING.
2.2 LED LUMINAIRES
UL 1598, NEMA C82.77 and UL 8750. Provide luminaires as indicated in luminaire schedule and XL plates or details on project plans. Provide luminaires complete with light sources of quantity, type, and wattage indicated. All luminaires of the same type shall be provided by the same manufacturer.
2.2.1 General Requirements
a. LED luminaire housings shall be die cast or extruded aluminum.
b. LED luminaires shall be rated for operation within an ambient temperature range of minus 22 degrees F to 104 degrees F.
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c. Luminaires shall be UL listed for wet locations per UL 1598.
d. LED luminaires shall produce a minimum efficacy as shown in the following table, tested per IES LM-79. Theoretical models of initial raw LED lumens per watt are not acceptable.
Application Luminaire Efficacy in Lumens per Watt
Exterior Pole/Arm-Mounted Area and 65 Roadway Luminaires
Exterior Pole/Arm-Mounted Decorative 65 Luminaires
Exterior Wall-Mounted Area Luminaires 60
Bollards 35
Parking Garage Luminaires 70
e. Luminaires shall have IES distribution and NEMA field angle classifications as indicated in luminaire schedule on project plans per IES HB-10.
f. Housing finish shall be baked-on enamel, anodized, or baked-on powder coat paint. Finish shall be capable of surviving ASTM B117 salt fog environment testing for 2500 hours minimum without blistering or peeling.
g. Luminaires shall not exceed the following IES TM-15 Backlight, Uplight and Glare (B.U.G.) ratings:
1. Maximum Backlight (B) rating shall be determined by lighting zone in which luminaire is placed.
2. Maximum Uplight (U) rating shall be U0.
3. Maximum Glare (G) rating shall be determined by lighting zone in which luminaire is placed.
h. Luminaires shall be fully assembled and electrically tested prior to shipment from factory.
i. The finish color shall be as indicated in the luminaire schedule or detail on the project plans.
j. Luminaire arm bolts shall be 304 stainless steel or zinc-plated steel.
k. Luminaire lenses shall be constructed of clear tempered glass or UV-resistant acrylic.
l. Incorporate modular electrical connections, and construct luminaires to allow replacement of all or any part of the optics, heat sinks, power supply units, ballasts, surge suppressors and other electrical components using only a simple tool, such as a manual or cordless electric screwdriver.
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m. Luminaires shall have a nameplate bearing the manufacturer's name, address, model number, date of manufacture, and serial number securely affixed in a conspicuous place. The nameplate of the distributing agent will not be acceptable.
n. Luminaire must pass 3G vibration testing in accordance with NEMA C136.31.
o. All factory electrical connections shall be made using crimp, locking, or latching style connectors. Twist-style wire nuts are not acceptable.
2.2.2 Luminaire Light Sources
2.2.2.1 LED Light Sources
a. Correlated Color Temperature (CCT) shall be in accordance with NEMA ANSLG C78.377:
Nominal CCT: As indicated in the Luminaire Schedule.
b. Color Rendering Index (CRI) shall be:
As indicated in the Luminaire Schedule.
2.2.3 Luminaire Power Supply Units (Drivers)
2.2.3.1 LED Power Supply Units (Drivers)
UL 1310. LED Power Supply Units (Drivers) shall meet the following requirements:
a. Shall be rated to operate between ambient temperatures of minus 22 degrees F and 104 degrees F.
b. Shall be designed to operate on the voltage system to which they are connected, typically ranging from 120 V to 277 V nominal.
c. Operating frequency shall be: 50 or 60 Hz.
d. Shall be mounted integral to luminaire. Remote mounting of power supply is not allowed.
2.3 EQUIPMENT IDENTIFICATION
2.3.1 Manufacturer's Nameplate
Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.
2.4 FACTORY APPLIED FINISH
Electrical equipment shall have factory-applied painting systems which shall, as a minimum, meet the requirements of NEMA 250 corrosion-resistance test.
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PART 3 EXECUTION
3.1 INSTALLATION
Electrical installations shall conform to IEEE C2, NFPA 70, and to the requirements specified herein.
3.1.1 GROUNDING
Ground noncurrent-carrying parts of equipment including luminaires, mounting arms, brackets, and metallic enclosures as specified in Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION. Where copper grounding conductor is connected to a metal other than copper, provide specially treated or lined connectors suitable for this purpose.
3.2 FIELD QUALITY CONTROL
Upon completion of installation, verify that equipment is properly installed, connected, and adjusted. Conduct an operating test after 100 hours of burn-in time to show that the equipment operates in accordance with the requirements of this section.
-- End of Section --
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DIVISION 31 EARTHWORK
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 31 00 00.00 14
EARTHWORK FOR PUMP STATION AND FLOODWALL 07/14 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM C33/C33M (2011a) Standard Specification for Concrete Aggregates
ASTM D1556 (2007) Density and Unit Weight of Soil in Place by the Sand-Cone Method
ASTM D1557 (2012) Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3) (2700 kN-m/m3)
ASTM D4253 (2000; R 2006) Maximum Index Density and Unit Weight of Soils Using a Vibratory Table
ASTM D4318 (2010) Liquid Limit, Plastic Limit, and Plasticity Index of Soils
ASTM D6938 (2010) Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)
ASTM D698 (2012) Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/cu. ft. (600 kN-m/cu. m.))
1.2 SEQUENCING AND SCHEDULING
Specification subparagraph text.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-01 Preconstruction Submittals
Shoring; G
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Dewatering Work Plan; G
Submit plan for accomplishing dewatering work.
Earthwork and Grading Plan; G
Submit a work plan detailing the proposed construction sequence, methodology, sheeting and shoring plan (if required), and schedule of all earthwork and grading.
Emergency Action Plan; G
The Contractor shall submit for approval a plan that addresses the intended measures to be taken to respond to a pending flood threat. The plan shall provide contact data and chain of command to be used in the event that the City of Fargo requires prompt restoration of flood protection defenses. 24 hour-7 day per week contact data shall be provided in the plan for key contractor personnel and the contractor's geotechnical engineering support. The plan shall describe river monitoring and communication protocols, and provide a description of how the contractor will communicate with key City staff. The plan shall discuss available on-site or off-site stockpiles, other material sources, and equipment availability.
SD-03 Product Data
Utilization of Excavated Materials; G
SD-06 Test Reports
Initial Test Results; G
Prior to placement of material for use in fill or backfill initial testing shall be completed and the results provided to the Owner's Representative to verify that material meets the requirements for which it is specified.
Testing
A summary of testing results indicated in paragraph TESTING shall be submitted when the work is substantially complete. The Owner's Representative shall be informed of test results daily for direction on corrective action require. Draft copies of field testing results shall be furnished to the Owner's Representative on a frequent and regular basis as directed, but do not need to be formally transmitted through the submittal process.
Daily Report
A compilation of the daily report forms for earthwork observation ordered by date shall be submitted when the work is substantially complete. Preliminary copies shall be furnished to the Owner's Representative on a weekly or monthly basis as directed, but do not need to be formally transmitted through the submittal process.
SD-07 Certificates
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Testing; G
1.4 SUBSURFACE INFORMATION
1.4.1 Boring Logs
Boring logs obtained for this project are provided in the geotechnical report. The borings are representative of subsurface conditions at their respective locations. Variations in the stratigraphy and characteristics of the soil are known to occur between borings. Normal variations in site geology will not be considered as differing materially within the purview of CONTRACT CLAUSE 52.236-2, DIFFERING SITE CONDITIONS. Ground water elevations measured in borings are not constant and will fluctuate.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Fill and Backfill
Fill and backfill shall be selected engineered fill material approved by Owner's Representative from site excavation or from off site borrow.
2.1.1.1 Engineered Fill
Engineered fill material may consist of sand, silty sand and clayey sand, although the liquid limit of these materials should not exceed 30 and plastic index of these materials should not exceed 15; and should contain less than 30 percent passing the number 200 sieve.
2.1.2 Granular Fill Under Screen Wall Footing and Inside Pump Station Structure
Granular fill under floor slabs-on-grade shall be clean, crushed, nonporous rock, crushed or uncrushed gravel conforming with ASTM C33/C33M gradation size No. 67, 3/4 inch to No. 4.
PART 3 EXECUTION
3.1 PROTECTION
3.1.1 Protect Existing Surface and Subsurface Features
Protect existing surface and subsurface features on-site and adjacent to site by providing barricades, coverings, or other types of protection necessary to prevent damage to existing items indicated to remain in place.
Protect and maintain bench marks, monuments or other established reference points and property corners. If disturbed or destroyed, replace at own expense to full satisfaction of Owner's Representative and controlling agency.
Verify location of utilities. Omission or inclusion of utility items does not constitute nonexistence or definite location. Secure and examine local utility records for location data. Take necessary precautions to protect existing utilities from damage due to any construction activity. Repair damages to utility items at own expense. In case of damage, notify Engineer at once so required protective measures may be taken.
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Maintain free of damage, existing sidewalks, structures, and pavement, not indicated to be removed. Any item known or unknown or not properly located that is inadvertently damaged shall be repaired to original condition. All repairs to be made and paid for by Contractor.
Provide full access to public and private premises, fire hydrants, street crossings, sidewalks and other points as designated by Owner's Representative to prevent serious interruption of travel.
Maintain stockpiles and excavations in such a manner to prevent inconvenience or damage to structures on-site or on adjoining property. Avoid surcharge or excavation procedures which can result in heaving, caving, or slides.
3.1.2 Salvageable Items
Carefully remove items to be salvaged, and store on Owner's Representative 's premises unless otherwise directed.
3.1.3 Disposal of Waste Materials
Dispose of waste materials, legally, off site. Burning, as a means of waste disposal, is not permitted.
3.2 SITE EXCAVATION AND GRADING
3.2.1 Excavation and Grading
The work includes all operations in connection with excavation, borrow, construction of fills and embankments, rough grading, and disposal of excess materials in connection with the preparation of the site(s) for construction of the proposed facilities.
Perform excavation and grading as required by the Contract Drawings. Contract Drawings may indicate both existing grade and finished grade required for construction of Project. Stake all units, structures, piping, roads, parking areas and walks and establish their elevations. Perform other layout work required. Replace property corner markers to original location if disturbed or destroyed.
3.2.2 Preparation of Ground Surface For Embankments or Fills
Before fill is started, scarify to a minimum depth of 6 inches in all proposed embankment and fill areas. Where ground surface is steeper than one vertical to four horizontal, plow surface in a manner to bench and break up surface so that fill material will bind with existing surface.
3.2.3 Protection of Finish Grade
During construction, shape and drain embankment and excavations. Maintain ditches and drains to provide drainage at all times. Protect graded areas against action of elements prior to acceptance of work. Reestablish grade where settlement or erosion occurs.
3.2.4 Borrow
Provide necessary amount of approved fill compacted to density equal to that indicated in this Specification. Include cost of all borrow material in original proposal. Fill material to be approved by Owner's
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Representative prior to placement.
3.2.5 Construction of Embankments and Fills
Construct embankments and fills at locations and to lines of grade indicated on the drawings. Completed fill shall correspond to shape of typical cross section or contour indicated regardless of method used to show shape, size, and extent of line and grade of completed work.
Provide approved fill material which is free from roots, organic matter, trash, frozen material, and stones having maximum dimension greater than 6 inches. Ensure that stones larger than 4 inches are not placed in upper 6 inches of fill or embankment. Do not place material in layers greater than 8 inches loose thickness. Place layers horizontally and compact each layer prior to placing additional fill. Compact by sheepsfoot, pneumatic rollers, vibrators, or by other equipment as required to obtain specified density. Control moisture for each layer necessary to meet requirements of compaction
3.3 USE OF EXPLOSIVES
3.3.1 Blasting
Blasting with any type of explosive is prohibited.
3.4 FIELD QUALITY CONTROL
3.4.1 Inspection Services
Do not include in bid price the cost of inspection services indicated herein as being performed by the Owner's Representative.
3.4.2 Moisture Density Relations
Moisture density relations to be established by the Owner's Representative required for all materials to be compacted.
Should any compaction density test or subgrade inspection fail to meet specification requirements, perform corrective work as necessary. Pay for all costs associated with corrective work and retesting resulting from failing compaction density tests.
3.5 COMPACTION DENSITY REQUIREMENTS
3.5.1 Compaction
Extent of compaction testing will be as necessary to assure compliance with specifications. Give minimum of 24 hours advance notice to Owner's Representative when ready for compaction or subgrade testing and inspection.
Obtain approval from Owner's Representative with regard to suitability of soils and acceptable subgrade prior to subsequent operations.
Provide dewatering system necessary to successfully complete compaction and construction requirements.
Remove frozen, loose, wet, or soft material and replace with approved material as directed by Owner's Representative.
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Stabilize subgrade with well graded granular materials as directed by Owner's Representative.
3.5.2 3.5.2 Compaction Densities Requirements
3.5.2.1 Structures
LOCATION COMPACTION DENSITY
Backfill outside structures 90% of maximum Standard Proctor Dry next to walls, piers, columns Density per ASTM D698 and at moisture and any other structure content between -1% and +4% of optimum. exterior member
3.5.2.2 Specific Areas
LOCATION COMPACTION DENSITY
Engineered fill within 5 feet of the 98% of maximum Standard Proctor Dry foundation bottom Density per ASTM D698 and at moisture content between -1% and +4% of optimum
Engineered fill between 5 and 10 100% of maximum Standard Proctor Dry feet below the foundation bottom Density per ASTM D698 and at moisture content between -1% and +4% of optimum Engineered fill deeper than 10 feet 100% of modified proctor maximum dry below the foundation bottom density per ASTM D1557 and at moisture content between -1% and +4% of optimum
Granular fill inside structure where 90% relative density per ASTM D4253. shown on Drawings and under screen wall footing
3.6 EXCAVATION, FILLING, AND BACKFILLING FOR STRUCTURES
3.6.1 General
In general, work includes, but is not necessarily limited to, excavation for structures, removal of underground obstructions and undesirable material, backfilling, filling, and fill, backfill, and subgrade compaction.
Obtain fill and backfill material necessary to produce grades required. Materials and source to be approved by Owner's Representative.
Excavated material approved by Owner's Representative may also be used for fill and backfill.
In this Specification Section, the word "foundations" includes footings, base slabs, foundation walls, mat foundations, grade beams, piers and any other support placed directly on soil.
In the paragraphs of this Specification Section, the word "soil" also
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includes any type of rock subgrade that may be present at or below existing subgrade levels.
3.6.2 Excavation Requirements for Structures
Do not commence excavation for foundations for structures until Owner's Representative approves:
A. The removal of topsoil and other unsuitable and undesirable material from existing subgrade.
B. Density and moisture content of site area compacted fill material meets requirements of specifications.
Owner's Representative shall grant approval to begin excavations.
3.6.3 Dimensions
Excavate to elevations and dimensions indicated or specified. Allow additional space as required for construction operations and inspection of foundations.
3.6.4 Removal of Obstructions
Removal of obstructions and undesirable materials in excavation includes, but is not necessarily limited to, removal of old foundations, existing construction, unsuitable subgrade soils, expansive type soils, and any other materials which may be concealed beneath present grade, as required to execute work indicated on Contract Drawings. If undesirable material and obstructions are encountered during excavation, remove material and replace as directed by Owner's Representative.
3.6.5 Excavations to Receive Foundations, Floor Slabs, Equipment Support Pads, or Compacted Fill
Level off bottoms of excavations to receive foundations, floor slabs, equipment support pads, or compacted fill. Remove loose materials and bring excavations into approved condition to receive concrete or fill material.
Where compacted fill material must be placed to bring subgrade elevation up to underside of construction, scarify existing subgrade upon which fill material is to be placed to a depth of 6 inches and then compact to density stated in this Specification Section before fill material can be placed thereon.
Do not carry excavations lower than shown for foundations except as directed by Owner's Representative or Engineer. If any part of excavations is carried below required depth without authorization, maintain excavation and start foundation from excavated level with concrete of same strength as required for superimposed foundation, and no extra compensation will be made to Contractor therefore. Make excavations large enough for working space, forms, damp proofing, waterproofing, and inspection.
Notify Owner's Representative and Engineer as soon as excavation is completed in order that subgrades may be inspected.
Do not commence further construction until subgrade under compacted fill material, under foundations, under floor slabs-on-grade and under equipment
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support pads has been inspected and approved by the Owner's Representative as being free of undesirable material, being of compaction density required by this specification, and being capable of supporting the allowable foundation design bearing pressures and superimposed foundation, fill, and building loads to be placed thereon.
Owner's Representative shall be given the opportunity to inspect subgrade below fill material both prior to and after subgrade compaction.
Place fill material, foundations, floor slabs-on-grade, and equipment support pads as soon as weather conditions permit after excavation is completed, inspected, and approved and after forms and reinforcing are inspected and approved.
Before concrete or fill material is placed, protect approved subgrade from becoming loose, wet, frozen, or soft due to weather, construction operations, or other reasons.
3.6.6 Dewatering
Where groundwater is or is expected to be encountered during excavation, install a dewatering system to prevent softening and disturbance of subgrade below foundations and fill material, to allow foundations and fill material to be placed in the dry, and to maintain a stable excavation side slope. Groundwater shall be maintained at least 3 feet below the bottom of any excavation.
Review soils investigation before beginning excavation and determine where groundwater is likely to be encountered during excavation. Employ dewatering specialist for selecting and operating dewatering system. Keep dewatering system in operation until dead load of structure exceeds possible buoyant uplift force on structure. Dispose of groundwater to an area which will not interfere with construction operations or damage existing construction. Install groundwater monitoring wells as necessary. Shut off dewatering system at such a rate to prevent a quick upsurge of water that might weaken the subgrade.
3.6.7 Subgrade Stabilization
If subgrade under foundations, fill material, floor slabs-on-grade, or equipment support pads is in a frozen, loose, wet, or soft condition before construction is placed thereon, remove frozen, loose, wet, or soft material and replace with approved compacted material as directed by Owner's Representative.
Proof roll the excavation bottoms with a loaded tandem axle dump truck for verification. Proof rolling should be performed with a fully loaded tandem axle dump truck having a minimum gross weight of 25 tons. Proof rolling will aid in identifying areas of unstable subgrade. Proof rolling should be performed in the presence of an Owner's Representative. If any soft or weak zones are identified during the proof roll, the material should be subcut as directed by Owner's Representative and replaced with suitably compacted engineered fill material. Proof rolling is not an indication that the subgrade strength is adequate or that it meets design requirements, but simply highlights potentially unsuitable subgrade conditions. In deep excavations, proof rolling may not be a feasible means of subgrade evaluation. An alternative to proof rolling is to conduct dynamic cone penetrometer tests to measure the suitability of the exposed subgrade, performed by Owner's Representative.
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Provide compaction density of replacement material as stated in this Specification Section.
Remove and replace frozen materials as directed by Owner's Representative. Method of stabilization shall be performed as directed by Owner's Representative. Do not place further construction on the repaired subgrades, until the subgrades have been approved by the Owner's Representative.
Do not place floor slabs-on-grade including equipment support pads until subgrade below has been approved, piping has been tested and approved, reinforcement placement has been approved, and Contractor receives approval to commence slab construction.
Do not place building floor slabs-on-grade including equipment support pads when temperature of air surrounding the slab and pads is or is expected to be below 40 degrees Fahrenheit before structure is completed and heated to a temperature of at least 50 degrees Fahrenheit.
3.6.8 Protection of Structures
Prevent new and existing structures from becoming damaged due to construction operations or other reasons. Prevent subgrade under new and existing foundations from becoming wet and undermined during construction due to presence of surface or subsurface water or due to construction operations.
3.6.9 Shoring
Shore, sheet pile, slope, or brace excavations as required to prevent them from collapsing. Remove shoring as backfilling progresses but only when banks are stable and safe from caving or collapse.
3.6.10 Drainage
Control grading around structures so that ground is pitched to prevent water from running into excavated areas or damaging structures. Maintain excavations where foundations, floor slabs, equipment support pads or fill material are to be placed free of water.
Provide pumping required to keep excavated spaces clear of water during construction. Should any water be encountered in the excavation, notify Engineer and Owner's Representative.
Provide free discharge of water by trenches, pumps, wells, well points, or other means as necessary and drain to point of disposal that will not damage existing or new construction or interfere with construction operations.
3.6.11 Frost Protection
Do not place foundations, slabs-on-grade, equipment support pads, or fill material on frozen ground. When freezing temperatures may be expected, do not excavate to full depth indicated, unless foundations, floor slabs, equipment support pads, or fill material can be placed immediately after excavation has been completed and approved. Protect excavation from frost if placing of concrete or fill is delayed.
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Where a concrete slab is a base slab-on-grade located under and within a structure that will not be heated, protect subgrade under the slab from becoming frozen until final acceptance of the Project by the Owner's Representative. Protect subgrade under foundations of a structure from becoming frozen until structure is completed and heated to a temperature of at least 50 degrees Fahrenheit.
3.6.12 Fill and Backfill Inside of Structure and Below Foundations, Base Slabs, Floor Slabs, Equipment Support Pads and Piping
3.6.12.1 General
Subgrade to receive fill or backfill shall be free of undesirable material as determined by Owner's Representative and scarified to a depth of 6 inches and compacted to density specified herein.
Surface may be stepped by at not more than 12 inches per step or may be sloped at not more than 2%.
Do not place any fill or backfill material until subgrade under fill or backfill has been inspected and approved by Owner's Representative as being free of undesirable material and compacted to specified density.
Obtain approval of fill and backfill material and source from Owner's Representative prior to placing the material.
3.6.12.2 Granular Fill Under Floor Slabs-on-Grade
Place all floor slabs-on-grade on a minimum of 6 inches of granular fill unless otherwise indicated.
3.6.12.3 Fill and Backfill Placement
Prior to placing fill and backfill material, optimum moisture and maximum density properties for proposed material shall be obtained from Owner's Representative.
Place fill and backfill material in 8 inch lifts to obtain required compaction density. Compact material by means of equipment of sufficient size and proper type to obtain specified density. Use hand operated equipment for filling and backfilling next to walls.
Do not place fill and backfill when the temperature is less than 40 degrees Fahrenheit and when subgrade to receive fill and backfill material is frozen, wet, loose, or soft.
Use vibratory equipment to compact granular material; do not use water.
3.6.12.4 Fill and Backfill Placement Below Foundations
Where fill material is required below foundations, place fill material, conforming to the required density and moisture content, outside the exterior limits of foundations located around perimeter of structure the following horizontal distance whichever is greater:
A. As required to provide fill material to indicated finished grade.
B. 5 feet.
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C. Distance equal to depth of compacted fill below bottom of foundations.
D. As directed by Owner's Representative.
3.6.13 Filling and Backfilling Outside of Structures
This paragraph of this Specification applies to fill and backfill placed outside of structures above bottom level of both foundations and piping but not under paving.
Provide material as approved by Owner's Representative for filling and backfilling outside of structures.
3.6.13.1 Fill and Backfill Placement
Prior to placing fill and backfill material, obtain optimum moisture and maximum density properties for proposed material from Owner's Representative. Place fill and backfill material in 8 inch lifts to obtain required compaction density. Compact material with equipment of proper type and size to obtain density specified.
Use only hand operated equipment for filling and backfilling next to walls and retaining walls.
Do not place fill or backfill material when temperature is less than 40 degrees Fahrenheit and when subgrade to receive material is frozen, wet, loose, or soft.
Use vibratory equipment for compacting granular material; do not use water.
3.6.13.2 Backfilling against Walls
Do not backfill around any part of structures until each part has reached specified 28-day compressive strength and backfill material has been approved.
Do not start backfilling until concrete forms have been removed, trash removed from excavations, pointing of masonry work, concrete finishing, damp proofing and waterproofing have been completed.
Do not place fills against walls until floor slabs at top, bottom, and at intermediate levels of walls are in place and have reached 28-day required compressive strength to prevent wall movement.
Bring backfill and fill up uniformly around the structures and individual walls, piers, or columns.
3.6.14 Backfilling Outside of Structures Under Piping or Paving
When backfilling outside of structures requires placing backfill material under piping or paving, the material shall be placed from bottom of excavation to underside of piping or paving at the density required for fill under piping or paving as indicated in this Specification Section.
This compacted material shall extend transversely to the centerline of piping or paving a horizontal distance each side of the exterior edges of piping or paving equal to the depth of backfill measured from bottom of excavation to underside of piping or paving.
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Provide special compacted bedding or compacted subgrade material under piping or paving as required by other Specification Sections for the Project.
3.7 TESTING
3.7.1 General
Quality control testing expenses shall be the Owner's Representative's responsibility and quality assurance testing expenses shall be the Owner's Representative's responsibility. Prior to sampling and testing the work, testing laboratories shall be inspected and approved in accordance with SECTION 01 45 04.00 13 CONTRACTOR QUALITY CONTROL. The wner's Representative reserves the right to direct the location and select the material for samples to be tested and to direct where and when tests shall be performed.
3.7.2 Field Denisty Tests
Report forms for summaries of field density tests shall include, at a minimum, information shown below. Additional data required by the applicable ASTM test methods shall be kept on file by the Owner's Representative. Tests shall be numbered sequentially throughout the job, and retests shall reference the original test number (1A, 1B, etc.).
1. Test Number.
2. Dry density, water content and gravel content of field test.
3. Proctor Number, maximum dry density, optimum water content, and gravel content of Proctor test.
4. Percent of Standard Proctor density.
5. Each test shall be plotted on the graphic presentation of the applicable Proctor test. Multiple field test results may be on one graph, provided each test is clearly marked, the Proctor test results are clearly marked and distinguishable from the field test results, and only one Proctor test applies to all the field tests.
3.7.3 Proctor Tests
Report forms for summaries of Proctor tests shall include the minimum information. A Proctor test includes sufficient individual samples (at least 4) of varying moisture content to generate a plot showing the maximum density and corresponding moisture content. Additional data required by the applicable ASTM test methods shall be kept on file by the Owner's Representative. Jar samples shall be retained by the testing laboratory for each Proctor test until field testing is completed.
1. Test Number and method.
2. Sample location and visual soil description.
3. Maximum dry density, and optimum water content.
4. Gravel contents in sample and test specimens.
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5. A graph of the moisture-density relationship.
3.7.4 Corrective ActionsSub Title
Tests of materials which do not meet the contract requirements (failing test) will not be counted as part of the required testing. Each such failing test must be retaken at the same location as the failing test was taken. If testing indicates material does not meet the contract requirements, the material represented by the failing test shall not be placed in the contract work or shall be recompacted or removed. The quantity of material represented by the failing test shall be determined by the Owner's Representative up to the quantity represented by the testing frequency. The Owner's Representative may increase testing frequency in the vicinity of a failing test in order to reduce removal requirements, as approved by the Owner's Representative. Such increases in testing frequency shall be at the Owner's Representative expense and at no additional cost to the Owner.
3.7.5 Testing Schedule
a. Moisture-Density Relations (ASTM D698).
Two tests for compacted material to be reused under pump station structure. Two tests for each material variation from the off site borrow source. Contractor shall perform additional tests at no additional expense if requested by the Owner's Representative.
b. In-Place Densities (ASTM D1556 or ASTM D6938).
