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HomeMy WebLinkAboutJ Fletcher Creamer & Son Inc; 2006-03-21; 39561-ADOC# 2008-0157694 p Recording requested by: CITY OF CARLSBAD When recorded mail to: City Clerk City of Carlsbad 1200 Carlsbad Village Dr. Carlsbad, CA 92008 MAR 25, 2008 3:30 PM OFFICIAL RECORDS SAN DIEGO COUNTY RECORDER'S OFFICE GREGORY J. SMITH. COUNTY RECORDER FEES: 0.00 PAGES: Space above this line for Recorder's Use NOTICE OF COMPLETION Notice is hereby given that: 1 . The undersigned is owner of the interest or estate stated below in the property hereinafter described. 2. The full name of the undersigned is Carlsbad Municipal Water District (CMWD), a municipal corporation. 3. The full address of the undersigned is 1200 Carlsbad Village Drive, Carlsbad, California 92008. 4. The nature of the title of the undersigned is: In fee. 5. A work of improvement on the property hereinafter described was completed substantially completed on August 10, 2007, and all punch list work and the maintenance periods were completed on December 7, 2007. 6. The name of the contractor for such work of improvement is J. Fletcher Creamer & Son, Inc. 7. The property on which the work of improvement was completed is in the City of Carlsbad, County of San Diego, State of California, and is described as follows: San Marcos Boulevard Water Transmission Pipeline Replacement, Project No. 3956, and the San Marcos Boulevard Widening, Project No. 6005. CARLSBAD MUNICIPAL WATER DISTRICT Ltrt f. f-ov GLENN PRIW Public Works Director VERIFICATION OF SECRETARY I, the undersigned, say: I am the Secretary of the Carlsbad Water Municipal District, 1200 Carlsbad Village Drive, Carlsbad, California, 92008. The Executive Board of said District on V?9£LM-h /X i , 2008, accepted the above described work as completed and ordered that a Notice of Completion be filed. I declare under penalty of perjury that the foregoing is true and correct. Executed on/?^E/tAA tf , 2008, at Carlsbad, California. C/NICIPAL WATER DISTRICT AB 651 Reso 1315 ,Ir. CARLSBAD MUNICIPAL WATER DISTRICT San Diego County California CONTRACT DOCUMENTS AND SPECIAL PROVISIONS FOR j SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CMWD PROJECT NO. 395^ CITY OF SAN MARCOS CIP Nd 274 CONTRACT NO. 39561-A BID NO. PWS06-14ENG Revised: 10/08/03 Contract No. 39561-A Page 1 of 82 Pages TABLE OF CONTENTS Item Page Notice Inviting Bids 5.. Contractor's Proposal 9.. Equipment Material Source Information 24 Bid Security Form 25 Bidder's Bond To Accompany Proposal 26 Guide For Completing The "Designation Of Subcontractors" Form 27 Designation Of Subcontractors & Amount Of Subcontractor's Bid 30 Bidder's Statement Of Financial Responsibility 3.1 Bidder's Statement OfTechnical Ability And Experience 32 Bidder's Certificate Of Insurance For General Liability, Employers' Liability Automotive Liability And Workers' Compensation 33 Bidder's Statement Of Re-Debarment 34 Bidder's Disclosure Of Discipline Record 35 Non-Collusion Affidavit To Be Executed By Bidder And Submitted With Bid 37 Contract Public Works 38 Labor And Materials Bond 44 Faithful Performance/Warranty Bond 46 Escrow Agreement For Surety Deposits In Lieu Of Retention (Optional) 48 Revised: 10/08/03 Contract No. 39561-A Page 2 of 82 Pages SUPPLEMENTAL PROVISIONS Parti General Provisions Section 1 Terms Definitions, Abbreviations And Symbols 1-1 Terms 51 1-2 Definitions 52 1-3 Abbreviations 53 Section 2 Scope And Control Of The Work 2-3 Subcontracts 53 2-4 Contract 53 2-5 Plans And Specifications 54 2-9 Surveying 56 2-10 Authority Of Board And Engineer .60 Section 3 Changes In Work 3-3 Extra Work 61 3-4 Changed Conditions 61 3-5 Disputed Work 62 Section 4 Control Of Materials 4-1 Materials And Workmanship 65 4-2 Materials Transportation, Handling And Storage 65 Section 5 Utilities 66 5-1 Location 66 5-4 Relocation 66 Section 6 Prosecution, Progress And Acceptance Of The Work 66 6-1 Construction Schedule And Commencement OfWork 72 6-2 Prosecution OfWork 7.2 6-6 Delays And Extensions Of Time .72 6-7 Time of Completion 7.2 6-8 Completion And Acceptance .73 6-9 Liquidated Damages 7.3 Section 7 Responsibilities Of The Contractor 7.3 7-3 Liability Insurance 7.3 7-4 Workers' Compensation Insurance 7.3 7-5 Permits 73 7-7 Cooperation and Collateral Work .7.4 7-8 Project Site Maintenance 74 7-10 Public Convenience And Safety .7.4 7-13 Laws To Be Observed 79 Section 8 Facilities For Agency Personnel 8-2 Field Office Facilities 79 8-6 Basis Of Payment 80 Section 9 Measurement & Payment 9-1 Measurement Of Quantities For Unit Price Work BO 9-3 Payment 80 **W Revised: 10/08/03 Contract No. 39561-A Page 3 of 82 Pages SUPPLEMENTAL PROVISIONS Part 2 Construction Materials Part 3 Construction Methods See Table of Contents at beginning of Section SPECIAL CONDITIONS TECHNICAL SPECIFICATIONS See Table of Contents at beginning of Section INFORMATION FOR CONTRACTOR A. TO OBTAIN A COPY OF CURRENT PLAN HOLDERS LIST: City of Carlsbad, Purchasing Phone (760) 602-4677 B. QUESTIONS PERTAINING TO PLANS AND CONTRACT DOCUMENTS: City of Carlsbad, Engineering David Ahles, Senior Civil Engineer Phone (760) 602-2748 Revised: 10/08/03 Contract No. 39561-A Page 4 of 82 Pages CARLSBAD MUNICIPAL WATER DISTRICT NOTICE INVITING BIDS Sealed bids will be deposited in the Bid Box located in the first floor lobby of the Faraday Center located at 1635 Faraday Avenue, Carlsbad, California, 92008-7314, until 3:00 P.M. on the 29th day of November, 2005, at which time they will be opened and read, for performing the work as follows: SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A The work shall be performed in strict conformity with the specifications as approved by the Board of Directors of the Carlsbad Municipal Water District on file with the Engineering Department. The specifications for the work include the Standard Specifications for Public Works Construction 2003 Edition, hereinafter designated "SSPWC" as issued by the Southern California Chapter of the American Public Works Association and as amended by the special provisions sections of this contract. Reference is hereby made to the plans and specifications for full particulars and description of the work. The Carlsbad Municipal Water District encourages the participation of minority and women-owned businesses. The Carlsbad Municipal Water District encourages all bidders, suppliers, manufacturers, fabricators and contractors to utilize recycled and recyclable materials when available, appropriate and approved by the Engineer. The Carlsbad Municipal Water District may disqualify a contractor or subcontractor from participating in bidding when a contractor or subcontractor has been debarred by the Carlsbad Municipal Water or another jurisdiction in the State of California as an irresponsible bidder. No bid will be received unless it is made on a proposal form furnished by the Purchasing Department. Each bid must be accompanied by security in a form and amount required by law. The bidder's security of the second and third next lowest responsive bidders may be withheld until the Contract has been fully executed. The security submitted by all other unsuccessful bidders shall be returned to them, or deemed void, within ten (10) days after the Contract is awarded. Pursuant to the provisions of law (Public Contract Code section 10263), appropriate securities may be substituted for any obligation required by this notice or for any monies withheld by the District to ensure performance under this Contract. Section 10263 of the Public Contract Code requires monies or securities to be deposited with the District or a state or federally chartered bank in California as the Escrow Agent. The Escrow Agent shall maintain insurance to cover negligent acts and omissions of the agent in connection with the handling of retentions under this section in an amount not less than $100,000 per contract. Revised: 10/08/03 Contract No. 39561-A Page 5 of 82 Pages The documents which comprise the Bidder's proposal and that must be completed and properly executed, including notarization where indicated are: 1. Contractor's Proposal 2. Bidder's Bond 3. Non-Collusion Affidavit 4. Designation of Subcontractors and Amount of Subcontractor Bid 5. Designation of Owner Operator/Lessors & Amount of Owner Operator/Lessor Work 6. Bidder's Statement of Financial Responsibility 7. Bidder's Statement of Technical Ability and Experience 8. Acknowledgment of Addendum(s) 9. Certificate of Insurance, the riders covering the City, its officials, employees and volunteers may be omitted at the time of bid submittal but shall be provided by the Bidder prior to award of this contract 10. Bidder' s Statement Re Debarment 11. Bidder's Disclosure Of Discipline Record 12. Escrow Agreement for Security Deposits - (optional, must be completed if the Bidder wishes to use the Escrow Agreement for Security) *Pursuant to California Public Contracts Code section 4104(a)(2)(A) portions of the information required on documents numbers four and five, above, may be submitted by the Bidder up to twenty- four (24) hours after the deadline for submitting bids contained in this "Notice Inviting to Bid". All bids will be compared on the basis of the Engineer's Estimate. The estimated quantities are approximate and serve solely as a basis for the comparison of bids. The Engineer's Estimate is $4,011,123 (Schedule "A"= $1,602,798, Schedule "B"= $2,408,325). Except as provided herein a bid submitted to the City by a Contractor who is not licensed as a contractor pursuant to the Business and Professions Code shall be considered nonresponsive and shall be rejected by the City. In all contracts where federal funds are involved, no bid submitted shall be invalidated by the failure of California law. Where federal funds are involved the contractor shall be properly licensed at the time the contract is awarded. In all other cases the contractor shall state their license number, expiration date and classification in the proposal, under penalty of perjury. This invitation to bid does not involve federal funds. The only classification are acceptable for this contract is Classification A, General Engineering. If the Contractor intends to utilize the escrow agreement included in the contract documents in lieu of the usual 10% retention from each payment, these documents must be completed and submitted with the signed contract. The escrow agreement may not be substituted at a later date. Sets of plans, special provisions, and Contract documents may be obtained at the Cashier's Counter on the first floor lobby at the Faraday Center located at 1635 Faraday Avenue, Carlsbad, California 92008-7314, for a non-refundable fee of $35.00 per set. If plans and specifications are to be mailed, the cost for postage should be added. Any prospective bidder who is in doubt as to the intended meaning of any part of the drawings, specifications or other contract documents, or finds discrepancies in or omissions from the drawings and specifications may submit to the Engineer a written request for clarification or correction. Any response will be made only by a written addendum duly issued by the Engineer a copy of which will be mailed or delivered to each person receiving a set of the contract documents. No oral response will be made to such inquiry. Prior to award of the contract neither addition to, modification of nor interpretation of any provision in the contract documents will be given by any agent, employee or contractor of the City of Carlsbad=nor may any bidder rely on directions given by any agent, employee or contractor of the City of Carlsbad except as hereinbefore specified. Revised: 10/08/03 Contract No. 39561-A Page 6 of 82 Pages The Carlsbad Municipal Water District reserves the right to reject any or all bids and to waive any minor irregularity or informality in such bids. The general prevailing rate of wages for each craft or type of worker needed to execute the Contract shall be those as determined by the Director of Industrial Relations pursuant to the sections 1770, 1773, and 1773.1 of the Labor Code. Pursuant to section 1773.2 of the Labor Code, a current copy of applicable wage rates is on file in the Office of the City Engineer. The Contractor to whom the Contract is awarded shall not pay less than the said specified prevailing rates of wages to all workers employed by him or her in the execution of the Contract. The Prime Contractor shall be responsible for insuring compliance with provisions of section 1777.5 of the Labor Code and section 4100 et seq. of the Public Contracts Code, "Subletting and Subcontracting Fair Practices Act." The District Engineer is the District's "duly authorized officer" for the purposes of section 4107 and 4107.5. The provisions of Part 7, Chapter 1, of the Labor Code commencing with section 1720 shall apply to the Contract for work. A pre-bid meeting and tour of the project site will not be held. All bids are to be computed on the basis of the given estimated quantities of work, as indicated in this proposal, times the unit price as submitted by the bidder. In case of a discrepancy between words and figures, the words shall prevail. In case of an error in the extension of a unit price, the corrected extension shall be calculated and the bids will be computed as indicated above and compared on the basis of the corrected totals. All prices must be in ink or typewritten. Changes or corrections may be crossed out and typed or written in with ink and must be initialed in ink by a person authorized to sign for the Contractor. Bidders are advised to verify the issuance of all addenda and receipt thereof one day prior to bidding. Submission of bids without acknowledgment of addenda may be cause of rejection of bid. The Contractor shall provide bonds to secure faithful performance and warranty of the work in an amount equal to one hundred percent (100%) of the Contract price will be required for work on this project. The Contractor shall provide bonds to secure payment of laborers and materials suppliers, in an amount equal to: 1) One hundred percent (100%) of the total amount payable by the terms of the contract when the total amount payable does not exceed five million dollars (5,000,000. 2) Fifty percent (50%) of the total amount payable by the terms of the contract when the total amount payable is not less than five million dollars ($5,000,000) and does not exceed ten million dollars ($10,000,000). 3) Twenty-five percent (25%) of the total amount payable by the terms of the contract if the contract exceeds ten million dollars ($10,000,000). These bonds shall be kept in full force and effect during the course of this project, and shall extend in full force and effect and be retained by the District until they are released as stated in the Supplemental Provisions section of this contract. All bonds are to be placed with a surety insurance carrier admitted and authorized to transact the business of insurance in California and whose assets exceed their liabilities in an amount equal to or in excess of the amount of the bond. The bonds are to be accompanied by the following documents: Revised: 10/08/03 Contract No. 39561-A Page 7 of 82 Pages 1) An original, or a certified copy, of the unrevoked appointment, power of attorney, by laws, or other instrument entitling or authorizing the person who executed the bond to do so. 2) A certified copy of the certificate of authority of the insurer issued by the insurance commissioner. If the bid is accepted, the District may require copies of the insurer's most recent annual statement and quarterly statement filed with the Department of Insurance pursuant to Article 10 (commencing with section 900) of Chapter 1 of Part 2 of Division 1 of the Insurance Code, within 10 calendar days of the insurer's receipt of a request to submit the statements. Insurance is to be placed with insurers that: 1) Have a rating in the most recent Best's Key Rating Guide of at least A-:V 2) Are admitted and authorized to transact the business of insurance in the State of California by the Insurance Commissioner. Auto policies offered to meet the specification of this contract must: 3) Meet the conditions stated above for all insurance companies. 4) Cover any vehicle used in the performance of the contract, used onsite or offsite, whether owned, non-owned or hired, and whether scheduled or non-scheduled. The auto insurance certificate must state the coverage is for "any auto" and cannot be limited in any manner. Workers' compensation insurance required under this contract must be offered by a company meeting the above standards with the exception that the Best's rating condition is waived. The District does accept policies issued by the State Compensation Fund meeting the requirement for workers' compensation insurance. The Contractor shall be required to maintain insurance as specified in the Contract. Any additional cost of said insurance shall be included in the bid price. The award of the contract by the Board of Director's is contingent upon the Contractor submitting the required bonds and insurance, as described in the contract, within twenty days of bid opening. If the Contractor fails to comply with these requirements, the District may award the contract to the second or third lowest bidder and the bid security of the lowest bidder may be forfeited. The prime contractor and all subcontractors are required to have and maintain a valid City of Carlsbad Business License for the duration of the contract. Approved by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, California, by Resolution No. 1257, adopted on the 18th day of October 2005. October 21.2005 Date KARfifJ KUlSlOT^Ass^nt Secretary Publish Date: October 27, 2005 Revised: 10/08/03 Contract No. 39561-A Page 8 of 82 Pages t CARLSBAD MUNICIPAL WATER DISTRICT n o P I ," G § f , SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A CONTRACTOR'S PROPH9WHLW™ESSED AND RECORDED: Board of Directors Carlsbad Municipal Water District 5950 El Camino Real Carlsbad, California 92008 DATE SIGNATURE ' The undersigned declares he/she has carefully examined the location of the work, read the Notice Inviting Bids, examined the Plans, Specifications, Special Provisions and addenda thereto, and hereby proposes to furnish all labor, materials, equipment, transportation, and servces required to do all the work to complete Contract No. 39561 -A in accordance with the Plans, Specifications, Supplemental Provisions and addenda thereto and that he/she will take in full payment therefor the following unit prices for each item complete, to wit: SCHEDULE "A" STREET IMPROVEMENTS (Drawing No. IP-4693) Total $ fa OOP.'* Item No. A-1 No Spec Description Mobilization at a Lump Sum Amount Not-to-Exceed $60,000 $Wfy +houWMl dttlM*Owi /MAD tortb Approximate Quantity and Unit 1 LS / Unit Price $ 60, MO*/ 300-1 A-3 300-2 Dollars (Lump Sum) Clearing and Grubbing Including Removal of Existing Retaining Wall at 1 LS Dollars (Lump Sum) Unclassified Excavation at . JUUI 400 CY $ 12*5.%) Dollars per Cubic Yarci /tfA ic Ya ^ 60, Revised: 1 0/08/03 Contract No. 39561 -A Page 9 of 82 Pages f: n n 0 0 . Approximate Item Quantity Unit No. Description and Unit Price Total A-4 Relocate Existing Traffic Sign 4 EA 206-7 nut SUM* Dollars Each A-5 Relocate Existing 4'Vinyl 163 LF Coated Chain Link Fence per SDRSD M-6 at 304-3 Dollars per Lineal Foot A-6 6'Vinyl Coated Chain Link 202 LF $ 5?-06 $ //, Fence per SDRSD M-6 (Top of Retaining Wall) at 304-3 Dollars per Lineal Foot A-7 Remove Existing Curb Inlets SEA $ <r> 1*50.06 $ (2, ¥50 . (atSMB Sta. 155+50, 168+50, and SE Corner SIvB & Viewpoint)201 htu* ^k&u&Hj CAW207 M+U dMtato>aw( A&U Ante 303 "dollars Each A-8 Remove and Relocate Pull 4 EA $ ^, If^O. W $ *lb, ttW- ox (4 on SMB South Side) at201 207 jui/tf OMfaAt AHtf /#** 303 uoliarsEach A-9 Adjust to Grade Pull Box (2 on SEA $ %/OQ.tQ $ % ^g . 0* SflB and 1 on RSF.) at 201 207 303 Dollars Each A-1Q Remove Roadway Paver 569 SF $ frfiop $ ft. Blocks at _ Spec CfinM* Dollars per Square Foot Revised: 10/08/03 Contract No. 39561-A , Page 10 of 82 Pages p_. Approximate j'" -.. Item Quantity Unit ^-—: No. Description and Unit Price Total '-< A-11 Remove Sidewalk Paver 1.025SF $ I!) f)D . $ /£. Blocks at ^ p No L Spec 0 p Dollars per Square Foot '' A-12 Adjust Manhole to Grade 2 EA $ / OOP'. r , (8MB Sta. 168,168+50) at 201 Htum'-207 303 Dollars Each A-13 Modify Storm Drain Cleanout 1 EA (SMB Sta. 168 at ROW line) 201 207 303 Dollars A-14 Cold Mill AC Pavement at 99,238 SF $0.29 203 TUutitti rug fan& 301 7 302 Dollars per Square Foot 600-3 A-15 Aggregate Base at 630 CY $_ 200 301 302 Dollars per Cubic Yard A-16 Asphalt Concrete Pavement 3,500 TON $ foO-00 (Type B) at 203 UAM fauMd^pUujMtAj */fnr~ 301 302 Dollars per Ton 600-3 A-17 Miscellaneous Concrete at 55 CY $_ 201 303 Wlff /k/; ar^rpDollars°per Cubic Yard t 201 ^/ hwiekjaA-18 18"RCP(D-1350)a,t 10LF $ /^O.OO Uk 207 flytTAtAt) 303 Dollars'per Lineal Foot .evised: 10/08/03 Contract No. 39561-A Page 11 of 82 Pages r c [j Item No. A-19 201 207 303 A-20 201 207 303 A-21 201 207 303 A-22 201 207 303 A-23 201 207 303 A-24 201 303 A-25 201 303 Description Channel Connection per SDRSD D-73 (Connect 4" PVC Sch 40 Wall Drain to Existing Brow Ditch) at AM! Dtotf Dollars Each New Curb Inlet Type A-1 per DRSD D-1 (1=18-) at fad llars Each New Drainage Inlet Type GO pe/ Caltrans Std D74B at &frr\ ii r-Dollars Each New Curb Outlet Type A per SDRSDD-25at „ 7tjiu mwAaw* rtiiu dtitlaiv Dollars Each Type G Curb and Gutter per SDRSD G-2 at Dollars per Lineal Foot Cross Gutter per SDRSD G-12 (Including Curb/Gutter and Sidewalk on Curb Return at SMB and Viewpoint at Dollars Each Approximate Quantity and Unit Dollars Each Convert Existing Drainage Box to Storm Drain Cleanout Type A-4 per SDRSD D-9 at SIVB Sia. 168+50 at 1 EA &*& 4 EA 1 EA Unit Price Total 1 EA $ ItOOO.OO $ 2EA $ 3*0)0.00 $ f ,. DO $ t $ .. PC $ . 1.952LF $_$ . 1EA O Revised: 10/08/03 Contract No. 39561-A Page 12 of 82 Pages f: Approximate Item Quantity Unit No. Description and Unit Price Total A-26 Type B1 Curb per SDRSD 3,208 LF $ at 201 303 p I, illars per Lineal Foot r, A-27 PCC Sidewalk (4" Thick) per 3,217 SF $ (f. *>° $ /*?, SDRSD G-7 at1 j 201 yw dot&ti/v aw* 303 fjfafo ' P Dollars per Square Foot °°A-28 Concrete Driveway per 1 EA $ *?.70Q,C'"' $ j^ SDRSD G-14C at Dollars Each 3 00A-29 New Pedestrian Ramps per 3 EA ~ ' " "' " Caltrans RSP A88A (2 on SMB and 1 on RSF) at v-r, -<rjAA^i TA^-<J^«^>VfS JVTN^A^ ^? 1 p Dollars-Each a A-30 Retrofit Pedestrian Ramp per SEA $ ^HO, °° $ \\, 510. °^ r • SDRSD G-28 with Gray Truncated Come (3 on RSF) ' at _ 201 jLui ^l^-vALt ft^ r^ Each"Dollar^ Ea A-31 Curb Inlet Baskets (by Suntree SEA $ /,*OQQt)0 $ Tech nologies-Oceanside (760) 433-7640, or Approved Equal) at No Spec faut Dollars Each A-32 Sawcutat 5,568 LF $ /• 00 203 301 302 Dollars per Lineal Foot levised: 10/08/03 Contract No. 39561-A Page 13 of 82 Pages F: p r Item No. Description Approximate Quantity and Unit Unit Price Total A-33206 304 308 310 A-34 D 201 303 A-35 e i: 201 303 A-36 i;209 306 310 313 Sidewalk Planting Grate at 16EA ) Dollarshach Concrete Retaining Wall (Integral Colored Concrete w/Texture. Color to be y Approved by Planning partment) at 1 LS $ 160, Q&O. ^ $ 1&0 , OOP."