1. Under pump station structure, not less than one test per 1000 square feet, or fraction thereof, of each lift of select impervious fill.
2. Adjacent to Structures, not less than 1 test for each lift.
c. Plasticity Index (ASTM D4318).
1. Cohesive soils, 1 test for each Proctor test.
3.8 SPECIAL REQUIREMENTS
3.8.1 Erosion Control
Conduct work to minimize erosion of site. Construct stilling areas to settle and detain eroded material. Remove eroded material washed off site.
Clean streets daily of any spillage of dirt, rocks or debris from equipment entering or leaving site.
-- End of Section --
SECTION 31 00 00.00 14 Page 13 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 33 UTILITIES
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 33 71 02
UNDERGROUND ELECTRICAL DISTRIBUTION 02/14 08/20/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)
AASHTO HB-17 (2002; Errata 2003; Errata 2005, 17th Edition) Standard Specifications for Highway Bridges
AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)
ACI 318M (2011; Errata 2013) Building Code Requirements for Structural Concrete & Commentary
ACI SP-66 (2004) ACI Detailing Manual
ASTM INTERNATIONAL (ASTM)
ASTM B1 (2013) Standard Specification for Hard-Drawn Copper Wire
ASTM B8 (2011) Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft
ASTM C32 (2013) Standard Specification for Sewer and Manhole Brick (Made from Clay or Shale)
ASTM C478 (2013) Standard Specification for Precast Reinforced Concrete Manhole Sections
ASTM C857 (2013) Standard Practice for Minimum Structural Design Loading for Underground Precast Concrete Utility Structures
ASTM C990 (2009) Standard Specification for Joints for Concrete Pipe, Manholes and Precast Box Sections Using Preformed Flexible Joint Sealants
ASTM F512 (2012) Smooth-Wall Poly (Vinyl Chloride) (PVC) Conduit and Fittings for Underground Installation
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INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 81 (2012) Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System
IEEE C135.30 (1988) Standard for Zinc-Coated Ferrous Ground Rods for Overhead or Underground Line Construction
IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-6 2013) National Electrical Safety Code
IEEE Stds Dictionary (2009) IEEE Standards Dictionary: Glossary of Terms & Definitions
INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)
NETA ATS (2013) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
ANSI C119.1 (2011) Electric Connectors - Sealed Insulated Underground Connector Systems Rated 600 Volts
NEMA RN 1 (2005; R 2013) Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit
NEMA TC 6 & 8 (2013) Standard for Polyvinyl Chloride (PVC) Plastic Utilities Duct for Underground Installations
NEMA TC 9 (2004) Standard for Fittings for Polyvinyl Chloride (PVC) Plastic Utilities Duct for Underground Installation
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA)
TIA-758 (2012b) Customer-Owned Outside Plant Telecommunications Infrastructure Standard
THE SOCIETY OF CABLE TELECOMMUNICATIONS ENGINEERS (SCTE)
ANSI/SCTE 77 (2013) Specification for Underground Enclosure Integrity
U.S. DEPARTMENT OF AGRICULTURE (USDA)
RUS Bull 1751F-644 (2002) Underground Plant Construction
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U.S. GENERAL SERVICES ADMINISTRATION (GSA)
CID A-A-60005 (Basic; Notice 2) Frames, Covers, Gratings, Steps, Sump And Catch Basin, Manhole
UNDERWRITERS LABORATORIES (UL)
UL 44 (2010) Thermoset-Insulated Wires and Cables
UL 467 (2007) Grounding and Bonding Equipment
UL 486A-486B (2013) Wire Connectors
UL 514B (2012) Conduit, Tubing and Cable Fittings
UL 6 (2007; reprint Nov 2010) Electrical Rigid Metal Conduit-Steel
UL 651 (2011; Reprint Mar 2012) Standard for Schedule 40 and 80 Rigid PVC Conduit and Fittings
UL 83 (2008) Thermoplastic-Insulated Wires and Cables
1.2 DEFINITIONS
a. Unless otherwise specified or indicated, electrical and electronics terms used in these specifications, and on the drawings, are as defined in IEEE Stds Dictionary.
b. In the text of this section, the words conduit and duct are used interchangeably and have the same meaning.
c. In the text of this section, "medium voltage cable splices," and "medium voltage cable joints" are used interchangeably and have the same meaning.
d. Underground structures subject to aircraft loading are indicated on the drawings.
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Precast underground structures; G
SD-03 Product Data
Precast concrete structures; G
Sealing Material
Pulling-In Irons
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Handhole frames and covers; G
Cable supports (racks, arms and insulators); G
SD-06 Test Reports
Cable Installation Plan and Procedure; G
Six copies of the information described below in 8-1/2 by 11 inch binders having a minimum of three rings from which material may readily be removed and replaced, including a separate section for each cable pull. Separate sections by heavy plastic dividers with tabs, with all data sheets signed and dated by the person supervising the pull.
a. Site layout drawing with cable pulls numerically identified.
b. A list of equipment used, with calibration certifications. The manufacturer and quantity of lubricant used on pull.
c. The cable manufacturer and type of cable.
d. The dates of cable pulls, time of day, and ambient temperature.
e. The length of cable pull and calculated cable pulling tensions.
f. The actual cable pulling tensions encountered during pull.
1.4 QUALITY ASSURANCE
1.4.1 Precast Underground Structures
Submittal required for each type used. Provide calculations and drawings for precast manholes and handholes bearing the seal of a registered professional engineer including:
a. Material description (i.e., f'c and Fy)
b. Manufacturer's printed assembly and installation instructions
c. Design calculations
d. Reinforcing shop drawings in accordance with ACI SP-66
e. Plans and elevations showing opening and pulling-in iron locations and details
1.4.2 Regulatory Requirements
In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "must" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction," or words of similar meaning, to mean the Owner's Representative. Equipment, materials, installation, and workmanship must be in accordance with the mandatory and advisory provisions of IEEE C2 and NFPA 70 unless more stringent requirements are specified or indicated.
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1.4.3 Standard Products
Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship. Products must have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year period must include applications of equipment and materials under similar circumstances and of similar size. The product must have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period. Where two or more items of the same class of equipment are required, these items must be products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in this section.
1.4.3.1 Alternative Qualifications
Products having less than a 2-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturers' factory or laboratory tests, is furnished.
1.4.3.2 Material and Equipment Manufacturing Date
Products manufactured more than 3 years prior to date of delivery to site are not acceptable, unless specified otherwise.
PART 2 PRODUCTS
2.1 CONDUIT, DUCTS, AND FITTINGS
2.1.1 Rigid Metal Conduit
UL 6.
2.1.1.1 Rigid Metallic Conduit, PVC Coated
NEMA RN 1, Type A40, except that hardness must be nominal 85 Shore A durometer, dielectric strength must be minimum 400 volts per mil at 60 Hz, and tensile strength must be minimum 3500 psi.
2.1.2 Plastic Conduit for Direct Burial
UL 651, Schedule 40 or Schedule 80 as indicated.
2.1.3 Plastic Duct for Concrete Encasement
UL 651 and ASTM F512, NEMA TC 6 & 8, Type EB-20-PVC, NEMA TC 6 & 8, Type EB-35-PVC, NEMA TC 2, Type EPC-40-PVC or as indicated.
2.1.4 Innerduct
Provide corrugated polyethylene (PE) or PVC innerducts, or fabric-mesh innerducts, with pullwire. Size as indicated.
2.1.5 Conduit Sealing Compound
Compounds for sealing ducts and conduit must have a putty-like consistency workable with the hands at temperatures as low as 35 degrees F, must
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neither slump at a temperature of 300 degrees F, nor harden materially when exposed to the air. Compounds must adhere to clean surfaces of fiber or plastic ducts; metallic conduits or conduit coatings; concrete, masonry, or lead; any cable sheaths, jackets, covers, or insulation materials; and the common metals. Compounds must form a seal without dissolving, noticeably changing characteristics, or removing any of the ingredients. Compounds must have no injurious effect upon the hands of workmen or upon materials.
2.1.6 Fittings
2.1.6.1 Metal Fittings
UL 514B.
2.1.6.2 PVC Conduit Fittings
UL 514B, UL 651.
2.1.6.3 PVC Duct Fittings
NEMA TC 9.
2.2 LOW VOLTAGE INSULATED CONDUCTORS AND CABLES
Insulated conductors must be rated 600 volts and conform to the requirements of NFPA 70, including listing requirements. Wires and cables manufactured more than 24 months prior to date of delivery to the site are not acceptable.
2.2.1 Conductor Types
Power Conductors No. 10 AWG and smaller must be solid. Control wiring conductors shall be stranded. Conductors No. 8 AWG and larger must be stranded. All conductors must be copper.
2.2.2 Conductor Material
Unless specified or indicated otherwise or required by NFPA 70, wires in conduit, other than service entrance, must be 600-volt, Type THWN-2/THHN-2 conforming to UL 83 or Type XHHW-2 conforming to UL 44. Conductors No. 8 AWG and larger shall be Type XHHW-2.
2.2.3 Jackets
Multiconductor cables must have an overall PVC outer jacket.
2.2.4 In Duct
Cables must be single-conductor cable.
2.2.5 Cable Marking
Insulated conductors must have the date of manufacture and other identification imprinted on the outer surface of each cable at regular intervals throughout the cable length.
Identify each cable by means of a fiber, laminated plastic, or non-ferrous metal tags, or approved equal, in each manhole, handhole, junction box, and each terminal. Each tag must contain the following information; cable
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type, conductor size, circuit number, circuit voltage, cable destination and phase identification.
Conductors must be color coded. Provide conductor identification within each enclosure where a tap, splice, or termination is made. Conductor identification must be by color-coded insulated conductors, plastic-coated self-sticking printed markers, colored nylon cable ties and plates, heat shrink type sleeves,or colored electrical tape. Control circuit terminations must be properly identified. Color must be green for grounding conductors and white for neutrals; except where neutrals of more than one system are installed in same raceway or box, other neutrals must be white with a different colored (not green) stripe for each. Color of ungrounded conductors in different voltage systems must be as follows:
a. 208/120 volt, three-phase
(1) Phase A - black
(2) Phase B - red
(3) Phase C - blue
b. 480/277 volt, three-phase
(1) Phase A - brown
(2) Phase B - orange
(3) Phase C - yellow
c. 208/120 volt, single phase: Black and red
2.3 LOW VOLTAGE WIRE CONNECTORS AND TERMINALS
Must provide a uniform compression over the entire conductor contact surface. Use solderless terminal lugs on stranded conductors.
a. For use with copper conductors: UL 486A-486B.
2.4 LOW VOLTAGE SPLICES
Provide splices in conductors with a compression connector on the conductor and by insulating and waterproofing using one of the following methods which are suitable for continuous submersion in water and comply with ANSI C119.1.
2.5 PULL ROPE
Plastic or flat pull line (bull line) having a minimum tensile strength of 200 pounds.
2.6 GROUNDING AND BONDING
2.6.1 Driven Ground Rods
Provide copper-clad steel ground rods conforming to UL 467 steel ground rods conforming to IEEE C135.30 not less than 3/4 inch in diameter by 10 feet in length. Sectional type rods may be used for rods 20 feet or longer.
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2.6.2 Grounding Conductors
Stranded-bare copper conductors must conform to ASTM B8, Class B, soft-drawn unless otherwise indicated. Solid-bare copper conductors must conform to ASTM B1 for sizes No. 8 and smaller. Insulated conductors must be of the same material as phase conductors and green color-coded, except that conductors must be rated no more than 600 volts. Aluminum is not acceptable.
2.7 UNDERGROUND STRUCTURES
Provide precast concrete underground structures or standard type cast-in-place manhole types as indicated, conforming to ASTM C857 and ASTM C478. Top, walls, and bottom must consist of reinforced concrete. Walls and bottom must be of monolithic concrete construction. Locate duct entrances and windows near the corners of structures to facilitate cable racking. Covers must fit the frames without undue play. Form steel and iron to shape and size with sharp lines and angles. Castings must be free from warp and blow holes that may impair strength or appearance. Exposed metal must have a smooth finish and sharp lines and arises. Provide necessary lugs, rabbets, and brackets. Set pulling-in irons and other built-in items in place before depositing concrete. Install a pulling-in iron in the wall opposite each duct line entrance. Cable racks, including rack arms and insulators, must be adequate to accommodate the cable.
2.7.1 Precast Concrete Structures, Risers and Tops
Precast units must be the product of a manufacturer regularly engaged in the manufacture of precast concrete products, including precast manholes.
2.7.1.1 General
Precast concrete structures must have the same accessories and facilities as required for cast-in-place structures. Likewise, precast structures must have plan area and clear heights not less than those of cast-in-place structures. Concrete materials and methods of construction must be the same as for cast-in-place concrete construction, as modified herein. Slope in floor may be omitted provided precast sections are poured in reinforced steel forms. Concrete for precast work must have a 28-day compressive strength of not less than 4000 psi. Structures may be precast to the design and details indicated for cast-in-place construction, precast monolithically and placed as a unit, or structures may be assembled sections, designed and produced by the manufacturer in accordance with the requirements specified. Structures must be identified with the manufacturer's name embedded in or otherwise permanently attached to an interior wall face.
2.7.1.2 Design for Precast Structures
ACI 318M. In the absence of detailed on-site soil information, design for the following soil parameters/site conditions:
a. Angle of Internal Friction (phi) = 30 degrees
b. Unit Weight of Soil (Dry) = 110 pcf, (Saturated) = 130 pcf
c. Coefficient of Lateral Earth Pressure (Ka) = 0.33
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d. Ground Water Level = 3 feet below ground elevation
e. Vertical design loads must include full dead, superimposed dead, and live loads including a 30 percent magnification factor for impact. Live loads must consider all types and magnitudes of vehicular (automotive, industrial, or aircraft) traffic to be encountered. The minimum design vertical load must be for H20 highway loading per AASHTO HB-17.
f. Horizontal design loads must include full geostatic and hydrostatic pressures for the soil parameters, water table, and depth of installation to be encountered. Also, horizontal loads imposed by adjacent structure foundations, and horizontal load components of vertical design loads, including impact, must be considered, along with a pulling-in iron design load of 6000 pounds.
g. Each structural component must be designed for the load combination and positioning resulting in the maximum shear and moment for thatparticular component.
h. Design must also consider the live loads induced in the handling, installation, and backfilling of the manholes. Provide lifting devices to ensure structural integrity during handling and installation.
2.7.1.3 Construction
Structure top, bottom, and wall must be of a uniform thickness of not less than 6 inches. Thin-walled knock-out panels for designed or future duct bank entrances are not permitted. Provide quantity, size, and location of duct bank entrance windows as directed, and cast completely open by the precaster. Size of windows must exceed the nominal duct bank envelope dimensions by at least 12 inches vertically and horizontally to preclude in-field window modifications made necessary by duct bank misalignment. However, the sides of precast windows must be a minimum of 6 inches from the inside surface of adjacent walls, floors, or ceilings. Form the perimeter of precast window openings to have a keyed or inward flared surface to provide a positive interlock with the mating duct bank envelope. Provide welded wire fabric reinforcing through window openings for in-field cutting and flaring into duct bank envelopes. Provide additional reinforcing steel comprised of at least two No. 4 bars around window openings. Provide drain sumps a minimum of 12 inches in diameter and 4 inches deep for precast structures.
2.7.1.4 Joints
Provide tongue-and-groove joints on mating edges of precast components. Shiplap joints are not allowed. Design joints to firmly interlock adjoining components and to provide waterproof junctions and adequate shear transfer. Seal joints watertight using preformed plastic strip conforming to ASTM C990. Install sealing material in strict accordance with the sealant manufacturer's printed instructions. Provide waterproofing at conduit/duct entrances into structures, and where access frame meets the top slab, provide continuous grout seal.
2.7.2 Manhole Frames and Covers
Provide cast iron frames and covers for manholes conforming to CID A-A-60005. Cast the words "ELECTRIC" or "TELECOMMUNICATIONS" in the top face of power and telecommunications manhole covers, respectively.
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2.7.3 Handhole Frames and Covers
Frames and covers of steel must be welded by qualified welders in accordance with standard commercial practice. Steel covers must be rolled-steel floor plate having an approved antislip surface.
2.7.4 Brick for Manhole Collar
Provide sewer and manhole brick conforming to ASTM C32, Grade MS.
2.7.5 Composite/Fiberglass Handholes and Covers
Provide handholes and covers of polymer concrete, reinforced with heavy weave fiberglass conforming to ANSI/SCTE 77.
2.8 CABLE SUPPORTS (RACKS, ARMS, AND INSULATORS)
The metal portion of racks and arms must be zinc-coated after fabrication.
2.8.1 Cable Rack Stanchions
The wall bracket or stanchion must be 4 inches by approximately 1-1/2 inch by 3/16 inch channel steel, or 4 inches by approximately 1 inch glass-reinforced nylon with recessed bolt mounting holes, 48 inches long (minimum) in manholes. Slots for mounting cable rack arms must be spaced at 8 inch intervals.
2.8.2 Rack Arms
Cable rack arms must be steel or malleable iron or glass reinforced nylon and must be of the removable type. Rack arm length must be a minimum of 8 inches and a maximum of 12 inches.
2.8.3 Insulators
Insulators for metal rack arms must be dry-process glazed porcelain. Insulators are not required for nylon arms.
2.9 CABLE TAGS IN MANHOLES
Provide tags for each power cable located in manholes. The tags must be polyethylene. Do not provide handwritten letters. The first position on the power cable tag must denote the voltage. The second through sixth positions on the tag must identify the circuit. The next to last position must denote the phase of the circuit and include the Greek "phi" symbol. The last position must denote the cable size. As an example, a tag could have the following designation: "11.5 NAS 1-8(Phase A)500," denoting that the tagged cable is on the 11.5kV system circuit number NAS 1-8, underground, Phase A, sized at 500 kcmil.
2.9.1 Polyethylene Cable Tags
Provide tags of polyethylene that have an average tensile strength of 3250 pounds per square inch; and that are 0.08 inch thick (minimum), non-corrosive non-conductive; resistive to acids, alkalis, organic solvents, and salt water; and distortion resistant to 170 degrees F. Provide 0.05 inch (minimum) thick black polyethylene tag holder. Provide a one-piece nylon, self-locking tie at each end of the cable tag. Ties must
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have a minimum loop tensile strength of 175 pounds. The cable tags must have black block letters, numbers, and symbols one inch high on a yellow background. Letters, numbers, and symbols must not fall off or change positions regardless of the cable tags' orientation.
PART 3 EXECUTION
3.1 INSTALLATION
Install equipment and devices in accordance with the manufacturer's published instructions and with the requirements and recommendations of NFPA 70 and IEEE C2 as applicable. In addition to these requirements, install telecommunications in accordance with TIA-758 and RUS Bull 1751F-644.
3.2 CABLE INSPECTION
Inspect each cable reel for correct storage positions, signs of physical damage, and broken end seals prior to installation. If end seal is broken, remove moisture from cable prior to installation in accordance with the cable manufacturer's recommendations.
3.3 CABLE INSTALLATION PLAN AND PROCEDURE
Obtain from the manufacturer an installation manual or set of instructions which addresses such aspects as cable construction, insulation type, cable diameter, bending radius, cable temperature limits for installation, lubricants, coefficient of friction, conduit cleaning, storage procedures, moisture seals, testing for and purging moisture, maximum allowable pulling tension, and maximum allowable sidewall bearing pressure. Prepare a checklist of significant requirements and submit along with the manufacturer's instructions in accordance with SUBMITTALS. Install cable strictly in accordance with the cable manufacturer's recommendations and the approved installation plan.
3.4 UNDERGROUND FEEDERS SUPPLYING BUILDINGS
Terminate underground feeders supplying building at a point 5 feet outside the building and projections thereof, except that conductors must be continuous to the terminating point indicated. Coordinate connections of the feeders to the service entrance equipment with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Provide PVC conduit from the supply equipment to a point 5 feet outside the building and projections thereof. Conduits passing through classified areas shall be PVC coated RGS. Protect ends of underground conduit with plastic plugs until connections are made.
Encase the underground portion of the conduit in a concrete envelope and bury as specified for underground duct with concrete encasement.
3.5 UNDERGROUND STRUCTURE CONSTRUCTION
3.5.1 Precast Concrete Construction
Set commercial precast structures on 6 inches of level, 90 percent compacted granular fill, 3/4 inch to 1 inch size, extending 12 inches beyond the structure on each side. Compact granular fill by a minimum of four passes with a plate type vibrator. Installation must additionally conform to the manufacturer's instructions.
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3.5.2 Pulling-In Irons
Provide steel bars bent as indicated, and cast in the walls and floors. Alternatively, pipe sleeves may be precast into the walls and floors where required to accept U-bolts or other types of pulling-in devices possessing the strengths and clearances stated herein. The final installation of pulling-in devices must be made permanent. Cover and seal exterior projections of thru-wall type pulling-in devices with an appropriate protective coating. In the floor the irons must be a minimum of 6 inches from the edge of the sump, and in the walls the irons must be located within 6 inches of the projected center of the duct bank pattern or precast window in the opposite wall. However, the pulling-in iron must not be located within 6 inches of an adjacent interior surface, or duct or precast window located within the same wall as the iron. If a pulling-in iron cannot be located directly opposite the corresponding duct bank or precast window due to this clearance limitation, locate the iron directly above or below the projected center of the duct bank pattern or precast window the minimum distance required to preserve the 6 inch clearance previously stated. In the case of directly opposing precast windows, pulling-in irons consisting of a 3 foot length of No. 5 reinforcing bar, formed into a hairpin, may be cast-in-place within the precast windows simultaneously with the end of the corresponding duct bank envelope. Irons installed in this manner must be positioned directly in line with, or when not possible, directly above or below the projected center of the duct bank pattern entering the opposite wall, while maintaining a minimum clear distance of 3 inches from any edge of the cast-in-place duct bank envelope or any individual duct. Pulling-in irons must have a clear projection into the structure of approximately 4 inches and must be designed to withstand a minimum pulling-in load of 6000 pounds. Irons must be hot-dipped galvanized after fabrication.
3.5.3 Cable Racks, Arms and Insulators
Cable racks, arms and insulators must be sufficient to accommodate the cables. Space racks in power manholes not more than 3 feet apart, and provide each manhole wall with a minimum of two racks. Space racks in signal manholes not more than 16 1/2 inches apart with the end rack being no further than 12 inches from the adjacent wall. Methods of anchoring cable racks must be as follows:
a. Provide a 5/8 inch diameter by 5 inch long anchor bolt with 3 inch foot cast in structure wall with 2 inch protrusion of threaded portion of bolt into structure. Provide 5/8 inch steel square head nut on each anchor bolt. Coat threads of anchor bolts with suitable coating immediately prior to installing nuts.
b. Provide concrete channel insert with a minimum load rating of 800 pounds per foot. Insert channel must be steel of the same length as "vertical rack channel;" channel insert must be cast flush in structure wall. Provide 5/8 inch steel nuts in channel insert to receive 5/8 inch diameter by 3 inch long steel, square head anchor bolts.
c. Provide concrete "spot insert" at each anchor bolt location, cast flush in structure wall. Each insert must have minimum 800 pound load rating. Provide 5/8 inch diameter by 3 inch long steel, square head anchor bolt at each anchor point. Coat threads of anchor bolts with suitable coating immediately prior to installing bolts.
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3.5.4 Field Painting
Cast-iron frames and covers not buried in concrete or masonry must be cleaned of mortar, rust, grease, dirt and other deleterious materials, and given a coat of bituminous paint.
3.6 UNDERGROUND CONDUIT AND DUCT SYSTEMS
3.6.1 Requirements
Run conduit in straight lines except where a change of direction is necessary. Provide numbers and sizes of ducts as indicated. Ducts must have a continuous slope downward toward underground structures and away from buildings, laid with a minimum slope of 3 inches per 100 feet. Depending on the contour of the finished grade, the high-point may be at a terminal, a manhole, a handhole, or between manholes or handholes. Short-radius manufactured 90-degree duct bends may be used only for pole or equipment risers, unless specifically indicated as acceptable. The minimum manufactured bend radius must be 18 inches for ducts of less than 3 inch diameter, and 36 inches for ducts 3 inches or greater in diameter. Otherwise, long sweep bends having a minimum radius of 25 feet must be used for a change of direction of more than 5 degrees, either horizontally or vertically. Both curved and straight sections may be used to form long sweep bends, but the maximum curve used must be 30 degrees and manufactured bends must be used. Provide ducts with end bells whenever duct lines terminate in structures.
3.6.2 Treatment
Ducts must be kept clean of concrete, dirt, or foreign substances during construction. Field cuts requiring tapers must be made with proper tools and match factory tapers. A coupling recommended by the duct manufacturer must be used whenever an existing duct is connected to a duct of different material or shape. Ducts must be stored to avoid warping and deterioration with ends sufficiently plugged to prevent entry of any water or solid substances. Ducts must be thoroughly cleaned before being laid. Plastic ducts must be stored on a flat surface and protected from the direct rays of the sun.
3.6.3 Conduit Cleaning
As each conduit run is completed, for conduit sizes 3 inches and larger, draw a flexible testing mandrel approximately 12 inches long with a diameter less than the inside diameter of the conduit through the conduit. After which, draw a stiff bristle brush through until conduit is clear of particles of earth, sand and gravel; then immediately install conduit plugs. For conduit sizes less than 3 inches, draw a stiff bristle brush through until conduit is clear of particles of earth, sand and gravel; then immediately install conduit plugs.
3.6.4 Galvanized Conduit Concrete Penetrations
Galvanized conduits which penetrate concrete (slabs, pavement, and walls) in wet locations must be PVC coated and must extend from at least 2 inches within the concrete to the first coupling or fitting outside the concrete (minimum of 6 inches from penetration).
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3.6.5 Multiple Conduits
Separate multiple conduits by a minimum distance of 3 inches, except that light and power conduits must be separated from control, signal, and telephone conduits by a minimum distance of 12 inches. Stagger the joints of the conduits by rows (horizontally) and layers (vertically) to strengthen the conduit assembly. Provide plastic duct spacers that interlock vertically and horizontally. Spacer assembly must consist of base spacers, intermediate spacers, ties, and locking device on top to provide a completely enclosed and locked-in conduit assembly. Install spacers per manufacturer's instructions, but provide a minimum of two spacer assemblies per 10 feet of conduit assembly.
3.6.6 Conduit Plugs and Pull Rope
New conduit indicated as being unused or empty must be provided with plugs on each end. Plugs must contain a weephole or screen to allow water drainage. Provide a plastic pull rope having 3 feet of slack at each end of unused or empty conduits.
3.6.7 Conduit and Duct Without Concrete Encasement
Depths to top of the conduit must be not less than 24 inches below finished grade. Provide not less than 3 inches clearance from the conduit to each side of the trench. Grade bottom of trench smooth; where rock, soft spots, or sharp-edged materials are encountered, excavate the bottom for an additional 3 inches, fill and tamp level with original bottom with sand or earth free from particles, that would be retained on a 1/4 inch sieve. The first 6 inch layer of backfill cover must be sand compacted as previously specified. The rest of the excavation must be backfilled and compacted in 3 to 6 inch layers. Provide color, type and depth of warning tape as specified in Section 31 00 00.14 EARTHWORK FOR PUMP STATION AND GATE WELL.
3.6.7.1 Encasement Under Roads and Structures
Under roads, paved areas, and railroad tracks, install conduits in concrete encasement of rectangular cross-section providing a minimum of 3 inch concrete cover around ducts. Concrete encasement must extend at least 5 feet beyond the edges of paved areas and roads, and 12 feet beyond the rails on each side of railroad tracks. Depths to top of the concrete envelope must be not less than 6/8 inch below finished grade.
3.6.7.2 Encasement for Generators and Service Conductors
Provide 3 inch concrete cover around ducts for all service and generator power and control conductors.
3.6.8 Duct Encased in Concrete
Construct underground duct lines of individual conduits encased in concrete. Depths to top of the concrete envelope must be not less than 54 inches below finished grade. Do not mix different kinds of conduit in any one duct bank. Concrete encasement surrounding the bank must be rectangular in cross-section and must provide at least 3 inches of concrete cover for ducts. Separate conduits by a minimum concrete thickness of 3 inches. Before pouring concrete, anchor duct bank assemblies to prevent the assemblies from floating during concrete pouring. Anchoring must be done by driving reinforcing rods adjacent to duct spacer assemblies and attaching the rods to the spacer assembly. Provide color, type and depth
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of warning tape as specified in Section 31 00 00.14 EARTHWORK FOR PUMP STATION AND GATE WELL.
3.6.8.1 Connections to Manholes
Duct bank envelopes connecting to underground structures must be flared to have enlarged cross-section at the manhole entrance to provide additional shear strength. Dimensions of the flared cross-section must be larger than the corresponding manhole opening dimensions by no less than 12 inches in each direction. Perimeter of the duct bank opening in the underground structure must be flared toward the inside or keyed to provide a positive interlock between the duct bank and the wall of the structure. Use vibrators when this portion of the encasement is poured to assure a seal between the envelope and the wall of the structure.
3.7 CABLE PULLING
Test existing duct lines with a mandrel and thoroughly swab out to remove foreign material before pulling cables. Pull cables down grade with the feed-in point at the manhole or buildings of the highest elevation. Use flexible cable feeds to convey cables through manhole opening and into duct runs. Do not exceed the specified cable bending radii when installing cable under any conditions, including turnups into switches, transformers, switchgear, switchboards, and other enclosures.
3.7.1 Cable Lubricants
Use lubricants that are specifically recommended by the cable manufacturer for assisting in pulling jacketed cables.
3.8 CABLES IN UNDERGROUND STRUCTURES
Do not install cables utilizing the shortest path between penetrations, but route along those walls providing the longest route and the maximum spare cable lengths. Form cables to closely parallel walls, not to interfere with duct entrances, and support on brackets and cable insulators. Support cable splices in underground structures by racks on each side of the splice. Locate splices to prevent cyclic bending in the spliced sheath. Install cables at middle and bottom of cable racks, leaving top space open for future cables, except as otherwise indicated for existing installations. Provide one spare three-insulator rack arm for each cable rack in each underground structure.
3.8.1 Cable Tag Installation
Install cable tags in each manhole as specified, including each splice. Tag wire and cable provided by this contract. Install cable tags over the fireproofing, if any, and locate the tags so that they are clearly visible without disturbing any cabling or wiring in the manholes.
3.9 CONDUCTORS INSTALLED IN PARALLEL
Conductors must be grouped such that each conduit of a parallel run contains 1 Phase A conductor, 1 Phase B conductor, 1 Phase C conductor, and 1 neutral conductor.
3.10 LOW VOLTAGE CABLE SPLICING AND TERMINATING
Do not splice underground cables.
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3.11 GROUNDING SYSTEMS
3.11.1 Grounding Electrodes
Provide cone pointed driven ground rods driven full depth plus 6 inches, installed to provide an earth ground of the appropriate value for the particular equipment being grounded. If the specified ground resistance is not met, an additional ground rod must be provided in accordance with the requirements of NFPA 70 (placed not less than 6 feet from the first rod). Should the resultant (combined) resistance exceed the specified resistance, measured not less than 48 hours after rainfall, notify the Owner's Representative immediately.
3.11.2 Grounding Connections
Make grounding connections which are buried or otherwise normally inaccessible, by exothermic weld or compression connector.
a. Make exothermic welds strictly in accordance with the weld manufacturer's written recommendations. Welds which are "puffed up" or which show convex surfaces indicating improper cleaning are not acceptable. Mechanical connectors are not required at exothermic welds.
b. Make compression connections using a hydraulic compression tool to provide the correct circumferential pressure. Tools and dies must be as recommended by the manufacturer. An embossing die code or other standard method must provide visible indication that a connector has been adequately compressed on the ground wire.
3.11.3 Grounding Conductors
Provide bare grounding conductors, except where installed in conduit with associated phase conductors. Ground cable sheaths, cable shields, conduit, and equipment with No. 6 AWG. Ground other noncurrent-carrying metal parts and equipment frames of metal-enclosed equipment. Ground metallic frames and covers of handholes and pull boxes with a braided, copper ground strap with equivalent ampacity of No. 6 AWG.
3.11.4 Manhole Grounding
Loop a 4/0 AWG grounding conductor around the interior perimeter, approximately 12 inches above finished floor. Secure the conductor to the manhole walls at intervals not exceeding 36 inches. Connect the conductor to the manhole grounding electrode with 4/0 AWG conductor. Connect all incoming 4/0 grounding conductors to the ground loop adjacent to the point of entry into the manhole. Bond the ground loop to all cable shields, metal cable racks, and other metal equipment with a minimum 6 AWG conductor.
3.12 EXCAVATING, BACKFILLING, AND COMPACTING
Provide in accordance with NFPA 70 and Section 31 00 00 EARTHWORK.
3.13 CAST-IN-PLACE CONCRETE
3.13.1 Concrete Slabs for Equipment
Unless otherwise indicated, the slab must be at least 8 inches thick, reinforced with a 6 by 6 - W2.9 by W2.9 mesh, placed uniformly 4 inches
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from the top of the slab. Slab must be placed on a 6 inch thick, well-compacted gravel base. Top of concrete slab must be approximately 4 inches above finished grade with gradual slope for drainage. Edges above grade must have 1/2 inch chamfer. Slab must be of adequate size to project at least 8 inches beyond the equipment.
Stub up conduits, with bushings, 2 inches into cable wells in the concrete pad. Coordinate dimensions of cable wells with transformer cable training areas.
3.13.2 Sealing
When the installation is complete, seal all conduit and other entries into the equipment enclosure with an approved sealing compound. Seals must be of sufficient strength and durability to protect all energized live parts of the equipment from rodents, insects, or other foreign matter.
3.14 FIELD QUALITY CONTROL
3.14.1 Performance of Field Acceptance Checks and Tests
Perform in accordance with the manufacturer's recommendations, and include the following visual and mechanical inspections and electrical tests, performed in accordance with NETA ATS.
3.14.1.1 Low Voltage Cables, 600-Volt
Perform tests after installation of cable, splices and terminations and before terminating to equipment or splicing to existing circuits.
a. Visual and Mechanical Inspection
(1) Inspect exposed cable sections for physical damage.
(2) Verify that cable is supplied and connected in accordance with contract plans and specifications.
(3) Verify tightness of accessible bolted electrical connections.
(4) Inspect compression-applied connectors for correct cable match and indentation.
(5) Visually inspect jacket and insulation condition.
(6) Inspect for proper phase identification and arrangement.
b. Electrical Tests
(1) Perform insulation resistance tests on wiring No. 6 AWG and larger diameter using instrument which applies voltage of approximately 1000 volts dc for one minute.
(2) Perform continuity tests to insure correct cable connection.
3.14.1.2 Grounding System
a. Visual and mechanical inspection
Inspect ground system for compliance with contract plans and specifications
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b. Electrical tests
Perform ground-impedance measurements utilizing the fall-of-potential method in accordance with IEEE 81. On systems consisting of interconnected ground rods, perform tests after interconnections are complete. On systems consisting of a single ground rod perform tests before any wire is connected. Take measurements in normally dry weather, not less than 48 hours after rainfall. Use a portable megohmmeter tester in accordance with manufacturer's instructions to test each ground or group of grounds. The instrument must be equipped with a meter reading directly in ohms or fractions thereof to indicate the ground value of the ground rod or grounding systems under test.
3.14.2 Follow-Up Verification
Upon completion of acceptance checks and tests, show by demonstration in service that circuits and devices are in good operating condition and properly performing the intended function. As an exception to requirements stated elsewhere in the contract, the Owner's Representative must be given 5 working days advance notice of the dates and times of checking and testing.
-- End of Section --
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DIVISION 35 WATERWAY AND MARINE CONSTRUCTION
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 35 05 40.17
SELF-LUBRICATED MATERIALS, FABRICATION, HANDLING, AND ASSEMBLY 05/14 08/05/2014
PART 1 GENERAL
1.1 SUMMARY
This section specifies fabrication, handling, cleaning, and installation requirements for self-lubricated materials and associated running surfaces.
1.2 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM A580/A580M (2013b) Standard Specification for Stainless Steel Wire
ASTM D1002 (2010) Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal)
ASTM D149 (2009; R 2013) Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies
ASTM D2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness
ASTM D3846 (2008) Standard Test Method for In-Plane Shear Strength of Reinforced Plastics
ASTM D412 (2006a; R 2013) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension
ASTM D570 (1998; E 2010; R 2010) Standard Test Method for Water Absorption of Plastics
ASTM D695 (2010) Standard Test Method for Compressive Properties of Rigid Plastics
ASTM E18 (2012) Standard Test Methods for Rockwell Hardness of Metallic Materials
1.3 SUBMITTALS
Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
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SD-01 Preconstruction Submittals
Assembly and Installation Plan; G
SD-02 Shop Drawings
Self-lubricated Component Shop Drawings; G
Show the complete dimensions, fabrication tolerances, and material callouts.
Self-Lubricated Component Field Installation Drawings; G
Show the installation and assembly details including alignment tolerances.
SD-03 Product Data
Self-Lubricated Material Product Data; G Bonding Adhesive Product Data; G
SD-07 Certificates
Manufacturer's Experience Record; G Self-Lubricated Material Manufacturer's Warranty; G Release Agreement FCB Material Certifications
SD-09 Manufacturer's Field Reports
Post-Assembly QC Report Alignment QC Report Acceptance Test Report
SD-10 Operation and Maintenance Data
Operation and Maintenance Manuals; G
1.4 MANUFACTURER'S QUALIFICATIONS AND WARRANTY
Self-lubricated material manufacturers are required to have a minimum of 10 years experience in manufacturing self-lubricated materials.
1.5 HANDLING
Handle self-lubricated components and their associated running surfaces in a manner that does not cause damage or affect the surface finish of the components. Perform lifting, and maneuvering of self-lubricated components and their running surfaces with fabric straps or other non-marring rigging. Do not allow self-lubricated materials and their mating surfaces to come into direct contact with chains, shackles, hooks, or wire ropes. Damage to self-lubricated components or their mating surfaces including scratches, nicks, chips, or marring is grounds for rejection of the components.
1.6 WARRANTY
Provide a warranty from the self-lubricated material manufacturer
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protecting products against defects in material and workmanship for a minimum of 5 years. Submit the Self-Lubricated Material Manufacturer's Warranty.
PART 2 PRODUCTS
2.1 GENERAL SELF-LUBRICATED MATERIAL REQUIREMENTS
Submit Self-Lubricated Material Product Data showing the materials selected for use are in compliance with the requirements of this specification. Self-lubricated materials must meet the following requirements:
a. Thermoset polymer approved for use in submerged and marine environments by the material manufacturer.
b. Self-lubricated materials cannot contain graphite.
c. Surfaces of the self-lubricated materials that come into contact with bearing running surfaces must have a minimum dielectric strength of 50V/mm as tested in accordance with ASTM D149.
d. Have a water absorption of less than 0.3 percent increase in weight for long term immersion as tested in accordance with ASTM D570.
e. Have an operating range of -30 to 100 degrees F.
f. Continuous and without measurable gaps for the full self-lubricated material surfaces that come into contact with the mating running surface.
2.1.1 Fabric Reinforced Polymer Self-Lubricated Materials
In addition to the general self-lubricated material requirements above fabric reinforced polymer self-lubricated materials must have the following features and properties:
a. Base materials must be isopthalic polyester, orthophthalic polyester, vinylester, or epoxy resin.
b. Polyester reinforcement, or a combination of polyester and polytetrafluoroethylene (PTFE) sheet fabric or fiber strand.
c. Fabric reinforced polymers rated by the self-lubricated material manufacturer for a minimum dynamic bearing pressure of 10,000 psi applied in a direction perpendicular to the fabric layers.
d. Fabric reinforced polymers must have a minimum compressive yield strength of 15,000 psi as tested in accordance with ASTM D695 with the load applied perpendicular to the fabric layers.
e. Fabric reinforced polymers must have a minimum in-plane shear strength of 10,000 psi as tested in accordance with ASTM D3846.
2.1.2 Extruded Homogeneous Polymer Self-Lubricated Materials
In addition to the general self-lubricated material requirements above extruded homogeneous self-lubricated materials must have the following features and properties:
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a. Extruded homogeneous polymer materials must be rated by the self-lubricated material manufacturer for a minimum dynamic bearing pressure of 10,000 psi.
b. Extruded homogeneous polymer materials must have a minimum compressive yield strength of 20,000 psi as tested in accordance with ASTM D695.
2.2 SELF-LUBRICATED MATERIAL BONDING ADHESIVE
Self-lubricated material bonding adhesives must meet the following requirements. Submit Bonding Adhesive Product Data showing that the minimum requirements listed are met.
a. Bonding adhesives must be approved by the adhesive manufacturer for use in submerged and marine environments.
b. Bonding adhesive must be approved by the adhesive manufacturer for use with the materials that it will be applied to.
c. After reaching full cure bonding adhesives must have a minimum compressive strength of 7,500 psi as tested in accordance with ASTM D695.
d. After reaching full cure bonding adhesives must have a minimum tensile lap shear strength of 4,000 psi as tested in accordance with ASTM D1002.
e. Bonding adhesive must be approved for service in the temperature range of -30 to 200 degrees F.
2.3 SELF-LUBRICATED MATERIAL MATING RUNNING SURFACES
The surface finish and hardness of the mating component of a self-lubricated material has a large effect on the successful operation of that self-lubricated material. Running surfaces typically need to be fabricated with a Rockwell hardness number between 30 and 40 on the Rockwell C scale (HRC 30 - HRC 40) in accordance with ASTM E18. Self-lubricated materials in applications with infrequent service typically require no rougher than a 32 micro-inches surface finish. Surface finishes, typically no rougher than 16 micro-inches are required for application that have frequent service. Verify that the surface finish and hardness requirements indicated for self-lubricated material running surfaces are in compliance with the self-lubricated material manufacturer's recommendations. If the indicated running surface requirements are outside of the self-lubricated material manufacturer's recommendations submit a variance request on the shop drawings.
2.4 Seals
Provide seals for the bearings meeting the following requirements.
2.4.1 Static Seals
Static seals must be synthetic ethylene propylene elastomeric o-rings and meeting the following material requirements:
PHYSICAL TEST TEST VALUE TEST METHOD SPECIFICATION Durometer Hardness 65 to 75 ASTM D2240 (Shore Type A)
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PHYSICAL TEST TEST VALUE TEST METHOD SPECIFICATION Tensile Strength 1450 psi (minimum) ASTM D412
Elongation at Break 150 percent minimum ASTM D412
300 percent Modulus 900 psi (minimum) ASTM D412
2.5 Centering Wires
Wires used to center the bearing during bonding must be 300 series stainless steel and meet the requirements of ASTM A580/A580M condition A.
2.6 TEST FITTING
Test the fit of self-lubricated components with their mating surfaces prior to transporting components on site.
PART 3 EXECUTION
3.1 FABRICATION
Fabricate self-lubricated components and their running surfaces from the materials, dimensions/tolerances, and qualities indicated.
3.2 INSTALLATION PLAN
Submit an Assembly and Installation Plan showing the proposed method to assemble and install the self-lubricated components. Include pre-assembly fabrication dimensions, a description of the bonding procedure, post-assembly dimensions, installation procedure, method to measure and confirm the alignment requirements.
3.3 INTERFERENCE FITTING OF SELF-LUBRICATED MATERIALS
3.3.1 Preparation of Interference Fit Surfaces
Remove coatings from bushing/bearing housing surfaces prior to interference fitting. Remove coatings including paint, galvanizing, and anodizing from the interference fit surfaces prior to assembling the joint. Clean interference fit surfaces of the bushing/bearing and housing of oil, grease, cutting fluids, or other substances prior to assembling the interference fit.
3.3.2 Press-Fitting
Do not use hammer blows or other impact type loading to press fit self-lubricated components. Use a method to press fit self-lubricated components that provides a smooth and constant force such as a hydraulic or other style of press. Protect components from damage during the press fitting process.
3.3.3 Shrink-Fitting
Perform shrink fitting by lowering the temperature of the inner component to a point where the outside diameter shrinks adequately to avoid interference with the outside part. Use a method to lower the temperature
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of self-lubricated materials that is approved by the self-lubricated material manufacturer. Ensure shrink-fit components are fully seated prior to allowing the parts to return to ambient temperature.
3.4 BONDING SELF-LUBRICATED MATERIALS
3.4.1 Protection of Work
Perform bonding of self-lubricated materials in a controlled environment. Perform bonding in a temperature controlled building that allows protection from the elements. In cases where outdoor installation of self-lubricated materials is necessary, protect the bonded surfaces and work area from the weather.
3.4.2 Preparation of Bonding Surfaces
Prepare surfaces to be bonded, including degreasing and abrading, in accordance with the bonding adhesive manufacturer's recommendations. Prepare the bond joint so that the adhesive bonds only to the parent materials of each component. Remove surface coatings such as paint, galvanizing, and anodizing from the surfaces to be bonded using an approved method prior to applying the adhesive. Clean surfaces to be bonded of oil, grease, cutting fluids, and substances that may affect the quality of the bonded joint. Only clean self-lubricated materials with cleaners that are approved for use by the self-lubricated material manufacturer.
3.4.3 Bonding
Mix and apply the bonding adhesive in accordance with the adhesive manufacturer's recommendations. Unless the adhesive manufacturer recommends otherwise, apply the adhesive evenly and completely across both bond surfaces prior to assembling the joint. Use a bonding procedure that prevents adhesive from coming into contact with the running surfaces of the self-lubricated materials. Prior to starting the bonding process, have a solvent or other cleaner approved by the self-lubricated material manufacturer on-hand and accessible. Quickly and completely clean off adhesive that ends up on self-lubricated material running surfaces during the bonding process.
3.4.3.1 Maintaining Dimensions of Bushings/Bearings During Bonding
While unsupported, self-lubricated materials have a tendency to slightly sag under their own weight creating an out-of-round condition. Prior to bonding bushings or bearings in place, check the diameter of the running surface of the bushings/bearings to verify they are within the dimension requirements shown. If the diameter is out of the required dimension, provide and use jigs or other devices, which do not harm the material, to maintain the required dimensions during bonding. Assemble bushings and bearings with the axis in a vertical orientation where feasible to minimize the possibility of bearing sag and non-conforming radial tolerances.
3.4.3.2 Bushing/Bearing Centering Wires
Use centering wires for situations that require assembly of bushings/bearings axis in a horizontal orientation. Place centering wires in the clearance between bushing/bearing outer diameter and housing inner diameter. Use centering wires that have a diameter equal to the radial clearance between bushing/bearing and housing. Use a minimum of eight wires evenly spaced around the circumference of the bushing/bearing. After
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the adhesive is fully cured cut centering wires flush with the surfaces of the bushing/bearing and file any sharp edges smooth.
3.4.4 Curing of Bonding Adhesive
Do not load self-lubricated materials until the bonding adhesive has fully cured. Follow the adhesive manufacturer's recommendations to achieve full cure of the adhesive.
3.5 VERIFYING DIMENSIONS AFTER ASSEMBLY
After shop assembly, measure self-lubricated components to verify contract required dimensions are met. If assembly dimensions are not met, machine or hone the self-lubricated materials to achieve the required dimensions. Perform machining and honing of self-lubricated components in accordance with the self-lubricated material manufacturer's recommendations. Some self-lubricated materials are fabricated with a layer of premium grade material applied only at the running surface of the part. Provide enough premium grade material at running surfaces to allow for post-assembly machining.
3.6 ASSEMBLY OF MATING COMPONENTS
3.6.1 Cleaning
Prior to final installation, clean self-lubricated materials and their running surfaces of oil, dirt, and debris using a method recommended by the self-lubricated material manufacturer.
3.6.2 Seal Installation
Install seals in accordance with the approved Assembly and Installation Plan.
3.6.3 Final Installation
Do not force components together in a manner that causes binding of the running surfaces of the components. Do not use lubricants to assemble self-lubricated components.
3.7 ACCEPTANCE TESTING
Following the completion of installation, checkout, adjustment, perform acceptance testing on each self-lubricated bearing system.
-- End of Section --
SECTION 35 05 40.17 Page 7 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 35 20 14
STOPLOGS 04/08 08/21/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN WELDING SOCIETY (AWS)
AWS D1.2/D1.2M (2008) Structural Welding Code - Aluminum
ASTM INTERNATIONAL (ASTM)
ASTM A276 (2010) Standard Specification for Stainless Steel Bars and Shapes
ASTM B209 (2010) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings; G
SD-03 Product Data
Manufacturer's installation instructions Welding Materials Identification System
Acknowledgement that products submitted meet the requirements of standards referenced.
1.3 QUALIFICATION OF WELDERS AND WELDING OPERATORS
Qualification of welders and welding operators shall conform to the requirements of Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
1.4 DELIVERY, STORAGE, AND HANDLING
Delivery, handling and storage of materials and fabricated items shall conform to the requirements specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS and in the manufacturer's written instructions.
SECTION 35 20 14 Page 1 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
1.4.1 Rubber Seals
Store rubber seals in a place which permits free circulation of air, maintains a temperature of 70 degrees F or less, and prevents the rubber from being exposed to the direct rays of the sun. Rubber seals shall be kept free of oils, grease, and other materials which would deteriorate the rubber. Rubber seals shall not be distorted during handling.
1.4.2 Identification System
Submit an Identification System which shows the disposition of specific lots of approved materials and fabricated items in the work, before completion of the contract.
PART 2 PRODUCTS
2.1 MATERIALS
Materials orders, materials lists and materials shipping bills shall conform to the requirements of Section 05 50 14 STRUCTURAL METAL FABRICATIONS. Provide stoplogs with frame guides and lifting device in accordance with the configuration shown on the contract drawings.
2.1.1 Metals
Aluminum, and other metal materials sections and standard articles shall be as shown and as specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.1.1.1 Aluminum
Aluminum shall conform to ASTM B209, Alloy 6061, Temper T6.
2.1.2 Rubber Seals
2.1.2.1 General Requirements
Rubber seals shall be neoprene conforming to ASTM D2000.
2.2 MANUFACTURED UNITS
Bolts, nuts, washers, screws and other manufactured units shall conform to the requirements specified and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.2.1 Bolts, Nuts and Washers
Bolts, nuts, and washers shall be stainless steel conforming to ASTM A276, Type 316. Bolts shall have hexagon heads. The finished shank of bolts shall be long enough to provide full bearing. Washers for use with bolts shall conform to the requirements specified in the applicable specification for bolts.
2.3 FABRICATION
2.3.1 Detail Drawings
Detail drawings of stoplogs and appurtenant shop fabricated items, including fabrication drawings, shop assembly drawings, delivery drawings,
SECTION 35 20 14 Page 2 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
and field installation drawings, shall conform to the requirements specified and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.3.1.1 Fabrication Drawings
Show on the fabrication drawings complete details of materials, tolerances, connections, and proposed welding sequences which clearly differentiate shop welds and field welds.
2.3.1.2 Shop Assembly Drawings
Show on the shop assembly drawings details for connecting the adjoining fabricated components in the shop to assure satisfactory field installation.
2.3.1.3 Delivery Drawings
Show on the delivery drawings descriptions of methods of delivering components to the site, including details for supporting fabricated components during shipping to prevent distortion or other damages.
2.3.1.4 Field Installation Drawings
Show on the field installation drawings a detailed description of the field installation procedures. The description shall include the location and method of support of installation and handling equipment; provisions to be taken to protect concrete and other work during installation; method of maintaining components in correct alignment; and methods for installing appurtenant items.
2.3.2 Structural Fabrication
Structural fabrication shall conform to the requirements specified and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.3.3 Welding
Submit schedules of welding procedures for structural steel and welding processes for aluminum. Welding shall conform to the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS. All welds shall be performed by welders with AWS D1.2/D1.2M and AWS D1.6 certification.
2.3.4 Bolted Connections
Bolted connections shall conform to the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.3.5 Machine Work
Machine work shall conform to the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.3.6 Miscellaneous Provisions
Miscellaneous provisions for fabrication shall conform to the requirements specified and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
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2.3.7 Fabrications
2.3.7.1 Stoplogs
Stoplogs shall be fabricated of extruded aluminum with a minimum thickness of 5/16 inches conforming to ASTM B209, Alloy 6061, Temper T6. Each stoplog shall be 18 inches tall unless otherwise indicated on the Contract Drawings. All structural components of the stoplogs shall have adequate strength to prevent distortion during normal handling, installation, and operation. Provide two (2) slots in the top of each stoplog for removal and installation. Provide identification tag indicating manufacturer, width of opening, and maximum head rating. Provide identification tags on each side of stoplog indicating "dry side" and "wet side." Identification tags shall be welded to each stoplog.
2.3.7.2 Stoplog Guides
Stoplog guides and inverts shall be fabricated of extruded aluminum with a minimum thickness of 1/4 inch. ASTM B209, Alloy 6061, Temper T6. The invert shall be welded to the lower ends of the guides. All structural components of the frame guides shall have adequate strength to prevent distortion during normal handling, installation, and operation. Frame design shall allow for embedded mounting or mounting directly to a wall with stainless steel anchor bolts and EPDM gaskets. Mounting style shall be as shown on the Contract Drawings.
2.3.7.3 Miscellaneous Embedded Metals
Corner protection angles, frames, base plates, and other embedded metal items required for complete installation shall conform to the details shown. All aluminum in contact with concrete shall be shop coated with a heavy coat of bitumastic paint.
2.3.7.4 Finish
Provide mill finish on all aluminum. Welds shall be mechanically passivated in accordance with ASTM A380 to remove weld burn and scale. All iron and steel components shall be properly prepared and shop coated with a primer.
2.3.8 Seal Assemblies
Provide continuous resilient seal along bottom and both sides of each stoplog.