° favl i- > ^-" 209 306 310 313 Dollars (Lump Sum) Retaining Wall Architectural Treatment (Architectural Treatment Shall Conform to the San Marcos Ledger Stone Texture Used on the Las Posas/SR 78 Interchange Retaining Walls. Sample Panel to be Approved by Construction Manager) athwufatf L/fy 300 SF $ ^^ 000.00 Dollars per Square Foot Signal Modification Including Video Detection and Monitoring (San Marcos Boulevard/Viewpoint Drive Intersection) atunotw* Mvfa 1 LS $ I toff OOP PO $ H00 OOP. Ol> Dollars (Lump Sum AtM m; A-37 Signal Modification Including Video Detection and Monitoring (San Marcos Boulevard/Rancho Santa Fe 1 LS $ I^VM-OQ $ Joad Intersection) at Dollars (Lump Sum) Revised: 10/08/03 Contract No. 39561 -A Page 14 of 82 Pages Approximate Item Quantity Unit No. Description and Unit Price Total n C A-38 Sawcut/Remove Pavement 2,000 SF $ ID-OO Full Depth AC at U M ni) 302 Dollars (Lump Sum 313 A-42 Irrigation System at 1 0,290 SF $212 308 f ' Dollars per Square Foot A-43 krigation Repair Off-Sjte at 1 LS $ *2 ^00.r 212 njut WWuMMH II 308 .00 209 306 310 Dollars per Square Foot 313 A-39 Roal Striping & Marking at 1 LS $ 1$ Q0Q. 0Q $ 210 V^y UA 214 302 Dollars (Lump Sum 310 312 313 A-40 Jraffic Control at - 1 LS $ }*)(), 000-00 $ 210 214 O A-41 Stamped Paving (Landscaped 9,812 SF $ /2 ^/9 $ //?, Median on SMB) atr 201 fluUt/j dOUM [.. 303 /j^U/ Dollars per Square Foot Dollars (Lump Sum) A-44 Jrrigation Controller at 1 EA $ > "O- OQ $ 212 308 Dollars Each Revised: 10/08/03 Contract No. 39561-A Page 15 of 82 Pages Approximate Item Quantity Unit No. Description and Unit Price Total R A-45 Irrjgatio^P.O.C. at: , 1 EA $ %##> $ %&.OQ 212 Jft&f 308 Dollars Each A-46 24" Box Trees at . 27 EA $ X -f V OO • $_ 308 fM dM/AWiSllrt <4(M6 Unfa Dollars Each SGallon £ 212 TlMtfH n n A-47 ^Gallon Shrubs at , 808 EA $ 2A-OQLi 308 Dollars Each r 308 ^^ xM Ls U 212 JW/V 308 Dollars per Square Foot A-53 JGallon Vines at 34 EA $ .W5.GQ , 212 ~TUM^u fug 308 *- " - Dollars Each Dollars Each A-52 Flatted Ground Cover Of-Site 2,300 SF $ ^. ^ $_ A-48 Bark Mulch at 10,290 SF $ ^?. *%) r' 212 I 308 "'— • Dollars per Square Foot L:L_J A-49 SpilPrepat 10,290 SF $_ ^ ^ ,212 fUtCf MfttV 308 • v O Dollars per Square Foot A-50 120 Day Maintenance at 10,290 SF $ Q. 1$ $ ^O^.Od |-j 308 Dollars per Square Foot P A-51 5J3allon Shrubs Off-Site at 29 EA $ 23 OQO 212 Revised: 10/08/03 Contract No. 39561-A Page 16 of 82 Pages r' .i \ [" F: Fr Item No. A-54 212 308 A-55 Description Water Pollution Control atnfatttA WwuMjflti. cfaifa /In* SftAb Ctoifc Dollars (Lump Sum) Install removable basket-type Approximate Quantity and Unit 1 LS fr SEA Unit Price Total $ 1*0.000.00 $ l<0,t)dOV() $ l.^oo.oc $ ^,<%OOM t; r fossil filter by Suntree Tech. ' ' Or approved equalx2^/ -Hwiudwx rut/ huntied H ftCt/fJAt Mbd tl Dollars Each Total amount ob bid in words for Schedule "A" (Item Nos. A4 through A-55): Total amount of bid in numbers for Schedule "A" (IterrTNos. A-1 through A-55): $ c :evised: 10/08/03 Contract No. 39561-A Page 17 of 82 Pages r, P I..;' i; SCHEDULE "B" TRANSMISSION MAIN (Drawing No. 425-1) Approximate Item Quantity Unit No. Description and Unit Price Total B-1 Mobilization, Demobilization, 1 LS $ fa \000 ^ $ Iff 0.000- 00 Providing Project Sign, Compliance with all General and Supplementary Conditions and Providing Cleanup of Construction Site Complete In Place (Not-to-Exceed $60,000) at o sUAt) s (tumDollars (tump Sum) B-2 Perform Exploratory 1 LS Excavations for Underground Utilities at~ A*M s LumDollars (Lump Sum) B-3 Construct 30-Inch Diameter 3,930 LF $ ^0 .DO $ /, ^32) 'ft® -00 CML Tape Wrapped and Mortar Coated Steel Pipe Transmission Main athwnduflus AM Dollars per Lineal Foot B-4 Provide all Necessary and 1 LS $ 60,000-00 $ Required Traffic Control to Perform Construction in Bid Item No. 3 at Dollars (Lump Sum) B-5 Construct the Connection to 1 LS $ ^7, tfaD. Of) $_ the Existing 30-Inch Diameter Transmission Main Along San Marcos Boulevard at Acacia rive at Dollars (Lump Sum) Revised: 10/08/03 Contract No. 39561-A Page 18 of 82 Pages r; Item No. B-6 n B-7 B-8 B-9 B-10 B-11 Description Construct the Connection to the Existing 21-Inch Diameter Transmission Main Along San Marcos Boulevard at Rancho Santa Fe Avenue at Approximate Quantity and Unit 1 LS Total ) £0£03 £0 OHM Dollars (Lump Sum) Furnish and Construct a 2- Inch Air Release and Vacuum Relief Valve Assembly per Carlsbad Municipal Water District Standard Drawing No. W7-Aatw Dollars Each Furnish and Construct a 6-Inch Blow-Off Assembly per Carlsbad Municipal Water District Standard Drawing No. W11-Aat jfaAO Dollars Each Furnish and Install 30-Inch Butterfly Valve per Carlsbad Municipal Water District Standard Drawing No. W1 7 at w /UA4 Dollars Each Furnish and Install Cathodic Protection for 30-Inch CML Tape Wrapped and Mortar Coated Steel Pipe Transmission Main at Dollars (Lump Sum) Provide Permanent Video Traffic Signal Devices and monitoring (San Marcos /d.Acacia) at 7 EA $ 3.0&> 00 $ 4 EA $ It 000.06 $ W. 00& CO 2 EA $ //, 000. 00 $ LS $ ^. %00-OQ 2 EA $ 00 0 '. CO $ s> ()00.VO fart Dollars Each Revised: 10/08/03 Contract No. 39 561 -A Page 1 9 of 82 Pages r o Approximate Item Quantity Unit No. Description and Unit Price Total B-12 Install and Remove 1 LS $ Z.QDO > OQ Construction Inspection Field Tcailer atFu/t )ollars (tump Sum) B-13 Provide and Prepare Drawings 1 LS for SWPPP and BMP Permits. Furnish and Install Erosion and Water Pollution Control Devices per Approved Shop Drawing Submittais at /to Dollars ^(Lump Sum) B-14 Provide Excavation Safety 1 LS $ fy.CPQ. 00 $_ Measures Including Sheeting, Shoring and Bracing, or Equivalent Method for the Protection of Life and Limb in Trenches and Open Excavation in Conformance with Applicable Safety Orders Dollars (Lump Sum) B-15 Backfill Existing 21-Inch 1.465LF $ ^flP $_ Diameter Pipe with Sand Slufryat- _. . .favt p Dollars per Lineal Foot & B-16 Construct Trench Restoration 3,930 LF $ 'D-OO $_ per Typical Trench Section p Shewn on Sh^et 10 of 20 at Dollars per Lineal Foot Total amount of bid in words for Schedule "B" (Item Nos. B-1 through B-16): Total amount of bid numbers for Schedule "B" (Item Nos. B-1 through B-16): $ /2.j \ c\4} 005 , o o Price(s) given above are firm for 90 days after date of bid opening and do comprise the Contract Unit Prices for the Work. Revised: 10/08/03 Contract No. 39561-A Page 20 of 82 Pages r Total amount of bid forSchedules "A" and "B" in words: ' MJUuuif- Total amount of bid forSchedules "A" and "B" in numbers: $ - The basis of award will be the sum of Schedule "A" and Schedule "B. UNIT PRICES FOR ALL WORK SHALL BE FAIR AND REASONABLE, SO THAT EACH AGENCY ENDS UP PAYING A FAIR AND REASONABLE AMOUNT FOR ITS PORTION OF THE WORK. ALL UNBALANCED BIDS ARE SUBJECT TO REJECTION. ttai Addendum(a) No(s).JX. _ has/have been received and is/are included in this proposal. The Undersigned has carefully checked all of the above figures and understands that the District will not be responsible for any error or omission on the part of the Undersigned in preparing this bid. The Undersigned agrees that in case of default in executing the required Contract with necessary bonds and insurance policies within twenty (20) days from the date of award of Contract by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, the District may administratively authorize award of the contract to the second or third lowest bidder and the bid security of the lowest bidder may be forfeited. The Undersigned bidder declares, under penalty of perjury, that the undersigned is licensed to do business or act in the capacity of a contractor within the State of California, validly licensed under license number 58792Q _ , classification "A" _ which expires on 2/28/2006 _ , and that this statement is true and correct and has the legal effect of an affidavit. A bid submitted to the District by a Contractor who is not licensed as a contractor pursuant to the Business and Professions Code shall be considered nonresponsive and shall be rejected by the City § 7028. 15(e). In all contracts where federal funds are involved, no bid submitted shall be invalidated by the failure of the bidder to be licensed in accordance with California law. However, at the time the contract is awarded, the contractor shall be properly licensed. Public Contract Code § 10164. I The Undersigned bidder hereby represents as follows: L 1. That no Board of Directors member, officer, agent, or employee of the Carlsbad Municipal Water I = District is personally interested, directly or indirectly, in this Contract, or the compensation to be paid j ; hereunder; that no representation, oral or in writing, of the Board of Directors, its officers, agents, or employees has inducted him/her to enter into this Contract, excepting only those contained in this form of Contract and the papers made a part hereof by its terms; and 2. That this bid is made without connection with any person, firm, or corporation making a bid for the same work, and is in all respects feir and without collusion or fraud. i " Accompanying this proposal is Bond (Cash, Certified Check, Bond or Cashier's Check) for ten percent (10%) of the amount bid. Revised: 10/08/03 Contract No. 39561-A Page 21 of 82 Pages State Of Cafifarnk CONTRACTORS STATE UCOISE BOARD - ACTIVE LICENSE. 587920 ^ CORP J FLETCHER CREAMER & SON INC A"! 02/28/2006 1 License Detail Page 1 of2 California Home Welcome to Thursday, Decemf License Detail Contractor License # 587920 CALIFORNIA .CONTRACTORS, STATE LiCEN DISCLAIMER A license status check provides information taken from the CSLB license data base. Before on this information, you should be aware of the following limitations: i • CSLB complaint disclosure is restricted by law (B&P7124.6). If this entity is subject tc complaint disclosure, a link for complaint disclosure will appear below. Click on the lin button to obtain complaint and/or legal action information. • Per B&P 7071.17, only construction related civil judgments reported to the CSLB are disclosed. • Arbitrations are not listed unless the contractor fails to comply with the terms of the arbitration. • Due to workload, there may be relevant information that has not yet been entered ont Board's license data base. * * * Extract Date: 12/08/2005 Business Information J FLETCHER CREAMER & SON INC 12874 SAN FERNANDO ROAD SYLMAR, CA91342 Business Phone Number: (818) 367-9748 Entity: Corporation Issue Date: 02/06/1990 Expire Date: 02/28/2006 * * *License Status This license is current and active. All information below should be reviewed. * * *Classifications * * * Class Description 'A .GENERAL ENGINEER!NG CONTRACTOR * * *Bonding Information * * * CONTRACTOR'S BOND: This license filed Contractor's Bond number 687198 in the ami $10,000 with the bonding company http://www2.cslb.ca.gov/CSLB_LIBRARY/License+Detail.asp 12/08/2005 License Detail Page 2 of 2 SURETY COMPANY OF THE PACIFIC. Effective Date: 01/01/2004 Contractor's Bonding History BOND OF QUALIFYING INDIVIDUAL(I): This license filed Bond of Qualifying Individual i 9086778 for JOHN ANTHONY SOLIS in the amount of $7,500 with the bonding comp AMERICAN CONTRACTORS INDEMNITY COMPANY. Effective Date: 10/05/2004 * * * Workers Compensation Information * * * This license has workers compensation insurance with the TRAVELERS PROPERTY CASUALTY COMPANY OF AMERICA Policy Number: RTC2JUB4683B30A05 Effective Date: 03/31/2005 Expire Date: 03/317 Workers Compensation History Personnel listed on this license (current or disassociated) are listed on other licei Personnel List Other Licenses [LicenseNumber Request [contractor Name Request Personnel Name Request I Salesperson Request •Salesperson Name Request © 2005 State of California. Conditiqns_ofJJse Privacy Policy http://www2.cslb.ca.gov/CSLB_LIBRARY/License+Detail.asp 12/08/2005 L The Undersigned is aware of the provisions of section 3700 of the Labor Code which requires every employer to be insured against liability for workers' compensation or to undertake self-insurance in accordance with the provisions of that code, and agrees to comply with such provisions before commencing the performance of the work of this Contract and continue to comply until the contract is complete. p to the general prevailing rate of wages for each craft or type of worker needed to execute the The Undersigned is aware of the provisions of the Labor Code, Part 7, Chapter 1, Article 2, relative to the general prevailing rate of wages for eacl Contract and agrees to comply with its provisions. IF A SOLE OWNER OR SOLE CONTRACTOR SIGN HERE: (1) Name under which business is conducted N/A (2) Signature (given and surname) of proprietor (3) Place of Business ' (Street and Number) City and State (4) Zip Code Telephone No. (5) E-Mail Address IF A PARTNERSHIP. SIGN HERE: (1) Name under which business is conducted N/A (2) Signature (given and surname and character of partner) (Note: Signature must be made by a general partner) (3) Place of Business (Street and Number) City and State (4) Zip Code Telephone No. (5) E-Mail Address Revised: 10/08/03 Contract No. 39561-A Page 22 of 82 Pages IF A CORPORATION. SIGN HERE: (1) Name under which business is conducted J. Fletcher Creamer & Son, Inc. Bree Zinsmeister Corporate Agent (Title) (3) Incorporated under the laws of the State of New Jersey (4) Place Of Business 12874 San Fernando Rnad (Street and Number) City and State Sylmar, California Impress Corporate Seal here (5) Zip Code 91342 Telephone No. 818.367.9748 (6) E-Mail Address bzinsmeister@jfcson.com NOTARIAL ACKNOWLEDGMENT OF EXECUTION BY ALL SIGNATORIES MUST BE ATTACHED List below names of president, vice president, secretary and assistant secretary, if a corporation; if a partnership, list names of all general partners, and managing partners: J. Fletcher Creamer, GEO Glenn L. Creamer, Executive VP George Kreis, VP-Operations Joseph T.Walsh, VP - Utilities John Martin, Treasurer J. Fletcher Creamer, Jr., President Dale A. Creamer, VP Brad Jorrey, VP- Heavey Const. Andrew Clark Wood, CFO Es'telle R. Marafino, Secretary Revised: 10/08/03 Contract No. 39561-A Page 23 of 82 Pages J. FLETCHER CREAMER & SON, INC. CONTRACTORS "AN EQUAL OPPORTUNITY EMPLOYER" 101 EAST BROADWAY, HACKENSACK, NEW JERSEY 07601 (201) 488-9800 Corporate Officer Name Number & Street City, State & Zip Chief Executive Officer/Director President/Director Executive Vice President/Director Vice President/Director Vice President - Operations Vice President - Heavy Const. e President - Utilities Chief Financial Officer Treasurer Secretary J. Fletcher Creamer J. Fletcher Creamer, Jr. Glenn L. Creamer Dale A. Creamer George Kreis Brad Jorrey Joseph T. Walsh Andrew Clark Wood John Martin Estelle R. Marafino 101 East Broadway 101 East Broadway 175 Chestnut Ridge Road 426 Airmount Avenue 47 Mill Road RD 2 - Bartbull Road 23 Winding Brook Way 40 Sheffield Road 3 Newark Avenue 41 Van Orden Road Hackensack, NJ 07601 Hackensack, NJ 07601 Saddle River, NJ 07458 Ramsey, NJ 07446 Woodcliff Lake, NJ 07675 Middletown, NY 10940 Shrewsbury, NJ 07702 Summit, NJ 07901 Westwood, NJ 07675 Harrington Park, NJ 07640 Directors Name J. Fletcher Creamer J. Fletcher Creamer, Jr. Glenn L. Creamer Dale A. Creamer Number & Street City. State & Zip Hackensack, NJ 07601 Hackensack, NJ 07601 101 East Broadway 101 East Broadway 175 Chestnut Ridge Road Saddle River, NJ 07458 426 Airmount Avenue Ramsey, NJ 07446 CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT State of California County of Los Angeles ss. On November 29, 2005before me, James Allen Dale Name and Title of Officer (e.g., "Jane Doe, Notary Public") personally appeared J.Fletcher Creamer, J. Fletcher Creamer, Jr.. iGlenn L. Creamer, Dale A. Creamer^5"*818™'8' IGeorge Kreis, Brad Jorrey D personally known to me fjoseph T. Walsh, Andrew C. Wood « P^ved to me on the basis of satisfactory |John Martin, Estelle R. Marafino evidence to be the person(s) whose name(s) is/are subscribed to the within instrument and acknowledged to me that hXXQS/they executed the same in ljj§(tjer/their authorized capacity(ies), and that by XlMKKr/their signature(s) on the instrument the person(s), or the entity upon behalf of which the person(s) acted, executed the instrument.JAMES AUEN Comrrteton # 1594921 Notary Pubte - CoMomto Los Angeles County My Comm. Expires Jul 14.2009 WITNE tiand and official seal. Signature of Notary Public OPTIONAL Though the information below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Document Date: Signer(s) Other Than Named Above:. Capacity(ies) Claimed by Signer Signer's Name: D Individual D Corporate Officer — Title(s): D Partner — D Limited D General n Attorney-in-Fact D Trustee D Guardian or Conservator D Other: Signer Is Representing:_ . Number of Pages:. RIGHT THUMBPRINT OF SIGNER Top of thumb here © 1999 National Notary Association • 9350 De Soto Ave., P.O. Box 2402 • Chatsworth, CA 91313-2402 • www.NationalNotary.org Reorder: Call Toll-Free 1-800-876-6827 J. flfTCHffl CREAMER £ SON, INC. To Whom It May Concern: This will confirm that Natalie Bree Zinsmeister, of J. Fletcher Creamer & Son, Inc., has authority to sign bids for work to be performed on behalf of the Company. J. FLETCHER CREAMER & SON, INC. By:y ____ J. raetcher Creamer, Jr., President/ Attest: .. Hofheinz/Xssistant EQUIPMENT/MATERIAL SOURCE INFORMATION TO ACCOMPANY PROPOSAL SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A The bidder shall indicate opposite each item of equipment or material listed below, the name of the one supplier and manufacturer of each item or equipment or material proposed to be furnished under the bid. Awarding of a contract under this bid will not imply approval by District or the manufacturers listed by the Bidder. Equipment/Material Manufacturer 1. 30-inch diameter CML tape wrapped and mortar coated steel pipe transmission *yp main. AjficT^ UJt"5"f rfr 2. 30-inch butterfly valve i TATT r Revised: 10/08/03 Contract No. 39561-A Page 24 of 82 Pages BID SECURITY FORM (Check to Accompany Bid) SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A (NOTE: The following form shall be used if check accompanies bid.) Accompanying this proposal is a *Certified *Cashiers check payable to the order of CARLSBAD MUNICIPAL WATER DISTRICT, in the sum of dollars ($_ this amount being ten percent (10%) of the total amount of the bid. The proceeds of this check shall become the property of the District provided this proposal shall be accepted by the District through action of its legally constituted contracting authorities and the undersigned shall fail to execute a contract and furnish the required Performance, Warranty and Payment Bonds and proof of insurance coverage within the stipulated time; otherwise, the check shall be returned to the undersigned. The proceeds of this check shall also become the property of the District if the undersigned shall withdraw his or her bid within the period of fifteen (15) days after the date set for the opening thereof, unless otherwise required by law, and notwithstanding the award of the contract to another bidder. i.: I: r BIDDER *Bond Issued *Delete the inapplicable word. (Note: If the Bidder desires to use a bond instead of check, the Bid Bond form on the following pages shall be executed—the sum of this bond shall be not less than ten percent (10%) of the total amount of the bid.) L : 10/08/03 Contract No. 39561-A Page 25 of 82 Pages BIDDER'S BOND TO ACCOMPANY PROPOSAL SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A KNOW ALL PERSONS BY THESE PRESENTS: That we. J. Fletcher Creamer & Son . as Principal, and Safeco Tnsnranr,P Cn. . as Surety are held and firmly bound unto the Carlsbad Municipal Water District, Carlsbad, California, in an amount as follows: (must be at least ten percent (10%) of the bid amount) Ten Percent 10% for which payment, well.and truly made, we bind ourselves, our heirs, executors and administrators, successors or assigns, jointly and severally, firmly by these presents. THE CONDITION OF THE FOREGOING OBLIGATION IS SUCH that if the proposal of. the above- bounden Principal for: SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A in the City of Carlsbad, is accepted by the Board of Directors, and if the Principal shall duly enter into and execute a Contract including required bonds and insurance policies within twenty (20) days from the date of award of Contract by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, being duly notified of said award, then this obligation shall become null and void; otherwise, it shall be and remain in full force and effect, and the amount specified herein shall be forfeited to the said District. : 10/08/03 Contract No. 39561 -A Page26of 82 Pages BIDDER'S BOND TO ACCOMPANY PROPOSAL SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A KNOW ALL PERSONS BY THESE PRESENTS: That we. J. FLETCHER CREAMER & SON, INC., as Principal, and SAFECO INSURANCE COMPANY OF AMERICA as Surety are held and firmly bound unto the Carlsbad Municipal Water District, Carlsbad, California, in an amount as follows: (must be at least ten percent (10%) of the bid amount) TEN PERCENT OF THE TOTAL * for which payment, well.and truly made, we bind ourselves, our heirs, executors and administrators, successors or assigns, jointly and severally, firmly by these presents. *AMOUNT BID ($—10%—) THE CONDITION OF THE FOREGOING OBLIGATION IS SUCH that If the proposal of the above- bounden Principal for: SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A in the City of Carlsbad, is accepted by the Board of Directors, and if the Principal shall duly enter into and execute a Contract including required bonds and insurance policies within twenty (20) days from the date of award of Contract by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, being duly notified of said award, then this obligation shall become null and void; otherwise, it shall be and remain in full force and effect, and the amount specified herein shall be forfeited to the said District. VRevised: 10/08/03 Contract NO. 39561-A Pane. •>«/*«<) In the event Principal executed this bond as an.individual, it is agreed that the death of Principal shall not exonerate the Surety from its obligations under this bond. Executed by PRINCIPAL this 29TH day of NOVEMBER , 20 05 , PRINCIPAL: J. FLETCHER CREAMER & SON. INC. (name of Principal) By:ty (/ (sign he/fc / J. FLETCHER CREAMER, JR. President Executed by SURETY this 29TH day of NOVEMBER , 20 05 . SURETY: SAFECO INSURANCE COMPANY OF AMERICA (name of Surety) 1200 MACARTHUR BOULEVARD MAHWAH. NJ 0743Q (address of Surety) 201-327-7606 (telephone number of Surety) (print name here) J. FLETCHER CREAMER & SON INC. (Trtle and,Organization of Signatory) BvJ %Z£^L (C- (sign hire) Corporate Secretary By: (signature of Attomsy-ln-Fact) CHERYL R. COLEMAN (printed name of Attomey-in-Fact) (Attach corporate resolution showing' current power of attorney.)(print name here) J. FLETCHER CREAMER & SON INC. (title and organization of signatory) (Proper notarial acknowledge of execution by PRINCIPAL and SURETY must be attached.) (President or vice-president and secretary .or assistant secretary must sign for corporations. If only one officer signs, the corporation must .attach a resolution certified by the secretary or assistant secretary under corporate seal empoviering .that officer to bind the corporation.) ' i ' (If signed by an individual partner, the partnership must attach a statement of partnership authorizing the partner to execute this instrument.) APPROVED AS TO FORM: RONALD R. BALL General Counsel Deputy General Couns V.Revised: 10/08/03 Contract No. 39561-A Pane 27 of 82 Pages •; TOTPL P.06 ACKNOWLEDGMENT BY PRINCIPAL, IF A CORPORATION STATE OP NEW JERSEY COUNTY OF Bergen On this 29TH day of NOVEMBER 2005 before me personally came J. Fletcher Creamer, Jr. to me known to be the person duly sworn, did depose and say, that he/she resides in Park Ridge. NJ that he/she is President of J. FLETCHER CREAMER & SON, INC. the corporation described in and which executed the foregoing instrument; that he/she knew the seal of said corporation; that the seal affixed to said instrument was such corporate seal; that it was affixed by order of the Board of Directors of said corporation, and that he/she signed his/her name thereto by like order. Sworn before me the date set forth above Notary Public RAFFAELLA BELLINI NOTARY PUBLIC STATE OF NEW JERSEY MY COMMISSION EXPIRES SEPT. 20,2007 ID # 2292025 ACKNOWLEGEMENT OF SURETY STATE OF NEW JERSEY COUNTY OF MORRIS On this 29th day of November 2005, before me personally came Cheryl R. Coleman , to me known, who being duly sworn, did depose and say that he/she is an Attorney-In-Fact of Safeco Insurance Company of America _ and knows the corporate seal thereof; that the seal affixed to said annexed instrument is such corporate seal; and was thereto affixed by authority of the Power of Attorney of said Company, of which a Certified Copy is hereto attached, and that he/she signed said instrument as an Attorney-In-Fact of said Company by like authority. My Commission Expires CHARLOTTE GOODMAN Notary Public Notary Public Of New Jersey My Commission Expires April 21, 2008 SAFECO INSURANCE COMPANY OF AMERICA GENERAL INSURANCE COMPANY OF AMERICA FIRST NATIONAL INSURANCE COMPANY OF AMERICA HOME OFFICE SAFECO PLAZA SEATTLE. WASHINGTON »t\K CONSENT OF SURETY We, the undersigned, SAFECO INSURANCE COMPANY OF AMERICA, a corporation organized and existing under the laws of the State of Washington and authorized to do business in the State CALIFORNIA with offices at 1200 MACARTHUR BLVD., MAHWAH, NJ 07430 do hereby consent and agree with CARLSBAD MUNICIPAL WATER DISTRICT, CA that if the foregoing proposal of J. FLETCHER CREAMER & SON, INC. for SAN MARCOS BOULEVARD - TRANSMISSION MAIN AND STREET IMPROVEMENTS - CONTRACT NO. 39561-A be accepted and the contract be timely awarded and executed by J. FLETCHER CREAMER & SON, INC. we will, upon its being so awarded and entered into, become surety for the said J. FLETCHER CREAMER & SON, INC. in a sum not to exceed ONE HUNDRED PERCENT OF THE TOTAL CONTRACT AMOUNT Dollars ($ 100%- payment of said contract. •) for the faithful performance and Signed, sealed and dated this 29TH day of NOVEMBER, 2005. SAFECO INSURANCE COMPANY OF AMERICA BY: Cheryl R\.\ Coleman, Attorney-In-Fact Safeco POWER OF ATTORNEY Safeco Insurance Companies PO Box 34526 Seattle, WA 98124-1526 12893 KNOW ALL BY THESE PRESENTS:No. That SAFECO INSURANCE COMPANY OF AMERICA and GENERAL INSURANCE COMPANY OF AMERICA, each a Washington corporation, does each hereby appoint CHERYL R. COLEMAN; JEFFREY R. KANE; MARIA RODRIGUES; MARC N. WALDOR; PETER R. WALDOR; P3rk New jgrsgv********^*^*****"*"^*^*******^ its true and lawful attomey(s}-in-fact, with full authority to execute on its behalf fidelity and surety bonds or undertakings and other documents of a similar character issued in the course of its business, and to bind the respective company thereby. IN WITNESS WHEREOF, SAFECO INSURANCE COMPANY OF AMERICA and GENERAL INSURANCE COMPANY OF AMERICA have each executed and attested these presents this 13th day of September 2005 STEPHANIE DALEY-WATSON.SECRETARY MIKE PETERS. PRESIDENT. SURETY CERTIFICATE Extract from the By-Laws of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA: "Article V, Section 13. - FIDELITY AND SURETY BONDS ... the President, any Vice President, the Secretary, and any Assistant Vice President appointed for that purpose by the officer in charge of surety operations, shall each have authority to appoint individuals as attorneys-in-fact or under other appropriate titles with authority to execute on behalf of the company fidelity and surety bonds and other documents of similar character issued by the company in the course of its business... On any instrument making or evidencing such appointment, the signatures may be affixed by facsimile. On any instrument conferring such authority or on any bond or undertaking of the company, the seal, or a facsimile thereof, may be impressed or affixed or in any other manner reproduced; provided, however, that the seal shall not be necessary to the validity of any such instrument or undertaking." Extract from a Resolution of the Board of Directors of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA adopted July 28, 1970. "On any certificate executed by the Secretary or an assistant secretary of the Company setting out, W The provisions of Article V, Section 13 of the By-Laws, and (ii) A copy of the power-of-attomey appointment, executed pursuant thereto, and (iii) Certifying that said power-of-attomey appointment is in full force and effect, the signature of the certifying officer may be by facsimile, and the seal of the Company may be a facsimile thereof." I, Stephanie Daley-Watson , Secretary of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA, do hereby certify that the foregoing extracts of the By-Laws and of a Resolution of the Board of Directors of these corporations, and of a Power of Attorney issued pursuant thereto, are true and correct, and that both the By-Laws, the Resolution and the Power of Attorney are still in full force and effect. IN WITNESS WHEREOF, I have hereunto set my hand and affixed the facsimile seal of said corporation this 29th day of November 2005 S-0974/DS 4/05 STEPHANIE DALEY-WATSON, SECRETARY Safeco® and the Safeco logo are registered trademarks of Safeco Corporation. WEB PDF SAFECO INSURANCE COMPANY OF AMERICA FINANCIAL STATEMEJvT — DECEMBER 31, 2004 Assets Cash and Bank Deposits S (52,492,321) *Bonds — U.S Government 251,982.058 "Other Bonds 2,582,533.516 *Stocks 444,878,607 Real Estate 9,485,908 Agents' Balances or Uncollectsd Premiums 367,916,616 Accrued Interest and Rents 39,230,044 Other Admitted Assets 342.067.106 Total Admitted Assets. Liabilities Unearned Premiums Reserve for Claims and Claims Expense Funds Held Under Reinsurance Treaties Reserve for Dividends to Policyholders , Additional Statutory Reserve...., Reserve for Commissions, Taxes and Other Liabilities Total. Capital Stock J 5,000,000 Paid in Surplus 233,187,958 Unassigned Surplus 805.209.270 Surplus to Policyholders „ Total Liabilities and Surplus.. S 730,499,599 ...1,590,324.590 114,437 836,898 440.428.802 £2,742,204,306 1.043.397.228 * Bonds are stated at amortized or investment value; Stocks at Association Market Values. Securities carried at SI 53,000,775 are deposited as required by law. I MICHAEL C. PETERS, president of SAFBCO Insurance Company, do hereby certify that the foregoing is a true, and correct statement of fee Assets and Liabilities of said Corporation, as of December 31, 2004, to the best of my knowledge and belief. IN WITNESS WHEREOF, I have hereunto set mv hand and affixed the seal of said Corporation at Seattle, Washington, this 1st day of March, 2005. President S-12622 3/02 6> A registered trademark of SAFECO Corporation GUIDE FOR COMPLETING THE "DESIGNATION OF SUBCONTRACTORS" FORM REFERENCES Prior to preparation of the following Subcontractor disclosure form Bidders are urged to review the definitions in section 1-2 of the SSPWC ("Greenbook") and in the Supplemental Provisions to this Contract, especially, "Bid", "Bidder", "Contract", "Contractor", "Contract Price", "Contract Unit Price", "Engineer", "Subcontractor" and "Work" and the definitions in section 1-2 of the Supplemental Provisions especially "Own Organization." Bidders are further urged to review sections 2-3 SUBCONTRACTS of the Greenbook and section 2-3.1 of these Supplemental Provisions. CAUTIONS This form will be used by the Agency to determine the percentage of work that the Bidder proposes to perform. Bidders are cautioned that failure to provide complete and correct information may result in rejection of the bid as non-responsive. Any bid that proposes performance of more than 50 percent of the work by subcontractors or otherwise to be preformed by forces other than the Bidder's own organization will be rejected as non-responsive. Specialty items of work that may be so designated by the Engineer on the "Contractor's Proposal" are not included in computing the percentage of work proposed to be performed by the Bidder. INSTRUCTIONS The Bidder shall set forth the name and location of business of each and every subcontractor whom the Bidder proposes to perform work or labor or render service in or about the work or improvement, and every subcontractor licensed as a contractor by the State of California whom the Bidder proposes to specially fabricate and install any portion of the work or improvement according to detailed drawings contained in the plans and specifications in excess of one-half of one percent (0.5%) of the Bidder's total bid or, in the case of bids or offers for the construction of streets and highways, including bridges, in excess of one-half of one percent (0.5%) or ten thousand dollars ($10,000) whichever is greater. Said name(s) and location(s) of business of subcontractor(s) shall be set forth and included as an integral part of the bid offer. The Designation of Subcontractors form must be submitted as a part of the Bidder's sealed bid. Failure to provide complete and correct information may result in rejection of the bid as non- responsive. Suppliers of materials from sources outside the limits of work are not subcontractors. The value of materials and transport of materials from sources outside the limits of work, as shown on the plans, shall be assigned to the Contractor or the Subcontractor as the case may be, that the Bidder proposes as installer of said materials. The value of material incorporated in any Subcontractor- installed bid item that is supplied by the Bidder shall be included as a part of the work that the Bidder proposes to be performed by the Subcontractor installing said item. When a Subcontractor has a Carlsbad business license, the number must be entered on the proper form. If the Subcontractor does not have a valid business license, enter "NONE" in the appropriate space. When the Bidder proposes using a Subcontractor to construct or install less than 100 percent of a bid item, the Bidder shall attach an explanation sheet to the Designation of Subcontractor form. The explanation sheet shall clearly apprise the City of the specific facts that show the Bidder proposes to perform no less than fifty percent (50%) of the work with its own forces. Revised: 10/08/03 Contract No. 39561-A Page 28 of 82 Pages Determination of the subcontract amounts for purposes of award of the contract shall be determined by the Board of Directors in conformance with the provisions of the contract documents and the Supplemental Provisions. The decision of the Board of Directors shall be final. Contractor is prohibited from performing any work on this project with a subcontractor who is ineligible to perform work on a public works project pursuant to Labor Code Sections 1771.1 or 1777.7. Bidders shall make any additional copies of the disclosure forms as may be necessary to provide the required information. The page number and total number of additional form pages shall be entered in the location provided on each type of form so duplicated. Revised: 10/08/03 Contract No. 39561-A Page 29 of 82 Pages DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID ITEMS SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A The Bidder certifies that it has used the sub-bid of the following listed subcontractors in preparing this bid for the Work and that the listed subcontractors will be used to perform the portions of the Work as designated in this list in accordance with applicable provisions of the specifications and section 4100 et seq. of the Public Contract Code, "Subletting and Subcontracting Fair Practices Act." The Bidder further certifies that no additional subcontractor will be allowed to perform any portion of the Work in excess of one-half of one percent (0.5%) of the Bidder's total bid, or in the case of bids or offers for construction of streets and highways, including bridges, in excess of one-half of one percent (0.5%) or ten thousand dollars ($10,000), whichever is greater, and that no changes in the subcontractors listed work will be made except upon the prior approval of the Agency. SUBCONTRACTOR'S BID ITEMS Portion U ctn A <«r n O'» f\d c.r\ i p> n c. Subcontractor Name and Location of Business r V n tvi H A r\ A ex^c-.•» V\ \A c\ CA CA C.C ITS rv\fvO>, A ^ Li L**vie. 4A- L S H fe J 1 \ V Ccrcna. , C A Licenc A df by Subcbntractor (,47.20 \ 65") t>S"O.. QQ 1 i4 co Subcontractor's License No.* Page \ of "2- pages of this Subcontractor Designation form Pursuant to section 4104 (a)(2)(A) California Public Contract Code, receipt of the information preceded by an asterisk may be submitted by the Bidder up to 24 hours ater the deadline for submitting bids contained in the "Notice Inviting Bids." Revised: 10/08/03 Contract No. 39561-A Page 30 of 82 Pages DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID ITEMS SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A The Bidder certifies that it has used the sub-bid of the following listed subcontractors in preparing this bid for the Work and that the listed subcontractors will be used to perform the portions of the Work as designated in this list in accordance with applicable provisions of the specifications and section 4100 et seq. of the Public Contract Code, "Subletting and Subcontracting Fair Practices Act." The Bidder further certifies that no additional subcontractor will be allowed to perform any portion of the Work in excess of one-half of one percent (0.5%) of the Bidder's total bid, or in the case of bids or offers for construction of streets and highways, including bridges, in excess of one-half of one percent (0.5%) or ten thousand dollars ($10,000), whicheyer is greater, and that no changes in the subcontractors listed work will be made except upon the prior approval of the Agency. SUBCONTRACTOR'S BID ITEMS Pprtioji^fVyorK* FVst-,V^\V Pru^rNft ' " ' ' Jl Sicy^>\S J \XA Subcontractor Name and Location of Business F\\\ P\Toe<-;e^cv PVspV^A V f*~ S" ^\- L--* t' fr'X'N'^e. ^^ ^- Ci T O T ^ ~ *t ^•(cct ^lecfrtc LiC^^-^O^f.p.o.t?oy m^ ^>"ivto^ol^ci CA ^i^"^^' Amount of Work by Subcontractor in Dollars* MV*. ^SU'it IQ'ii'WO.OO Subcontractor's License No.* Page "2- of 'Z. pages of this Subcontractor Designation form * Pursuant to section 4104 (a)(2)(A) California Public Contract Code, receipt of the information preceded by an asterisk may be submitted , by the Bidder up to 24 hours ater the deadline for submitting bids contained in the "Notice Inviting Bids." Revised: 10/08/03 Contract No. 39561-A Page 30 of 82 Pages BIDDER'S STATEMENT OF FINANCIAL RESPONSIBILITY (To Accompany Proposal) SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A Copies of the latest Annual Report, audited financial statements or Balance Sheets may be submitted under separate cover marked CONFIDENTIAL. Please See Attached J. Fletcher Creamer & Son, Inc. Ra I Ending December 31, 2004. evised: 10/08/03 Contract No. 39561-A Page 31 of 82 Pages J. Fletcher Creamer & Son, Inc. Balance Sheets Year Ended December 31, 2004 J. Fletcher Creamer & Son, Inc. Index to Financial Statements Year Ended December 31, 2004 Page Independent Auditors' Report 1 Balance Sheets 2 Notes to Financial Statements 3 SAX MACY FROMM S CO..PC CERTIFIED PUBLIC ACCOUNTANTS AND CONSULTANTS Independent Auditors' Report To the Board of Directors and Stockholders of J. Fletcher Creamer & Son, Inc.: We have audited the accompanying balance sheets of J. Fletcher Creamer & Son, Inc. as of December 31, 2004 and 2003. These financial statements are the responsibility of the Company's management. Our responsibility is to express an opinion on these financial statements based on our audits. We conducted our audits in accordance with auditing standards generally accepted in the United States of America. Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements. An audit also includes assessing the accounting principles used and significant estimates made by management, as well as evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion. In our opinion, the financial statements referred to above present fairly, in all material respects, the financial position of J. Fletcher Creamer & Son, Inc. as of December 31, 2004 and 2003, and the results of its operations and its cash flows for the years then ended in conformity with accounting principles generally accepted in the United States of America. Sax Macy Fromm & Co., PC Certified Public Accountants Clifton, New Jersey March 21, 2005 855 VALLEY ROAD • CLIFTON, NJ 07013 • TEL (973) 472-6250 • FAX (973) 472-7172 • WWW.SMF-CPA.COM NEW JERSEY • NEW YORK • CONNECTICUT • FLORIDA Assets J. Fletcher Cr Balar Current Assets: Cash and cash equivalents Marketable equity securities Requisitions, accounts, retainages, and other receivables, net of allowance for doubtful accounts of $257,130 and $637,296 in 2004 and 2003, respectively Costs and estimated earnings in excess of billings on contracts in progress Inventory Prepaid expenses and other current assets Total Current Assets December 31, 2004 $ 1,839,562 334,628 43,095,259 5,951,306 1,637,696 2.055,217 December 31, 2003 $ 2,971,072 370,435 38,134,446 8,322,257 1,582,379 1,307.462 $54,913,668 $ 52,688,051 Property and Equipment: Land improvements 164,789 Leasehold improvements 2,938,938 Furniture and fixtures 541,416 Helicopter 320,006 Construction and automotive equipment 56,353,544 Computer equipment 1,649,543 Total 61,968,236 Less: Accumulated depreciation and amortization 47,644,103 Net Property and Equipment Other Assets: Investment in joint ventures 1,142,610 Other assets 874,446 Total Other Assets 14,324,133 164,789 2,800,276 528,908 320,006 54,463,391 1,619,347 59,896,717 44.431,759 1,046,025 885,215 15,464,958 2.017.056 1.931,240 Total Assets $71,254,857 $ 70,084,249 The Accompanying Notes are an Inh -3- J. Fletcher Creamer & Son, Inc. Notes to Financial Statements Note 1 - Summary of Significant Accounting Policies: A. Nature of Business - J. Fletcher Creamer & Son, Inc. (the Company) is a construction contractor with operations throughout the United States. The principal services of the Company include heavy and general construction, the construction and installation of various roadwork barriers, curbs, guiderails, and signs, the installation of gas, water, and sewer mains, electric and fiber optic conduit, fiber optic cable, and the cleaning and lining of water and sewer mains. The work is performed under fixed price, unit price, and time and material contracts. The length of the Company's contracts varies, but is typically less than three years. B. Method of Accounting for Income from Construction Contracts - Income from long-term construction contracts is recognized under the percentage-of-completion method. Under this method estimated profit to be earned upon completion of a contract is recognized in the proportion that direct costs incurred to date bears to estimated total costs to complete the contract. Cost and profit estimates are subject to revision as contracts extend over one or more periods, and any required adjustments are made in the period in which revisions become known. Provisions are made for the full amount of anticipated losses in the period in which they are first determinable. Claims for additional contract revenues are recognized to the extent of costs incurred if it is probable that the claim will result in additional revenue and the amount can be reliably estimated. Profit on such claims is not recognized until the claims have been allowed. Revenues earned from time and material contracts are recognized on the basis of costs incurred during the period plus the fee earned, measured by the cost-to- cost method. The asset, "Costs and estimated earnings in excess of billings on contracts in progress", represents revenue recognized in excess of amounts billed. The liability, "Billings in excess of costs and estimated earnings on contracts in progress", represents billings in excess of revenues recognized. C. Estimates - The preparation of financial statements in conformity with accounting principles generally accepted in the United States of America requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities and disclosure of contingent assets and liabilities at the date of the financial statements and the reported amounts of revenues and expenses during the reporting period. Actual results could differ from those estimates. D. Balance Sheet Classification - In accordance with industry practice, the Company includes in current assets and liabilities amounts realizable and payable under long-term construction contracts. These contracts extend to periods of up to three years. E. Marketable Equity Securities - Marketable equity securities are classified as available for sale and are carried at fair market value. The cost of securities sold is based on specific identification. -4- Note 1 - Summary of Significant Accounting Policies (Continued): F. Inventory - Inventory is stated at the lower of cost (determined on a first-in, first-out basis) or market, and consists principally of job materials that have been purchased for construction contracts. G. Property and Equipment - Property and equipment are recorded at cost and items are depreciated under the accelerated and straight line methods. Depreciation is provided in amounts sufficient to write off the cost of depreciable assets, less salvage value, over their estimated useful lives. H. Income Taxes - The Company, with the consent of its stockholders, has elected under the Internal Revenue Code and New Jersey Tax Code to be taxed as an S Corporation. In lieu of corporate federal income taxes, the stockholders of an S Corporation are taxed on their proportionate share of the Company's taxable income. Therefore, no provision or liability for federal income taxes has been included in these financial statements. The provision for state taxes has been computed at the reduced rate allowed for New Jersey S Corporations. The Company will continue to be subject to state taxes of those jurisdictions in which it currently operates at the applicable state tax rates. I. Cash Equivalents - For purposes of the statements of cash flows, the Company considers all highly liquid debt instruments purchased with a maturity of three months or less to be cash equivalents. J. Concentration of Credit Risk for Cash Held at Banks - The Company maintains cash balances at several banks. Accounts at each institution are insured by the Federal Deposit Insurance Corporation up to $100,000. The Company invests excess cash in high quality money market mutual funds which subjects the Company to concentrations of credit risk. K. Reclassifications - Certain reclassifications have been made to prior year amounts in order to conform to the current year presentation. Note 2 - Unbilled Accounts Receivable: Included in requisitions, accounts, retainages, and other receivables are unbilled accounts receivable of $1,591,458 and $363,228 as of December 31, 2004 and 2003, respectively, which were substantially billed in the following month. -5- Note 3 - Marketable Equity Securities: Marketable equity securities are classified as available-for-sale securities. Available-for-sale securities are recorded at fair value, with the change in fair value during the period excluded from retained earnings and recorded as a separate component of equity. Cost and fair values of marketable equity securities at December 31, 2004 and 2003, are as follows: Cost Unrealized Fair Basis Gain Value December 31. 