2.3.9 Lifting Device
One (1) lifting device shall be provided. Lifting device shall be constructed of stainless steel and shall be outfitted with UHMW guide bars and stainless steel fasteners. Provide lifting hooks designed to engage the slots in the top of the stoplogs. Provide lanyard release mechanism.
PART 3 EXECUTION
3.1 INSTALLATION
Installation shall conform to the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS and in the manufacturer's written instructions..
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3.1.1 Embedded Metals
Corner protection angles, frames, base plates, and other embedded metal items required for complete installation shall be accurately installed to the alignment and grade required to ensure accurate fitting and matching of components. Embedded metals shall be given a primer coat of the required paint on all surfaces prior to installation in concrete forms. Anchors for embedded metals shall be installed as shown. Items requiring two concrete pours for installation shall be attached to the embedded anchors after the initial pour, adjusted to the proper alignment, and concreted in place with the second pour.
3.2 PROTECTION OF FINISHED WORK
Protection of finished work shall conform to the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
3.3 ACCEPTANCE TRIAL OPERATION
After completion of installation, the Owner's Representative will examine the stoplog installation for final acceptance. The individual components of the stoplog installation will be examined first to determine whether or not the workmanship conforms to the specification requirements. The Contractor will be required to place the stoplogs in the guides a sufficient number of times to demonstrate that the stoplogs fit properly and seat uniformly. Required repairs or replacements to correct defects, shall be made at no cost to the Owner's Representative. The trial operation shall be repeated after defects are corrected.
3.3.1 Field Leakage Test
Test stoplogs under design seating head to confirm leakage does not exceed 0.05 gpm per foot of wetted seat perimeter.
-- End of Section --
SECTION 35 20 14 Page 5 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 35 20 16.53
VERTICAL LIFT GATES 01/08 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN WATER WORKS ASSOCIATION (AWWA)
AWWA C561 (2004) Fabricated Stainless Steel Slide Gates
ASTM INTERNATIONAL (ASTM)
ASTM A276 (2010) Standard Specification for Stainless Steel Bars and Shapes
ASTM B584 (2012a) Standard Specification for Copper Alloy Sand Castings for General Applications
1.2 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings; G
SD-03 Product Data
Manufacturer's Installation Instruction; G Materials; G Welding; G Materials; G
Acknowledge that products submitted meet the requirements of standards referenced.
SD-05 Design Data
Design Calculations; G
Provide design calculations for selection of gate, gate stem and actuator.
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1.3 QUALIFICATION OF WELDERS AND WELDING OPERATORS
Qualification of welders and welding operators shall conform to the requirements of Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
1.4 DELIVERY, STORAGE, AND HANDLING
1.4.1 General
Perform delivery, handling, and storage of materials and fabricated items conforming to the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
1.4.2 Rubber Seals
Store rubber seals in a place which permits free circulation of air, maintains a temperature of 70 degrees F or less, and prevents the rubber from being exposed to the direct rays of the sun. Keep rubber seals free of oils, grease, and other materials which would deteriorate the rubber. Rubber seals shall not be distorted during handling.
PART 2 PRODUCTS
2.1 MATERIALS
Submit system of identification which shows the disposition of specific lots of approved materials and fabricated items in the work before completion of the contract. Furnish materials orders, material lists and material shipping bills conforming with the requirements of Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.1.1 Metals
Stainless steel, bronze, aluminum bronze, brass and other metal materials used for fabrication shall conform to the requirements as shown and as specified herein.
2.1.1.1 Stainless Steel Bars and Shapes
Stainless steel bars and shapes shall conform to ASTM A276, Type 316. All structural stainless steel used in the construction of slides, frames, and well Thimbles shall have a minimum material thickness of 1/4 inch.
2.1.1.2 Stainless Steel Plate, Sheet, and Strip
Stainless steel plate, sheet, and strip shall conform to ASTM A276 Type 316.
2.1.2 Seals
The Seal system shall consist of self-adjusting UHMWPE seals with a rubber compression cord. The UHMWPE seals shall be arranged to ensure that there is no metal-to-metal contact between the slide and frame. The compression cord shall be contained by the UHMWPE seal so that it shall not be in contact with the slide. Seal system shall be self-adjusting for the life of the gate. Adjustable wedging devices such as wedges, wedge bars and pressure pads are not acceptable. On upward-opening gates, rubber side seals and/or top seals such as J-bulb seals, P-seals and D-seals are not acceptable in lieu of UHMWPE seals. The invert seals on upward opening gates shall use a compressible rubber seal located on the bottom of the
SECTION 35 20 16.53 Page 2 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
slide or in the invert of the frame. The invert seal shall be of a flush bottom arrangement and shall be mechanically fastened with stainless steel bolts. Invert seals attached soley by the use of adhesives are not acceptable. All seals shall be secured with assembly bolts. All seals shall be field removable and field replaceable without the need to remove the gate frame from the wall.
2.1.3 Frames
The frame shall be constructed of stainless steel plate, with the guide section formed into a "C" shaped channel to house the seal, and shall be reinforced to withstand the the specified operating conditions. The frame shall be rigid, one-piece assembly with a flanged frame arrangement. Flat frames shall only be provided on gates with frames that will be embedded in the concrete wall or mounted inside existing channels. Flanged frame sections shall extend the length of the frame. The use of angles as extensions from the guides to the yolk is not acceptable. The frame shall have a minimum weight of 13 pounds per foot. Lifting lugs shall be provided on all frame styles.
2.1.4 Stem Couplings
Stem couplings shall be bronze conforming to ASTM B584.
2.1.5 Stems
Stems shall be stainless steel conforming to ASTM A276, Type 304. Provide rising stems and stemcovers on all gates. Stem shall be able to withstand an operating force of 80 lbs without damage. Stem shall not have a slenderness ratio for unsupported lengths of L/r > 200.
2.2 MANUFACTURED UNITS
Bolts, nuts, washers, screws and other manufactured units shall conform with the requirements as shown and as specified and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.2.1 Bolts, Nuts and Washers
Bolts, nuts, and washers shall conform to ASTM A276, Type 304. Bolts 1/2 inch and larger shall have hexagon heads. The finished shank of bolts shall be long enough to provide full bearing. Washers for use with bolts shall conform to the requirements specified in the applicable specification for bolts.
2.3 FABRICATION
2.3.1 Detail Drawings
Submit detail drawings, including fabrication drawings, shop assembly drawings, delivery drawings, and field installation drawings, conforming to the requirements specified and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.3.1.1 Fabrication Drawings
Fabrication drawings shall show complete details of materials, tolerances, connections, and proposed welding sequences which clearly differentiate shop welds and field welds.
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2.3.1.2 Shop Assembly Drawings
Shop assembly drawings shall provide details for connecting the adjoining fabricated components in the shop to assure satisfactory field installation.
2.3.1.3 Delivery Drawings
Delivery drawings shall provide descriptions of methods of delivering components to the site, including details for supporting fabricated components during shipping to prevent distortion or other damages.
2.3.1.4 Field Installation Drawings
Field installation drawings shall provide a detailed description of the field installation procedures. The description shall include the location and method of support of installation and handling equipment; provisions to be taken to protect concrete and other work during installation; method of maintaining components in correct alignment; and methods for installing other appurtenant items.
2.3.2 Structural Fabrication
Structural fabrication shall conform to the requirements as shown and specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS. Dimensional tolerances shall be as specified and as shown. Splices shall occur only where shown. Pin holes shall be bored in components after welding, straightening, stress-relieving, and threading operations are completed. Brackets, eye bar sections, and other components requiring straightening shall be straightened by methods which will not damage the material. Bushings shall be press-fitted with supporting components. Bolt connections, lugs, clips, or other pick-up assembly devices shall be provided for components as shown and required for proper assembly and installation.
2.3.2.1 Bolted Connections
Bolted connections shall conform with the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.3.2.2 Machine Work
Machine work shall conform with the requirements specified in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.3.2.3 Miscellaneous Provisions
Miscellaneous provisions for fabrication shall conform with the requirements specified herein and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
2.3.3 Sluice Gates
Provide gates, stems, lifts and other appurtenances of size, type, material and construction shown on the Contract Drawings and specified. Gates shall meet the requirements of AWWA C561 as modified per the Specification Section. Gates shall meet the requirements of Table 1.
Table 1
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TAG# TYPE SIZE SEATING UNSEATING LIFE CLOSURE (WxH) (HD.FT) (HD.FT) TYPE
SG-1 Sluice 48 IN DIA 8 19 Elec Conv
SG-2 Sluice 72x72 IN 19 30 Elec Conv
SG-3 Sluice 72x72 IN 19 16 Elec Conv
SG-4 Sluice 72x96 IN 19 16 Elec Conv
Abreviations: Ped - Pedestal Conv - Conventional Elec - Electric
Provide design calculations confirming the appropriate selection of gate stem and operator. Sluice gate manufacturer shall be responsible for coordination of all components including gate, gate stem, operator, gate frame, and guides.
Gates shall be designed such that under the design seating or unseating head, the leakage shall not exceed 0.5 US gallon per minute per foot of seating perimeter.
2.3.4 Wall Thimbles
Wall thimbles shall be designed and fabricated according to AWWA C561. Wall thimbles shall be fabricated of the same material as the gate which will be mounted to it.
2.3.5 Gate Operators and Lifts
Provide lifts in accordance with AWWA C561 or as modified in this Specification Section. Provide all lifts with clear butyrate plastic stem cover with Mylar open-close indicator. Gate manufacturer is responsible for coordination with the actuator supplier to ensure proper actuator fit and function.
2.3.5.1 Electric Operators
Electric motor-operated lift mechanism including electric motor, reduction gearing, stem nut, pedestal, torque and limit switches, enclosure strip heaters, reversing magnetic starter, pushbutton control, indicator lights, shop wiring, gear case, and handwheel for operation in case of power failure. Unit to be complete in a NEMA 4X enclosure requiring only the field connection of 3 PH, 460 V electric power. Gate operation speed: 12 inches per minute.
Handwheel for manual operation shall be located approximately 36 inches above the operation floor, unless otherwise shown. Maximum effort of 40 pounds on handwheel shall operate gate after unseating gate based upon seating and unseating heads specified.
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2.4 TESTS, INSPECTIONS, AND VERIFICATIONS
2.4.1 Operation Tests
The operation of the shop-assembled gate assembly shall be tested by opening and closing the gate several times by use of the operating machinery. The force used to operate the gate shall be the minimum required to open and close the gate. Since the sill of the unembedded gate frame is not fully supported during the operation tests, special precaution shall be taken to prevent the application of excessive force on the gate leaf and frame when the gate is closed.
PART 3 EXECUTION
3.1 INSTALLATION
Installation shall conform with the requirements specified, manufacturer's written instructions and in Section 05 50 14 STRUCTURAL METAL FABRICATIONS. Gate and appurtenant items shall be assembled for installation in strict accordance with the contract drawings, approved installation drawings, and shop match-markings. Bearing surfaces requiring lubrication shall be thoroughly cleaned and lubricated with an approved lubricant before assembly and installation. Components to be field welded shall be in correct alignment before welding is commenced.
3.1.1 Embedded Metals
Frames, bases, and other embedded metal items shall be accurately installed to the alignment and grade required to ensure accurate fitting and matching of components. Shims, jackbolts, or other supports required to align and hold components rigidly in place until embedment concrete has attained the specified strength shall be provided. Anchors shall be installed as shown. Embedded metals shall be given a primer coat of the required paint on all surfaces prior to installation in concrete forms. Items requiring two concrete pours for installation shall be attached to the embedded anchors after the initial pour, adjusted to the proper alignment, and concreted in place with the second pour.
3.1.2 Gate Assembly
Gate assembly shall be connected to embedded anchors, aligned, and rigidly blocked in place prior to the placement of second-pour concrete. The sealing surfaces of the slide gate frame seal bars shall serve as the reference plane for the installation alignment. Alignment shall be to two theoretical control planes described as control plane "A" and control plane "B". Control plane "A" is a vertical plane that is normal to the water passageway and is located at the sealing surface of the gate frame seal bars. Control plane "B" is a vertical plane that is parallel to the water passageway and is located at the centerline of the water passageway. The gate frame shall be aligned to within 0.015 inch of control planes "A" and "B". A taut piano wire and an electric micrometer or some other approved method shall be used to measure the vertical alignment tolerances. The alignment of frame and guides shall be such that planes through the bearing surfaces of track plates and the sealing surfaces of seal plates shall be within 1/16 inch of the alignment shown. Gate frame and guides shall be tested for proper alignment and clearances prior to being embedded in concrete by lowering and raising the gate leaf through the full operating range.
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3.1.3 Operating Machinery
Operating machinery for the gate assembly and supporting components, including pedestal, and base plate, shall be positioned and aligned to the installed location of the gate frame and guides and anchored in place. The location of the slide gate stem shall be projected to and scribed on the sill of the installed gate frame to serve as a reference point for the alignment of operating machinery and supporting components. Operating machinery and components shall be aligned to within 0.030 inch of the reference point. Prior to being embedded in concrete, an alignment template shall be bolted to the marked, and drilled to match the exact center point of the gate stem.
3.1.4 Concrete and Concrete Grout Placement
The embedment of the gate frame and other components in concrete shall be performed in an approved manner to fill all voids, secure anchorage, prevent seepage, and provide uniform finish surfaces. After embedment concrete has cured for at least 7 days, any voids around embedded components shall be filled by pumping concrete grout around the components. After the pumped grout has cured for at least 7 days, hammer blows to the components shall be used to detect any remaining voids. Where remaining voids are located, 1 inch diameter grout holes shall be drilled in the components and the voids shall be filled by pressure grouting through the grout holes. Grout holes in the components shall be plugged by welding and shall be ground flush.
3.1.5 Painting
Exposed parts of the gate and appurtenance components, except machined surfaces, corrosion-resistant surfaces, surfaces of anchorages embedded in concrete, and other specified surfaces, shall be painted as specified in Section 09 90 00 PAINTS AND COATINGS.
3.2 ACCEPTANCE TRIAL OPERATION AND TEST
Installation Check and Start-up:
1. Employ and pay for services of the equipment manufacturer's field service representative(s) fully commissioned and authorized by manufacturers to do the following:
a. Inspect equipment covered by this Specification Section.
b. Supervise adjustments, calibrations and installation checks and full commissioning.
c. Perform basic operational checks.
d. Provide Owner's Representative with a written statement that manufacturer's equipment has been installed properly, lubricated, and calibrated and is ready for operation by the Owner's Representative.
2. Field leakage test for sluice gate:
a. Test gate under design for seating head and unseating head, adjust to maximum leakage of 0.05 gallon per minute per foot of seating perimeter.
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3.3 PROTECTION OF FINISHED WORK
Protection of finished work shall conform to the requirements of Section 05 50 14 STRUCTURAL METAL FABRICATIONS.
-- End of Section --
SECTION 35 20 16.53 Page 8 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014
DIVISION 40 PROCESS INTEGRATION
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 40 05 13
PIPELINES, LIQUID PROCESS PIPING 10/07 08/21/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
AMERICAN WATER WORKS ASSOCIATION (AWWA)
AWWA C104/A21.4 (2013) Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water
AWWA C110/A21.10 (2012) Ductile-Iron and Gray-Iron Fittings for Water
AWWA C111/A21.11 (2012) Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings
AWWA C151/A21.51 (2009) Ductile-Iron Pipe, Centrifugally Cast, for Water
AWWA C504 (2010) Standard for Rubber-Seated Butterfly Valves
AWWA C508 (2009; Addenda A 2011) Swing-Check Valves for Waterworks Service, 2 In. (50 mm) Through 24 In. (600 mm) NPS
ASME INTERNATIONAL (ASME)
ASME B31.3 (2012) Process Piping
ASTM INTERNATIONAL (ASTM)
ASTM A126 (2004; R 2009) Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings
ASTM A240/A240M (2013c) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications
ASTM A307 (2012) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength
ASTM A395/A395M (1999; R 2009) Standard Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures
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ASTM A48/A48M (2003; R 2012) Standard Specification for Gray Iron Castings
ASTM A536 (1984; R 2009) Standard Specification for Ductile Iron Castings
ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
ASTM D2000 (2012) Standard Classification System for Rubber Products in Automotive Applications
ASTM D2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness
ASTM D3892 (1993; R 2009) Packaging/Packing of Plastics
ASTM F402 (2005; R 2012) Safe Handling of Solvent Cements, Primers, and Cleaners Used for Joining Thermoplastic Pipe and Fittings
MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)
MSS SP-25 (2013) Standard Marking System for Valves, Fittings, Flanges and Unions
MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation
MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 704 (2012) Standard System for the Identification of the Hazards of Materials for Emergency Response
PLASTICS PIPE INSTITUTE (PPI)
PPI TR-21 (2001) Thermal Expansion and Contraction in Plastic Piping Systems
THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)
SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning
U.S. DEPARTMENT OF DEFENSE (DOD)
UFC 3-310-04 (2013) Seismic Design for Buildings
SECTION 40 05 13 Page 2 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)
29 CFR 1910 Occupational Safety and Health Standards
1.2 SYSTEM DESCRIPTION
This specification covers the requirements for above and below grade liquid process pipe,including stormwater pipe (STM) and sump piping (SU) as shown on the drawings, pipe supports, fittings, equipment and accessories located both inside and outside of the Pump Station.
1.2.1 Design Requirements
Support systems shall be selected and designed in accordance with MSS SP-58, MSS SP-69, and MSS SP-58 within the specified spans and component requirements. The absence of pipe supports and details on the contract drawings does not relieve the Contractor of responsibility for sizing and providing supports throughout facility. The structural design, selection, fabrication and erection of piping support system components shall satisfy the seismic requirements in accordance with UFC 3-310-04.
1.2.2 Performance Requirements
The pressure ratings and materials specified represent minimum acceptable standards for piping systems. The piping systems shall be suitable for the services specified and intended. Each piping system shall be coordinated to function as a unit. Flanges, valves, fittings and appurtenances shall have a pressure rating no less than that required for the system in which they are installed.
1.2.2.1 Above Grade Piping Systems
Piping systems shall be suitable for design conditions, considering the piping both with and without internal pressure, and installation factors such as insulation, support spans, and ambient temperatures. Consideration shall be given to all operating and service conditions both internal and external to the piping systems.
1.3 SUBMITTALS
The following shall be submitted in accordance with the SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Materials and Equipment; G Cable System; G
SD-03 Product Data
Qualifications; G Welders; G Waste Water Disposal; G Manufacturer's Field Services; G Delivery, Storage and Handling; G Materials and Equipment; G Installation; G Pipe Schedule; G Valve Schedule; G
SECTION 40 05 13 Page 3 CONTRACT AWARD DOCUMENTS - OCTOBER 9, 2014 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
Operator Schedule; G Flap Gates; G
SD-06 Test Reports
Pipe Leakage Tests Flap Gate Leakage Tests Hydrostatic Tests Pneumatic Tests Valve Testing Disinfection
SD-10 Operation and Maintenance Data
Piping and Appurtenances; G Flap Gates; G
1.4 QUALIFICATIONS
1.4.1 Contractor
Submit a statement certifying that the Contractor has the specified experience. Contractor shall have successfully completed at least 3 projects of the same scope and size or larger within the last 6 years. Contractor shall demonstrate specific experience in regard to the system installation to be performed.
1.5 DELIVERY, STORAGE, AND HANDLING
Materials delivered and placed in storage shall be stored with protection from the weather, excessive humidity variation, excessive temperature variation, dirt, dust and/or other contaminants. Proper protection and care of material before, during and after installation is the Contractor's responsibility. Any material found to be damaged shall be replaced at the Contractor's expense. During installation, piping shall be capped to keep out dirt and other foreign matter. A material safety data sheet in conformance with 29 CFR 1910 Section 1200(g) shall accompany each chemical delivered for use in pipe installation. At a minimum, this includes all solvents, solvent cements, glues and other materials that may contain hazardous compounds. Handling shall be in accordance with ASTM F402. Storage facilities shall be classified and marked in accordance with NFPA 704. Materials shall be stored with protection from puncture, dirt, grease, moisture, mechanical abrasions, excessive heat, ultraviolet (UV) radiation damage, or other damage. Pipe and fittings shall be handled and stored in accordance with the manufacturer's recommendation. Plastic pipe shall be packed, packaged and marked in accordance with ASTM D3892.
1.6 PROJECT/SITE CONDITIONS
1.6.1 Existing Conditions
Verify existing piping and penetrations. Prior to ordering materials, expose all existing pipes which are to be connected to new pipelines. Verify the size, material, joint types, elevation, horizontal location, and pipe service of existing pipes, and inspect size and location of structure penetrations to verify adequacy of wall sleeves, and other openings before installing connecting pipes.
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1.7 SEQUENCING AND SCHEDULING
For slab, floor, wall, and roof penetrations, keep on site pertinent wall pipes and sleeves before they are required for placement in concrete forms. Verify and coordinate the size and location of building and structure pipe penetrations before forming and placing concrete.
1.8 MAINTENANCE
1.8.1 Service
Services for automatic valve systems shall be provided by a manufacturer's representative who is experienced in the installation, adjustment and operation of the equipment specified. The representative shall inspect the installation, and supervise the adjustment and testing of the equipment.
1.8.2 Extra Materials
Submit the manufacturer's installation recommendations or instructions for each material or procedure to be utilized, including materials preparation. Concurrent with delivery and installation of the specified piping systems and appurtenances, spare parts for each different item of material and equipment specified that is recommended by the manufacturer to be replaced any time up to 3 years of service shall be furnished. For each type and size of valve, the following extra materials shall be provided: lubricator, lubricant (with appropriate temperature rating), lubricator/isolating valve. Extra materials shall include 2 of the following spare parts for each type and size of valve: gaskets; O-ring seals; diaphragms (molded); all elastomer parts; stem packing; and seat rings.
PART 2 PRODUCTS
2.1 MATERIALS AND EQUIPMENT
Submit manufacturer's descriptive and technical literature for each piping system, including design recommendations; pressure and temperature ratings; dimensions, type, grade and strength of pipe and fittings; thermal characteristics (coefficient of expansion and thermal conductivity); and chemical resistance to each chemical and chemical mixture in the liquid stream. Provide piping materials and appurtenances as specified and as shown on the drawings, and suitable for the service intended. Piping materials, appurtenances, and equipment supplied as part of this contract shall be of equal material and ratings as the connecting pipe, new and unused except for testing equipment. Components that serve the same function and are the same size shall be identical products of the same manufacturer. The general materials to be used for the piping systems shall be in accordance with TABLE I and are indicated by service in the contract drawings. Submit a list of piping systems, pressure ratings and source of supply for each piping system broken out by material, size and application as indicated on the contract drawings. A list of any special tools necessary for each piping system and appurtenances furnished for adjustment, operation, maintenance and disassembly of the system. Pipe fittings shall be compatible with the applicable pipe materials.
2.1.1 Standard Products
Provide material and equipment which are the standard products of a manufacturer regularly engaged in the manufacturing of the products and
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that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Submit the following: Equipment shop drawings and support system detail drawings showing piping systems and appurtenances, such as mechanical joints, flap gates, valves, local indicators and hangers, including a complete list of equipment and materials. As-built drawings showing pipe anchors and guides, and layout of piping systems relative to other parts of the work including clearances for maintenance and operation. As-built piping and instrumentation diagrams (P&IDs) identifying and labeling equipment, instrumentation, valves, vents, drains, and all other inline devices; if the contract drawings contained P&IDs, the P&IDs found in the contract drawings shall be revised to reflect the constructed process system, as directed by the Owner's Representative. Nominal sizes for standardized products shall be used. Pipe, valves, fittings and appurtenances shall be supported by a service organization that is, in the opinion of the Owner's Representative, reasonably convenient to the site.
2.1.2 Identification and Tagging
Each piece of pipe shall bear the ASTM designation and all other markings required for that designation. Valves shall be marked in accordance with MSS SP-25 and shall bear an identification tag securely attached using No. 12 AWG copper wire. Identification tags shall be 1.375 inch minimum diameter, made of brass. Indentations shall be black for reading clarity. The service, valve identification number shown on the contract drawings, the manufacturer's name, and the valve model number shall be displayed.
2.2 DUCTILE IRON PIPING SYSTEM
2.2.1 Ductile Iron Pipe
Ductile iron pipe for pressure service shall have a design and wall thickness conforming to AWWA C151/A21.51. Pressure class shall be Class 250 minimum. Ductile iron pipe shall have a double thickness cement lining conforming to AWWA C104/A21.4.
2.2.2 Ductile Iron Joints
Joints shall have a working pressure rating for liquids equal to the pressure rating of the connected pipe. Dielectric fittings or isolation joints shall be provided between all dissimilar metals. All above grade ductile iron pipe shall have flanged joints unless noted otherwise.
2.2.2.1 Flanged Joints
Flanged joints shall conform to AWWA C110/A21.10. Gaskets, bolts and nuts shall be provided with flanged joints in sufficient quantity for the complete assembly of each joint. Gaskets shall be vulcanized synthetic rubber, reclaimed rubber is not acceptable.
2.2.3 Ductile Iron Fittings
Fittings shall be gray iron ASTM A48/A48M or ductile iron AWWA C110/A21.10. Up to 36 inches inclusive, the fittings shall be 250 psig rated. Gray iron fittings shall be cement mortar lined double thickness. Flanges and flanged fittings shall conform to AWWA C110/A21.10 and shall be rated for 250 psig service. Materials shall be ductile iron. For tie-in to existing flanges, field check existing flanges for nonstandard bolt hole configurations and design as required to assure new pipe and flange mate
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properly. Bolts and nuts shall be carbon steel conforming to ASTM A307, Grade B. Bolts shall be provided with washers of the same material as the bolts. Gaskets shall be rubber full face, maximum 0.125 inch thick.
2.2.4 Corrosion Control
Ductile iron piping shall be coated with the manufacturer's standard asphaltic coating, approximately 1 mil thick, applied to the outside of pipe and fittings.
2.3 ISOLATION JOINTS AND COUPLINGS
2.3.1 Metallic Piping Couplings
Thrust ties shall be provided where shown on the contract drawings and where required to restrain the force developed by 1.5 times the maximum allowable operating pressures specified. For metallic pipe other than ductile iron, thrust ties shall be attached with fabricated lugs. For ductile iron pipe, thrust ties shall be attached with socket clamps against a grooved joint coupling or flange. For exposed installations, zinc-plated nuts and bolts shall be used. However, high-strength, low-alloy steel, in accordance with AWWA C111/A21.11, may be substituted for use on cast iron and ductile iron couplings. For buried and submerged installations, TP304 stainless steel bolts and nuts shall be provided. Steel middle rings and followers shall be pressure tested beyond yield point.
2.3.1.1 Sleeve-Type Couplings
Sleeve-type couplings shall be used for joining plain end pipe sections in a flexible manner with a diameter to properly fit the pipe. A coupling shall consist of one ductile iron middle ring, two ductile iron followers, two elastomeric wedge section gaskets and elliptic-neck, track-head steel bolts designed to properly compress the gaskets. For pipe sizes between 0.5 through 1.5 inch, the followers shall be ductile iron, and the middle ring shall be in accordance with ASTM A395/A395M with AWWA C111/A21.11 bolting. For pipe sizes 2 inch and larger, the followers shall be ASTM A395/A395M, and the middle ring shall be ASTM A395/A395M with AWWA C111/A21.11 bolting. Gaskets shall be natural rubber.