2004 Equity securities $ 215.749 $ 118,879 $ 334,628 December 31. 2003 Equity securities $ 220,358 $ 150,077 $ 370,435 The change in the net unrealized gain (loss) on marketable equity securities included in stockholders' equity was ($31,198) and $794,133 for the years ended December 31, 2004 and 2003, respectively. Note 4 - Investment in Joint Ventures: The Company is accounting for its investment in joint ventures by recording the investment in the balance sheet under the equity method of accounting under which the Company's share of the net income for the joint venture is added to the investment account, and distributions received from the joint venture are treated as a reduction of the investment account. In the income statement the Company's proportionate share of revenues and expenses of the joint ventures are presented separately as revenues and expenses. -6- Note 4 - Investment in Joint Ventures (Continued): The Company has a one-third interest in Bishop-Sanzari-Creamer (a Joint Venture). The joint venture performs heavy highway and general construction services throughout Northern New Jersey. The condensed financial information of Bishop-Sanzari-Creamer as of and for the years ended December 31, 2004 and 2003 consisted of the following: December 31 2004 2003 Balance Sheet Total current and total assets Total current and total liabilities Total partners' capital Total Liabilities and Partners' Capital $ 8,964,804 $ 7,442,616 3.112.278 2.826.620 $ 12.077.082 Year Ended December 31 2004 2003 $ $_ 39,508,537 38,991,095 517,442 (243,361) 11,577 .285,658 $ $ 39,359,656 35,382,713 3,976,943 (298,992) 6,876 3,684,827 Income Statement Contract revenue earned Cost of revenue earned Gross Profit General and administrative expenses Other income Net Income Distributions received from the joint venture for the years ended December 31, 2004 and 2003 amounted to $-0- and $1,537,500, respectively. The Company also has a 50% interest in Mitchell/J. Fletcher (a Joint Venture). The Company also had a 50% interest in S.M. Electric/J. Fletcher Creamer (a Joint Venture) which was completed as of December 31, 2003. The condensed financial information of these joint ventures as of December 31, 2004 included current and total assets of $216,635, total liabilities of $13,326, total partners' capital of $203,309, and net income of $2,732. The condensed financial information of these joint ventures as of December 31, 2003 included current and total assets of $234,248, total liabilities of $26,612, total partners' capital of $207,636, and net loss of $221,734. -7- Note 5 - Contracts in Progress: Contracts in progress are summarized as follows: December 31 2004 2003 Total contract prices, including approved extras Estimated gross profit on completion Estimated Total Direct Costs $ 278,151,791 $ 336,640,090 19.694.445 31.521,166 $ 258,457,346 $ 305,118,924 Direct costs incurred to date Gross profit recognized to date Contract Revenue Earned to Date Billings to date Net Overbillings 159,517,141 8,188.889 167,706,030 169.534.159 165,011,759 13,616,462 178.628,221 178.973.393 $ (1.828,129) $ (345,172) The net billings in excess of contract revenue earned on contracts in progress on the above contracts are included in the balance sheet under the following captions: December 31 2004 2003 Costs and estimated earnings in excess of billings on contracts in progress Billings in excess of costs and estimated earnings on contracts in progress Net Overbillings $ 5,951,306 $ 8,322,257 (7,779,435)(8,667.429) $ (1,828,129) $ (345,172) The Company has entered into certain contracts in which estimated costs have been revised. As a result of these revisions, losses are anticipated to be incurred on these contracts. Provision has been made and management's estimates of these losses are included on the Company's balance sheet under the liability "Accrued losses on contracts in progress". Note 6 - Short-Term Borrowings: The Company has a revolving line of credit with Wachovia Bank in the amount of $14,000,000. The Company had $6,425,000 and $7,100,000 in outstanding borrowings as of December 31, 2004 and 2003, respectively. Also, there were $1,178,779 of outstanding letters of credit issued against this line at December 31, 2004 and 2003, each year. Cash is restricted in the amount of $350,424 as of December 31, 2004 due to these outstanding letters of credit. Interest is payable monthly at the bank's floating prime rate, which was 5.25% at December 31, 2004. This agreement is subject to periodic review by the bank and expires on July 31, 2005. The line of credit is personally guaranteed by the stockholders of the Company. -8- Note 6 - Short-Term Borrowings (Continued): The Company is also subject to certain financial covenants and predefined ratios under the agreement, and is precluded from such transactions as mergers, changes in ownership, and repurchases of capital stock without the written consent of the lender. As of December 31, 2004, the Company was in violation of certain covenants. However, the Company has obtained a waiver of the violations from the bank and has renegotiated new covenants with the bank. Note 7 - Notes and Loans Payable: Notes and loans payable at December 31, 2004 and 2003 consisted of the following: December 31 Notes Payable: Fifty-five notes payable collateralized by various construction and computer equipment. The notes bear interest at rates that range between 0% and 9.25% per annum. The average interest rate on these notes is approximately 3.78%. $ Loan Payable for Insurance: A loan payable uncollateralized and bears interest at the rate of 4.32% per annum. Loans Payable to Related Parties: Four loans payable to various related parties. These loans are uncollateralized and bear interest at rates that range between 4% and the prime rate of the Company's lender, which was 5.25% at December 31, 2004. Total Less: Current portion Notes and Loans Payable, Net of Current Portion 2004 372,764 2.178.000 8,291,890 3.954.472 2003 5,741,126 $ 7,934,419 162,875 1.178,000 9,275,294 6,332.119 $ 4.337.418 $ 2.943.175 Maturities of notes and loans payable are as follows: Years Ending December 31 2005 2006 2007 2008 2009 and thereafter Total 3,954,472 1,160,536 1,695,075 303,807 1,178,000 $ 8,291,890 -9- Note 8 - Leases: The Company is obligated under non-cancelable operating leases with certain partnerships whose partners are also stockholders of the Company for office, yard, and warehouse space in New Jersey. The leases require minimum annual rent payments of $42,000 and $456,464 and expire on April 30, 2005 and December 31, 2012, respectively. In addition, the leases call for certain expenses such as real estate taxes, common area maintenance, and insurance. The Company also leases various garage and yard storage space on a month-to-month basis. Rent expense under operating leases, exclusive of construction related equipment rental, for the years ended December 31, 2004 and 2003, amounted to $956,568 and $1,002,953, respectively. Note 9 - Profit-Sharing Plan: The Company has a qualified profit-sharing plan, covering all eligible employees who meet the minimum age and length of service requirements and are not covered by union contracts. The Company provided for profit-sharing plan contributions of $-0- and $325,436 for the years ended December 31, 2004 and 2003, respectively. Note 10 - Contingencies: The Company has various claims and other contingent matters, including the usual liabilities of contractors for completion of contracts, and possible liabilities in connection with performance and indemnity bonds. Management is of the opinion that settlements, if any, will not have a material adverse effect on the financial position of the Company. The Company has an employee medical benefit plan to self-insure claims up to $40,000 per year for each individual covered; with an aggregate liability limit of approximately $1,152,000; claims above the $40,000 are covered by a stop-loss insurance policy. The Company and those employees covered under family coverage contribute to the fund to pay the claims and stop-loss insurance premiums. At December 31, 2004, management believes that the Company has made provisions sufficient to cover estimated claims, including claims incurred but not yet reported. Note 11 - Related Party Transactions: The Company, at times, provides construction services in the form of labor and other related services and purchases materials from various entities that are controlled by the Company's principal stockholders. Following is a summary at December 31, 2004 and 2003 of balances with related parties: December 31 2004 2003 Due from related parties (included in accounts receivable in the accompanying balance sheet) $ 3,464,740 $ 2,897,984 Due to related parties (included in accounts payable, accrued expenses, and other long-term liabilities in the accompanying balance sheet) $ 2,940,042 $ 1,014,429 -10- Note 11 - Related Party Transactions (Continued): Included in the statement of income for the year ended December 31, 2004 are construction contract revenues of $618,844 and construction contract costs of $1,787,581 relating to work performed for these entities. Included in the statement of income for the year ended December 31, 2003 are construction contract revenues of $4,994,036 and construction contract costs of $3,600,455 relating to work performed for these entities. The Company also provides administrative services to related parties. Fees for those services reduced general and administrative expenses for the years ended December 31, 2004 and 2003 and by $450,750 and $325,050, respectively. Note 12 - Contract Backlog (Unaudited): Backlog as of December 31, 2004, is approximately $109,000,000 for signed contracts in existence as of that date. Note 13 - Major Customers: For the year ended December 31, 2004, revenue from two customers totaled $46,921,999. The amount due from these customers included in trade accounts receivable at December 31, 2004 was $7,802,700. For the year ended December 31, 2003, revenue from one customer totaled $33,080,279. The amount due from one customer included in trade accounts receivable at December 31, 2003 was $1,560,438. Note 14- Supplemental Cash Flows Information: A. Cash paid during the years ended December 31, 2004 and 2003 for interest and income taxes was as follows: Year Ended December 31 2004 2003 Interest $ 722,697 $ 664,421 Income taxes $ 2,000 $ 210,167 B. During the years ended December 31, 2004 and 2003, the Company financed the acquisition of certain property and equipment in the amount of $3,173,350 and $6,495,583, respectively. -11 - Note 15 - Pending Adoption of Accounting Standard and Relationship with ReShore Risk Management. Ltd.: In 2003, the Financial Accounting Standards Board (FASB) issued FASB Interpretation No. 46, "Consolidation of Variable Interest Entities" (FIN 46) and its amendment FIN 46R. This interpretation clarifies existing accounting principles related to the preparation of consolidated financial statements when the equity investors in an entity do not have the characteristics of a controlling financial interest or when the equity at risk is not sufficient for the entity to finance its activities without additional subordinated financial support. FIN 46R requires a company to evaluate all existing arrangements to identify situations where a company has a "variable interest" in a "variable interest entity" and further determine when such variable interests require a company to consolidate the variable interest entities' financial statement with its own. The Company must adopt this interpretation by the beginning of its 2005 fiscal year. It is reasonably possible the Company will consolidate the financial statements of ReShore Risk Management, Ltd., when FIN 46 becomes effective. The Company reissued certain of its risks through ReShore Risk Management, Ltd. The effect of the consolidation would be to increase total assets by approximately $4,925,866 and increase total liabilities by $4,322,060. Because of the effects of reporting minority interest and the elimination of insurance expense, total equity and net income are not expected to change materially. Note 16 - Subsequent Events: On January 21, 2005, the Company borrowed $1,000,000 from its stockholders. The loan bears interest at 5.25% and will be repaid in 35 monthly interest only payments beginning on February 21, 2005 and one interest and total principal payment of the remaining balance of the loan on January 21, 2008. Note 17 - Management's Plans: During the year ended December 31, 2004 and 2003, the Company incurred losses of $6,819,099 and $7,858,235, respectively. The Company's cash flow from operations was $4,537,775, and $(4,700,020) during the respective periods. As of December 31, 2004, current assets exceeded current liabilities by $4,380,055. Management has reevaluated its bidding and estimating process and is redirecting the Company's focus to more profitable lines of business. Management has also made several personnel and organizational changes within its operational structure which it believes will substantially improve the Company's financial performance. BIDDER'S STATEMENT OF TECHNICAL ABILITY AND EXPERIENCE (To Accompany Proposal) SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A * PLEASE SEE ATTACHED The Bidder is required to state what work of a similar character to that included in the proposed Contract he/she has successfully performed and give references, with telephone numbers, which will enable the District to judge his/her responsibility, experience and skill. An attachment can be used. Date Contract Completed Name and Address of the Employer Name and Phone No. of Person to Contract Type of Work Amount of Contract Revised: 10/08/03 Contract No. 39561-A Page 32 of 82 Pages JFC Son Recently Completed Projects Project Owner Contact Value Date Completed 16" PVC & 36" Cml&c Pipeline Inland Impire Utility Agency Gabe De Saddi $ 2,344,857.00 March , 2005 6075 Kimball Ave. Bldg. B Chino, Ca. 91710 (909)993-1600 Hwy 110 CCTV Improvements 24,701'of 8" to 12" Watermain Replacement Install 8" Hdpe Slip Lining Paul Wang $ 3,678,999.00 April, 2005Caltrans 14620 Carmenita Rd Norwalk, Ca. 90650 (562) 926-2945 City of Oxnard Lou Balderrama $ 2,289,529.00 March, 2005 305 W. 3rd Street Oxnard, Ca. 98030 (805) 385-7820 City of Corona EricSchoenen $ 266,875.00 May, 2004 730 Corporation Yard Corona, Ca. 92882 (909) 279-3675 Relocate Wet & Dry Utilities Undergound Service Conversion Port of Long Beach 925 Harbor Plaza Long Beach, Ca. 90802 (562)901-1755 City of Palm Desert 73-510 Fred Waring Dr. Palm Desert, Ca. 92260 (760) 346-0611 Thomas Baldwin $ 3,826,997.00 May, 2003 PatConlin $ 1,982,806.00 March, 2004 24" Hdpe by Pipe Bursting 10 Ea Pressure Reducing Stations 35,000 If of 8" to 20" Dip Reclaimed Watermain Padre Dam MWD 10887 Woodside Ave. Santee, Ca. 92071 (619)448-3111 Padre Dam MWD 10887 Woodside Ave. Santee, Ca. 92071 (619)448-3111 City of San Luis Obispo 955 Morro Street San Luis Obispo, Ca.93401 (805)781-7220 Dan Black $ 1,985,725.00 September, 2004 AILau $1,090,000.00 September, 2004 John Moss $ 5,024,528.00 June, 2004 30" Reservoir Piping Otay Water District Randy Klaasen $ 1,126,323.00 2554 Sweetwater Springs Spring Valley, Ca. 91978 (619)670-2725 April, 2004 JFC Son Recently Completed Projects Clean & Line 24" to 36" Steel Watermains Clean& Line 10" DIP Watermains Install12,663lfof24"to 36" Recycled Watermain Adjust Manholes & Test Sewer Clean & Line Small Diameter Dip Watermains 54,000 If of 8" to 16" Recycled Watermains 45,000 If of 20" Watermain Livermore-Amador Valley Vivian Housen $4,287,373.00 Water Agency P.O. Box 2945 Dublin, Ca. 94568 June 2005 (925)551-4841 City of Anaheim P.O. Box 3222 Anaheim, Ca. 92803 RudyEmami $ 271,121.10 March 2005 Inland Impire Utility Agency Mike McFarland $3,181,336.00 July 2005 6075 Kimball Ave. Bldg. B Chino, Ca. 91710 (909) 993-1600 Inland Impire Utility Agency Clyde McNeil $ 139,615.00 April 2005 6075 Kimball Ave. Bldg. B Chino, Ca. 91710 909-993-1600 L.A. Dept. of Water & Power 111 North Hope St. Los Angeles, Ca. 90012 (213)367-2231 City of Carlsbad 5950 El Camino Real Carlsbad, Ca. 92008 (760) 602-2780 LucyMatsurra $ 1,786,653.00 June 2005 Bill Lopez $ 8,775,466.00 Mojave Water Agency Mike Limbaugh $3,726,433.94 22450 Headquarters Dr. Apple Valley, Ca. 92307 (760) 240-9201 BIDDER'S CERTIFICATE OF INSURANCE FOR GENERAL LIABILITY, EMPLOYERS' LIABILITY, AUTOMOTIVE LIABILITY AND WORKERS' COMPENSATION (To Accompany Proposal) SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A As a required part of the Bidder's proposal the Bidder must attach either ofthe following to this page. 1. Certificates of insurance showing conformance with the requirements herein for: a Comprehensive General Liability 0 Workers Compensation B' Automobile Liability ^Employer's Liability 2. Statement with an insurance carrier's notarized signature stating that the carrier can, and upon payment of fees and/or premiums by the Bidder, will issue to the Bidder Policies of insurance for Comprehensive General Liability, Employer's Liability, Automobile Liability and Workers Compensation in conformance with the requirements herein and Certifcates of insurance to the Agency showing conformance with the requirements herein. All certificates of insurance and statements of willingness to issue insurance for auto policies offered to meet the specification of this contract must: (1) Meet the conditions stated in The Notice Inviting Bids, the Standard Specifications for Public Works Construction and the Supplemental Provisions for this project for each insurance company that the Contractor proposes. (2) Cover any vehicle used in the performance of the contract, used onsite or offsite, whether owned, non-owned or hired, and whether scheduled or non-scheduled. The auto insurance certificate must state the coverage is for "any auto" and cannot be limited in anymanner. Revised: 10/08/03 Contract No. 39561-A Page 33 of 82 Pages 'ACORD^ nFRTIFIHATF OF 1 IARII 1 PRODUCER INSURED 877-945-7378 Willis North America, Inc. - Regional Cert Center 26 Century Blvd. P. O. Box 305191 Nashville, TN 372305191 J. Fletcher Creamer & Son, Inc. 101 East Broadway Hackensack, NJ 07601 1 TY INSURANCE page i of 3 02/0^/2006 THIS CERTIFICATE IS ISSUED AS A MATTER OF INFORMATION ONLY AND CONFERS NO RIGHTS UPON THE CERTIFICATE HOLDER. THIS CERTIFICATE DOES NOT AMEND, EXTEND OR ALTER THE COVERAGE AFFORDED BY THE POLICIES BELOW. INSURERS AFFORDING COVERAGE INSURERS: The Insurance Company of the State of Fen INSURER C: The Travelers Indemnity Company INSURER D: INSURERS: NAIC# 31194-002 19429-001 25658-001 COVERAGES THE POLICIES OF INSURANCE LISTED BELOW HAVE BEEN ISSUED TO THE INSURED NAMED ABOVE FOR THE POLICY PERIOD INDICATED. NOTWITHSTANDING ANY REQUIREMENT, TERM OR CONDITION OF ANY CONTRACT OR OTHER DOCUMENT WITH RESPECT TO WHICH THIS CERTIFICATE MAY BE ISSUED OR MAY PERTAIN, THE INSURANCE AFFORDED BY THE POLICIES DESCRIBED HEREIN IS SUBJECT TO ALL THE TERMS, EXCLUSIONS AND CONDITIONS OF SUCHPOLICIES. AGGREGATE LIMITS SHOWN MAY HAVE BEEN REDUCED BY PAID CLAIMS. INSRLTR A A B A C A ADD'LNSRD TYPE OF INSURANCE GENERAL LIABILITY X COMMERCIAL GENERAL LIABILITY | CLAIMS MADE | X 1 OCCUR X X,C,U X Blk. Contractual Liab GEN'L AGGREGATE LIMIT APPLIES PER: 1 POLICY Hx! JECT 1 1 LOC AUTOMOBILE LIABILITY X ANY AUTO ALL OWNED AUTOS SCHEDULED AUTOS X HIRED AUTOS X NON-OWNED AUTOS GARAGE LIABILITY ANY AUTO EXCESS LIABILITY X i OCCUR | j CLAIMS MADE DEDUCTIBLE 1 RETENTION $ WORKERS COMPENSATION AND EMPLOYERS' LIABILITY ANY PROPRIETOR/PARTNER/EXECUTIVE OFFICER/MEMBER EXCLUDED? If yes, describe underSPECIAL PROVISIONS below OTHER POLICY NUMBER RTJEXGL7276B121TIL05 RTC2JCAP2398A397TIL05 46056325 RTC2JUB4683B30A05 6KUB7470B31105 RTRJUB4707B00005 POLICY EFFECTIVEDATE(MM/DD/YY) 3/31/2005 3/31/2005 3/31/2005 3/31/2005 3/31/2005 3/31/2005 POLICY EXPIRATIONDATE (MM/DD/YY) 3/31/2006 3/31/2006 3/31/2006 3/31/2006 3/31/2006 3/31/2006 LIMITS EACH OCCURRENCE DAMAGE TO RENTEDPREMISES (Ea occurence) MED EXP (Anyone person) PERSONAL & ADV INJURY GENERAL AGGREGATE PRODUCTS - COMP/OP AGG COMBINED SINGLE LIMIT (Ea accident) BODILY INJURY (Per person) BODILY INJURY(Per accident) PROPERTY DAMAGE(Per accident) AUTO ONLY - EA ACCIDENT OTHER THAN EAACC AUTO ONLY:AGG EACH OCCURRENCE AGGREGATE xlT^rml E.L. EACH ACCIDENT °ETS- E.L DISEASE - EA EMPLOYEE E.L. DISEASE - POLICY LIMIT $ 1,000,000 $ 1,000,000 I 10,000 $ 1,000,000 $ 2,000,000 J 2,000,000 $ 1,000,000 $ $ $ $ $ $ $ 5,000,000 $ 5,000,000 $ $ $ $ 1,000,000 $ 1,000,000 $ 1,000.000 JFC JOB# 05-5277-San Marcos Blvd. Transmission Main & Street Improvements - REBID Project No. 39561-A City of Carlsbad, The District and City, its officials, employees, and volunteers are named as Additional Insured on the General Liability policy as respects operations of the Named Insured. 