2.4 FLAP GATES
2.4.1 Pump Discharge and Flap Gates
Flap gate shall be designed specifically for use on pump discharge lines. Flap gates shall be stainless steel with flange frame suitable for mounting on a pipe flange.
2.4.2 Flap Gate Materials
The flap gate frame, flap, stiffeners, and hinge arms and pins shall be stainless steel, Type 304, ASTM A240/A240M with the mounting flange faced and drilled. Mounting shall be as shown on the Contract Darwings. The flange drilling shall conform to 125 pounds standard. The resilient seat shall be neoprene, ASTM D2000 or BUNA-N rubber. Bushings shall be bronze.
2.4.3 Hinge Arms
Hinge arms shall be constructed of formed stainless steel plate with a minimum thickness of 1/4 inch and shall connect the frame to the flap.
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Dual hinge arms shall be provided on all flap gates in excess of 18 inches wide. Flap gates in excess of 30 inches wide shall have two pivot joints per arm. An adjustable lower pivot with limited rotation and a fixed or adjustable upper hinge lug arrangement to permit adjustment of the opening sensitivity to unseating head. The hinge pins shall have a minimum diameter of 1-3/8 inch and shall be constructed of solid stainless steel rod.
2.4.4 Flap
The flap and reinforcing stiffeners shall be constructed of stainless steel plate with a minimum thickness of of 1/4 inch. The flap shall not deflect more than 1/360 of the span under the maximum design head. Reinforcing stiffeners shall be welded to the flap.
2.4.5 Seals
All flap gates shall be provided with a seal system to restrict leakage to a maximum of 0.1 gpm per foot of wetted seal perimeter at seating head condition. A continuous resilient seal shall be mounted to the seating surface of the frame to restrict leakage. The seal system shall be durable and shall be designed to accomodate frequent operation without loosening or suffering damage. All seals must be bolted or otherwise mechanically fastened to the frame. Arrangement with seals that are force fit and/or held in place with adhesives are unacceptable. The seals shall be mounted so as not to obstruct the water way opening.
2.4.6 Anchor Bolts
Anchor bolts shall be provided by the flap gate manufacturer for mounting the gates when shown on the Contract Drawings. Quantity and location shall be determined by the gate manufacturer. If epoxy type anchor bolts are provided, the gate manufacturer shall provide the studs and nuts. Anchor bolts shall have a minimum diamter of 1/2 inch.
2.4.7 Finish
Mill finish on stainless steel. Welds shall be sandblasted to remove weld burn and scale.
2.4.8 Round Flap Gates
A bumper shall be provided for round flap gates to limit the travel of the flap during rapid opening conditions. Round gates shall be designed for at least 10 feet of seating head.
2.4.9 Rectangular Flap Gates
Rectangular gates shall be designed for at least 40 feet of seating head. Rectangular gates shall be equipped with lifting rings near each bottom corner.
2.4.10 Wall Thimbles
Wall thimbles shall be provided where indicated on the drawings. Wall thimbles shall be constructed of minimum 1/4 inch thick plate and shall be the same material as the flap gate.
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2.5 SWING CHECK VALVE
Comply with AWWA C508.
Materials:
1. Body and Cover: Cast iron.
2. Seat ring, hinge: Bronze.
3. Disc: Cast iron with bronze face.
4. Hinge shaft: Stainless steel.
5. Bearings, connecting hardware: Bronze.
Design Requirements:
1. 175 psi working pressure.
2. Furnish with outside weight and lever.
2.6 PLUG VALVES
Materials:
1. Body: Cast iron ASTM A126, Class B.
2. Plug: One-piece construction ductile iron, ASTM A536 65-45-12 or cast iron, ASTM A126, Class B.
3. Plug facing: Grease and/or petroleum-resistant resilient Neoprene or Buna-N coumpound, 70 Type A durometer hardness per ASTM D2240.
4. Shaft bearing bushings: Permanently lubricated TFE or Delrin sleeve type stainless steel or bronze.
5. Valve seats: Welded-in overlay of 90% nickel, minimum Brinell hardness of 200, (minimum 1/8 inch thick).
6. Stem seal: Nitrile butadiene packing or Buna-N dual U-cups per AWWA C504.
Design Requirements:
1. Port Area:
a. Equal to or exceed 80% of full pipe area.
2. Valve body: Fitted with bolted bonnet.
3. End Connections: Flanged.
4. Stem seal: Adjustable and replaceable witout disassembling valve or bonnet.
5. Designed for seating drip tight in any flow direction.
6. Rating: 175 psi working pressure.
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PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Owner's Representative of any discrepancy before performing the work.
3.2 PREPARATION
3.2.1 Protection
Pipe and equipment openings shall be closed with caps or plugs during installation. Equipment shall be protected from dirt, water, and chemical or mechanical damage.
3.2.2 System Preparation
3.2.2.1 Pipe and Fittings
Pipe and fittings shall be inspected before exposed piping is installed or buried piping is lowered into the trench. Clean the ends of pipes thoroughly, remove foreign matter and dirt from inside of pipes, and keep piping clean during and after laying.
3.2.2.2 Damaged Coatings
Repair damaged coating areas in the field with material equal to the original coating, except for damaged glass-lined pipe which shall be promptly removed from the site. Do not install damaged piping materials. Field repair of damaged and uncoated areas of galvanized piping shall conform to ASTM A780/A780M.
3.2.2.3 Field Fabrication
Notify the Owner's Representative at least 2 weeks prior to the field fabrication of pipe or fittings and at least 3 days prior to the start of any surface preparation or coating application work.
3.3 EXPOSED PIPING INSTALLATION
Exposed piping shall be run as straight as practical along the alignment shown on the contract drawings and with a minimum of joints. Piping and appurtenances shall be installed in conformance with reviewed shop drawings, manufacturer's instructions and ASME B31.3. Piping shall be installed without springing or forcing the pipe.
3.3.1 Anchors and Fasteners
Impact expansion (hammer and explosive charge drive-type) anchors and
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fastener systems are not acceptable. Lead shields, plastic or fiber inserts, and drilled-in plastic sleeve/nail drive systems are also not acceptable.
3.3.2 Piping Expansion and Contraction Provisions
The piping shall be installed to allow for thermal expansion and contraction resulting from the difference between installation and operating temperatures. Design for installation of plastic pipe exposed to ambient conditions or in which the temperature variation of the contents is substantial shall have provisions for movement due to thermal expansion and contraction documented to be in accordance with PPI TR-21. Anchors shall be installed as shown in the contract drawings to withstand expansion thrust loads and to direct and control thermal expansion. An intermediate pipe guide shall be installed for every pipe at each metal channel framing support not carrying an anchor or alignment guide. Where pipe expansion joints are required, pipe alignment guides shall be installed adjacent to the expansion device and within four pipe diameters. Expansion devices shall be installed in accordance with the manufacturer's instructions.
3.3.3 Piping Flexibility Provisions
Thrust protection shall be provided as required. Flexible couplings and expansion joints shall be installed at connections to equipment, and where shown on the contract drawings. Additional pipe anchors and flexible couplings beyond those shown on the contract drawings, shall be provided to facilitate piping installation, in accordance with reviewed shop drawings.
3.3.4 Couplings, Adapters and Service Saddles
Pipes shall be thoroughly cleaned of oil, scale, rust, and dirt in order to provide a clean seat for gaskets. Gaskets shall be wiped clean prior to installation. Flexible couplings and flanged coupling adapter gaskets shall be lubricated with the manufacturer's standard lubricant before installation on the pipe ends. Couplings, service saddles, and anchor studs shall be installed in accordance with manufacturer's instructions. Bolts shall be tightened progressively, drawing up bolts on opposite sides a little at a time until all bolts have a uniform tightness. Torque-limiting wrenches shall be used to tighten bolts.
3.3.5 Piping Equipment Installation
Piping components shall be installed in accordance with manufacturer's instructions. Valves and miscellaneous devices shall be provided for an operable installation.
3.3.6 Pipe Flanges
Pipe flanges shall be set level, plumb, and aligned. Flanged fittings shall be installed true and perpendicular to the axis of the pipe. The bolt holes shall be concentric to the centerline of the pipe and shall straddle the vertical centerline of the pipe.
3.3.7 Valve Locations
Valves shall be located in accordance with the contract drawings where actuators are shown. Where actuators are not shown, valves shall be located and oriented to permit easy access to the valve operator, and to avoid interferences.
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3.4 EXTERNAL CORROSION PROTECTION
Protect all pipe and piping accessories from corrosion and adverse environmental conditions.
3.4.1 Above Grade Metallic Piping
3.4.1.1 Ferrous Piping
Shop primed surfaces shall be touched up with ferrous metal primer. Surfaces that have not been shop primed shall be solvent cleaned. Surfaces that contain loose rust, mill scale or other foreign substances shall be mechanically cleaned by power wire brushing conforming to SSPC SP 6/NACE No.3 and primed with a ferrous metal primer. Primed surfaces shall be finished with two coats of exterior oil paint in accordance with Section 09 90 00 PAINTS AND COATINGS.
3.5 PENETRATIONS
Steel pipe sleeves shall be hot-dipped galvanized after fabrication for above grade applications in nonsubmerged areas. For below grade, or in submerged and damp environments, steel pipe sleeves shall be lined and coated as specified in Section 09 90 00 PAINTS AND COATINGS. Embedded metallic piping shall be isolated from concrete reinforcement using coated pipe penetrations. Coatings shall be as specified in Section 09 90 00 PAINTS AND COATINGS. Wall pipes shall be securely supported by form work to prevent contact with reinforcing steel and tie-wires. Joints shall be sealed with a wall penetration seal. For existing concrete walls, rotary drilled holes may be provided in lieu of sleeves.
3.6 PIPE IDENTIFICATION, PAINTING AND COLOR CODING
Color, coating, and lettering requirements for exposed piping shall be in accordance with Section 09 90 00 PAINTS AND COATINGS. Except where piping is required to be completely painted in its code color, piping or its insulation covering may be banded either with plastic adhesive tapes or painted stripes around pipe designating piping contents.
3.7 FIELD QUALITY CONTROL
3.7.1 Pipe Leakage Tests
Unless approved by the Owner's Representative, leakage testing shall be conducted after the pressure tests have been satisfactorily completed. The duration of each leakage test shall be at least 2 hours, and during the test the piping shall be subjected to not less than 200 psig pressure. Leakage is defined as the quantity of the test liquid, water, that is supplied to the piping system, or any valved or approved section thereof, in order to maintain pressure within 5 psi of the specified leakage test pressure after the piping has been filled with the test liquid and all air is expelled. No piping installation will be accepted if leakage exceeds the allowable leakage determined by the following formula:
L = Cf x N x D x P0.5 Cf = conversion factor = 0.0001351 L = allowable leakage, gallons per hour N = number of joints in the length of piping tested D = nominal pipe diameter, inches
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P = average test pressure during the test, psig.
Should any test disclose leakage greater than that allowed, the leaks shall be located and repaired until the leakage is within the specified allowance, without additional cost.
3.8 FINAL CLEANING
3.8.1 Interim Cleaning
Prevent the accumulation of weld rod, weld spatter, pipe cuttings and filings, gravel, cleaning rags, and other foreign material within piping sections during fabrication. The piping shall be examined to assure removal of these and other foreign objects prior to assembly and installation.
3.8.2 Flushing
Following assembly and testing, and prior to final acceptance, piping systems shall be flushed with water to remove accumulated construction debris and other foreign matter. The piping shall be flushed until all foreign matter is removed from the pipeline. Provide all hoses, temporary pipes, ditches, and other items as required to properly dispose of flushing water without damage to adjacent properties. The minimum flushing velocity shall be 2.5 fps. For large diameter pipe where it is impractical to flush the pipe at the minimum flushing velocity, the pipeline shall be cleaned in-place from the inside by brushing and sweeping, then flushing the pipeline at a lower velocity. Cone strainers shall be installed in the flushing connections of attached equipment and left in place until cleaning is completed. Accumulated debris shall be removed through drains, or by removing spools or valves.
3.9 WASTE WATER DISPOSAL
Submit the method proposed for disposal of waste water from hydrostatic tests and disinfection, and all required permits, prior to performing hydrostatic tests. The water used for testing, cleaning, flushing and/or disinfection shall be disposed of in accordance with all applicable regulations. Disposal is solely the responsibility of the Contractor. The method proposed for disposal of waste water shall be provided to, and approved by, the Owner's Representative prior to performing any testing, cleaning, flushing and disinfection activities.
-- End of Section --
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Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 40 95 00
PROCESS CONTROL 10/07 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
NEMA 250 (2008) Enclosures for Electrical Equipment (1000 Volts Maximum)
NEMA ICS 1 (2000; R 2008; E 2010) Standard for Industrial Control and Systems: General Requirements
NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V
NEMA ICS 4 (2010) Terminal Blocks
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code
UNDERWRITERS LABORATORIES (UL)
UL 508A (2001; Reprint Feb 2010) Industrial Control Panels
1.2 DEFINITIONS
Architecturally finished area: Offices, laboratories, conference rooms, restrooms, corridors and other similar occupied spaces.
Non-architecturally Finished Area: Pump, chemical, mechanical, electrical rooms and other similar process type rooms.
Highly Corrosive and Corrosive Areas: Rooms or areas identified on the Drawings where there is a varying degree of spillage or splashing of corrosive materials such as water, wastewater or chemical solutions; or chronic exposure to corrosive, caustic or acidic agents, chemicals, chemical fumes or chemical mixtures.
Outdoor Area: Exterior locations where the equipment is normally exposed to the weather and including below grade structures, such as vaults, manholes, handholes and in-ground pump stations.
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Intrinsically Safe Circuit: A circuit in which any spark or thermal effect is incapable of causing ignition of a mixture of flammable or combustible material in air under test conditions as prescribed in UL 913.
Calibrate: To standardize a device so that it provides a specified response to known inputs.
1.3 SYSTEM DESCRIPTION
The process instrumentation and control system shall be used to monitor and control the operation of process equipment as specified and in accordance with the sequence of control and control schematics shown on the drawings. The control system shall provide for operator interaction, overall control system supervision, and process equipment control and monitoring. Provide hardware configured and sized to support expansion as specified and shown on the drawings.
1.3.1 Operation and Maintenance Data Requirements
Outline the step-by-step procedures required for system startup, operation and shutdown. Include in the instructions layout, wiring and control diagrams of the system as installed, the manufacturer's name, model number, service manual, parts list and a brief description of all equipment and their basic operating features.
List routine maintenance procedures, possible breakdowns and repairs and trouble shooting guides.
1.4 SUBMITTALS
The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Submittals shall be original printed material or clear unblemished photocopies of original printed material.
Facsimile information is not acceptable.
Limit the scope of each submittal to one (1) Specification Section.
Each submittal must be submitted under the Specification Section containing requirements of submittal contents.
SD-03 Product Data
Instrument Catalog Cut Sheets; G
Instrument Data Sheets; G: ISA S20 or approved equal. Separate data sheet for each instrument.
Materials of construction; G
Physical limits of components including temperature and pressure limits; G
Size and weight; G
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Electrical power requirements and wiring diagrams; G
NEMA rating of housing.; G
Submittals shall be marked with arrows to show exact features to be provided
Comprehensive set of wiring diagrams for control panels and control and signal circuits; G
Control Panel Wiring Diagrams; G: Shall consist of the following:
Panel power distribution diagrams. Control and instrumentation wiring diagrams identifying each wire as it is to be labeled; include colors and wire size. PLC/RTU I/O information:
Model number of I/O module. Description of I/O module type and function. Rack and slot number. Terminal number on module. Point or channel number. Programmed point addresses. Signal function and type.
Panel Fabrication Drawings; G, AE
Control Panel Bill of Materials; G, AE: Provide complete bill of materials for each panel and include the following component information: Instrument tag number. Quantity. Functional name or description. Manufacturer. Complete model number. Size or rating.
Panel Exterior Layout Drawings; G, AE: Shall be to scale and shall indicate the following: Panel materials of construction, dimensions, and total assembled weight. Panel access openings. Conduit access locations. Front panel device layout. Nameplate schedule: Nameplate location. Legend which indicates text, letter height and color, and background color.
Panel Interior Layout Drawings; G, AE: Shall be drawn to scale and shall indicate the following: Sub-panel or mounting pan dimensions. Interior device layouts. PLC/RTU general arrangement layouts. Wire-way locations, purpose, and dimensions. Terminal strip designations. Location of external wiring and/or piping connections. Location of lighting fixtures, switches and receptacles.
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PLC technical data; G, AE including: Annotated hard copies of PLC Ladder Diagrams. Annotate program listing to include the following: Written description of each rung's function. Reference to control loop number for each rung where applicable. Reference to instrumentation tag number of I/O devices for each rung where applicable. Provide written descriptions completely defining all function blocks used in program. Provide list of all addresses referenced in logic diagram with description of data associated with each address. PLC Catalog Cut Sheets shall contain information on all PLC components.
"As-Installed" documentation; G, AE: Verifying the following performance inforamtion for each radio in the radio communication system:
1. Data communication rate (actual throughput), signal strength and signal quality for each radio in the network (i.e. Pump Station, Repeater and WWTP). 2. Electromagnetic noise level at each site. 3. Data rate for each radio. 4. Received radio signal strength at installed antenna height for each radio. 5. Fade margin in dB (difference between weakest signal the radio can read and actual received signal strength).
Drawings, systems, and other elements are represented schematically in accordance with ISA S5.1 and ISA S5.3. The nomenclature, tag numbers, equipment numbers, panel numbers, and related series identification contained in the Contract Documents shall be employed exclusively throughout submittals. All Shop Drawings shall be modified with as-built information/corrections. All panel and wiring drawings shall be provided in both hardcopy and softcopy. Furnish electronic files on CD-ROM or DVD-ROM media; drawings shall be in AUTO CAD format. Provide a parameter setting summary sheet for each field configurable device.
Legend and abbreviation sheet shall indicate the following: Description of symbols and abbreviations used Panel construction notes including enclosure NEMA rating, finish type and color, wire type, wire color strategy, conductor sizes, and wire labeling strategy Confirmation that the panel(s) are to be affixed with a UL 508A label prior to shipment from the factory
Electrical Load Calculations for each panel; include total connected load and peak electrical demand for each panel.
SD-06 Test Reports
Results of Factory Testing Procedures; G, AE
Instrument Certification Sheets; G, AE
Loop Checkout Sheets; G, AE
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SD-07 Certifications
Qualifications of Installation Supervisor; G, AE
Qualifications of Programmer(s); G, AE
Certification documentation is required for all equipment for which the specifications require independent agency approval.
SD-10 Operation and Maintenance Data; G, AE
Training Manual Instrumentation and Control System
PART 2 PRODUCTS
2.1 MATERIALS AND EQUIPMENT
2.1.1 Standard Products
Materials and equipment shall be standard unmodified products of a manufacturer regularly engaged in the manufacturing of such products. Units of the same type of equipment shall be products of a single manufacturer. Items of the same type and purpose shall be identical and supplied by the same manufacturer, unless replaced by a new version approved by the Owner's Representative.
2.1.2 Nameplates and Instrument ID Tags
Instrumentation Equipment (e.g., flow control valves, primary elements, etc.): Provide either stainless steel, phenolic or fiberglass reinforced plastic identification tags containing instrument tag number provided in Contract Documents and fastened with stainless steel chain.
Control Panels/Enclosures (e.g., PLC control panels, etc.): Provide Phenolic Name Plates fastened with screws to panel. Letter height shall be 1/2 IN minimum.
Components inside equipment enclosure, (e.g., PLC's, control relays, contactors, and timers): Provide Self-Adhesive Tape Tags and use minimum 3/16 IN letter height.
Through enclosure door mounted components (e.g., selector switches, controller digital displays, etc.): Provide Phenolic Name Plates fastened with screws and utilize ¼ IN minimum letter height.
2.2 MONITORING AND CONTROL PARAMETERS
The control system shall be complete including sensors, field preamplifiers, signal conditioners, offset and span adjustments, amplifiers, transducers, transmitters, control devices, engineering units conversions and algorithms for the applications; and shall maintain the specified end-to-end process control loop accuracy from sensor to display and final control element.
Provide Instrument Catalog Cut Sheets for all instruments in accordance with SUBMITTALS Article.
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2.2.1 Level Instrumentation
2.2.1.1 Float-Tilt Type Level Switch
Acceptable manufacturers:
a. Anchor Scientific Inc. b. Siemens.
Materials:
a. Float material: Polypropylene or Teflon coated type 316 stainless steel. b. Cable jacket: PVC, neoprene. c. Cable clamp: Polypropylene or 316 stainless steel.
Design and fabrication:
a. Mechanical switch in float. b. Provide switch complete with flexible electrical cables. c. Contact rated at 4.5 amp at 120 Vac. d. Direct acting float switch: 1) Switch actuates on rising level. 2) Switch deactuates when liquid falls 1 IN below actuation level. e. Terminate cables in junction box. f. Install floats per Drawing details and as listed in schedule below.
Schedule:
TAG NUMBER SERVICE CONTACT NO/NC MOUNTING ELEVATION LSHH-200 Wetwell level high-high NC TBD LSLL-200 Stormwater Pump Trip/Alarm NO TBD LSH-206 Submersible Pump ON NC TBD LSL-206 Submersible Pump OFF NO TBD LSHH-206 Underpass Wetwell NC TBD high-high level LSLL-206 Underpass Wetwell NO TBD low-low level
2.2.1.2 Ultrasonic Type Level Transmitters
Acceptable manufacturers: a. Siemens Milltronics. b. Endress + Hauser. c. Magnetrol. Materials: a. Sensor wetted parts: PVC, polypropylene, KYNAR or polyvinylidene fluoride (PVDF). Design and Fabrication: a. Sensor: emits ultrasonic sound, detects return echo reflected from surface, and converts it to electrical energy proportional to level. b. Temperature compensated. c. Capable of being configured to ignore false targets. d. Operating temperature: -4 to 140 DegF. e. Humidity: 95 percent non-condensing. f. Transmitter: 1) Capable of producing output signal proportional to level of 4-20 mA DC into 500 ohm load. 2) Power supply: 120 VAC (+/-10 percent), 60 Hz.
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3) Inaccuracy: 0.25 percent of range or 0.24 IN, whichever is greater. 4) Resolution: 0.1 percent of span or 0.08 IN, whichever is greater. 5) Display: Four-digit LED or LCD scalable to engineering units with selectable decimal point. 6) Temperature: -5 to 122 DegF. 7) Humidity: 95 percent noncondensing. 8) Memory: EEPROM (non-volatile). Schedule:
TAG SERVICE SPAN MOUNT
LE/LIT-200A Wet Well 0-20 Feet Sensor: 8 IN Flange Transmitter: Wall
LE/LIT-200B Wet Well 0-20 Feet Sensor: 8 IN Flange Transmitter: Wall
2.2.2 Process Analytical Instrumentation
2.2.2.1 Combustible Gas Sensor
Acceptable manufacturers:
a. MSA Instruments.
Design and Fabrication:
a. Minimum three-digit display of gas concentration associated with each sensor. b. Alarm status indicators for each gas sensing channel: 1) Trouble. 2) High gas level detected. 3) High high gas level detected. c. Alarm relay outputs: 1) Separate contacts for each alarm or trouble condition associated with each gas sensing channel. 2) Separate "system trouble" contact to indicate trouble in the event any of the following conditions are true: a) System power loss. b) Signal loss from any sensor. c) Signal out of appropriate range. d) Control module malfunction or removal. 3) Each output contact shall be Form C, SPDT, rated for 3 amps resistive at 120 Vac. d. Output signals: 4-20 mA signal representing gas concentration for each gas sensor. e. Temperature range: 32 to 158 DegF. f. Relative humidity range: 0-95 percent non-condensing.
Sensor and transmitter design and fabrication:
a. Gas sensor shall be catalytic bead type with demonstrated resistance to poisoning by silicones and hydrogen sulfide gases. b. Interconnect wiring from sensor to transmitter (if not integral) or control unit shall be 3 wire shielded cable.
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c. Sensing element shall have minimum useful life of one (1) year. d. Transmitter output: 4-20 mA signal proportional to measured gas level. 1) Capable of driving 600 ohm load at 24 Vdc supply voltage. e. Accuracy: 1) Combustible gas detection: a) +3 percent LEL to 50 percent full scale. b) +5 percent LEL, 50 to 100 percent full scale. f. Environmental: 1) Ambient operating temperature: -40 to 185 DegF. 2) Relative humidity: 0-95 percent non-condensing. g. Housing: In accordance with the area classification shown on Drawings. h. Provide nonintrusive means of calibration. i. Local displays: 1) 3-1/2 digit LCD or LED display of measured gas level. 2) Fault LED. j. Stand alone sensors and transmitters (without central control unit): 1) Provide relay contacts rated at 1/2 amps at 120 Vac for each of the following conditions: a) High gas level (warning level). b) High high gas level (alarm level). c) Sensor fault condition. k. Relay contacts shall be normally energized (normally closed); contacts shall open in the event of a warning, alarm or trouble condition. l. Minimum detector response time when exposed to 100 percent LEL gas concentration: 1) 10 seconds to 50 percent LEL. 2) 30 seconds to 90 percent LEL. m. Store calibration data in nonvolatile memory or back up with battery.
Provide one (1) calibration kit for each type of gas monitored.
a. Calibration kits shall be furnished complete with all tubing, regulators, fittings, communication devices, and accessories required to calibrate sensors. b. Calibration kit shall utilize nonintrusive means of calibrating sensors/transmitters.
Provide two (2) full cylinders of each type of calibration check gas.
a. Cylinder size: 17 liters.
Provide the same quantity of zero air cylinders as the total required number of calibration check gas cylinders (of all types).
Schedule:
TAG NO SERVICE RANGE SETPOINT
AE-210 Wet Well 0-100% LEL
AIT-210 Wet Well 0-100% LEL
ASH-210 Wet Well 10% LEL
XS-210 Wet Well Sensor Malfunction
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TAG NO SERVICE RANGE SETPOINT
AE-211 Underpass Pump Cell 0-100% LEL
AIT-211 Underpass Pump Cell 0-100% LEL
ASH-211 Underpass Pump Cell 10% LEL
XS-211 Underpass Pump Cell Sensor Malfunction
2.3 PROGRAMMABLE LOGIC CONTROLLER (PLC)
Subject to compliance with the Contract Documents, the following manufacturers are acceptable:
1. Rockwell Automation, Allen-Bradley, Compact Logix. a. No "equals" acceptable.
The PLC system shall accomplish the control requirements of the loop descriptions, Drawings, and Specifications.
PLC programming shall be documented and factory tested.
Provide each of the following in accordance with the SUBMITTALS Article.