1 CERTIFICATE HOLDER CANCELLATION I City of Carlsbad 1635 Faraday Avenue Carlsbad, CA 92008 SHOULD ANY OF THE ABOVE DESCRIBED POLICIES BE CANCELLED BEFORE THE EXPIRATION DATE THEREOF, THE ISSUING INSURER WILL ENDEAVOR TO MAIL 3 ° DAYS WRITTEN NOTICE TO THE CERTIFICATE HOLDER NAMED TO THE LEFT, BUT FAILURE TO DO SO SHALL IMPOSE NO OBLIGATION OR LIABILITY^ ANY KIND UPON THE INSURER, ITS AGENTS OR REPRESENTATIVES. //^ AUTHORIZED REPRESENTATIVE/ / V/ / / -^ ACORD 25 (2001/08)Coll:1531597 Tpl:355966 Cert:6920167 ©ACORD CORPORATION 1988 Willis CERTIFICATE OF LIABILITY INSURANCE Page 2 <* 3 02/0^2006 PRODUCER 877-945-7378 Willis North America, Inc. - Regional Cert Center 26 Century Blvd. P. 0. Box 305191 Nashville, TN 372305191 INSURED j_ Fletcher Creamer & Son, Inc. 101 East Broadway Haclcensack, NJ 07601 1 THIS CERTIFICATE IS ISSUED AS A MATTER OF INFORMATION ONLY AND CONFERS NO RIGHTS UPON THE CERTIFICATE HOLDER. THIS CERTIFICATE DOES NOT AMEND, EXTEND OR ALTER THE COVERAGE AFFORDED BY THE POLICIES BELOW. INSURERS AFFORDING COVERAGE INSURER A: Travelers Property Casualty Company of Am INSURERS: The Insurance Company of the State of Fen INSURER C: The Travelers Indemnity Company INSURER D: INSURER E: NAIC# 31194-002 19429-001 25658-001 Coverage under this policy shall be primary and noncontributing with any other insurance available to the City of Carlsbad. A waiver of subrogation applies as required by contract. SIR as follows: General Liability - $175,000 SIR Automobile - $100,000 Deductible Workers Compensation - $350,000 Deductible Umbrella - $10,000 SIR Coll:1531597 Tpl:355966 Cert:6920167 Page 3 of 3 IMPORTANT If the certificate holder is an ADDITIONAL INSURED, the policy(ies) must be endorsed. A statement on this certificate does not confer rights to the certificate holder in lieu of such endorsement(s). If SUBROGATION IS WAIVED, subject to the terms and conditions of the policy, certain policies may require an endorsement. A statement on this certificate does not confer rights to the certificate holder in lieu of such endorsement(s). DISCLAIMER The Certificate of Insurance on the reverse side of this form does not constitute a contract between the issuing insurer(s), authorized representative or producer, and the certificate holder, nor does it affirmatively or negatively amend, extend or alter the coverage afforded by the policies listed thereon. ACORD25(2001/08) Coll: 1531597 Tpl:355966 Cert: 6920167 ADDITIONAL PROTECTED PERSONS ENDORSEMENT- CONTRACTORS GENERAL LIABILITY - INCLUDING COMPLETED WORK This endorsement changes your Contractors Commercial General Liability Protection How Coverage Is Changed There are two changes which are described below. 1. The following is added to the Who is Protected Under This Agreement section. This change adds certain protected persons and limits their protection. Additional protected person. The person or organization named below is an additional protected person as required by a contract or agreement entered into by you. But only for covered injury or damage arising out of: • your work for that person or organization; • your completed work for that person or organization if your contract or agreement requires such coverage; • premises you own, rent, or lease from that person or organization; or • your maintenance, operation, or use of equipment leased from that person or organization. We explain what we mean by your work and your completed work in the Products and completed work total limit section. If the additional protected person is an architect, engineer, or surveyor, we won't cover injury or damage arising out of the performance or failure to perform architect, engineer, or surveyor professional services. Architect, engineer, or surveyor professional services includes: • the preparation or approval of maps, drawings, opinions, reports, surveys, change orders, designs, or specification; and • supervisory, inspection, or engineering services. 2. The following is added to the Other primary insurance section. This change broadens coverage. Well consider this insurance to be primary to and non-contributory with the insurance issued directly to the additional protected persons listed below if: • your contract specifically requires that we consider this insurance to be primary or primary and non-contributory insurance; or • you request before a loss that we consider this insurance to be primary or primary and non-contributory insurance. Other Terms All other terms of your policy remain the same. Person Or Organization: Any Person or Organization You Are Required By Written Contract to Add as an Additional Protected Person. City of Carlsbad, The District and City, its officials, employees, and volunteers Name of Insured: Policy Number: Effective Date 03/31/2005 Processing Date 02/02/2006 Policy Number: RTJEXGL7276B121TIL05 J. Fletcher Creamer & Sons Inc. G0322 Rev. 12-97 Printed in U.S.A. Endorsement ©St. Paul Fire and Marine Insurance Co. 1997 All Rights Reserved Page 1 of 1 BIDDER'S STATEMENT RE DEBARMENT (To Accompany Proposal) SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A 1. Have you or any of your subcontractors ever been debarred as an irresponsible bidder by another jurisdiction in the State of California? yes no 2. If yes, what was/were the name(s) of the agency(ies) and what was/were the period(s) of debarment(s)? Attach additional copies of this page to accommodate more than two debarments. party debarred party debarred L agency period of debarment agency period of debarment l r i: BY CONTRACTOR: J. Fletcher Creamer & S>on. Inc. Jname of Contractor) By: MO\JU~ Bree Zinsmeister Corporate Agent (print name/title) Page of 1 of 1 pages of the Re Debarment form evised: 10/08/03 Contract No. 39561-A Page 34 of 82 Pages r r; BIDDER'S DISCLOSURE OF DISCIPLINE RECORD (To Accompany Proposal) SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A Contractors are required by law to be licensed and regulated by the Contractors' State License Board which has jurisdiction to investigate complaints against contractors if a complaint regarding a patent act or omission is filed within four years of the date of the alleged violation. A complaint regarding a latent act or omission pertaining to structural defects must be filed within 10 years of the date of the alleged violation. Any questions concerning a contractor may be referred to the Registrar, Contractors' State License board, P.O. Box26000, Sacramento, California 95826. 1) Have you ever had your contractor's license suspended or revoked by the California Contractors' State license Board two or more times within an eight year period? x yes no 2) Has the suspension or revocation of your contractors license ever been stayed? X yes no 3) Have any subcontractors that you propose to perform any portion of the Work ever had their contractor's license suspended or revoked by the California Contractors' State license Board two or more times within an eight year period? X yes no 4) Has the suspension or revocation of the license of any subcontractor's that you propose to perform any portion of the Work ever been stayed? X yes no 5) If the answer to either of 1. or 3. above is yes fully identify, in each and every case, the party disciplined, the date of and violation that the disciplinary action pertain to, describe the nature of the violation and the disciplinary action taken therefor. N/A . (If needed attach additional sheets to proM'de full disclosure.) Page 1 of 1 pages of this Disclosure of Discipline form Revised: 10/08/03 Contract No. 39561 -A Page 35 of 82 Pages BIDDER'S DISCLOSURE OF DISCIPLINE RECORD (CONTINUED) (To Accompany Proposal) ^ SAN MARCOS BOULEVARD 1 TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A ' 6) If the answer to either of 2. or 4. above is yes fully identify, in each and every case, the party who's discipline was stayed, the date of the violation that the disciplinary action pertains to, i describe the nature of the violation and the condition (if any) upon which the disciplinary action ( was stayed. !..; N/A If needed, attach additional sheets to provide full disclosure. BY CONTRACTOR: J. Fletcher Creamer & Son, Inc. (name of Contractor) (sigprriere) Bree Zinsmeislfer, Corporate Agent (print name/title) *... Page 1 of 1 pages of this Disclosure of Discipline form I M^'^U Revised: 10/08/03 Contract No. 39561-A Page 36 of 82 Pages NON-COLLUSION AFFIDAVIT TO BE EXECUTED BY BIDDER AND SUBMITTED WITH BID PUBLIC CONTRACT CODE SECTION 7106 r L SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A State of California ) ) ss. County of Los Angeles ) Bree Zinsmeister (Name of Bidder) and says thatXfe or she is Corporate Agent , being first duly sworn, deposes (Title) of J.Fletcher Creamer & Son, Inc. (Name of Firm) the party making the foregoing bid that the bid is not made in the interest of, or on behalf of, any undisclosed person, partnership, company, association, organization, or corporation; that the bid is genuine and not collusive or sham; that the bidder has not directly or indirectly induced or solicited any other bidder to put in a false or sham bid, and has not directly or indirectly colluded, conspired, connived, or agreed with any bidder or anyone else to put in a sham bid, or that anyone shall refrain from bidding; that the bidder has not in any manner, directly or indirectly, sought by agreement, communication, or conference with anyone to fix the bid price of the bidder or any other bidder, or to fix any overhead, profit, or cost element of the bid price, or of that of any other bidder, or to secure any advantage against the public body awarding the contract of anyone interested in the proposed contract; that all statements contained in the bid are true; and, further, that the bidder has not, directly or indirectly, submitted his or her bid price or any breakdown thereof, or the contents thereof, or divulged information or data relative thereto, or paid, and will not pay, any fee to any corporation, partnership, company association, organization, bid depository, or to any member or agent thereof to effectuate a collusive or sham bid. I declare under penalty of perjury that the foregoing is true and correct and that this affidavit was executed on the 29th _ day of November _ , f6K_20.05 Bree Zinsmeister Signature of Bide/ Subscribed ana"sworn to before me on the 29th day of November _, i®_zno5, (NOTARY SEAL) JAMES ALLEN Commission # 1594921 Notary Public - California Los Angeles County My Comm. Expire* JU14.2009 : 10/08/03 Contract No. 39561 -A Page 37 of 82 Pages City of Carlsbad Public Works November 21, 2005 ADDENDUM NO. 1 RE: SAN MARCOS BLVD. TRANSMISSION MAIN AND STREET IMPROVEMENTS - REBID BID NO. PWS06-14ENG, CONTRACT NO. 39561-A Please include the attached addendum in the Notice to Bidder/Request for Bids you have for the above project. This addendum-receipt acknowledged-must be attached to your Request for Bid when your bid is submitted. KEVIN DAVIS Buyer KD:rh Attachment I ACKNOWLEDGE RECEIPT OF ADDENDUM NO. 1 Bidder's Signature 1635 Faraday Avenue • Carlsbad, CA 92OO8-7314 • (76O) 6O2-273O • FAX (76O) 602-8562 CARLSBAD MUNICIPAL WATER DISTRICT SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS Contract No. 39561-A Addendum No. 1 From: David Ahles, Project Manager Phone: (760)602-2748 Fax: (760) 602-8562 No. of Pages: 4 (including this page) Date: November 21, 2005 Bid Opening Date: November 27, 2005 3:00 pm (No change) A. Supplemental Provisions, Part 3, Section 300-13-1.3, Payment, (Page 90 of 115), Change this section to "Payment for preparation, implementation and management of SWPPP will be made at the lump sum price named in the bid schedule for each project. B. Supplemental Provisions, Part 3, Section 303-7.3, Payment, (Page 96 of 115), Change the following: Delete the words "and 6'chain link fence (vinyl coated)" and "4'chain link fence (vinyl coated)" from the first sentence of this section. C. Technical Specifications, Section 01025 Measurement and Payment, Section 3.3 Change the following: Title shall be "Bid Schedule No. "B". D. Drawing IP-4693, San Marcos Boulevard Street Improvements (Sheet 2 of 31), Change the following: Change the proposed San Marcos Boulevard structural section in all cross sections to 5" AC, 8" CAB, scarify and compact 6" sub base. Contract No. 39561-A Page 1 of 4 Pages Addendum No. 1 E. Specification Section 02223: Trenching, Excavation, Backfilling, and Compaction: Delete Part 2.02 Imported Granular Material - Pipe Zone and replace with the following: "Imported Sand - Pipe Zone Imported sand material shall be used for steel pipe installation. Imported sand shall be free from clay balls, organic matter, and have a coefficient of permability greater than 0.014 (ASTM D2434) or a sand equivalent of greater than 30 (ASTM D2419). Resistivity for imported sand shall be not less than 2,000 ohn-cm when measured in accordance with Caltrans Test Method 643. Imported sand shall conform to the following gradation: Sieve Size Percent passing by Weight %-inch 100 No. 4 50-95 No. 30 25-45 No. 200 0-9" F. Specification Section 02223: Trenching, Excavation, Backfilling, and Compaction: Delete Part 2.03 Imported Granular Material - Trench Zone and replace with the following: "Earth Backfill - Pipe Zone Earth Backfill is defined as material removed from the required excavations and used as backfill or earth fill. Earth backfill shall be excavated material that is free from organic matter, roots, debris, and rocks larger than 6 inches in the greatest dimension." Responses to written Questions received: Question 1: Supplemental Provision Section 6-7.2 Working Day explains that all work shall be between the hours of 8;30pm and 5:30 am. Yet the specifications for the traffic signals state that the traffic signals can only be turned on during the Tuesday and Thursdays between 9am and 2pm. Will the engineer make an exception for traffic turn on? Response: All work involved in the signal modification work, except for initial turn-ons, can be performed during the work hours. The restriction of "turn-ons" is to assure that the initial turn-on of controller equipment will not be performed during peak hours. The early afternoon cut off, 2:00 p.m., allows for appropriate time to troubleshoot any problems and adequately program new controllers before the p.m. peak hour occurs. The restriction of turn-on hours is intended for initial turn-on of a signal. All of the signal work involved with this project is modification work and would not be considered an initial turn-on, unless during the course of construction it was determined that new controller(s) were needed. Question 2: Supplemental Provision Section 300-3.2, the design of the soldier pile wall is provided in the project plans. What additional design calculations are being referred to? Contract No. 39561-A Page 2 of 4 Pages Addendum No. 1 Response: Engineer requires review of shop drawings for precast panels as detailed in the Specifications 300-3.2. The term "calculations" in the specifications refers to the preparation of Shop Drawings with panel layout and dimensions, number and layout of steel reinforcement, method of installation of soldier piles, method of placing lagging, limits of structure excavation lifts, and type of drilling and excavation equipment to be used, etc. Questions: Supplemental Provision Section 300-6.1, Stamped Concrete General says that the concrete shall be 560-C-3250 with 6"X6" - 10 gauge wire mesh yet the landscaping plans Sheet 24 of 31 says that the stamped concrete shall have #4 bar at 12" O.C. each way and shall use a mix design of 3,000 psi concrete. Response: The 6x6 #10 wire mesh in a 4" slab is acceptable for all stam ped concrete areas with the exception of the curb depression for maintenance truck access. For curb depressions for maintenance truck access, replace the 6x6 #10 wire mesh with #3 rebar at 16" on center, both directions, overlapping wire mesh at the perimeters. Stamped Concrete shall be 560-C-3250. Question 4: Currently, there are many palm trees that line San Marcos Blvd. In the area in which the Contractor is supposed to widen the street. Who is going to be responsible for moving the palm trees? Do they become the property of the contractor? If the contractor has to move them, where does the Contractor get paid for moving the trees? Response: As noted on the drawing 425-1 sheet 5 & 6: "Contractor to stake southerly ROW boundary as first order of work. All work shall be within the public ROW. Protect Landscaping trees and landscaping adjacent to southerly ROW boundary." Trees are currently located on private property and are not anticipated to be moved. Trees will remain under the ownership of the private property owner, if survey finds trees are encroaching into public ROW the property owner will be notified to move the trees. Question 5: The street improvements plans (Page 2 of 31) call out the new paving section as 5" AC over 6" CAB. The specifications say that the Contractor is to use Caltrans Class 2 Base material. Does the City want Crushed Aggregate Base of Caltrans Class 2 Base? Response: The Engineer has deferred to City of San Marco's Standards for Typical Roadway Sections 5" AC over 8" CAB, See Item "F" change in CAB depth. The Engineer makes no exception to Crushed Aggregate Base or Caltrans Class 2 Base as long as the base is appropriately compacted according to design and specifications. Question 6: The street improvements plans (Page 17 of 31) provide a partial traffic control plans for the median improvements but does not address the median work east of View Point Drive. Is the contractor expected to design and submit it's own traffic control plans for this work? What are the parameters for temporary closure during construction? Response: Contractor to design and submit traffic control plan to the Construction Manager based on City of San Marcos, Greenbook, or Caltrans standards. Traffic control plans are anticipated to be in effect during all working hours with flaggers, cones, and barricades as necessary. Contract No. 39561-A Addendum No. 1 Page 3 of 4 Pages Question 7: The street improvements plans (Page 26 of 31) states that contractor to arrange and pay for 11 Ov service with SDG&E. Please provide further information in order to properly price or consider including an allowance for the contractor to provide the service once more information is obtained. Response: In lieu of new SDG&E meter, contractor may connect to existing City of San Marcos Irrigation Controller located at approximately Station 154+OO. Provide trench, wire and conduit as required. Question 8: The retaining wall contains integral color for concrete. What is the color? Response: Color subject to approval during sample panel review, however the City of San Marcos would like to wall to be similar in color and texture as used on the Las/Posas/SR-78 Interchange walls. Question 9: Supplemental Provisions Section 8-2 Field Office Facilities. Please provide a location in which the Field Office is to be located so proper pricing for temp power and water can be obtained. Response: The contractor may provide office space in an existing commercial building subject to approval of location. Question 10: Can the initial trench cut be accomplished by grinding in lieu of saw cutting? Response: Yes. Question 11: Can asphalt grindings be utilized in the trench zone backfill? Response: No. Question 12: Is the contractor responsible for soils/compaction/material testing in addition to survey? Response: Soils/compaction/material testing will be per the General Conditions Section 4-1.4. Agency will hire engineer and pay initial tests, contractor will pay for retests necessary by noncompliance. Question 13: Can crushed rock be used for backfill within the pipe and trench zone? Response: No, Pipe Zone for Steel Pipeline requires Imported Sand Material, SE>30, per this Addendum, See Item E & F. Contract No. 39561-A Addendum No. 1 Page 4 of 4 Pages 11-28-O5; 3:31PM;CITY OF CARLSBAD ;76O 6O2 8562 #2/3 City of Carlsbad Public Works November 28, 2005 ADDENDUM NO. 2 RE: SAN MARCOS BL. TRANSMISSION MAIN & STREET IMPROVEMENTS - REBID BID NO. PWS06-14ENG, CONTRACT NO. 39561-A Please include the attached addendum in the Notice to Bidder/Request for Bids you have for the above project. This addendum-receipt acknowledged-must be attached to your Request for Bid when your bid is submitted. KEVIN DAVIS Buyer KD:rh Attachment ACKNOWLEDGE RECEIPT OF ADDENDUM NO. 2 LL \ Bidder's Signature 1635 Faraday Avenue • Carlsbad, CA 92008-7314 - (760) 6O2-2730 • FAX (76O) 602-8562 11-28-O5; 3:31PM;CITY OF CARLSBAD ;76O 6O2 8562 CARLSBAD MUNICIPAL WATER DISTRICT SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS Contract No. 39561-A Addendum No. 2 From: David Ahles, Project Manager Phone: (760)602-2748 Fax: (760)602-8562 No. of Pages: 1 (including this page) Date: November 28, 2005 Bid Opening Date: December 7, 2005 3:00 pm (New Date) A. Notice Inviting Bids: Revise the bold part of the first sentence to, until 3:OOP.M. on the 7th day of December, 2005. B. Modify Addendum No. 1 Item "F" as follows: Specification Section 02223: Trenching, Excavation, Backfilling, and Compaction: Delete Part 2.03 Imported Granular Material - Trench Zone and replace with the following: "Earth Backfill - Trench Zone Earth Backfill is defined as material removed from the required excavations and used as backfill or earth fill. Earth backfill shall be excavated material that is free from organic matter, roots, debris, and rocks larger than 6 inches in the greatest dimension." Contract No. 39561-A Page 1 of 1 Pages Addendum No. 2 CONTRACT PUBLIC WORKS This agreement is made this cx/ST day of /nO/MMl _ , 20 <^ , by and between the Carlsbad Municipal Water District of Carlsbad, California, a municipal corporation, (hereinafter called "District"), and _ J. FLETCHER CREAMER & SONS. INC. _ whose principal place of business is _ 12874 SAN FERNANDO ROAD SYLMAR CA 91342 _ (hereinafter called "Contractor"). District and Contractor agree as follows: 1. Description of Work. Contractor shall perform all work specified in the Contract documents for: SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A (hereinafter called "project") 2. Provisions of Labor and Materials. Contractor shall provide all labor, materials, tools, equipment, and personnel to perform the work specified by the Contract Documents. 3. Contract Documents. The Contract Documents consist of this Contract, Notice Inviting Bids, Contractor's Proposal, Bidder's Bond, Designation of Subcontractors, Designation of Owner Operator/Lessors, Bidder's Statements of Financial Responsibility, Technical Ability and Experience, Re Debarment, Non-collusion Affidavit, Escrow Agreement, Release Form, the Plans and Specifications, the Supplemental Provisions, addendum(s) to said Plans and Specifications and Supplemental Provisions, and all proper amendments and changes made thereto in accordance with this Contract or the Plans and Specifications, and all bonds for the project; all of which are incorporated herein by this reference. Contractor, her/his subcontractors, and materials suppliers shall provide and install the work as indicated, specified, and implied by the Contract Documents. Any items of work not indicated or specified, but which are essential to the completion of the work, shall be provided at the Contractor's expense to fulfill the intent of said documents. In all instances through the life of the Contract, the District will be the interpreter of the intent of the Contract Documents, and the District's decision relative to said intent will be final and binding. Failure of the Contractor to apprise subcontractors and materials suppliers of this condition of the Contract will not relieve responsibility of compliance. 4. Payment. For all compensation for Contractor's performance of work under this Contract, District shall make payment to the Contractor per section 9-3 PAYMENT of the Standard Specifications for Public Works Construction (SSPWC) 2003 Edition hereinafter designated "SSPWC", as issued by the Southern California Chapter of the American Public Works Association, and as amended by the Supplemental Provisions section of this contract. The Engineer will close the estimate of work completed for progress payments on the last working day of each month. Revised: 10/08/03 Contract No. 39561-A Page 38 of 82 Pages 5. Independent Investigation. Contractor has made an independent investigation of the jobsite, the soil conditions at the jobsite, and all other conditions that might affect the progress of the work, and is aware of those conditions. The Contract price includes payment for all work that may be done by Contractor, whether anticipated or not, in order to overcome underground conditions. Any information that may have been furnished to Contractor by District about underground conditions or other job conditions is for Contractor's convenience only, and District does not warrant that the conditions are as thus indicated. Contractor is satisfied with all job conditions, including underground conditions and has not relied on information furnished by District. 6. Hazardous Waste or Other Unusual Conditions. If the contract involves digging trenches or other excavations that extend deeper than four feet below the surface Contractor shall promptly, and before the following conditions are disturbed, notify District, in writing, of any: A. Hazardous Waste. Material that Contractor believes may be material that is hazardous waste, as defined in section 25117 of the Health and Safety Code, that is required to be removed to a Class I, Class II, or Class III disposal site in accordance wth provisions of existing law. B. Differing Conditions. Subsurface or latent physical conditions at the site differing from those indicated. C. Unknown Physical Conditions. Unknown physical conditions at the site of any unusual nature, different materially from those ordinarily encountered and generally recognized as inherent in work of the character provided for in the contract. District shall promptly investigate the conditions, and if it finds that the conditions do materially so differ, or do involve hazardous waste, and cause a decrease or increase in contractor's costs of, or the time required for, performance of any part of the work shall issue a change order under the procedures described in this contract. In the event that a dispute arises between District and Contractor whether the conditions materially differ, or involve hazardous waste, or cause a decrease or increase in the contractor's cost of or time required for, performance of any part of the work, contractor shall not be excused from any scheduled completion date provided for by the contract, but shall proceed with all work to be performed under the contract. Contractor shall retain any and all rights provided either by contract or by law which pertain to the resolution of disputes and protests between the contracting parties. 7. Immigration Reform and Control Act. Contractor certifies it is aware of the requirements of the Immigration Reform and Control Act of 1986 (8 USC sections 1101-1525) and has complied and will comply with these requirements, including, but not limited to, verifying the eligibility for employment of all agents, employees, subcontractors, and consultants that are included in this Contract. 8. Prevailing Wage. Pursuant to the California Labor Code, the director of the Department of Industrial Relations has determined the general prevailing rate of per diem wages in accordance with California Labor Code, section 1773 and a copy of a schedule of said general prevailing wage rates is on file in the office of the City Engineer, and is incorporated by reference herein. Pursuant to California Labor Code, section 1775, Contractor shall pay prevailing wages. Contractor shall post copies of all applicable prevailing wages on the job site. Revised: 10/08/03 Contract No. 39561-A Page 39 of 82 Pages 9. Indemnification. Contractor shall assume the defense of, pay all expenses of defense, and indemnify and hold harmless the District and the City of Carlsbad, and its officers and employees, from all claims, loss, damage, injury and liability of every kind, nature and description, directly or indirectly arising from or in connection with the performance of the Contract or work; or from any failure or alleged failure of Contractor to comply with any applicable law, rules or regulations including those relating to safety and health; and from any and all claims, loss, damages, injury and liability, howsoever the same may be caused, resulting directly or indirectly from the nature of the work covered by the Contract, except for loss or damage caused by the sole or active negligence or willful misconduct of the District or City. The expenses of defense include all costs and expenses including attorneys' fees for litigation, arbitration, or other dispute resolution method. Contractor shall also defend and indemnify the City and District against any challenges to the award of the contract to Contractor, arising in whole or in part from alleged inaccuracies or misrepresentation by Contractor, whether intentional or otherwise, and Contractor will pay all costs, including defense costs for the City and District. Defense costs include the cost of separate counsel for City and District, if City or District request separate counsel. 10. Insurance. Contractor shall procure and maintain for the duration of the contract insurance against claims for injuries to persons or damage to property which may arise from or in connection with the performance of the work hereunder by the Contractor, his or her agents, representatives, employees or subcontractors. Said insurance shall meet the District's policy for insurance as stated in Resolution No. 772. (A) Coverages And Limits Contractor shall maintain the types of coverages and minimum limits indicted herein: a. Comprehensive General Liability Insurance: $1,000,000 combined single limit per occurrence for bodily injury and property damage. If the policy has an aggregate limit, a separate aggregate in the amounts specified shall be established for the risks for which the District and City, or its agents, officers or employees are additional insured. b. Automobile Liability insurance: $1,000,000 combined single limit per accident for bodily injury and property damage. In addition, the auto policy must cover any vehicle used in the performance of the contract, used onsite or offsite, whether owned, non-owned or hired, and whether scheduled or non-scheduled. The auto insurance certificate must state the coverage is for "any auto" and cannot be limited in any manner. c. Workers' Compensation and Employers' Liability Insurance: Workers' compensation limits as required by the Labor Code of the State of California and Employers' Liability limits of $1,000,000 per incident. Workers' compensation offered by the State Compensation Insurance Fund is acceptable to the City. (B) Additional Provisions. Contractor shall ensure that the policies of insurance required under this agreement with the exception of Workers' Compensation and Business Automobile Liability Insurance contain, or are endorsed to contain, the tllowing provisions: a. The District and City, its officials, employees and volunteers are to be covered as additional insured as respects: liability arising out of activities performed by or on behalf of the Contractor; products and completed operations of the contractor; premises owned, leased, hired or borrowed by the contractor. The coverage shall contain no special limitations on the scope of protection afforded to the District or City, its officials, employees or volunteers. All additional insured endorsements must be evidenced using separate documents attached to the certificate of insurance; one for each company affording general liability and employers' liability. Revised: 10/08/03 Contract No. 39561 -A Page 40 of 82 Pages b. The Contractor's insurance coverage shall be primary insurance as respects the District and City, its officials, employees and volunteers. Any insurance or self-insurance maintained by the District or City, its officials, employees or volunteers shall be in excess of the contractor's insurance and shall not contribute with it. c. Any failure to comply with reporting provisions of the policies shall not affect coverage provided to the District and City, its officials, employees or volunteers. d. Coverage shall state that the contractor's insurance shall apply separately to each insured against whom claim is made or suit is brought, except with respect to the limits of the insurer's liability. (C) Notice Of Cancellation. Each insurance policy required by this agreement shall be endorsed to state that coverage shall not be nonrenewed, suspended, voided, canceled, or reduced in coverage or limits except after thirty (30) days' prior written notice has been given to the District by certified mail, return receipt requested. (D) Deductibles And Self-Insured Retention (S.I.R.) Levels. Any deductibles or self-insured retention levels must be declared to and approved by the City. At the option of the District, either: the insurer shall reduce or eliminate such deductibles or self-insured retention levels as respects the District and City, its officials and employees; or the contractor shall procure a bond guaranteeing payment of losses and related investigation, claim administration and defense expenses. (E) Waiver Of Subrogation. All policies of insurance required under this agreement shall contain a waiver of all rights of subrogation the insurer may have or may acquire against the District or City or any of its officials or employees. (F) Subcontractors. Contractor shall include all subcontractors as insured under its policies or shall furnish separate certificates and endorsements for each subcontractor. Coverages for subcontractors shall be subject to all of the requirements stated herein. (G) Acceptability Of Insurers. Insurance is to be placed with insurers that have a rating in Best's Key Rating Guide of at least A-:V. Insurers must also be authorized to transact the business of insurance by the State of California Insurance Commissioner as admitted carriers as evidenced by a listing in the official publication of the Department of Insurance of the State of California and/or under the standards specified by the Board of Directors in Resolution No. 772. (H) Verification Of Coverage. Contractor shall furnish the District with certificates of insurance and original endorsements affecting coverage required by this clause. The certificates and endorsements for each insurance policy are to be signed by a person authorized by that insurer to bind coverage on its behalf. The certificates and endorsements are to be in forms approved by the District and are to be received and approved by the District before the Contract is executed by the District. (I) Cost Of Insurance. The Cost of all insurance required under this agreement shall be included in the Contractor's bid. oRevised: 10/08/03 Contract No. 39561-A Page 41 of 82 Pages 11. Claims and Lawsuits. All claims by contractor for $375,000 or less shall be resolved in accordance with the provisions in the Public Contract Code, Division 2, Part 3, Chapter 1, Article 1.5 (commencing with section 20104) which are incorporated by reference. A copy of Article 1.5 is included in the Supplemental Provisions I section. The contractor shall initially submit all claims over $375,000 to the District using the informal dispute resolution process described in Public Contract Code subsections 20104.2(a), (c), (d). Notwithstanding the provisions of this section of the contract, all claims shall comply with the Government Tort Claim Act (section 900 et seq., of the California Government Code) for any claim or cause of action for money or damages prior to filing any lawsuit for breach of this agreement. (A) Assertion of Claims. Contractor hereby agrees that any contract claim submitted to the District must be asserted as part of the contract process as set forth in this agreement and not in anticipation of litigation or in conjunction with litigation. (B) False Claims. Contractor acknowledges that if a false claim is submitted to the District, it may be considered fraud and the Contractor maybe subject to criminal prosecution. (C) Government Code. Contractor acknowledges that California Government Code sections 12650 et seq., the False Claims Act, provides for civil penalties where a person knowingly submits a false claim to a public entity. These provisions include false claims made with deliberate ignorance of the false information or in reckless disregard of the truth or felsity of the information. (D) Penalty Recovery. If the Carlsbad Municipal Water District seeks to recover penalties pursuant to the False Claims Act, it is entitled to recover its litigation costs, including attorneys fees. (E) Debarment for False Claims. Contractor hereby acknowledges that the filing of a false claim may subject the Contractor to an administrative debarment proceeding wherein the Contractor may be prevented from further bidding on public contracts for a period of up to five years. (F) Carlsbad Municipal Code. The provisions of Carlsbad Municipal Code sections 3.32.025, 3.32.026, 3.32.027 and 3.32.028 pertaining to felse claims are incorporated herein by reference. (G) Debarment from Other Jurisdictions. Contractor hereby acknowledges that debarment by another jurisdiction is grounds for the Carlsbad Municipal Water District to disqualify the Contractor or subcontractor from participating in future contract bidding. (H) Jurisdiction. Contractor agrees and hereby stipulates that the proper venue and jurisdiction for resolution of any disputes between the parties arising out of this agreement is San Diego County, California. I have read and understand all provisions of Section 11 above. _ ^itial) 12. Maintenance of Records. Contractor shall maintain and make available at no cost to the City, upon request, records in accordance with sections 1776 and 1812 of Part 7, Chapter 1, Article 2, of the Labor Code. If the Contractor does not maintain the records at Contractor's principal place of business as specified above, Contractor shall so inform the District by certified letter accompanying the return of this Contract. Contractor shall notify the District by certified mail of any change of address of such records. 13. Labor Code Provisions. The provisions of Part 7, Chapter 1, commencing with section 1720 of the Labor Code are incorporated herein byreference. Revised: 10/08/03 Contract No. 39561 -A Page 42 of 82 Pages 14. Security. Securities in the form of cash, cashier's check, or certified check may be substituted for any monies withheld by the District to secure performance of this contract for any obligation established by this contract. Any other security that is mutually agreed to by the Contractor and the District may be substituted for monies withheld to ensure performance under this Contract. 15. Provisions Required by Law Deemed Inserted. Each and every provision of law and clause required by law to be inserted in this Contract shall be deemed to be inserted herein and included herein, and if, through mistake or otherwise, any such provision is not inserted, or is not correctly inserted, then upon application of either party, the Contract shall forthwith be physically amended to make such insertion or correction. 16. Additional Provisions. Any additional provisions of this agreement are set forth in the "General Provisions" or" Supplemental Provisions" attached hereto and made a part hereof NOTARIAL ACKNOWLEDGMENT OF EXECUTION BY ALL SIGNATORIES MUST BE ATTACHED (CORPORATE SEAL) CONTRACTOR: J.RETCHER CREAMER A SON INC. A ^Wz<X9 XV CARL muni, ISTICT, a of California (sign (print name and title) President or vice-president and secretary or assistant secretary must sign for corporations. If only one officer signs, the corporation must attach a resolution certified by the secretary or assistant secretary under the corporate seal empowering that officer to bind the corporation. If signed by an individual partner, the partnership must attach a statement of partnership authorizing the partner to execute this instrument. APPROVED AS TO FORM: RONALD R. BALL General Counsel By: ATTEST: Deputy General Counsel LORRAINE WOOD Secretary Revised: 10/08/03 Contract No. 39561-A of 82 Pages CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT New JerseyState of Ssftfcsmra County of Bergen On 2/2/06 Daw personally appeared J. },, J before me Raffaella Bellini, Notary Public Nom» and Tills al Officer (8.9., Maoa Do«, notary PuWO Fletcher Creamer, Jr. & Juergen R. Hofhienz President & Assistant Secretary Respectively Nam«(s| of Signal) @ personally known to me D proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) is/are subscribed to the within instrument and acknowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their signature(s) on the instalment the person(s), or the entity upon behalf of which the person(s) acted, executed the instalment. WITNESS my hand and official seal. I INI Place Nouiry S»al Abava OPTIONAL •OF NEW JERSEY MY COMMISSION EXPIRES SEPT. 20,2007IP * usua Though ffte information 6e/ow is not r&juired by law, it may prove valuable to parsons relying on tfie document and could prevent fraudulent removal and raattachmant of this form to another document Description of Attached Document Title or Type of Document: Document Date: Number of Pages: Sianer(s) Other Than Named Above: Capacity(ies) Claimed by Signer Signers Name: ,.,.., ._,,—u individual D Coroorate Officer — Title(s): D Partner — d Limited Q General D Attorney in Fact D Trustee a Guardian or Conservator G Other: Sianer Is Representing: RIGHT THUMbPKINT Of- SICNhK Top of thumb hers Surety stipulates and agrees that no change, extension of time, alteration or addition to the terms of the Contract, or to the work to be performed thereunder or the specifications accompanying the same shall affect its obligations on this bond, and it does hereby waive notice of any change, Revised: 10/08/03 Coniract No. 39B61-A Page 44 of B2 Pages JFC #05-5277 BQHD MO. 6372438 .>!'•"<;' •, .% :-!'.''""i LABOR AND MATERIALS BOND 'J;A';' 'P WHEREAS, the Board of Directors of the Carlsbad Municipal Water District of the Cjty of Carlsbad,' State of California, by Resolution No.1267. adopted January 17.2006 , has awarded to__ J. FLETCHER CREAMER & SONS. INC, _, (hereinafter designated as the "Principal"), a Contract for: SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A in the City of Carlsbad, in strict conformity with the drawings and specifications, and ..other Contract Documents now on file in the Office of the Secretary of the Board of Directors (City Clerk of the City of Carlsbad) and all of which are incorporated herein by this reference. WHEREAS, Principal has executed or is about to execute said Contract and the,; terms thereof require the furnishing of a bond, providing that if Principal or any of their subcontractors shall fail to pay for any materials, provisions, provender or other supplies or teams used in, upon or about the performance of the work agreed to be done, or for any work or labor done thereon of any kind, the Surety on this bond will pay the same to the extent hereinafter set forth. NOW, THEREFORE, WE J. FLET»ER CREAMER & SONS. INC. _ . as Principal,(hereinafter designated as the 'Contractor"), and SAFECO INSUEANCE COMPANY OF AMERICA , as Surety, are held and firmly bound unto the Cartsbad Municipal Water District, In the sum of FOUR MILLION THREE HUNDRED FORTY EIGHT THOUSAND TWO HUNDRED THIRTY SEVEN Dollars and FIFTY Cents ($4.348,237 50), said sum being equal to one hundred percent (100%) of the estimated amount of the Contract, to'be paid to District or its certain attorney, its successors and assigns; for which payment, well and truly to be made, we bind ourselves, our heirs, executors and administrators, successors or assigns, jointly and severally, firmly by these presents. THE CONDITION OF THIS OBLIGATION IS SUCH that if the Contractor or his/her subcontractors fail to pay for any materials, provisions, provender, supplies, or teams used in, upon, for, or about the performance of the work contracted to be done, or for any other work or labor thereon of any kind, consistent with California Civil Code section 3181, or for amounts due under the Unemployment insurance Code with respect to the work or labor performed under this Contract, or for any amounts required to be deducted, withheld, and paid over to the Employment Development Department from the wages of employees of the contractor and subcontractors pursuant to section 13020 of the Unemployment Insurance Code with respect to the work and labor, that the Surety will pay for the same, and, also, in case suit is brought upon the bond, reasonable attorney's fees, to be fixed by the court consistent with California Civil Code section 3248. This bond shall inure to the benefit of any of the persons named in California Civil ,Cod.e section 3181, so as to give a right of action to those persons or their assigns in any suit brought upon the bond. - ,: •' f .,' , _ y ' - In the event that Contractor is an individual, it is agreed that the death of any such iCpntractor shall not exonerate the Surety from its obligations under this bond. Executed by CONTRACTOR this 31ST day of.JANUARY CONTRACTOR: J. FLETCHER CREAMER & SpN/ IHC> (name of Contractor] fly; .20 06 Executed by SURETY this 31 ST Of JANUARY ,20 SURETY: SAFECO INSURANCE COMPANY OF AMERICA (sign here) J. Fletcher Creamer, Jr. (print name here) President (titl/^and organization ofjsigrjatJ. Flertther Cre 1200 MACARTHUR BOULEVARD MAHWAH. NJ 07430 (address of Surety) 201-327-7606 ' . . (telephone number of Surety) (sign heri)/ Juergen R. Hofhelnz (print name here) Assistant Secretary (signabjr&of Attomjjy*ln-Fact) CHERYL R. COLEMAN (printed name of Attorney^n-Fact) (attach corporate resolution showing current power of attorney) <^ \ f ;,>•:/>'.-• j1^;?.'-'(;€v^' (title and organization of signatory) J. Fletcher Creamer & Son, Inc.(Proper notarial acknowledge of execution by CONTRACTOR and SURETY must be, attached.) (President or vice-president and secretary or assistant secretary must sign for corporations If only, : one officer signs, the corporation must attach a resolution certified by the secretary or assistant "•' secretary under corporate seal empowering that officer to bind the corporation..) APPROVED AS TO FORM: RONALD R. BALL General Counsel By: Deputy General Couniel Revised: 10/06/03 Contract No.. 39561-A Pape 45 of 62 Pages C , f- ,' >\, v'V,i i1,'..!./:';•• s "'('•*' <r ' i> ACKNOWLEDGMENT BY PRINCIPAL, IF A CORPORATION STATE OF NEW JERSEY COUNTY OF Bergen On this 31ST day of JANUARY 2006 before me personally came J. Fletcher Creamer, Jr. to me known to be the person duly sworn, did depose and say, that he/she resides in Park Ridge, NJ that he/aha is President of J. FLETCHER CREAMER & SON, INC. the corporation described in and which executed the foregoing instrument; that he/she knew the seal of said corporation; that the seal affixed to said instrument was such corporate seal; that it was affixed by order of the Board of Directors of said corporation, and that he/she signed his/her name thereto by like order. Sworn before me the date set forth above Notary Public RAFFAEtlA BELLINI NOTARY PUBLIC STATE OF NEW JERSEY MY COMMISSION EXPIRES SEPT. 20,2007 ID # 2292025 CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT New Jersey State of Saitfamta County of Ber8en On January 31. Oslo personally appeared . 