- PLC Ladder Diagrams - PLC Catalog Cut Sheets for all PLC components - Qualifications of Installation Supervisor - Qualifications of Programmer(s)
The PLC system shall operate in ambient conditions of 32 to 140 DegF temperature and 5 to 95 percent relative humidity without the need for purging or air conditioning.
Environmental Controls: Furnish circulation fans in control system enclosures.
1. Where several equipment units operate in parallel, but are not considered assigned to a particular equipment train (e.g., multiple stormwater water pumps all discharging into a common system), the PLC I/O modules associated with each equipment unit shall be assigned so that the failure of any one (1) I/O module does not affect all of the parallel operating equipment units.
Incorporate the following minimum safety measures:
1. Watchdog function to monitor: a. Internal processor clock failure. b. Processor memory failure. c. Loss of communication between processor and I/O modules. d. Processor ceases to execute logic program. 2. Safety function wiring: Emergency shutdown switches shall not be wired into the controller. 3. Safe wiring: a. Unless otherwise specified, activation of alarms and stopping of equipment shall result from the de-energization of control circuits, rather than the energization of control circuits. b. Low voltage control signal wires:
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1) Place in conduit segregated for that purpose only. 2) Twisted shielded wire pair. 3) Not located in the same conduit or bundle with power wiring. 4. Initial safety conditions: a. Utilize program module to dictate output states in a known and safe manner prior to running of control program. b. Utilize program each time PLC is re-initiated and the control program activated. 5. Monitoring of internal faults and display: a. Internal PLC system status and faults shall be monitored and displayed. 1) Monitored items shall include: a) Memory ok/loss of memory. b) Processor ok/processor fault. c) Scan time overrun. 6. Control of programs: Protect access to PLC program loading with password protection or with locked, key operated selector switches. 7. Design PLC system with high noise immunity to prevent occurrence of false logic signals resulting from switching transients, relay and circuit breaker noise or conducted and radiated radio frequency interference.
PLC System Central Processor Unit (CPU):
1. CPU shall provide communications with other control systems and man-machine interfaces as specified. 2. Memory: a. EEPROM program back-up: 1) Automatically download to RAM in the event RAM is corrupted. 3. Plug-in card design to allow quick field replacement of faulty devices. a. Provide unit designed for field replacement and expansion of memory without requiring rewiring or use of special tools. 4. 20 percent minimum spare useable memory capacity after all required programming is in place and operating. 5. Capable of executing all control functions required by the Specifications and Drawings. 6. On-line reconfigurable. 7. Lighted status indicators for "RUN" and "FAILURE."
Input/output (I/O) Modules:
1. Provide input/output modules to accomodate points list included at the end of this Section. 2. Provide plug-in modular-type I/O racks with cables to connect to all other required PLC system components. 3. Provide I/O system with: a. I/O solid state boards with status lights indicating I/O status. b. Electric isolation between logic and field device. c. Capability of withstanding low energy common mode transient to 1000 V without failure. d. Incorporate noise suppression design. e. Capable of meeting or exceeding electrical noise tests, NEMA ICS 1-109.60-109.66. f. Capable of being removed and inserted into the I/O rack under power, without affecting any other I/O modules in the rack. g. Install I/O modules with 20 percent spare I/O points. 4. Input/output connection requirements: a. Make connections to I/O subsystem by terminating all field wiring on terminal blocks within the I/O enclosure.
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b. Prewire I/O modules to terminal blocks. c. Provide terminal blocks with continuous marking strip. d. Size terminals to accommodate all active data base points and spares. e. Provide terminals for individual termination of each signal shield. f. Field wiring shall not be disturbed when removing or replacing an I/O module. 5. Discrete I/O modules: a. Interface to ON/OFF devices. b. I/O status indicator on module front. c. Voltage rating to match circuit voltage. d. Output module current rating: 1) Match maximum circuit current draw. 2) Minimum 1.0 continuous A/point for 120 Vac applications. e. Isolated modules for applications where one (1) module interfaces with devices utilizing different sources of power. 6. Discrete outputs shall be fused: a. Provide one (1) fuse per common or per isolated output. b. Provide blown fuse indication. c. External fusing shall be provided if output module does not possess internal fusing. d. Fuses provided external to output model shall: 1) Be in accordance with module manufacturer's specifications. 2) Be installed at terminal block. 7. Analog I/O modules: a. Input modules to accept signals indicated on Drawings or Specifications. b. Minimum 12 bit resolution. c. I/O chassis supplied power for powering connected field devices. d. Differential inputs and outputs. e. User configurable for desired fault-response state. f. Provide output signals as indicated on Drawings and Specifications. g. Individual D/A converter for each output module. h. Individual A/D converter for each input module.
Power Supply Units:
1. Acceptable manufacturers: a. Sola Hevi-Duty. b. Phoenix Contact. c. Rockwell Automation 2. Design and fabrication: a. Capable of supplying PLC system when all of the specified spare capacity is utilized. b. Each power supply shall be sized such that it will carry no more than 75 percent of capacity under normal loads. c. Separate AC circuit breakers shall be provided for each power supply. d. If the PLC system is field expandable beyond the specified spare capacity, and if such expansion requires power supply modification, note such requirements in the submittals and allow room for power supply modification in the PLC system enclosure. e. Converts 120 Vac input to DC power at required voltage. f. DIN rail mount with enclosure (i.e., not open frame). g. Switching type. h. AC input: 120 Vac +/-15 percent, nominal 60 Hz. i. Efficiency: Minimum 86 percent. j. Rated mean time between failure (MTBF): 500,000 HRS. k. Voltage regulation:
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1) Static: Less than 1.0 percent Vout. 2) Dynamic: +/-2 percent Vout overall. l. Output ripple/noise: Less than 100 mV peak to peak (20 MHz). m. Overload, short circuit and open circuit protection. n. Temperature rating: 0 to 60 DegC full rated, derated linearly to 50 percent at 70 DegC. o. Humidity rating: Up to 90 percent, non-condensing. p. LED status indication for DC power. q. Capable of meeting or exceeding electrical noise tests, NEMA ICS 1-109.60-109.66. r. Power distribution: 1) Immune to transients and surges resultant from noisy environment. 2) Shall provide constant voltage level DC distribution to all devices.
Isolation Transformers:
1. Acceptable manufacturers: a. Topaz Noise Suppressor Noise Isolator. b. MGE UPS Systems, Topaz T1. 2. Design and fabrication: a. Protects sensitive electronic equipment from electrical noise. b. Common-mode noise attenuation: 146 dB at 0.0005 pF coupling capacitance. c. Normal-mode attenuation: 60 dB. d. Input voltage range: ±10 percent of rated. e. Regulation: 3.5 percent or less from full-load to no-load. f. Dielectric strength: 2,500 Vac minimum. g. Harmonic distortion: 1 percent maximum. h. Electromagnetic interference: 0-1 gauss maximum at 18 IN. i. UL listed.
Uninterruptible Power Supply (UPS):
1. Provide uninterruptible power supply (UPS) to sustain full power to UPS powered loads listed below for a minimum of 15 minutes following loss of primary power and to ensure that the transient power surges and dips do not affect the operation of the PLC system. a. UPS powered loads: 1) All rack mounted PLC components. 2) Local operator consoles. 3) All power supplies furnished with the PLC and associated loads. 2. Acceptable manufacturers: a. Double conversion type to be utilized in conjunction with input isolation transformer: 1) Eaton Powerware 9130 UPS. 3. Design and Fabrication: a. Minimum 10 minutes power ride through without incoming power. b. Frequency range: 45-65 Hz. c. Input protection: 1) Fuse or circuit breaker. d. Output voltage regulation: 1) ±2 percent online. 2) ±3 percent on battery mode. e. Battery: Sealed, lead-acid; maintenance free. f. Operating temperature: 32 to 104 DegF. g. Relative humidity: 0-95 percent non-condensing.
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Component Placement:
1. Mount all controller components within the enclosure to allow maximum convection cooling. 2. Either install power supplies above all other equipment with at least 10 IN of clearance between the power supply and the enclosure top, or adjacent to other components, but with sufficient spacing for circulation of cooling air. 3. Do not place I/O racks directly above the CPU or power supply. 4. Locate incoming line devices (isolation or constant voltage transformers, local power disconnects, surge suppressors, etc.) so as to keep power wire runs within an enclosure as short as possible. 5. If items such as magnetic starters, contactors, relays, and other electromagnetic devices must be located within the same enclosure as the PLC system components, place a barrier with at least 6 IN of separation between the magnetic area and the control area. 6. Place circulating fans close to major heat generating devices. 7. Segregate input/output modules into groups of identical type.
Termination requirements:
a. Make connections to I/O subsystem by terminating all field wiring on terminal blocks within the enclosure. b. Prewire I/O modules to terminal blocks. c. Size terminals to accommodate all active database points and spares. d. Provide terminals for individual termination of each signal shield. e. Field wiring shall not be disturbed when removing or replacing an I/O module.
PLC System Software and Programming:
1. Provide all hardware and programming required to provide communication between the PLC and the OIT. 2. Provide programming to accomplish all control and monitoring requirements of the Drawings and Specifications. 3. Provide two (2) copies of control logic program on 3-1/2 IN disks or on CD. 4. Full documentation capability. a. Provide description for each rung. 5. Two-step commands requiring operator verification prior to deletion of any programming.
2.3.1 ACCESSORIES
Provide all accessories required to furnish a complete PLC control system to accomplish the requirements of the Drawings and Specifications.
2.3.2 SOURCE QUALITY CONTROL
Provide a performance test after factory completion and prior to shipment.
1. Conduct a test where the system is operated continuously and checked for correct operation including loop controls, displays, printing, keyboard functions, alarm responses, and on/off sequencing control. 2. Conduct testing with dummy I/Os to verify each control loop operation. 3. Allow for Owner's Representative and Engineer representatives to witness testing program. a. Provide minimum of 15 days notice prior to testing. 4. Do not ship prior to successful completion of this testing program.
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2.3.3 MAINTENANCE/SPARE MATERIALS
Furnish Owner's Representative with the following extra materials:
1. One (1) spare I/O card of each card type for every 10 cards or fraction thereof installed.
2.4 PLC SOFTWARE
2.4.1 Control Sequences and Control Loops
See Section 40 95 00B, Control Loop Descriptions.
2.5 CONTROL PANELS/ENCLOSURES
Provide each Control Panel/Enclosure affixed with a UL 508A label "Listed Enclosed Industrial Control Panel" prior to shipment to the jobsite. Control panel(s) without an affixed UL 508A label shall be rejected and sent back to the Contractor's factory.
Provide each of the following in accordance with the SUBMITTALS Article.
- Control Panel Wiring Diagrams - Control Panel Bill of Material - Panel Exterior Layout Drawings - Panel Interior Layout Drawings
Provide enclosures/housing for control system components in accordance with the following:
1. Areas designated as wet: NEMA Type 4. 2. Areas designated as wet and/or corrosive: NEMA Type 4X. 3. Either architecturally or non-architecturally finished areas designated as dry, noncorrosive, and nonhazardous: NEMA Type 12.
General:
1. Fabricate panels with instrument arrangements and dimensions identified in the Contract Documents. 2. Provide panel(s) with the required enclosure rating per NEMA 250 to meet classifications identified in the Contract Documents. 3. Devices installed in panel openings shall have a NEMA enclosure rating at least equal to the panel enclosure rating. a. Devices that cannot be obtained with an adequate NEMA rating shall be installed behind a transparent viewing window. b. The window shall maintain the required NEMA rating of the enclosure. 4. Panel(s) shall be completely assembled at the Contractor's factory. a. No fabrication other than correction of minor defects or minor transit damage shall be performed on panels at the jobsite. 5. Painting: a. Panels fabricated from steel shall have their internal and external surfaces prepared, cleaned, primed, and painted. 1) Mechanically abrade all surfaces to remove rust, scale, and surface imperfections. 2) Provide final surface treatment with 120 grit abrasives or finer, followed by spot putty to fill all voids. 3) Utilize solvent or chemical methods to clean panel surfaces.
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4) Apply surface conversion of zinc phosphate prior to painting to improve paint adhesion and to increase corrosion resistance. 5) Electrostatically apply polyester urethane powder coating to all inside and outside surfaces. 6) Bake powder coating at high temperatures to bond coating to enclosure surface. a) Panel interior shall be white with semi-gloss finish. b) Panel exterior shall be ANSI #61 gray with flat finish. 7) Application of alkyd liquid enamel coating shall be allowed in lieu of polyester urethane powder for wall mounted NEMA 1 or NEMA 12 rated panels. b. Panels fabricated from stainless steel, aluminum, or fiberglass shall not be painted. 6. Finish opening edges of panel cutouts to smooth and true surface conditions. a. Panels fabricated from steel shall have the opening edges finished with the panel exterior paint. 7. Panel shall meet all requirements of UL 508A. a. If more than one (1) disconnect switch is required to disconnect all power within a panel or enclosure, provide a cautionary marking with the word "CAUTION" and the following or equivalent, "Risk of Electric Shock-More than one (1) disconnect switch required to de-energize the equipment before servicing." 8. Provide control panel in accordance with NFPA 70, Article 409. a. In the event of any conflict between NFPA 70, Article 409 and UL 508A, the more stringent requirement shall apply.
Wall Mounted Panels:
1. Seams continuously welded and ground smooth. 2. Rolled lip around all sides of enclosure door opening. 3. Gasketed dust tight. 4. Three-point latching mechanism operated by oil tight key-locking handle. 5. Key doors alike. 6. Continuous heavy GA hinge pin on doors. a. Hinges rated for 1.5 times door plus instrument weight. 7. Front full opening door. 8. Brackets for wall mounting.
Internal Panel Wiring:
1. Panel wire duct shall be installed between each row of components, and adjacent to each terminal strip. a. Route wiring within the panel in wire-duct neatly tied and bundled with tie wraps. b. Follow wire-duct manufacturer's recommended fill limits. c. Wire-duct shall have removable snap-on covers and perforated walls for easy wire entrance. d. Wire-duct shall be constructed of nonmetallic materials with rating in excess of the maximum voltage carried therein. 2. Wiring shall be installed such that if wires are removed from one (1) device, source of power will not be disrupted to other devices. 3. Splicing and tapping of wires permitted only at terminal blocks. 4. Wire bunches to doors shall be secured at each end so that bending or twisting will be around longitudinal axis of wire. a. Protect bend area with sleeve. 5. Arrange wiring neatly, cut to proper length, with surplus wire removed. a. Arrange wiring with sufficient clearance.
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b. Provide abrasion protection for wire bundles that pass through openings or across edges of sheet metal. 6. AC circuits shall be routed separate from analog signal cables and digital signal cables. a. Separate by at least 6 IN, except at unavoidable crossover points and at device terminations. 7. Provide at least 6 IN of separation between intrinsically safe devices and circuits and non-intrinsically safe devices and circuits. 8. Wiring to pilot devices or rotary switches shall be individually bundled and installed with a "flexible loop" of sufficient length to permit the component to be removed from panel for maintenance without removing terminations. 9. Conductors for AC and DC circuits shall be type MTW stranded copper listed for operation with 600 V at 90 DegC. a. Conductor size shall be as required for load and 16 AWG minimum. b. Internal panel wiring color code: 1) AC circuits: a) Power wiring: Black. b) Control interconnections: Yellow. c) Neutral: White. d) Ground: Green. 2) Low voltage DC circuits: a) Power wiring: Blue. b) Control interconnections: Violet. 3) Foreign voltage circuits: Pink. 4) Annunciator circuits: Red. 5) Intrinsically safe circuits: Orange. 10. Analog signal cables shall be of 600 V insulation, stranded copper, twisted-shielded pairs. a. Conductor size: 20 AWG minimum. b. Terminate shield drain conductors to ground only at one (1) end of the cable. 11. High precision 250 ohm resistors with 0.25 percent accuracy shall be used where 4-20 mA DC analog signals are converted to 1-5 Vdc signals. a. Resistors located at terminal strips. b. Resistors terminated using individual terminal blocks and with no other conductors. c. Resistor leads shall be un-insulated and of sufficient length to allow test or calibration equipment (e.g., HART communicator, loop calibrator) to be properly attached to the circuit with clamped test leads. 12. Analog signals for devices in separate enclosures shall not be wired in series. a. Loop isolators shall be used where analog signals are transmitted between control enclosures. 13. Wire and cable identification: a. Wire and cables numbered and tagged at each termination. b. Wire tags: 1) Slip-on, PVC wire sleeves with legible, machine-printed markings. 2) Adhesive, snap-on, or adhesive type labels are not acceptable. c. Markings as identified in the Shop Drawings.
Grounding Requirements:
1. Equipment grounding conductors shall be separated from incoming power conductors at the point of entry. 2. Minimize grounding conductor length within the enclosure by locating the ground reference point as close as practical to the incoming power
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point of entry. 3. Bond electrical racks, chassis and machine elements to a central ground bus. a. Nonconductive materials, such as paint, shall be removed from the area where the equipment contacts the enclosure. 4. Bond the enclosure to the ground bus. a. It is imperative that good electrical connections are made at the point of contact between the ground bus and enclosure. 5. Panel-mounted devices shall be bonded to the panel enclosure or the panel grounding system by means of locknuts or pressure mounting methods. 6. Sub-panels and doors shall be bonded to ground.
Termination Requirements:
1. Wiring to circuits external to the panel connected to interposing terminal blocks. 2. Terminal blocks rigidly mounted on DIN rail mounting channels. 3. Terminal strips located to provide adequate space for entrance and termination of the field conductors. 4. One (1) side of each strip of terminal blocks reserved exclusively for the termination of field conductors. 5. Terminal block markings: a. Marking shall be the same as associated wire marking. b. Legible, machine-printed markings. c. Markings as identified in the shop drawings. 6. Terminal block mechanical characteristics, and electrical characteristics shall be in accordance with NEMA ICS 4. 7. Terminal blocks with continuous marking strips. a. Each terminal block shall be identified with machine printed labels. 8. Terminals shall facilitate wire sizes as follows: a. 120 Vac applications: Conductor size 12 AWG minimum. b. Other: Conductor size 14 AWG minimum. 9. Analog signal cable shield drain conductors shall be individually terminated. 10. Install minimum of 20 percent spare terminals. 11. Bladed, knife switch, isolating type terminal blocks where control voltages enter or leave the panel. 12. Fused terminal blocks shall be used in the following circuits: a. Control voltage is used to energize a solenoid valve. b. DC power is connected to 2-wire, loop-powered instruments. 13. Fused terminal blocks shall be provided with blown fuse indicators. 14. When control circuits require more than one (1) field conductor connected to a single wiring point, a sufficient number of terminal points shall be connected internally to allow termination of only one (1) field conductor per terminal block. 15. DIN rail mounting channels shall be installed along full length of the terminal strip areas to facilitate future expansion. 16. Connections to devices with screw type terminals shall be made using spade-tongue, insulated, compression terminators.
Component Mounting and Placement:
1. Components shall be installed per manufacturer instructions. 2. Control relays and other control auxiliaries shall be mounted on DIN rail mounting channels where practical. 3. Front panel devices shall be mounted within a range of 40 to 70 IN above the finished floor, unless otherwise shown in the Contract
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Documents. 4. PLC/RTU and I/O rack installation: a. Located such that the LED indicators and switches are readily visible with the panel door open. b. Located such that repair and/or replacement of component can be accomplished without the need to remove wire terminations or other installed components. 5. Locate power supplies with sufficient spacing for circulation of air. 6. Where components such as magnetic starters, contactors, relays, and other electromagnetic devices are installed within the same enclosure as the PLC/RTU system components, provide a barrier of at least 6 IN of separation between the "power area containing the electromagnetic devices" and the "control area". 7. Components mounted in the panel interior shall be fastened to an interior sub-panel using machine screws. a. Fastening devices shall not project through the outer surface of the panel enclosure. 8. Excess mounting space of at least 20 percent for component types listed below to facilitate future expansion: a. Fuse holders. b. Circuit breakers. c. Control relays. d. Time delay relays. e. Intrinsically safe barriers and relays. 9. Components installed on sub-panels shall be provides with a minimum spacing between component and wire duct of 1 IN. a. Minimum of 2 IN separation between terminal strips and wire ducts.
Power Distribution:
1. Main incoming power circuits shall be protected with a thermal magnetic circuit breaker. a. Limit load to maximum of 80 percent of circuit breaker rating. 2. Each control panel with PLC/RTU components shall be furnished with power protection in the form of a double conversion UPS. 3. Equip each panel with necessary power supplies with ratings required for installed equipment and with minimum 25 percent spare capacity. 4. Constant voltage transformers, balancing potentiometers, and rectifiers as necessary for specific instrument requirements.
Internal Panel Lighting and Service Receptacles:
1. Panels less than or equal to 4 FT wide: a. One (1) electrical GFCI duplex receptacle. b. One (1) compact fluorescent light fixture with manual switch(es). 2. Panels or panel faces greater than 4 FT wide: a. One (1) duplex electrical GFCI receptacle per 6 FT of length. b. Continuous fluorescent lighting strip with manual switches.
Environmental Controls:
1. Internal circulation fans for panels containing PLC. 2. Internal corrosion inhibitors. a. Contains chemical which vaporizes and condenses on surfaces in the enclosure. b. Inhibitor shall be applied in accordance with manufacturer instructions for the enclosure volume. c. Inhibitor shall be applied in the panel(s) prior to shipment from the Contractor's factory.
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2.5.1 Components
2.5.1.1 Standard Indicator Light
Indicator lights shall comply with NEMA ICS 1, NEMA ICS 2 and UL 508A. Lights shall be heavy duty, round and shall mount in a 0.875 inch mounting hole. Indicator lights shall be LED type and shall operate at 120 vAc or 24 vDc. Long life bulbs shall be used. Indicator light shall be provided with a legend plate. Lens color shall be as indicated on the drawings. Lights shall be push to test (lamp) type.
2.5.1.2 Selector Switches
Selector switches shall comply with NEMA ICS 1, NEMA ICS 2 and UL 508A. Selector switches shall be heavy duty, round and shall mount in a 0.875 inch mounting hole. Switches shall be rated for 600 volts, 10 amperes continuous. Selector switches shall be provided with a legend plate. Where indicated or required, dual auxiliary contacts shall be provided for the automatic position to provide position sensing at the central station or workstation. Auxiliary contacts shall be rated for 120 vAc, 1A as a minimum.
2.5.1.3 Push Buttons
Push buttons shall comply with NEMA ICS 1, NEMA ICS 2 and UL 508A. Push buttons shall be heavy duty, round and shall mount in a 0.875 inch mounting hole. Push buttons shall be rated for 600 volts, 10 amperes continuous. Push buttons shall be provided with a legend plate.
2.5.1.4 Relays
Acceptable manufacturers:
1. Idec. 2. Potter & Brumsfield. 3. Allen-Bradley.
Design and fabrication:
1. Plug-in general purpose relay. 2. Blade connector type. 3. Switching capacity: 10 A. 4. Contact material: Silver cadmium oxide. 5. Provide relays with a minimum of 3 SPDT contacts. 6. Coil voltage: 120 Vac or 24 Vdc. 7. Relay sockets are DIN rail mounted. 8. Internal neon or LED indicator is lit when coil is energized. 9. Clear polycarbonate dust cover with clip fastener. 10. Check button. 11. Temperature rise: a. Coil: 85 DegF max. b. Contact: 65 DegF max. 12. Insulation resistance: 100 Meg min. 13. Frequency response: 1800 operations/hour. 14. Operating temperature: -20 to +150 DegF.
Time Delay Relays:
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1. Acceptable manufacturers: a. Eagle Signal Controls. b. Idec. c. Omron. 2. Design and fabrication: a. Melt design test and performance requirements of NEMA ICS 2-218. b. Heavy-duty. c. Solid-state construction. d. External adjusting dial. e. Auxiliary relays as required to perform functions specified or shown on Drawings. f. Operates on 117 Vac (±10 percent) power source. g. Contact rating: A150 per NEMA ICS 2-125. h. Furnish with "on" and "timing out" indicators.
2.5.1.5 Terminal Blocks
Acceptable manufacturers:
1. Phoenix Contact. 2. Allen-Bradley.
Design and fabrication:
1. Modular type with screw compression clamp. 2. Screws: Stainless steel. 3. Current bar: Nickel-plated copper allow. 4. Thermoplastic insulation rated for -40 to +90 DegC. 5. Wire insertion area: Funnel-shaped to guide all conductor strands into terminal. 6. Install end sections and end stops at each end of terminal strip. 7. Install machine-printed terminal markers on both sides of block. 8. Spacing: 6 mm. 9. Wire size: 22-12 AWG. 10. Rated voltage: 600 V. 11. Din rail mounting. 12. UL listed.
Standard-type block:
1. Rated current: 30 A. 2. Color: Gray body.
Bladed-type block:
1. Terminal block with knife blade disconnect which connects or isolated the two (2) sides of the block. 2. Rated current: 10 A. 3. Color: a. Panel control voltage leaves enclosure - normal: Gray body, orange switch. b. Foreign voltage entering enclosure: Orange body, orange switch.
Grounded-type block:
1. Electrically grounded to mounting rail. 2. Use to terminal ground wires and analog cable shields. 3. Color: Green and yellow body.
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2.5.1.6 FUSE HOLDERS
Acceptable manufacturers:
a. Phoenix Contact. b. Allen-Bradley.
Design and fabrication:
1. Modular-type with screw compression clamp. 2. Screws: Stainless steel. 3. Current bar: Nickel-plated copper alloy. 4. Thermoplastic insulation rated for -40 to +105 DegC. 5. Wire insertion area: Funnel-shaped to guide all conductor strands into terminal. 6. Blocks can be ganged for multi-pole operation. 7. Install end sections and end stops at each end of terminal strip. 8. Install machine-printed terminal markers on both sides of block. 9. Spacing: 9.1 mm. 10. Wire size: 30-12 AWG. 11. Rated voltage: 300 V. 12. Rated current: 12 A. 13. Fuse size: 1/4 x 1-1/4. 14. Blown fuse indication. 15. DIN rail mounting. 16. UL listed.
2.5.2 Panel Schedule
TAG NEMA NUMBER LOCATION SERVICE TYPE RATING
CP-201 Electrical PLC (See Note 1 Wall 12 Room Below) Mount
CP-202 Electrical Pump Backup Control Wall 12 Room (See Note 2 Below) Mount
Notes:
1. Provide Electrical Load Calculations for control panel in accordance with SUBMITTALS Article.
2. Pump Backup Control Panel features/design requirements:
a. 480V, 15A, 1-phase input power with main disconnet.
b. 480V:120V control power transformer with fused primary and secondary, sized as required for the application.
c. See Section 40 95 00B for description of control requirements.
d. Utilize "de-energized to trip" hardwired circuits to trip pumps on low-low wet well level conditions.
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2.6 PANEL MOUNTED OPERATOR INTERFACE TERMINALS (OIT)
Acceptable Manufacturers:
1. Allen-Bradley Panel View Plus 1000.
Design and Fabrication:
1. Display: color graphics. 2. Touch screen. 3. Either 120 Vac or 24 Vdc power supply. 4. Real time battery-backed clock, time stamp data. 5. Provide password protection to prevent unauthorized entries for a minimum of two (2) levels: a. Authorization to operate. b. Authorization to adjust setpoints. 6. Operating temperature: 32 DegF to 131 DegF. 7. Humidity: 10 to 90 percent RH non-condensing.
Configuration software:
1. Provide latest version of configuration software licensed to Owner's Representative.
Schedule:
1. Provide flat face panels on the face of each of the control panels as indicated below.
TAG NO. LOCATION SIZE, INCHES OIT-201 CP-201 10
2.7 SURGE SUPPRESSION DEVICES (SPDs)
Install within control panels containing PLC or microprocessors on the incoming 120 V power. Install on the line side of 120 V power terminals to equipment (e.g., PLCs, transmitters). Connect in series with the panel's or equipment's branch circuit. Provide fuse protection as recommended by manufacturer. Flange mount or DIN rail mount in control panel. Connect all SPDs in the panel to the same grounding point.
Approved Products:
1. Eaton AGSHW CH-120N-15-XS. 2. EDCO HSP121BT-1RU. 3. MTL MA15/D/1/SI. 4. Phoenix Contact SFP 1-20/120AC (2856702).
Standards: UL 1449.
Design and fabrication requirements:
1. Mounted internally to control panels for point-of-use loads. 2. MOV based or multi-stage hybrid solid state high performance suppression system. 3. Designed for series connection. 4. Field connection: Provide unit with external terminal screws for each phase, neutral and ground that will accept #14 through #12 conductors. 5. Device monitoring: Long-life, solid state, externally visible
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indicators that monitors the on-line status of the units suppression filter system or power loss in any of the phases. 6. Operating voltage: 120 Vac. 7. Operating current: 15 A minimum. 8. Operating frequency: 45 to 65 Hz. 9. Modes of protection: All modes, L-N, L-G and N-G. 10. Maximum continuous operating voltage: Less than 130 percent of system peak voltage. 11. Maximum surge current: 20,000A per phase, 10,000A per mode minimum. 12. Minimum repetitive surge current capacity: 1000 impulses with no degradation of more than 10 percent deviation of the clamping voltage. 13. Fusing: Optional integral unit level and/or component level short circuit and/or thermal overload protection. a. External protection as recommended by manufacturer. 14. Maximum clamping voltages, dynamic test with voltages measured from the zero voltage reference and 90 degree phase angle:
IEEE C62.41 System Voltage Test Mode B Comb. Wave A Ring Wave UL 1449 L-N = 120 V L-N 400 V 300 V 330 V L-G 500 V 400 V 400 V N-G 500 V 400 V 400 V
2.8 ALARM DEVICES
Alarm Horns:
1. Vibrating horn type. 2. PLC compatible as required. 3. Heavy-duty die cast housing with corrosion resistant finish. 4. Volume at 10FT:
a. Non-hazardous type: Adjustable 78 to 103 dB.
5. Voltage: 120 Vac or as required. 6. Enclosures/mountings:
a. Flush wall or panel mounting in dry areas.
1) Basis of Design: Edwards 870 series.
b. Surface mount in dry areas:
1) Basis of Design: Edwards 874 series.
c. NEMA 4X surface mounting in wet areas.
1) Basis of Design: Edwards 876 series.
Alarm Lights:
1. Go / No-Go lights:
a. Heavy-duty, NEMA 4X, multicolor LED type. b. Housing: Glass-reinforced thermoplastic polyester resin. c. Lens: Shatter resistant polycarbonate fresnel. d. Switchable banks of red and green LEDs (amber bank not used). e. Electrical rating: 120V. f. Mounting: Wall mount horizontally.
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g. Basis of Design: Edwards 105XBRiRGA Series with 105BX outlet box.
2. Non-hazardous locations:
a. Heavy-duty strobe type. b. Weatherproof shatter resistant polycarbonate lens and cast base. c. Optically designed fresnel lens, red in color. d. Immune to shock and vibration, no moving parts. e. Xenon flash tube providing a minimum of 65 single flashes per minute and 800,000 peak candlepower. f. Electrical rating: 120 V. g. Mounting: Conduit or wall bracket as required. h. Basis of Design: Edwards 93 series.
3. Signage:
a. Provide phenolic or fiberglass sign adjacent to each alarm light.
1) Red with black letters.
b. At Go/No-Go lights, sign to read: RED: ATMOSPHERE MAYBE EXPLOSIVE. GREEN: NO DETECTED COMBUSTIBLE GASSES. c. At strobe lights, sign to read: ATMOSPHERE MAYBE EXPLOSIVE.
2.9 RADIOS
A. Acceptable Manufacturer's:
1. Microwave Data Systems (MDS), model 9710.
2. No Substitutions or "equals" accepted.
B. Design/Fabrication:
1. Frequency range: 880-960 MHz FCC licensed Band.
2. Provide all Owner's Representative support as required to incorporate new radio to Owner's Representative's existing licensed radio network.
2.10 ANTENNAS, MASTS, TRANSMISSON CABLE AND ACCESSORIES
A. Antenna Design and Fabrication:
1. Type: Yagi.
2. Lightning protected: Mast direct connection to ground system.
3. Materials:
a. Antenna:
1). Aluminum or aluminum with Teflon impregnated power coat finish.
b. Mounting hardware:
1). 316 stainless steel or aluminum.
c. Masts:
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1). Aluminum or galvanized steel.
4. Frequency range: Specified by manufacturer to match frequencies at which radios operate.
5. Provide all masts, supports, lightning suppressors, and other apparatus requried to make a complete and operable radio telemetry system.
B. Antenna Transmission Cable:
1. Acceptable transmission cable manufacturer's:
a. Andrew Corp. LDF Series.
b. Times Microwave Systems LMR Series.
2. Design and facbrication:
a. Provide low-loss foam-dielectic type cable conecting radio antenna port(s) with the antenna.
b. Cable: 12 inches or larger diameter as required to prevent signal losses in cable from degrading performance.
c. Weatherproof, suitble for direct environmental exposure.
1). Use "O" ring seals on connections.
d. Provide "superflexible" transmission cable (length as required) at the radio antenna port.
e. Provide standard Type N connectors for connection to a continuous piece of cable extending to the antenna.
C. Provide antenna surge suppressor and coonet to coaxial cable in cabinet housing radio.
1. Acceptable manufacturer:
a. Polyphaser.
D. Provide grounding connections to the antenna in accordance with with manufacturer's recommendations.
E. Accessories:
1. Provide all accessories required to furnish a complete telemetry system to accomplish the requriements of the Drawings and Specifications.
F. Performance Verifications:
1. Provide "As-Installed" documentation verifying the folowing performance information for each radio in the radio comminication sysyetm:
a. Data communication rate (actual throughput), signal strength
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and signal quality for each radio in the network (i.e. Pump Station Repeater and WWTP).
b. Electromagnetic noise level at each site.
c. Data rate for each radio.
d. Received radio signal strength at installed antenna height for each radio.
e. Fade margin in dB (differnce between weakest signal the radio can read and actual received signal strength).
2.11 ETHERNET SWITCHES
A. Acceptable Manufacturers: 1. Phoenix Contact. 2. N-TRON. 3. GarrettCom. 4. Sixnet. B. Design and fabrication: 1. Managed Switch. 2. Support Ethernet 100 MBit/s. 3. Port for connection to multimode fiber. 4. 10/100 MBit/s twisted pair ports (RJ45) as required for communication with devices as depicted in the Contract Documents. 5. Provide at least one (1) spare 10/100 MBit/s port (twisted pair) at Ethernet switch. 6. Check all received data for validity. a. Discard invalid and defective frames or fragments. b. Monitor connected TP/TX line segments for short-circuit or interrupt using regular link test pulses in accordance with IEEE 802.3. c. Monitor attached fiber optic lines for open circuit conditions in accordance with IEEE 802.3. 7. As applicable, meet requirements of IEEE 802.3. 8. Power switch with 24 Vdc power input. 9. Provide LED status lights to indicate: a. Power: Supply voltage present. b. Fault. c. Port status. 10. Environmental rating: a. Operating temperature: 32 Deg F to 122 Deg F. b. Humidity: 95 percent relative humidity, non-condensing.
2.12 FACTORY TEST
The control system shall be tested at the factory prior to shipment. Written notification of planned testing shall be given to the Owner's Representative at least 21 days prior to testing, and in no case shall notice be given until after the Contractor has received written Owner's Representative approval of the test procedures.
Provide a performance test after factory completion and prior to shipment.
1. Conduct a test where the PLC based control system is operated continuously and checked for correct operation including loop controls, displays, printing, keyboard functions, alarm responses, and on/off sequencing control.
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2. Conduct testing with dummy I/Os to verify each control loop operation. 3. Allow for Owner's Representative and Engineer representatives to witness testing program. a. Provide minimum of 15 days notice prior to testing. 4. Tests shall be fully documented and signed by the Contractor's factory supervisor. 5. The panel shop shall fully test the control panel for correct wiring. a. Each I/O point shall be checked by measuring or connecting circuits at the field terminal blocks. 6. Burn-in test: Panel(s) shall be fully energized for a minimum period of 48 HRS. 7. The following functions shall be tested as a minimum: a. Demonstrate functions of the panel(s) required by the Contract Documents. b. Correctness of wiring from all panel field terminals to all I/O points and to all panel components. c. Simulate and test each discrete signal at the field terminal strips. d. Simulate and test each analog signal using loop calibrators. e. Correct operation of communications between PLC system Central Processing Units (CPUs) and Remote I/O bases. f. Correct operation of single-loop controllers (including digital communication to microprocessor based devices). g. Correct operation of all digital communication devices. h. Demonstrate online and offline diagnostic tests and procedures. i. The Contractor shall notify the Engineer in writing a minimum of 15 calendar days prior to the Factory Tests. 1) Engineer has the option to witness all required tests. 8. Make following documentation available to the Engineer at test site during the tests: a. Contract Documents. b. Factory Demonstration Testing procedures. c. List of equipment to be testing including make, model, and serial number. d. Shop Drawing submittal data for equipment being tested. 9. Deficiencies shall be corrected prior to shipment from the Contractor's factory. 10. Do not ship prior to successful completion of this testing program.
2.12.1 Factory Test Setup
Assemble and integrate the factory test setup as specified to prove that performance of the system satisfies all requirements of this project, including system communications requirements in accordance with the approved test procedures. The factory test shall take place during regular daytime working hours on weekdays. Equipment used shall be the same equipment that is to be delivered to the site.
2.12.2 Factory Test Procedure
Test procedures shall define the tests required to ensure that the system meets technical, operational, and performance requirements. The test procedures shall define location of tests, milestones for the tests, and identify simulation programs, equipment, personnel, facilities, and supplies required. Provide for testing all control system capabilities and functions specified and shown. Ccover actual equipment and sequences to be used for the specified project and include detailed instructions for test setup, execution, and evaluation of test results. The test reports shall document results of the tests.
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2.12.3 Factory Test Report
Submit original copies of data produced during the factory test, including results of each demonstration procedure within 7 days after completion of each test. Arrange the report so that commands, responses, and data acquired are correlated to allow logical interpretation of the data.
Provide Results of Factory Testing Procedures in accordance with SUBMITTALS Article.
PART 3 EXECUTION
3.1 EQUIPMENT INSTALLATION REQUIREMENTS
3.1.1 Installation
Install system components and appurtenances in accordance with the manufacturer's instructions and provide necessary interconnections, services, and adjustments required for a complete and operable system. Adjust or replace devices not conforming to the required accuracies. Replace factory sealed devices, rather than adjusting.
a. Install instrumentation and communication equipment and cable grounding as necessary to preclude ground loops, noise, and surges from adversely affecting system operation.
Wherever feasible, use bottom entry for all conduit entry to instruments and junction boxes.
Panel-Mounted Instruments:
1. Mount and wire so removal or replacement may be accomplished without interruption of service to adjacent devices. 2. Locate all devices mounted inside enclosures so terminals and adjustment devices are readily accessible without use of special tools and with terminal markings clearly visible.
Field Quality Control:
1. Maintain accurate daily log of all startup activities, calibration functions, and final setpoint adjustments. a. Documentation requirements include the utilization of the forms located at the end of this Specification Section. 1) Loop Check-out Sheet. 2) Instrument Certification Sheet.
Instrumentation Calibration:
1. Verify that all instruments and control devices are calibrated to provide the performance required by the Contract Documents. 2. Calibrate all field-mounted instruments, other than local pressure and temperature gages, after the device is mounted in place to assure proper installed operation. 3. Calibrate in accordance with the manufacturer's specifications. 4. Bench calibrate pressure and temperature gages. a. Field mount gage within seven (7) days of calibration. 5. Check the calibration of each transmitter and gage across its specified range at 0, 25, 50, 75, and 100 percent.
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a. Check for both increasing and decreasing input signals to detect hysteresis. 6. Replace any instrument which cannot be properly adjusted. 7. Calibration equipment shall be certified by an independent agency with traceability to NIST. a. Certification shall be up-to-date. b. Use of equipment with expired certifications shall not be permitted. 8. Calibration equipment shall be at least three (3) times more accurate as the device being calibrated.
Provide Instrument Certification Sheets in accordance with SUBMITTALS Article.
Loop check-out requirements are as follows:
1. Check control signal generation, transmission, reception and response for all control loops under simulated operating conditions by imposing a signal on the loop at the instrument connections. a. Use actual signals where available. b. Closely observe controllers, indicators, transmitters, HMI displays, recorders, alarm and trip units, remote setpoints, ratio systems, and other control components. 1) Verify that readings at all loop components are in agreement. 2) Make corrections as required. a) Following any corrections, retest the loop as before. 2. Stroke all control valves, cylinders, drives and connecting linkages from the local control station and from the control room operator interface. 3. Check all interlocks to the maximum extent possible. 4. In addition to any other as-recorded documents, record all setpoint and calibration changes on all affected Contract Documents and turn over to the Owner's Representative.
Provide Loop Checkout Sheets in accordance with SUBMITTALS Article.
Provide verification of system assembly, power, ground, and I/O tests.
Verify existence and measure adequacy of all grounds required for instrumentation and controls.
3.1.1.1 Isolation, Penetrations and Clearance from Equipment
Dielectric isolation shall be provided where dissimilar metals are used for connection and support. Penetrations through and mounting holes in the building exteriors shall be made watertight. Holes in concrete, brick, steel and wood walls shall be drilled or core drilled with proper equipment; conduits installed through openings shall be sealed with materials which are compatible with existing materials. Openings shall be sealed with materials which meet the requirements of NFPA 70. Installation shall provide clearance for control-system maintenance. Control system installation shall not interfere with the clearance requirements for mechanical and electrical system maintenance.
3.1.1.2 Device Mounting
Devices shall be installed in accordance with manufacturers' recommendations and as shown. Control devices to be installed in piping shall be provided with required gaskets, flanges, thermal compounds,
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insulation, piping, fittings, and manual valves for shutoff, equalization, purging, and calibration. Any deviations shall be documented and submitted to the Owner's Representative for approval prior to mounting. Damaged insulation shall be replaced or repaired after devices are installed to match existing work. Damaged galvanized surfaces shall be repaired by touching up with zinc paint.
3.1.2 Sequences of Operation
Study the operation and sequence of local equipment controls, as a part of the conditions report, and note any deviations from the described sequences of operation on the contract drawings. Perform necessary adjustments to make the equipment operate in an optimum manner and shall fully document changes made.
3.2 INSTALLATION OF EQUIPMENT
Install equipment as specified, as shown and as required in the manufacturer's instructions for a complete and fully operational control system.
3.3 SCREEN CONFIGURATION REVIEW MEETINGS
Conduct a minimum of two configuration conferences with the Owner's Representative to review and discuss system configuration programming and related topics.
1. The purpose of the conferences will be to discuss, in detail, how each I/O point will be handled and the types, quantities, hierarchies, and functioning of display screens. 2. Review of the Owner's Representative's existing systems, standards, conventions, file and tag naming requirements, font type and size requirements, and reporting requirements must be part of each conference. 3. Review the navigation bar to be utilized. 4. Conferences will be held at a site designated by the Owner's Representative. 5. Each screen will be reviewed at each conference. a. If required, to review all screens, each conference will occur on multiple days. 6. Submit 10 color copies of printed screens via shop drawing submittal process 10 calendar days before each conference. 7. Bring equipment to project screens on wall or provide multiple monitors for viewing by attendees.
Proposed graphic screens and report formats must be reviewed with the Owner's Representative throughout the configuration process.
Utilize graphic screen displays at the OIT to provide monitoring and control functionality.
1. Hierarchy of OIT screens is in descending order as follows: a. Plant overview screen(s). b. Process overview screens. c. Process screens. d. Pop-up/control screens.
OIT operator interface functionality shall include:
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1. Indication of process variables. 2. Configuration of control loop parameters (e.g., setpoints, gains, etc.). 3. Adjustment of controller output. 4. Display of real time and historical process trends. 5. Selector switch and pushbutton station controls. 6. System and process status indicators. 7. Graphic representation of plant operations with interactive status and measurement symbols. 8. Annunciation.
Graphics:
1. Utilize dynamic variables with unique tags per graphic. 2. All monitored and or controlled process equipment shall be animated or color-highlighted to indicate status changes. a. For example, a pump "running" condition shall be signified by the pump color changing to bright red. 3. Wet well levels shall be indicated with a tabular data field and by graphic "fill" simulating a rising or falling level within the wet well. 4. Provide the ability to "drill down" to detail screens or graphics. 5. All operator adjustments (e.g., set point adjustment, mode selection) shall be accomplished via a pop-up display, and shall not be allowed on the process screen.
PLC Hardware/HMI Status Screen:
1. Provide a status screen to depict status conditions and diagnostic information for all major networked equipment. 2. Depict communication status for all networked communicating devices, such as PLC processors, Ethernet switches, PCs, and radios.
Alarm Monitoring:
1. Provide standard alarm screen functionality to ensure flexibility and quick access to live alarms, alarm history and alarm grouping parameters. a. As a minimum, include the following features and functionality: 1) Buttons to dynamically switch between Alarm Summary and Alarm History. 2) A menu to allow user to select and open historical alarm archives. a) Utilize a time-date stamp file structure. 3) Capability to sort alarms by priority and to define priority for all system alarms. 4) Capability to filter or group alarms. 2. Analog alarms: a. The SCADA software shall monitor analog and discrete variables and calculated conditions, and determine if the variable is in an alarm condition. b. For each Analog Tag, an alarm for each of the following conditions shall be assignable: 1) Low-low. 2) Low. 3) High. 4) High-high. c. Provide adjustable dead bands and delay timers for all analog alarms. 3. Present alarms in order of: a. Time of occurrence.
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b. Non-acknowledged presented ahead of acknowledged. 4. Utilize single keystroke or pushbutton to: a. Acknowledge alarms. 5. Alarm list presented to operator shall include: a. Time of occurrence or priority. b. Time of acknowledgement. c. Description. d. Acknowledgement status. 6. Audible alarming capability for user selected alarms.
3.4 FIELD TESTING AND ADJUSTING EQUIPMENT
Provide personnel, equipment, instrumentation, and supplies necessary to perform site testing. The Owner's Representative will witness the PVT, and written permission shall be obtained from the Owner's Representative before proceeding with the testing. Original copies of data produced, including results of each test procedure, during PVT shall be turned over to the Owner's Representative at the conclusion of each phase of testing prior to Owner's Representative approval of the test. The test procedures shall cover actual equipment and functions specified for the project.
3.4.1 Testing, Adjusting and Commissioning
Deliver a report describing results of functional tests, diagnostics, calibrations and commissioning procedures including written certification to the Owner's Representative that the installed complete system has been calibrated, tested, adjusted and commissioned and is ready to begin the PVT. The report shall also include a copy of the approved PVT procedure.
3.5 MANUFACTURERS' FIELD SERVICES
Obtain the services of a manufacturer's representative experienced in the installation, adjustment, and operation of the equipment specified. The representative shall supervise the installing, adjusting, and testing of the equipment.
Maintain and submit an accurate daily or weekly log of all commissioning functions. All commissioning functions may be witnessed by the Engineer. All reports shall be cosigned by the Contractor and the Engineer if witnessed. Provide Owner's Representative with a written statement that manufacturer's equipment has been installed properly, started up, and is ready for operation by Owner's Representative's personnel.
3.6 FIELD TRAINING
Field training oriented to the specific system shall be provided for designated personnel. Furnish a copy of the training manual for each trainee plus two additional copies. Manuals shall include an agenda, the defined objectives for each lesson, and a detailed description of the subject matter for each lesson. Furnish audiovisual equipment and other training supplies and materials. Copies of the audiovisuals shall be delivered with the printed training manuals. The Owner's Representative reserves the right to videotape training sessions for later use. A training day is defined as 8 hours of classroom instruction, excluding lunchtime, Monday through Friday, during the daytime shift in effect at the training facility. Submit the training manual and schedule to receive approval from the Owner's Representative at least 30 days before the training.
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3.6.1 Operator and Maintenance Training
Prior to the start of field testing, preliminary operator training shall be taught at the project site for one consecutive training day. Upon completion of this course, each student, using appropriate documentation, should be able to perform elementary operations with guidance and describe the general hardware architecture and functionality of the system. This course shall include: general system architecture; functional operation of the system, including workstations; operator commands; application programs, control sequences, and control loops; calibration procedures, preventive maintenance procedures, schedules, troubleshooting, diagnostic procedures and repair instructions.
-- End of Section --
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SECTION 40 95 00A
PLC POINTS LIST 08/20/2014
ANALOG INPUTS NO. TAG DESCRIPTION POINT TYPE HARDWIRED – HW ETHERNET - EN 1. LI-200A Main Wet Well level HW 2. LI-200B Main Wet Well level HW 3. AI-210 Wetwell combustible gas level HW 4. AI-211 Underpass Pump cell combustible gas level HW
DISCRETE INPUTS NO. TAG DESCRIPTION POINT TYPE HARDWIRED – HW ETHERNET - EN 1. HS-200 Backup Control Mode RESET HW 2. LAHH-200 Wetwell level high-high alarm HW 3. LALL-200 Wetwell level low-low pump trip and alarm HW 4. TAHH-201 Stormwater Pump P-1 motor winding temp high HW 5. XA-201B Stormwater Pump P-1 RVSS fault alarm EN 6. XA-201C Stormwater Pumps P-1, P-2 lube system general HW alarm 7. XA-201D Stormwater Pumps P-1, P-2 lube system failure alarm HW
8. YI-201 Stormwater Pump P-1 run status EN 9. ZI-201 Stormwater Pump P-1 in REMOTE mode EN 10. ZOI-201 Stormwater Pump P-1 lube valve open HW 11. TAHH-202 Stormwater Pump P-2 motor winding temp high HW 12. XA-202B Stormwater Pump P-2 RVSS fault alarm EN 13. YI-202 Stormwater Pump P-2 run status EN 14. ZI-202 Stormwater Pump P-2 in REMOTE mode EN 15. ZOI-202 Stormwater Pump P-2 lube valve open HW 16. TAHH-203 Stormwater Pump P-3 motor winding temp high HW 17. XA-203B Stormwater Pump P-3 RVSS fault alarm EN 18. XA-203C Stormwater Pumps P-3, P-4 lube system general HW alarm 19. XA-203D Stormwater Pumps P-3, P-4 lube system failure alarm HW 20. YI-203 Stormwater Pump P-3 run status EN 21. ZI-203 Stormwater Pump P-3 in REMOTE mode EN 22. ZOI-203 Stormwater Pump P-3 lube valve open HW 23. TAHH-204 Stormwater Pump P-4 motor winding temp high HW 24. XA-204B Stormwater Pump P-4 RVSS fault alarm EN 25.0 YI-204 Stormwater Pump P-4 run status EN 26. ZI-204 Stormwater Pump P-4 in REMOTE mode EN
SECTION 40 95 00A Page 1 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach DISCRETE INPUTS NO. TAG DESCRIPTION POINT TYPE HARDWIRED – HW ETHERNET - EN 27. ZOI-204 Stormwater Pump P-4 lube valve open HW 28. TAHH-205 Stormwater Pump P-5 motor winding temp high HW 29. XA-205B Stormwater Pump P-5 RVSS fault alarm EN 30. XA-205C Stormwater Pump P-5 lube system general alarm HW 31. XA-205D Stormwater Pump P-5 lube system failure alarm HW 32. YI-205 Stormwater Pump P-5 run status EN 33. ZI-205 Stormwater Pump P-5 in REMOTE mode EN 34. ZOI-205 Stormwater Pump P-5 lube valve open HW
35. TAHH-206 Submersible Pump P-6 motor winding temp high- HW high 36. XA-206C Submersible Pump P-6 RVSS fault alarm EN 37. XA-206B Submersible Pump P-6 seal leak HW 38. YI-206 Submersible Pump P-6 run status EN 39. ZI-206 Submersible Pump P-6 in REMOTE mode EN 40. LALL-206 Underpass Wet Well low-low level HW 41. LAHH-206 Underpass Wet Well high-high level HW 42. LHI-206 Submersible Pump P-6 ON elevation HW 43. LLI-206 Submersible Pump P-6 OFF elevation HW 44. TAHH-207 Dewatering Pump P-7 motor winding temp high-high HW
45. XA-207 Dewatering Pump P-7 seal leak HW 46. AAH-210 Wetwell combustible gas level high HW 47. XS-210 Combustible gas sensor AE-210 malfunction HW 48. AAH-211 Underpass Pump cell combustible gas level high HW 49. XS-211 Underpass Pump cell combustible gas sensor AE- HW 211 malfunction 50. XA-220A Standby Generator trouble alarm EN (note 1)
51. XA-220B Standby Generator shutdown alarm EN (note 1)
52. YI-220 Standby Generator run status EN (note 1)
53. To be To be determined EN (note 1) determined 54. To be To be determined EN (note 1) determined 55. To be To be determined EN (note 1) determined 56. XA-230 ATS Fault alarm HW
57. ZI-230B ATS in Emergency Power mode HW
58. LAL-240 Main Fuel Tank low level alarm EN (note 1)
SECTION 40 95 00A Page 2 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach DISCRETE INPUTS NO. TAG DESCRIPTION POINT TYPE HARDWIRED – HW ETHERNET - EN 59. XA-240 Main Fuel Tank leak detection alarm EN (note 1)
60. XA-241 Day Tank low level alarm EN (note 1)
61. XA-250 SWBDA surge protection device fault HW
62. XA-255 SWBDG surge protection device fault EN (note 1)
63. XA-261 Loss of CP-201 control power alarm HW
Note 1: Monitoring signal to be communicated to CP-201 via fiber optic cable from remote control panel provided by others.