2006. before me. Juergen R. of J. Fletcher & Son, Inc. V ss. Raffaella Bellini.Nntarv Puhl ic Nam* and Tills of Offlcar (9. a.. 'Jans Do«, Notary PuWO Hofheinz, Assistant Corporate Secretary Cr earner^1""!'* "' 3isn««») S personally known to me D proved to me on the basis of evidence satisfactory RAFFAELLA BELLINI NOTARY PUBLIC STATE OF NEW JERSEY MY COMMISSION EXPIRES SEPT 20, 2007 to be the person(s) whose nama(s) is/are subscribed to the within instrument and acknowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their signature(s) on the instrument the person(s), or the entity upon behalf of which the person(s) acted, executed the instrument. WITNESS my hand and official seal. OPTIONAL Though tfia information Oelow is not r&juired by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and rsBttacfiment of this form to another document Description of Attached Document Document Date: Number of Paqes: Siqner(s) Other Than Named Above: Capacity(ies) Claimed by Signer Signer's Name: i-"i -i- -_iU individual D Coroorate Officer — Title(s): D Partner — Q Limited D General D Attorney in Fact D Trustee O Guardian or Conservator D Other: Sianer Is Representing: RIGHT THUMBPWNTOP SICNtK Too of thumb haw 1 5[ & I I I 1•*> ACKNOWLEGEMENT OF SURETY STATE OF NEW JERSEY COUNTY OF MORRIS On this 31st day of _ January _ , 2006, before me personally came Cheryl R. Coleman , to me known, who being duly sworn, did depose and say that he/she is an Attorney-In-Fact of Safeco Insurance Company of America _ and knows the corporate seal thereof; that the seal affixed to said annexed instrument is such corporate seal; and was thereto affixed by authority of the Power of Attorney of said Company, of which a Certified Copy is hereto attached, and that he/she signed said instrument as an Attorney-In-Fact of said Company by like authority. My Commission Expires•> •otary Public CHARLOTTE GOODMAN Notary Public Of New Jersey My Commission Expires April 21 , 2008 POWER Safeco Insurance Companies OF ATTORNEY 12893 KNOW ALL BY THESE PRESENTS: Na That SAFECO INSURANCE COMPANY OF AMERICA and GENERAL INSURANCE COMPANY OF AMERICA, each a Washington corporation, does each hereby appoint •mmmiiiiiiCHERYL R. COLEMAN; JEFFREY R. KANE; MARIA RODRIGUES; MARC N. WALDOR; PETER R. WALDOR; Florham Park, New Jersey"""""""""""""""""""""""""""""""""" ..... •*»»•»*»••••»»* Its true and lawful attomey(s)-ln-ract, with full authority to execute on Its behalf fidelity and surety bonds or undertakings and other documents of a similar character issued In the course of its business, and to bind the respective company thereby. IN WITNESS WHEREOF, SAFECO INSURANCE COMPANY OF AMERICA and GENERAL INSURANCE COMPANY OF AMERICA have each executed and attested these presents 13th September 20°5 this _ day of - ' - STEPHANff r^AI FY-WATSQM.SECRETARY _ MIKE PETERS. PRESIDENT. SURETY CERTIFICATE Extract from the By-Laws Of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA: •Article V, Section 13. - FIDELITY AND SURETY BONDS ... the President, any vice President, the Secretary, and any Assistant Vice President appointed for that purpose by the officer In charge of surety operations, shall each have authority to appoint Individuals as attomeys-in-fact or under other appropriate titles with authority to execute on behalf of the company fidelity and surety bonds and other documents of similar character issued by the company in the course of Its business... On any instrument making or evidencing such appointment, the signatures may be affixed by facsimile. On any instrument conferring such authority or on any bond or undertaking of the company, the seal, or a facsimile thereof, may be Impressed or affixed or in any other manner reproduced; provided, however, that the seal shall not be necessary to the validity of any such instrument or undertaking.* Extract from a Resolution of the Board of Directors of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA adopted July 28. 1970. "On any certificate executed by the Secretary or an assistant secretary of the Company setting out. ffl The provisions of Article V, Section 13 of the By-Laws, and (il) A copy of the powers-attorney appointment, executed pursuant thereto, and (Hi) Certifying that said power-of-attomey appointment to in fuH force and effect, the signature of the certifying officer may be by facslmte, and the seal of the Company may be a facsimile thereof.* I, Stephanie Daley-Watson , Secretary of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA, do hereby certify that the foregoing extracts of the By-Laws and of a Resolution of the Board of Directors of these corporations, and of a Power of Attorney issued pursuant thereto, are true and correct and thai both the By-Laws, the Resolution and the Power of Attorney are sail in full force and effect. IN WITNESS WHEREOF, I have hereunto set my hand and affixed the facsimile eeal of said corporation this _ 31ST _ dayof JANUARY _ • 2QQ6 ' STEPHANIE DALEY-WATSON, SECRETARY Saftco* and the Safaoo logo are ragistared trademark! of Safeco Corporation. S-0974/DS4/05 WEB PDF SAFECO INSURANCE COMPANY OF AMERICA FINANCIAL STATEMENT — DECEMBER 31, 2004 Assets Cash and Bank Deposits _ $ (52.492.321) *Boncis — U.S Government •_ 251,9X2,058 *0tber Bonds , 2,522,533,516 'Stocks 444,878,607 Real Estate 9,4X5,908 Agents' Balances or Uncollcctecf Premiums 367,916,616 Accrued Interest and Rents 39.230,044 Other Admitted Assets .-. ] 42.067.106 Total Admitted Assets £3.7S5.< Liabilities Unearned Premiums _ _ _ S 710,499,599 Reserve for Claims and Claims Expense l,59(L324p90 Funds Held Under Reinsurance Treaties II 4.417 Reserve for Dividends to Policyholders £36,898 Additional Statutory Reserve......... _ Reserve for Commissions, Taxes and Other Liabilities 440.428.802 Total S2,742,204,306 Capita] Stock J 5,000,000 Paid in Surplus _ 233,187,258 Unassigned Surplus 805.209.270 Surplus to PoIicyhoJders - 1.043.397.228 Total Liabilities and Surplus S3.78 Bonds are stated at amortized or investment value; Stocks at Association Market Values. Securities carried at S153..000.775 are deposited as required by law. I MICHAEL C. PETERS, president of SAFECO Insurance Company, do hereby certify that the foregoing is a true, and correct statement of the A-ssets and Liabilities of said Corporation, as of December 31, 2004, to the best of my knowledge and belief. IN WITNESS WHEREOF, I have hereunto set my hand and affixed the seal of said Corporation at Seattle, Washington, this 1st day of March, 2005. President S-125223/D2 ©A registered trademark of SAFECO ColpcraSon JFC #05-5277 BOHD NO. 6372438 FAITHFUL PERFORMANCE/WARRANTY B0AD'. WHEREAS, the Board of Directors of the Carlsbad Municipal Water District of the' City of Carlsbad,, State of California, by Resolution No. 1267. adopted January 17. 2006 has awarded, to J, FLETCHER CREAMER & SONS. INC. : , (hereinafter designated as the "Principal"), a Contract for: SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A in the Carlsbad Municipal Water District, in strict conformity with the contract, the .drawings and ' .:yiY -.-f;; :, specifications, and other Contract Documents nowon file in the Office of the Secretary of the Board1 -'>'':, ^i^, \ of Directors (City Clerk of the City of Carlsbad), all of which are incorporated herein by this reference, WHEREAS, Principal has executed or Is about to execute said Contract and the terms thereof require the furnishing of a bond for the faithful performance and warranty of said Contract; NOW, THEREFORE, WE, J. FLETCHER CREAMER & SONS. INC., as Principal, (hereinafter designated as the "^Contractor"), and SAFECO INSURANCE COMPANY OF AMERICA , as Surety, are held and firmly bound unto the-Carlabad Municipal Water District, in the sum of FOUR MILLION THREE HUNDRED FORTY EIGHT THOUSAND TWO HUNDRED THIRTY SEVEN Dollars and FIFTY Cents ($4,348,237.SO),,said sum being equal to one hundred percent (100%) of the estimated amount of the Contract to be. paid to District or its certain attorney, its successors and assigns; for which payment, well and truly to be made, we bind ourselves, our heirs, executors and administrators, successors or assigns, jointly and severally, firmly by these presents. THE CONDITION OF THIS OBLIGATION IS SUCH that if the above bounden"Contractor, their heirs, executors, administrators, successors or assigns, shall in all things stand to and,abide by, and well and truly keep and perform the covenants, conditions, and agreements In the Cpritract and any alteration thereof made as therein provided on their part, to be kept and performed at the firne and in the manner therein specified, and in all respects according to their true intent and meaning, and shall indemnity and save harmless the Carlsbad Municipal Water District, its officers, employees and agents, as therein stipulated, then this obligation shall become null and void; otherwise It shall remain in full force and effect. As a part of the obligation secured hereby and in addition to the fece amount specified therefor, there shall be included costs and reasonable expenses and fees, including reasonable attome/s fees, incurred by the District in successfully enforcing such obligation, all to be taxed as costs and included In any judgment rendered. Surety stipulates and agrees that no change, extension of time, alteration or addition to the terms of the Contract, or to the work to be performed thereunder or the specifications accompanying the same shall affect its obligations on this bond, and rt does hereby waive notice of any change, extension of time, alterations or addition to the terms of the contract or to the work or to the specifications. Revised: 10/08/03 Contract No. 39561 -A Page.4$ of 82 Pages In the event that Contractor is an individual, It is agreed that the death of any such Contractor sha.fl, not exonerate the Surety from its obligations under this bond. Executed by CONTRACTOR this 31ST day of JANUARY , 20 06. CONTRACTOR: J. FLETCHER CREAMER & SON, INC. (s^gn here) / J'. Fletcher Creamer, Jr. (print name here) President (Title and Organization of Signatory) J. Fletcher Creamer & Son, Inc. Executed by SURETY this 31ST day of •' ' f - JANUARY _, 20_06_ SURETY; SAFECO INSURANCE COMPAN? OF AMERICA (name of Surety),' 1200 MACARTHUR BOULEVARD MAHWAH, NJ 07430 (address of Surety) 201-327-7606 . (telephone number of Surety) .^;>Wr^v.ff'-* *>. (sign heref Juergen R. Hofheinz (sfgnature( d|f Attorney-infFaict) CHERYL R. COLEMAN _ (printed name of Attomey-Jn-Fact) (Attach corporate resolution -showing current power of attorney.)(print name here) Assistant Secretary (Title and Organization of signatory) J. Fletcher Creamer & Son, Inc. (Proper notarial acknowledge of execution by CONTRACTOR and SURETY must.be:a8ached,) (President or vice-president and secretary or assistant secretary must sign for corpdratioris. If only one officer signs, the corporation must attach a resolution certified by the secretary or assistant secretary under corporate seal empowering that officer to bind the corporation.) APPROVED AS TO FORM: RONALD R. BALL General Counsel By: Depdty TSeneraf Counsel «..':*f •*K' <•*•»&_ Revised: 10/08/03 ComracT No. 39561-A Page 47 of 82 Pages ACKNOWLEDGMENT BY PRINCIPAL, IF A CORPORATION STATE OF NEW JERSEY COUNTY OF Bergen On this 31ST day of JANUARY 2006 before me personally came J. Fletcher Creamer, Jr. to me known to be the person duly sworn, did depose and say, that he/sfae resides in Park Ridge. NJ that he/she is President of J. FLETCHER CREAMER & SON, INC. the corporation described in and which executed the foregoing instrument; that he/she knew the seal of said corporation; that the seal affixed to said instrument was such corporate seal; that it was affixed by order of the Board of Directors of said corporation, and that he/she signed his/her name thereto by like order. Sworn before me the date set forth above Notary Public COMMISSION EXPIRES SEPT.20,2007 ID # 2292025 CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT New Jersey State of Satitootat County of Bergen On Januarv 31. 2006. before me. Oaia oersonallv appeared Juergen R. of J. Fletcher }, Raffae}.!^ Bellini. Notary PuMir i Nairn and Tills of Offlcar (a.fl., 'Jans Oo«, Notary PuWO Hofheinz, Assistant Corporate Secretary Creamer1"11"*1' a( Sisn«t») i & Son, Inc. a personally known to me :'- Q proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) is/are subscribed to the within instrument and acknowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their signature(s) on the instrument the person(s), or the entity upon behalf of which the person(s) actsd, executed the instrument. RAFFAELLA BELLINI NOTARY PUBLIC STATE OF NEW JERSEY MY COMMISSION EXPIRES SEPT 20,2007 ID #2292025 «=« *"*•? *•" •W""' WITNESS my hand and official seal. Signature si rtetsry Pudis OPTIONAL Though tfia faJbmatfco below is nQtr&juirvd by law, it mayprova valuable to parsons raiying on tha document and cooW pravent fraudulent removal and reattacftm&nt of this form to another document Description of Attached Document Title or Type of Document [ ___ Document Date:. Number of Pages:, Signer(s) Other Than Named Above:. Capacity(ies) Claimed by Signer Signer's Name: O Individual aa aa a a Corporate Officer —Title(s): Partner—Q Limited Q General Attorney in Fact Trustee Guardian or Conservator Other RIGHT THUIWbFWNT CFSlCNfcK Too of thumb h«« Signer Is Representing: 3 1937 National Nola/y Association • 3350 Ca Solo Avo.. P.O. Sot 2402 • Chaiswortti. CA 91313-2402 Proa. No. SS07 Raortar: Cill TciUrrau 1-aCO-37B^327 ACKNOWLEGEMENT OF SURETY STATE OF NEW JERSEY COUNTY OF MORRIS On this 31st day of January 5 2006, before me personally came Cheryl R. Coleman , to me known, who being duly sworn, did depose and say that he/she is an Attorney-In-Fact of Safeco Insurance Company of America and knows the corporate seal thereof; that the seal affixed to said annexed instrument is such corporate seal; and was thereto affixed by authority of the Power of Attorney of said Company, of which a Certified Copy is hereto attached, and that he/she signed said instrument as an Attorney-In-Fact of said Company by like authority. My Commission Expires Notary Public CHARLOTTE GOODMAN Notary Public Of New Jersey My Commission Expires April 21,2008 POWER Safeco Insurance Companies OF ATTORNEY a 12893 KNOW ALL BY THESE PRESENTS: No' - That SAFECO INSURANCE COMPANY OF AMERICA and GENERAL INSURANCE COMPANY OF AMERICA, each a Washington corporation, does each hereby appoint """""""CHERYL R. COLEMAN; JEFFREY R. KANE; MARIA RODRIGUES; MARC N. WALDOR; PETER R. WALDOR; Florham Park, New Jersey""""""""""""""""""" ..... ••»«.»•»»»•.»•. ............ ............... Its true and lawful attomey(s)-in-fact, with full authority to execute on Its behalf fidelity and surety bonds or undertakings and other documents of a similar character issued in the course of its business, and to bind the respective company thereby. IN WITNESS WHEREOF, SAFECO INSURANCE COMPANY OF AMERICA and GENERAL INSURANCE COMPANY OF AMERICA have each executed and attested theee presents 13th September 2005 <"'» _ day of - ' STEPHAMIP riAl EY-WATSQM.SECRETARY _ MIKE PETERS. PRESIDENT. SURETY CERTIFICATE Extract from the By-Laws of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA: •Article V, Section 13. - FIDELITY AND SURETY BONDS ... the President, any vice President, the Secretary, and any Assistant Vice President appointed for that purpose by the officer In charge of surety operations, shall each have authority to appoint Individuals as attomeys-in-fact or under other appropriate titles with authority to execute on behalf of the company fidelity and surety bonds and other documents of similar character issued by the company in the course of Its business... On any instrument making or evidencing such appointment the signatures may be affixed by facsimile. On any Instrument conferring such authority or on any bond or undertaking of the company, the seal, or a facsimile thereof, may be Impressed or affixed or in any other manner reproduced; provided, however, that the seal shaH not be necessary to the validity of any such instrument or undertaking.' Extract from a Resolution of the Board of Directors of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA adopted July 26, 1 970. "On any certificate executed by the Secretary or an assistant secretary of the Company setting out, <Q The provisions of Arficto V, Section 13 of the By-Laws, and(II) A copy of the power-of-attomey appointment executed pursuant thereto, and (III) Certifying that said power-of-attomey appointment is in fufl force and effect, the signature of the certifying officer may be by facsimfts, and the seal of the Company may be a facsimile thereof." I, Stephanie Daley-Watson , Secretary of SAFECO INSURANCE COMPANY OF AMERICA and of GENERAL INSURANCE COMPANY OF AMERICA, do hereby certify that the foregoing extracts of the By-Laws and of a Resolution of the Board of Directors of these corporations, and of a Power of Attorney issued pursuant thereto, are true and correct and that both the By-Laws, the Resolution and the Power of Attorney are still in full force and effect IN WITNESS WHEREOF, I have hereunto set my hand and affixed the facsimile eeal of aald corporation tni, _ 31ST _ dayof JANUARY _ • 2QQ6 • STEPHANIE DALEY-WATSON, SECRETARY Safeoo8 ind the Safeco logo ere regisMnd trademarks of Safeco Corporation. S-0974/DS4/05 WEB PDF SAFECO INSURANCE COMPANY OF AMERICA •' FINANCIAL STATEMENT — DECEMBER 31, 2004 Assets Cash and Bank Deposits _ S (52.492321) *Bonds— U.S Government , 251,982,058 *Other Bonds ; 2,582,533,516 *Stocks r 444,872,607 Real Estate _ 9,485,908 Agents' Balances or Uacollected Premiums 367,916,616 Accrued Interest and Rents 39230,044 Other Admitted Assets -. , 142.067.106 Total Admitted Assets __ S3/ZS5J Liabilities Unearned Premiums _.... 5 710,499,599 Reserve for Claims and Claims Expense 1,590,324,590 Funds Held Under Reinsurance Treaties 114.417 Reserve forUividends to Policyholders 836,898 Additional Statutory Reserve _ Reserve for Commissions, Taxes and Other Liabilities 440.428.802 Total J2,742,204,306 Capital Stock S 5,000,000 Paid in Surplus _ 233,187,958 Unassigned Surplus _ 805-209.270 Surplus to Policyholders.. Total Liabilities and Surplus.. 1.043.397.228 * Bonds are stated at amortized or investment value; Stocks at Association Market Values. Securities carried at SI 53.000,775 are deposited as required by law. L. MICHAEL C. PETERS, president of SAhbCO Insurance Company, do hereby certify that the foregoing is a true, and correct statement of the Assets and Liabilities of said Corporation, as of December 31. 2004, to the best of my knowledge and belief. IN WITNESS WHEREOF, I have hereunto set my hand and affixed me sea! of Said Corporation at Seattle, Washington, this 1st day of March, 2005. President S-t2S2a 3/D2 ® A mastered tradema/fc of SA.-cCO Co/pcrmfion OPTIONAL ESCROW AGREEMENT FOR SECURITY DEPOSITS IN LIEU OF RETENTION This Escrow Agreement is made and entered into by and between the Carlsbad Municipal Water District whose address is 5950 El Camino Real, Carlsbad, California, 92008, hereinafter called "District" and J. Fletcher Creamer & Son, Inc. whose address is 1?R7A San Fernanrln TM. , SylTnar, P.A Q1342 hereinafter Called "Contractor" and d/r^^^^ s*£-*4***s/ sfafacHa &,*, whose address is ^HcS^^/d?*^ s/-.3'i(z.Ji/<e><£>f,~52»ff£l<r**?j*e!a> <*s? <?•?/// hereinafter caHed Escrow Ageril" For the consideration hereinafter set forth, the District, Contractor and Escrow Agent agree as follows: 1 Pursuant to sections 22300 and 10263 of the Public Contract Code of the State of California, the Contractor has the option to deposit securities with the Escrow Agent as a substitute for retention earnings required to be withheld by the District pursuant to the Construction Contract entered into between the District and Contractor for: SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561-A in the amount of $4,348,237.50 dated ; (hereinafter referred to as the "Contract") Alternatively, on written request of the Contractor, the District shall make payments of the retention earnings directly to the Escrow Agent. When the Contractor deposits the securities as a substitute for Contract earnings, the Escrow Agent shall notify the District within 10 days of the deposit. The Escrow Agent shall maintain insurance to cover negligent acts and omissions of the Escrow Agent in connection with the handling of retentions under these sections in an amount not less than $100,000 per contract. The market value of the securities at the time of the substitution shall be a least equal to the cash amount then required to be withheld as retention under the terms of the contract between the District and Contractor. Securities shall be held in the name of the District and shall designate the Contractor as the benefcial owner 2. The District shall make progress payments to the Contractor for such funds which otherwise would be withheld from progress payments pursuant to the Contract provisions, provided that the Escrow Agent holds securities in the form and amount specified above. 3. When the District makes payment of retentions earned directly to the Escrow Agent, the Escrow Agent shall hold them for the benefit of the Contractor until such time as the escrow created under this contract is terminated. The Contractor may direct the investment of the payments into securities All terms and conditions of this agreement and the rights and responsibilities of the parties shall be equally applicable and binding when the District pays the Escrow Agent directly 4. The Contractor shall be responsible for paying all fees for the expenses incurred by the Escrow Agent in administering the Escrow Account and all expenses of the District. These expenses and payment terms shall be determined bythe District, Contractor and Escrow Agent. Revised: 10/08/03 Contract No 39561 -A Page 48 of 82 Pages 5.. The interest earned on the securities or the money market accounts held in escrow and all interest earned on that interest shall be for the sole account of Contractor and shall be subject to withdrawal by Contractor at anytime and from time to time without notice to the District, 6. Contractor shall have the right to withdraw all or any part of the principal in the Escrow Account only by written notice to Escrow Agent accompanied by written authorization from District to the Escrow Agent that District consents to the withdrawal of the amount sought to be withdrawn by Contractor. 7 The District shall have a right to draw upon the securities in the event of default by the Contractor. Upon seven days' written notice to the Escrow Agent from the District of the default, the Escrow Agent shall immediately convert the securities to cash and shall distribute the cash as instructed by the District. 8 Upon receipt of written notification from the District certifying that the Contract is final and complete and that the Contractor has complied with all requirements and procedures applicable to the Contract, the Escrow Agent shall release to Contractor all securities and interest on deposit less escrow fees and charges of the Escrow Account.. The escrow shall be closed immediately upon disbursement of alt moneys and securities on deposit and payments of fees and charges. 