DISCRETE OUTPUTS NO. TAG DESCRIPTION POINT TYPE HARDWIRED – HW ETHERNET - EN 1. HS-201 Stormwater Pump P-1 start/stop control EN 2. HS-202 Stormwater Pump P-2 start/stop control EN 3. HS-203 Stormwater Pump P-3 start/stop control EN 4. HS-204 Stormwater Pump P-4 start/stop control EN 5. HS-205 Stormwater Pump P-5 start/stop control EN 6. HS-206 Submersible Pump P-6 start/stop control EN
SECTION 40 95 00A Page 3
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 40 95 00B CONTROL LOOP DESCRIPTIONS 08/20/2014
1.1 CONTROLS OVERVIEW A. The Pump Station will utilize a PLC to control the five Stormwater Pumps and the Submersible Pump. B. All five Storm Water Pumps and the Submersible Pump will be operated at constant speed. When placed in the AUTOMATIC control mode, the pumps will be controlled by a PLC located in the Pump Station Electrical Room in accordance with various wet well levels as detected by level transmitters and as described in control loops herein. C. In the event the level reaches the high-high level float in the wet well, hardwired backup control will override the primary (PLC) controls and take over control of the Stormwater Pumps. D. All pumps may be manually operated independently of the PLC from the face of the pump’s RVSS (Reduced Voltage Soft Starter) or motor starter. However, normally it is expected that each pump will be placed in the REMOTE control mode to enable AUTOMATIC PLC control. E. The Storm Water Pumps will trip via hardwired interlock in the event the low-low float switch (LSLL-200) detects low-low level in the wet well. A high-high wet well level is annunciated at the OIT. F. Selected indications and alarm conditions will be communicated via radio for display at the HMI (Human Machine Interface) located at the City of Fargo’s Wastewater Treatment Plant (WWTP). G. These control loop descriptions are not intended to be an inclusive listing of all elements and appurtenances required to execute loop functions, but are rather intended to supplement and complement the Drawings and other Specification Sections. 1. The control loop descriptions shall not be considered equal to a bill of materials. H. Provide all programming and configuration of the remote HMI, the station OIT, radios and PLCs as necessary to perform control functions as described herein and on the Drawings. I. Provide instrumentation hardware and software as necessary to perform control functions specified herein and shown on Drawings. J. General Requirements: 1. Programming will be ladder logic. 2. In addition to the requirements specifically stated within the control loop descriptions, all control software and hardware shall be provided as required to ensure the safe and reliable operation of all controlled equipment. 3. A "transmitter trouble" alarm shall be generated upon the loss of each transmitter signal, or if the signal is "out-of-range" (outside the 4 to 20 mA signal). 4. A "fail-safe" design shall be incorporated into the design such that the loss of any signal or loss of power shall not endanger personnel or result in equipment damage. 5. All "soft" alarms on analog signal shall reside in the PLC logic with de-bounce timers. The soft setpoint shall be able to be modified through the OIT system with appropriate security. 6. All alarm and trip time delays shall be operator adjustable from the OIT system with appropriate security. 7. All process values, ranges, and setpoints described herein shall be considered "Initial values" and may be changed during installation and start-up. 8. The PLC and OIT system shall validate all operator entered setpoint values before implementation. All Alarm Setpoint changes can be made by an Operator level password unless otherwise noted and all Trip Setpoint changes can be made by a Supervisor level password.
SECTION 40 95 00B Page 1 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
1.2 CONTROL LOOPS A. Control Loops 201, 202, 203, 204, 205: Stormwater Pumps and Wet Well Level Control. 1. Major Equipment: a. PLC in Control Panel CP-201. b. Stormwater Pump P-1 and associated RVSS. c. Stormwater Pump P-2 and associated RVSS. d. Stormwater Pump P-3 and associated RVSS. e. Stormwater Pump P-4 and associated RVSS. f. Stormwater Pump P-5 and associated RVSS. 2. Major Field Instruments: a. Low-low level float switch: LSLL-200. b. High-high level float switch: LSHH-200. c. Wet Well level sensors/transmitters: LE/LIT-200 A,B. d. Stormwater Pump P-1 High winding temperature switch: TSHH-201. e. Stormwater Pump P-2 High winding temperature switch: TSHH-202. f. Stormwater Pump P-3 High winding temperature switch: TSHH-203. g. Stormwater Pump P-4 High winding temperature switch: TSHH-204. h. Stormwater Pump P-5 High winding temperature switch: TSHH-205. 3. Control Logic – Normal Pump Operation: a. Pumps may be manually controlled via selections made via the keypad at the RVSS. When placed in the REMOTE control mode at the RVSS, pumps are controlled by PLC control logic as follows: b. The five Stormwater Pumps are controlled via operator selections made at the OIT. Pump control is in accordance with selections made via MANUAL/AUTO and START/STOP selector functions (HS-201A,B; 202A,B; 203A,B; 204A,B; 205A,B) and LEAD/LAG1/LAG2/LAG3/LAG4/AUTO ALTERNATE selector function HS-200B. c. When placed in the MANUAL mode, each pump is controlled via its START/STOP selector switch function. d. When placed in the AUTOMATIC control mode at the OIT, pump control is in accordance with level in the Wet Well and in accordance with selection made via LEAD/LAG1/LAG2/LAG3 /LAG4/ AUTOMATIC ALTERNATE switch function HS- 200B. e. Wet well level is measured by redundant wet well level sensors/transmitters LE/LIT- 2 00A and 200B. The operator selects one of the two level transmitters to be “in control”. Both level measurements are monitored, but only the selected transmitter will be used in automatic pump control. In the event the level signals from the two level transmitters differ by more than 2 inches, a high differential alarm will be generated (LDAH-200) at the OIT. In the event either signal fails (drops below 3.5 mA or rises above 20.5 mA), the PLC logic will automatically select the other transmitter to be “in control”. f. Operation is as follows: 1) PLC logic commands the LEAD pump to start when wet well level has risen to LEAD Pump ON set point (initially set at EL 880.5 FT). 2) PLC logic commands the LAG1 pump to start when wet well level has risen to LAG1 Pump ON set point (initially set at EL 881.5 FT). 3) PLC logic commands the LAG2 pump to start when wet well level has risen to LAG2 Pump ON set point (initially set at EL 882.5 FT). 4) PLC logic commands the LAG3 pump to start when wet well level has risen to LAG3 Pump ON set point (initially set at EL 883.5 FT). 5) PLC logic commands the LAG4 pump to start when wet well level has risen to LAG4 Pump ON set point (initially set at EL 884.5 FT). 6) PLC logic commands the LAG4 pump to stop when wet well level has fallen to LAG4 Pump OFF set point (initially set at EL 880.0 FT). 7) PLC logic commands the LAG3 pump to stop when wet well level has fallen to LAG3 Pump OFF set point (initially set at EL 879.0 FT).
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8) PLC logic commands the LAG2 pump to stop when wet well level has fallen to LAG2 Pump OFF set point (initially set at EL 878.0 FT). 9) PLC logic commands the LAG1 pump to stop when wet well level has fallen to LAG1 Pump OFF set point (initially set at EL 877.0 FT). 10) PLC logic commands the LEAD pump to stop when wet well level has fallen to LEAD Pump OFF set point (initially set at EL 876.0 FT). 11) In the event a pump fails to operate when commanded to run by the PLC, lead and lag selections will be automatically adjusted as listed below: a) If LEAD pump fails, the LAG1 pump becomes the LEAD pump, the LAG2 pump becomes the LAG1 pump, the LAG3 pump becomes the LAG2 Pump, and the LAG4 pump becomes the LAG3 pump. b) If LAG1 pump fails, the LAG2 pump becomes the LAG1 pump, the LAG3 pump becomes the LAG2 pump, and the LAG4 pump becomes the LAG3 pump. c) If LAG2 pump fails, the LAG3 pump becomes the LAG2 pump, and the LAG4 pump becomes the LAG3 pump. d) If LAG3 pump fails, the LAG4 pump becomes the LAG3 pump. 12) AUTOMATIC ALTERNATION: When AUTOMATIC ALTERNATION is selected via HS-200B, the pump modes will shift as listed below following each LEAD pump shutdown. a) Previous LEAD pump becomes the LAG4 pump. b) Previous LAG1 pump becomes the LEAD pump. c) Previous LAG2 pump becomes the LAG1 pump. d) Previous LAG3 pump becomes the LAG2 pump. e) Previous LAG4 pump becomes the LAG3 pump. g. Lubrication system control: 1) When a pump is requested to start there is a 30 second time delay to allow the automatic lubrication system time to pre-lube the pump bearings. This control is done within the RVSS enclosure. 2) When the time delay relay actuates it sends a start command to the lubrication system associated with that pump and opens the lubrication feed valve to the pump that is now on line (also via RVSS control). Opening of each Lube valve is confirmed by limit switch. 3) Trouble and failure alarms of the lubrication system are indicated on the OIT but are not pump shutdowns. h. Hardwired pump trips independent of PLC: 1) Pumps will trip via hardwire interlock if the following alarm condition exists: a) Low-low wet well level as sensed by level float switch LSLL-200. b) High-high winding temperature in the pump motor as sensed by the internal thermoswitches. i. Pump Operation During Loss of Normal Power: 1) When normal power has been lost and the generator is providing power to the station, PLC logic provides the following pump control: a) If more than one pump was running at the time normal power was lost, PLC logic prevents more than one pump from restarting at a time following availability of emergency power. Time delay logic requires a 30 second time delay (operator adjustable) between start of each pump. b) PLC logic prevents more than four (4) stormwater pumps from running at a time. 4. Control Logic – Backup Pump Operation: a. The Pump Station high-high level float LSHH-200 is set at an elevation above the elevation used for normal control of the pumps and low-low level float LSLL-200 is set at an elevation below the elevation used for normal control of the pumps. The floats are used for alarming purposes and to provide backup control mode of the pumps which is entirely independent of the PLC.
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b. Provide the required emergency control circuitry to backup the primary controls. If the wet well level increases and reaches the high-high level float in the wet well, override the primary (PLC) controls and start Pump P-1 followed by Pump P-2 after an adjustable time delay. Pump P-2 is only started if the time delay expires before the low-low level float is reached. After an adjustable time delay following the start of Pump P-2, Pump P-3 is commanded to start. Pump P-3 is only started if the time delay expires before the low-low level float is reached. After an adjustable time delay following the start of Pump P-3, Pump P-4 is commanded to start. Pump P-4 is only started if the time delay expires before the low-low level float is reached. After an adjustable time delay following the start of Pump P-4, Pump P-5 is commanded to start. Pump P-5 is only started if the time delay expires before the low-low level float is reached. 1) A time delay shall be implemented for the high-high level float alarm. The high- high level float alarm time delay shall be adjustable and set such that the station can run in backup mode (between high-high and low-low floats) and generate a high-high float alarm every time the backup mode cycles between the floats. c. The backup mode shall be designed such that the PLC control logic is isolated from controlling the pumps once backup mode is activated. Any design which merely parallels the backup mode with the PLC control will not be acceptable. The backup control mode shall be latched and a reset pushbutton on the face of the PLC Control Panel shall be provided to allow the system to return back to normal (PLC) operation. A panel mounted pilot light shall illuminate when the backup mode is active. d. In the event that normal power has been lost and the generator is providing power to the station, only four (4) pumps will be allowed to simultaneously. If more than one pump was running in backup control mode at the time normal power was lost, restart of each pump is separated by a time delay. A 30 second time delay (adjustable) is required between start of each pump. 5. Indications at Station OIT: a. Wet well level as measured by LE/LIT-200A: LI-200A. b. Wet well level as measured by LE/LIT-200B: LI-200B. c. Wet well level transmitter measurements differential high alarm: LDAH-200. d. Stormwater Pump P-1 run status: YI-201. e. Stormwater Pump P-1 total run time since last reset: KQI-201. f. Stormwater Pump P-1 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-201A. g. Stormwater Pump P-1 RVSS Fault: XA-201B. h. Stormwater Pump P-1 in REMOTE mode: ZI-201. i. Stormwater Pumps P-1, P-2 lube system general alarm: XA-201C. j. Stormwater Pumps P-1, P-2 lube system failure alarm: XA-201D. k. Stormwater Pumps P-1 lube valve open status: ZOI-201 (provide alarm ZOA-201 if valve is not open when P-1 is running). l. Stormwater Pump P-1 high winding temperature shutdown: TAHH-201. m. Stormwater Pump P-2 run status: YI-202. n. Stormwater Pump P-2 total run time since last reset: KQI-202. o. Stormwater Pump P-2 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-202A. p. Stormwater Pump P-2 RVSS Fault: XA-202B. q. Stormwater Pump P-2 in REMOTE mode: ZI-202. r. Stormwater Pump P-2 high winding temperature shutdown: TAHH-202. s. Stormwater Pump P-2 lube valve open status: ZOI-202 (provide alarm ZOA-202 if valve is not open when P-2 is running). t. Stormwater Pump P-3 run status: YI-203. u. Stormwater Pump P-3 total run time since last reset: KQI-203. v. Stormwater Pump P-3 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-203A. w. Stormwater Pump P-3 RVSS Fault: XA-203B.
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x. Stormwater Pump P-3 in REMOTE mode: ZI-203. y. Stormwater Pumps P-3, P-4 lube system general alarm: XA-203C. z. Stormwater Pumps P-3, P-4 lube system failure alarm: XA-203D. aa. Stormwater Pumps P-3 lube valve open status: ZOI-203 (provide alarm ZOA-203 if valve is not open when P-3 is running). bb. Stormwater Pump P-3 high winding temperature shutdown: TAHH-203. cc. Stormwater Pump P-4 run status: YI-204. dd. Stormwater Pump P-4 total run time since last reset: KQI-204. ee. Stormwater Pump P-4 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-204A. ff. Stormwater Pump P-4 RVSS Fault: XA-204B. gg. Stormwater Pump P-4 in REMOTE mode: ZI-204. hh. Stormwater Pump P-4 high winding temperature shutdown: TAHH-204. ii. Stormwater Pump P-4 lube valve open status: ZOI-204 (provide alarm ZOA-204 when valve is not open when P-4 is running. jj. Stormwater Pump P-5 run status: YI-205. kk. Stormwater Pump P-5 total run time since last reset: KQI-205. ll. Stormwater Pump P-5 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-205A. mm. Stormwater Pump P-5 RVSS Fault: XA-205B. nn. Stormwater Pump P-5 in REMOTE mode: ZI-205. oo. Stormwater Pump P-5 high winding temperature shutdown: TAHH-205. pp. Stormwater Pumps P-5 lube system general alarm: XA-205C. qq. Stormwater Pumps P-5 lube system failure alarm: XA-205D. rr. Stormwater Pumps P-5 lube valve open status: ZOI-205 (provide alarm ZOA-205 if valve is not open when P-5 is running). ss. Wet Well high-high level alarm: LAHH-200. tt. Wet Well low-low level alarm: LALL-200 (Note: This alarm is only generated if any of the stormwater pumps is running when the level is low-low). uu. Stormwater pumps in backup control mode: XA-200. 1) Note: this alarm does not clear until RESET pushbutton HS-200 is depressed on face of CP-201. 6. Indications at Remote HMI in WWTP: a. Stormwater Pump P-1 run status: YI-201. b. Stormwater Pump P-1 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-201A. c. Stormwater Pump P-2 run status: YI-202. d. Stormwater Pump P-2 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-202A. e. Stormwater Pump P-3 run status: YI-203. f. Stormwater Pump P-3 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-203A. g. Stormwater Pump P-4 run status: YI-204. h. Stormwater Pump P-4 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-204A. i. Stormwater Pump P-5 run status: YI-205. j. Stormwater Pump P-5 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-205A. k. Wet Well high-high level alarm: LAHH-200. l. Wet Well low-low level alarm: LALL-200. (Note: This alarm is only generated if any of the stormwater pumps is running when the level is low-low). m. Stormwater pumps in backup control mode: XA-200. 1) Note: This alarm does not clear until RESET pushbutton HS-200 is depressed on face of CP-201.
SECTION 40 95 00B Page 5 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
B. Control Loops 206: Underpass Wet Well Submersible Pump P-6: 1. Major Equipment: a. PLC in Control Panel CP-201. b. Underpass Wet Well Submersible Pump and associated motor starter. 2. Major Field Instruments: a. Low level float switch: LSL-206. b. Low-low level float switch: LSLL-206. c. High level float switch: LSH-206. d. High-high level float switch: LSHH-206. 3. Control Logic: a. Pump may be manually controlled via selections made at the motor starter. When placed in the REMOTE control mode at the motor starter, the pump is controlled by PLC control logic as follows: b. The pump is controlled from the OIT in accordance with HAND-OFF-AUTO selector switch function HS-206. The pump may be manually commanded to run so long as the wet well level is not lower than LSL-206. 1) When AUTO is selected via HS-206, the PLC will command the pump to run when the wet well level rises high enough to be detected by high level float LSH-206. The PLC will command the pump to stop when low level float switch LSL-206 no longer detects level in the wet well. c. Hardwired pump trips independent of PLC: 1) Pumps will trip via hardwire interlock if any of the following alarm conditions exist: a) Pump seal leak detected. b) High-high winding temperature in the pump motor as sensed by the internal thermoswitches. c) Low-low Underpass Wet Well level condition detected by LSLL-206. 4. Indications at Station OIT: a. Submersible Pump P-6 run status: YI-206. b. Submersible Pump P-6 total run time since last reset: KQI-206. c. Submersible Pump P-6 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-206A. d. Submersible Pump P-6 seal leak: XA-206B. e. Submersible Pump P-6 in REMOTE mode: ZI-206. f. Submersible Pump P-6 high winding temperature shutdown: TAHH-206. g. Submersible Pump P-6 ON Elevation: LHI-206. h. Submersible Pump P-6 OFF Elevation: LLI-206. i. Underpass Wet Well low-low level alarm: LALL-206. j. Underpass Wet Well high-high level alarm: LAHH-206. 5. Indications at Remote HMI in WWTP: a. Submersible Pump P-6 run status: YI-206. b. Submersible Pump P-6 pump fail alarm (pump not running within 10 seconds of PLC run command): XA-206A. c. Underpass Wet Well low-low level alarm: LALL-206. d. Underpass Wet Well high-high level alarm: LAHH-206.
C. Control Loop 207 –Dewatering Pump P-7. 1. Major Equipment: a. Dewatering Pump P-7 and associated motor starter. b. PLC in Control Panel CP-201. 2. Major Field Instruments: a. Low level switch: LSL-207.
SECTION 40 95 00B Page 6 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
3. Control Logic: a. Dewatering Pump P-7 is controlled in accordance with START and STOP pushbuttons located at the Motor Starter and in accordance with low level float switch LSL-207. 1) The pump will run whenever the START pushbutton at the motor starter is depressed; the will run until low level is detected in the Main Wet Well by LSL- 207. 4. Indications at Plant SCADA System HMIs: a. Motor high-high winding temperature: TAHH-207. b. Pump seal leak detected: XA-207. D. Control Loop 210 – Combustible Gas Monitoring in Main Wet Well. 1. Major Equipment: a. PLC in Control Panel CP-201. 2. Major Field Instruments: a. Combustible gas sensor/transmitter: AE/AIT-210. b. Switch contacts with AIT-210: 1) High combustible gas detected: ASH-210. 2) Combustible gas sensor malfunction: XS-210. 3. Control Logic: a. The following are energized in the event high combustible gas level is detected in the wet well: 1) NO GO lights at entrance from the outside to the Pump Room. 2) Alarm strobe and horn within the Pump Room. b. GO lights are energized at entrance from the outside to the Pump Room when no high combustible gas level is detected in the wet well. a. See Electrical Drawings for location of interior and exterior warning lights and horns. 4. Indications at Station OIT: a. Combustible gas level in Main Wet Well-AI-210. b. High combustible gas detected: AAH-210. c. Combustible gas sensor malfunction alarm: XA-210. 5. Indications at Remote HMI in WWTP: a. High combustible gas detected: AAH-210. b. Combustible gas sensor malfunction alarm: XA-210. c. Main Wet Well combustible gas LEL level indication: AI-210.
E. Control Loop 211 – Combustible Gas Monitoring in Underpass Wet Well. 1. Major Equipment: a. PLC in Control Panel CP-201. 2. Major Field Instruments: a. Combustible gas sensor/transmitter: AE/AIT-211. b. Switch contacts with AIT-211: 1) High combustible gas detected: ASH-211. 2) Combustible gas sensor malfunction: XS-211. 3. Control Logic: a. The NO GO light at the hatch entrance to the Wet Well is energized in the event high combustible gas level is detected in the Underpass Wet Well. b. GO light is energized at hatch entrance to Wet Well when no high combustible gas level is detected in the wet well. c. See Electrical Drawings for location of interior and exterior warning lights and horns. 4. Indications at Station OIT: a. Combustible gas level in Underpass Wet Well: AI-211. b. High combustible gas detected: AAH-211. c. Combustible gas sensor malfunction alarm: XA-211. 5. Indications at Remote HMI in WWTP: a. High combustible gas detected: AAH-211. b. Combustible gas sensor malfunction alarm: XA-211.
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F. Control Loop 220 – Standby Generator Monitoring. 1. Monitoring signals to be communicated to CP-201 via fiber optic cable from remote control panel provided by others. 2. Major Equipment: a. Standby Generator and associated control panel. b. PLC in Control Panel CP-201. 3. Indications at Station OIT: a. Generator trouble alarm: XA-220A. b. Generator shutdown alarm: XA-220B. c. Generator run status: YI-220. d. Three additional indications to be determined. 4. Indications at Remote HMI in WWTP: a. Generator trouble alarm: XA-220A. b. Generator shutdown alarm: XA-220B. c. Generator run status: YI-220. G. Control Loop 230 – Automatic Transfer Switch (ATS) Monitoring. 1. Major Equipment: a. Automatic Transfer Switch (ATS). b. PLC in Control Panel CP-201. 2. Indications at Station OIT: a. ATS Fault alarm: XA-230. b. ATS in Emergency Power mode (normal power lost): ZI-230. 3. Indications at Remote HMI in WWTP: a. ATS in Emergency Power mode (normal power lost): ZI-230.
H. Control Loop 240 – Main Fuel Tank Monitoring. 1. Note: Monitoring signals to be communicated to CP-201 via fiber optic cable from remote control panel provided by others. 2. Major Equipment: a. Main Fuel Tank and associated leak detection system. b. PLC in Control Panel CP-201. 3. Indications at Station OIT: a. Main Fuel Tank low level alarm: LAL-240. b. Main Fuel Tank leak detection alarm: XA-240. 4. Indications at Remote HMI in WWTP: a. Main Fuel Tank low level alarm: LAL-240. b. Main Fuel Tank leak detection alarm: XA-240.
I. Control Loop 250 – Switchboard (SWBDA) Surge Protection Device Fault Alarm Monitoring. 1. Major Equipment: a. Switchboard (SWBDA). b. PLC in Control Panel CP-201. 2. Indications at Station OIT: a. Switchboard (SWBDA) surge protection device fault alarm: XA-250. J. Control Loop 255 – Switchboard (SWBDG) Surge Protection Device Fault Alarm Monitoring. 1. Major Equipment: a. Switchboard (SWBDG). b. PLC in Control Panel CP-201. 2. Indications at Station OIT: a. Switchboard (SWBDG) surge protection device fault alarm: XA-255. K. Miscellaneous Alarms. 1. Indications at Station OIT: a. Communication Fail Alarm (loss of communication to WWTP): XA-260. b. Loss of control power in PLC Control Panel (CP-201): XA-261.
SECTION 40 95 00B Page 8 Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
2. Indications at Remote HMI in WWTP: a. Communication Fail Alarm (loss of communication to WWTP): XA-260. b. Loss of control power in PLC Control Panel (CP-201): XA-261.
END OF SECTION
SECTION 40 95 00B Page 9
DIVISION 4 6 ELECTRICAL POWER GENERATION
Fargo ND Moorhead Flood Risk Management Project FNDMRM2ST Red River Levees Phase 1 2nd Street Downtown Reach
SECTION 46 20 20
MANUALLY CLEANED TRASH RACK AND RAKE 02/11 09/12/2014
PART 1 GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
ASTM INTERNATIONAL (ASTM)
ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ASTM A47/A47M (1999; R 2009) Standard Specification for Ferritic Malleable Iron Castings
1.2 SUBMITTALS
Submit the following in accordance with the SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Materials And Equipment; G,
SD-03 Product Data
Spare Parts; G Framed Instructions; G
SD-06 Test Reports
Tests; G
SD-10 Operation and Maintenance Data
Operating and Maintenance Instructions; G
1.3 DELIVERY, STORAGE, AND HANDLING
Protect all equipment delivered and placed in storage from the weather, humidity and temperature variation, dirt and dust, or other contaminants.
PART 2 PRODUCTS
2.1 MATERIALS AND EQUIPMENT
a. Provide material and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of the products, that conform to the respective publications and other requirements specified and that essentially duplicate equipment that has been in satisfactory
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use at least 2 years prior to bid opening. Equipment shall be supported by a service organization that is, in the opinion of the Owner's Representative, reasonably convenient to the site.
b. Submit detail drawings consisting of a complete list of equipment and materials, including manufacturer's descriptive and technical literature, catalog cuts, and installation instructions. Detail drawings shall also contain complete wiring and schematic diagrams, equipment layout and anchorage, and any other details required to demonstrate that the system has been coordinated and will properly function as a unit.
2.1.1 Bearings
Self lubricating for submerged service in accordance with Section 35 05 40.17, SELF LUBRICATING MATERIALS, FABRICZATION, HANDLING, AND ASSEMBLING.
2.1.2 Iron, Steel, and Miscellaneous Metal
2.1.2.1 Miscellaneous Metal
Bolts, nuts, anchors, washers, and other types of supports necessary for the installation of equipment shall be of steel or wrought iron, galvanized according to the requirements of ASTM A153/A153M.
2.1.2.2 Malleable Iron
ASTM A47/A47M, grade No. 32510, minimum.
2.1.2.3 Aluminum
6061-T6, unless noted otherwise.
2.2 TRASH RACK
Trash rack shall consist of a stationary bar screen, a screen rake, and a rake mechanism operated by jib crane. Equipment shall be installed so as not to obstruct the flow of water to bar screen. Unless otherwise specified, metal that is submerged in the channel or that comes in contact with water shall be of steel or other equally corrosion-resistant metal.
Each trash rack shall be suitable for installation in a rectangular channel of the width and depth shown on the Drawings.
Each rake shall be fabricated to engage the rack between bars and be provided with four heavy duty stainless steel wheels with self lubricating bearings suitable for submerged service.
2.3 JIB CRANES
Provide two (2) jib cranes each with a minimum capacity of 2000 pounds. Provide Thern 5124 or approved equal. Each crane shall be constructed from stainless steel and equipped with a worm gear hand winch and 30 feet of 1/4 inch Type 304 stainless steel wire rope with swaged ball fitting compatible with quick disconnect on winch. Provide stainless steel bases as shown on the Drawings with base covers for each.
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PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Owner's Representative of any discrepancy before performing the work.
3.2 INSTALLATION
Install all materials and equipment as shown and in accordance with the approved written recommendations of the equipment manufacturer.
3.3 CLOSEOUT ACTIVITIES
3.3.1 Training
Provide a field training course for designated operating and maintenance staff members. Training shall be provided for a total period of 2 hours of normal working time and shall start after the system is functionally complete but prior to final acceptance tests.
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