9. The Escrow Agent shall rely on the written notifications from the District and the Contractor pursuant to sections (1) to (8), inclusive, of this agreement and the District and Contractor shall hold Escrow Agent harmless from Escrow Agent's release, conversion and disbursement of the securities and interest as set forth above 10.. The names of the persons who are authorized to give written notices or to receive written notice on behalf of the District and on behalf of Contractor in connection with the foregoing, and exemplars of their respective signatures are as follows: For District:Title FINANCE DIRECTOR Name Ll 5o. For Contractor:Title Name J. Fischer Cre For Escrow Agent: Signature Address [I 12874 San Fernando Rd Title President .. ffi Imar.CA 91342 Revised: 10/08/03 Contract No.. 39561-A Page 49 of 82 Pages At the time the Escrow Account is opened, the District and Contractor shall deliver to the Escrow Agent a fully executed counterpart of this Agreement,, IN WITNESS WHEREOF, the parties have executed this Agreement by their proper officers on the date first set forth above, For District:Title MAYOR For Contractor:Title President Name J- Fieier // Signature S Address y12874 San Fernando Rd., tfylmar, CA 91342 For Escrow Agent:Title Name Signature Address I MICHAEL E SUSNCm Vice President Revised: 10/08/03 Contract No 39561-A Page 50 of 82 Pages SUPPLEMENTAL PROVISIONS FOR SAN MARCOS BOULEVARD TRANSMISSION MAIN AND STREET IMPROVEMENTS CONTRACT NO. 39561 -A SUPPLEMENTAL PROVISIONS TO "GREENBOOK" STANDARD SPECIFICATIONS for PUBLIC WORKS CONSTRUCTION 2003 EDITION PART 1, GENERAL PROVISIONS SECTION 1 -- TERMS, DEFINITIONS ABBREVIATIONS AND SYMBOLS 1-1 TERMS Add the following section: 1-1.1 Reference to Drawings. Where words "shown", "indicated", "detailed", "noted", "scheduled", or words of similar import are used, it shall be understood that reference is made to the plans accompanying these provisions, unless stated otherwise. Add the following section: 1-1.2 Directions. Where words "directed", "designated", "selected", or words of similar import are used, it shall be understood that the direction, designation or selection of the Engineer is intended, unless stated otherwise. The word "required" and words of similar import shall be understood to mean "as required to properly complete the work as required and as approved by the Engineer," unless stated otherwise. Add the following section: 1-1.3 Equals and Approvals. Where the words "equal", "approved equal", "equivalent", and such words of similar import are used, it shall be understood such words are followed by the expression "in the opinion of the Engineer", unless otherwise stated. Where the words "approved", "approval", "acceptance", or words of similar import are used, it shall be understood that the approval, acceptance, or similar import of the Engineer is intended. Add the following section: 1-1.4 Perform. The word "perform" shall be understood to mean that the Contractor, at its expense, shall perform all operations, labor, tools and equipment, and further, including the furnishing and installing of materials that are indicated, specified or required to mean that the Contractor, at its expense, shall furnish and install the work, complete in place and ready to use, including furnishing of necessary labor, materials, tools, equipment, and transportation. levised: 10/08/03 Contract No. 39561-A Page 51 of 82 Pages 1-2 DEFINITIONS. Modify as follows: The following words, or groups of words, shall be exclusively defined by the definitions assigned to them herein. Agency - the Carlsbad Municipal Water District. City Council - the City Council of the City of Carlsbad. City Manager - the City Manager of the City of Carlsbad or his/her approved representative. Dispute Board - persons designated by the City Manager to hear and advise the City Manager on claims submitted by the Contractor. The City Manager is the last appeal level for informal dispute resolution. Engineer - the City Engineer of the City of Carlsbad or his/her approved representative. The Engineer is the third level of appeal for informal dispute resolution. Minor Bid Item - a single contract item constituting less than 10 percent (10%) of the original Contract Price bid. Own Organization - When used in Section 2-3.1 - Employees of the Contractor who are hired, directed, supervised and paid by the Contractor to accomplish the completion of the Work. Further, such employees have their employment taxes, State disability insurance payments, State and Federal income taxes paid and administered, as applicable, by the Contractor. When used in Section 2-3.1 "own organization" means construction equipment that the Contractor owns or leases and uses to accomplish the Work. Equipment that is owner operated or leased equipment with an operator is not part of the Contractor's Own Organization and will not be included for the purpose of compliance with section 2-3.1 of the Standard Specifications and these Supplemental Provisions. Owner Operator/Lessor - Any person who provides equipment or tools with an operator provided who is employed by neither the Contractor nor a subcontractor and is neither an agent or employee of the Agency or a public utility. Deputy City Engineer, Construction Management & Inspection - The Construction Manager's immediate supervisor and second level of appeal for informal dispute resolution. Project Inspector - the Engineer's designated representative for inspection, contract administration and first level for informal dispute resolution. Construction Manager- the Project Inspector's immediate supervisor and first level of appeal for informal dispute resolution. Revised: 10/08/03 Contract No. 39561-A Page 52 of 82 Pages 1-3 ABBREVIATIONS 1-3.2 Common Usage, add the following: Abbreviation Word or Words Apts Aprtment and Apartments Bldg Building and Buildings CMWD Carlsbad Minicipal Water District CSSD Carlsbad Supplement Standard Drawings cfs Cubic Feet per Second Comm Commercial DR Dimension Ratio E Electric EWA Encina Wistewater Authority G Gas gal Gallon and Gallons Gar Garage and Garages GNV Ground Not teible gpm gallons per minute IE Inert Elevation LWD Leucadia Wistewater District MSL Nftan Sea Level (see Regional Standard Drawing M-12) MTBM Nbrotunneling Boring Machine NCTD North CountyTransit District OHE Oerhead Electric OMWD Olrenhain Municipal Water District ROW Right-ofWay S Severer Slope, as applicable SDNR San Diego Northern Railvay SDRSD San Diego Regional S&ndard Drawings SFM Sever Force Main T flephone UE Underground Electric W Vttter, Wider or Width, as applicable VWD Vlllecitos Water District SECTION 2 - SCOPE AND CONTROL OF THE WORK 2-3 SUBCONTRACTS. 2-3.1 General, add the following: Should the Contractor fail to adhere to the provisions requiring the Contractor to complete 50 percent of the contract price with its own organization, the Agency may at its sole discretion elect to cancel the contract or deduct an amount equal to 10 percent ofthe value of the work performed in excess of 50 percent of the contract price by other than the Contractor's own organization. The City Council shall be the sole body for determination of a violation of these provisions. In any proceedings under this section, the prime contractor shall be entitled to a public hearing before the City Council and shall be notified ten (10) days in advance of the time and location of said hearing. The determination ofthe City Council shall be final. evised: 10/08/03 Contract No. 39561-A Page 53 of 82 Pages 2-4 CONTRACT BONDS, modify the second sentence of paragraph one as follows: Delete, "who is listed in the latest version of U.S. Department of Treasury Circular 570,". Modify paragraphs three and four to read: The Contractor shall provide a faithful performance/warranty bond and payment bond (labor and materials bond) for this contract. The faithful performance/warranty bond shall be in a sum not less than one hundred percent of the total amount payable by the terms of this contract. The Contractor shall provide bonds to secure payment of laborers and materials suppliers in a sum not less than one hundred percent of the total amount payable by the terms of this contract. Both bonds shall extend in full force and effect and be retained by the Agency during this project until they are released according to the provisions of this section. The faithful performance/warranty bond will be reduced to 25 percent of the original amount 30 days after recordation of the Notice of Completion and will remain in full force and effect for the one year warranty period and until all warranty repairs are completed to the satisfaction of the Engineer. The bonds to secure payment of laborers and materials suppliers shall be released six months plus 30 days after recordation of the Notice of Completion if all claims have been paid. Add the following: All bonds are to be placed with a surety insurance carrier admitted and authorized to transact the business of insurance in California and whose assets exceed their liabilities in an amount equal to or in excess of the amount of the bond. The bonds are to contain the following documents: 1) An original, or a certified copy, of the un-revoked appointment, power of attorney, by laws, or other instrument entitling or authorizing the person who executed the bond to do so. 2) A certified copy of the certificate of authority of the insurer issued by the insurance commissioner. If the bid is accepted, the Agency may require a financial statement of the assets and liabilities of the insurer at the end of the quarter calendar year prior to 30 days next preceding the date of the execution of the bond. The financial statement shall be made by an officer's certificate as defined in Section 173 of the Corporations Code. In the case of a foreign insurer, the financial statement may be verified by the oath of the principal officer or manager residing within the United States. 2-5 PLANS AND SPECIFICATIONS. 2-5.1 General, add the following: The specifications for the work include the Standard Specifications for Public Works Construction, (SSPWC), 2003 Edition, hereinafter designated "SSPWC", as written and promulgated by Joint Cooperative Committee of the Southern California Chapter American Public Works Association and Southern California Districts Associated General Contractors of California, and as amended by the Supplemental Provisions section of this contract. The construction plans consist of two sets of drawings associated with the project. The first set is designated as City of San Marcos "Improvement Plans for San Marcos Boulevard Street Improvements", City of San Marcos CIP No. 274, Drawing No. IP-4693 and consists of 31 sheets. The second set is designated as City of Carlsbad "San Marcos Boulevard Transmission Main", Project No. 3956, Drawing No. 425-1 and consists of 20 sheets. Revised: 10/08/03 Contract No. 39561-A Page 54 of 82 Pages The standard drawings used for this project are the latest edition of the San Diego Area Regional Standard Drawings, hereinafter designated SDRSD, as issued by the San Diego County Department of Public Works, together with the most recent editions of the City of San Marcos Standard Drawings, and the Carlsbad Municipal Water District Standard Plans hereinafter designated as CMWDSD, as issued by the Carlsbad Municipal Water District. Copies of some of the pertinent standard drawings are enclosed as an appendix to these Supplemental Provisions. 2-5.2 Precedence of Contract Documents, modify as follows: If there is a conflict between Contract Documents, the document highest in precedence shall control. The precedence shall be the most recent edition of the following documents listed in order of highest to lowest precedence: 1) Permits from other agencies as may be required by law. 2) Supplemental Provisions. 3) Technical Specifications 4) Plans. 3) City of Carlsbad Engineering Standards, 2004 Edition. 4) San Diego Regional Standard Drawings 5) State of California Department of Transportation Standard Plans 6) Standard Specifications for Public Works Construction 7) Reference Specifications 8) Manufacturer's Installation Recommendations Change Orders, Supplemental Agreements and approved revisions to Plans and Specifications will take precedence over items 2) through 79) above. Detailed plans and plan views shall have precedence over general plans. 2-5.3.3 Submittals, add the following: Each submittal shall be consecutively numbered. Resubmittals shall be labeled with the number of the original submittal followed by an ascending alphabetical designation (e.g. The label '4-C' would indicate the third instance that the fourth submittal had been given to the Engineer). Each sheet of each submittal shall be consecutively numbered. Each set of shop drawings and submittals shall be accompanied by a letter of transmittal on the Contractor's letterhead. The Letter of transmittal shall contain the following: 1) Project title and Agency contract number. 2) Number of complete sets. 3) Contractor's certification statement. 4) Specification section number(s) pertaining to material submitted for review. 5) Submittal number (Submittal numbers shall be consecutive including subsequent submittals for the same materials.) 6) Description of the contents of the submittal. 7) Identification of deviations from the contract documents. When submitted for the Engineer's review, Shop Drawings shall bear the Contractor's certification that the Contractor has reviewed, checked, and approved the Shop Drawings and that they are in conformance with the requirements of the Contract Documents. The Contractor shall subscribe to and shall place the following certification on all submittals: levised: 10/08/03 Contract No. 39561-A Page 55 of 82 Pages "I hereby certify that the (equipment, material) shown and marked in this submittal is that proposed to be incorporated into this Project, is in compliance with the Contract Documents, can be installed in the allocated spaces, and is submitted for approval." By: Title: Date: Company Name: Add the following: 2-5.4 Record Drawings, The Contractor shall provide and keep up-to-date a complete "as-built" record set of blue-line prints, which shall be corrected in red daily and show every change from the original drawings and specifications and the exact "as-built" locations, sizes and kinds of equipment, underground piping, valves, and all other work not visible at surface grade. Prints for this purpose may be obtained from the Agency at cost. This set of drawings shall be kept on the job and shall be used only as a record set and shall be delivered to the Engineer within ten (10) days of completion of the work. Payment for performing the work required by section 2-5.4 shall be included in the various bid items and no additional payment will be made therefore. 2-9 SURVEYING 2-9.1 Permanent Survey Markers, Delete sections 2-9.1 and replace with the following: The Contractor shall not cover or disturb permanent survey monuments or benchmarks without the consent of the Engineer. Where the Engineer concurs, in writing, with the Contractor that protecting an existing monument in place is impractical, the Contractor shall employ a licensed land surveyor or a registered civil engineer authorized to practice land surveying within the State of California, hereinafter Surveyor, to establish the location of the monument before it is disturbed. The Contractor shall have the monument replaced by the Surveyor no later than thirty (30) days after construction at the site of the replacement is completed. The Surveyor shall file corner record(s) as required by §§ 8772 and 8773, et seq. of the California Business and Professions Code. When a change is made in the finished elevation of the pavement of any roadway in which a permanent survey monument is located, the Contractor shall adjust the monument frame and cover to the new grade within 7 days of paving unless the Engineer shall approve otherwise. Monument frames and covers shall be protected during street sealing or painting projects or be cleaned to the satisfaction of the Engineer. 2-9.2 Survey Service, Delete sections 2-9.2 and replace with the following: The Contractor shall hire and pay for the services of a Surveyor, hereinafter Surveyor to perform all work necessary for establishing control, locating public right of way work limits, construction staking, records research and all other surveying work necessary to construct the work, provide surveying services as required herein and provide surveying, drafting and other professional services required to satisfy the requirements of the Land Surveyors Act. Surveyor shall be resident on the site during all surveying operations and shall personally supervise and certify the surveying work. Revised: 10/08/03 Contract No. 39561-A Page 56 of 82 Pages Add the following section: 2-9.2.1 Submittal of Surveying Data, All surveying data submittals shall conform to the requirements of section 2-5.3.3, "Submittals", herein. The Contractor shall submit grade sheets to the Engineer before commencing work in the area affected by the grade sheets. The Contractor shall submit field notes for all surveying required herein to the Engineer within ten days of performing the survey. All surveying field notes, grade sheets and survey calculations shall be submitted in bound form on 215mm by 280 mm (81/2n by 11") paper. The field notes, calculations and supporting data shall be clear and complete. Supporting data shall include all maps, affidavits, plats, field notes from earlier surveys and all other evidence used by the Surveyor to determine the location of the monuments set. The field notes and calculations will be labelled with name of the Surveyor, the party chief, the field crewmembers and the author of the field notes or calculations. They shall be annotated with the date of observation or calculation, be numbered with consecutive page numbers and shall be readable without resort to any electronic aid, computer program or documentation for any computer program. The field notes shall be prepared in conformance with the CALTRANS "Surveys Manual". The Contractor shall have a Record of Survey prepared by the Surveyor and file it in conformance with §§ 8700 - 8805 of the State of California Business and Professions Code when the Surveyor performs any surveying that such map is required under §§ 8762 of the State of California Business and Professions Code and whenever the Surveyor shall establish, set or construct any permanent survey monument. SDRS drawing M-10 type monuments, bolts, spikes, leaded tacks and nails (when set in concrete), iron pipes, reinforcing steel and all monuments and marks that are at, or accessory to, property corners and street centerlines are permanent survey monuments. The Record of Survey shall show all monuments set, control monuments used, the basis of bearings and all other data needed to determine the procedure of survey and the degree of accuracy attained by the field surveying including the unadjusted ratio of closure. The unadjusted ratio of closure shall not exceed 1 part in 40,000. The record of survey shall show the location and justification of location of all permanent monuments set and their relation to the street right-of-way. Record(s) of Survey(s) shall be submitted for the Engineer's review and approval before submittal to the County Surveyor and before submittal to the County Recorder. Add the following section: 2-9.2.2 Survey Requirements, Stakes shall be set at offsets approved by the Engineer at no greater intervals than specified in TABLE 2-9.2.2(A) as measured along the project stationing. Stakes shall be set to show the location and grade of future curbs adjacent to traffic signal locations where the curb is not being built as a part of this contract. Staking and marking shall be completed by the Surveyor and inspected and approved by the Engineer before the start of construction in the area marked. Centerline monument shall have the disk stamped with the date the monument was set and the registration number of the Surveyor. Habitat mitigation sites and other areas to be preserved that are shown on the plans shall be staked and flagged prior to the start of any other activities within the limits of the work. When curb and gutter does not exist and is not being installed as a part of the project the location of adjacent facilities being constructed as a part of the contract the Contractor shall place stakes defining the horizontal and vertical location of such adjacent utility vaults, poles or other facilities that are being installed as parts of, or adjunct to, the project either by the Contractor and/or those noted on the plans as to be installed by others. €5^W Revised: 10/08/03 Contract No. 39561-A Page 57 of 82 Pages TABLE 2-9.2.2(A) Survey Requirements for Construction Staking Feature Staked Street Centerline Clearing Slope Fence Rough Grade Cuts or Fills 2; 10 m (33') Final Grade (includes top of: Basement soil, subbase and base) Asphalt Pavement Finish Course Drainage Structures, Pipes & similar Facilities®, ® Curb Traffic Signal CD Signal Poles & Controller © Junction Box © Conduit CD Minor Structure © Abutment Fill Wall CD Stake Description © SDRS M-10 Monument Lath in soil, painted line on PCC & AC surfaces RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake, Blue- top in grading area RP, paint on previous course RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake + Line Stake RP + Marker Stake + Line Stake RP + Marker Stake + Line Point +Guard Centerline or Parallel to Centerline Spacing®, © <300m (1000'), Street Intersections, Begin and end of curves, only when shown on the plans lath - Intervisible, < 15m (50') on tangents & < 7.5m (25') on curves, Painted line - continuous Intervisible and < 15m (50') < 60 m (2001) on tangents, < 15m (50') on curves when R> 300m (1000') & 7.5m (25') on curves when R< 300m (1000') < 15m (50') < 15 m (50') on tangents & curves when R> 300m (1000') & < 7.5m (25') on curves when R< 300m (1000') < 7.5m (25') or as per the intersection grid points shown on the plan whichever provides the denser information - intervisible & < 7.5m (25'), beginning and end, BC & EC of facilities, Grade breaks, Alignment breaks, Junctions, Inlets & similar facilities, Risers & similar facilities (except plumbing), Skewed cut-off lines <: 7.5m (25'), BC & EC, at %A, 1/2A & %A on curb returns & at beginning & end Vertical locations shall be based on the ultimate elevation of curb and sidewalk at each pole & controller location at each junction box location < 15 m (50') on tangents & curves when R> 300m (1000') & < 7.5m (25') on curves when R < 300m (1000') or where grade < 0.30% for catch basins: at centerline of box, ends of box & wings & at each end of the local depression © < 15 m (50') & along end slopes & conic transitions < 15 m (501) and at beginning & end of: each wall, BC & EC, layout line angle points, changes in footing dimensions &/or elevation Lateral Spacing CD, © on street centerline at clearing line Grade Breaks & <7.6 m (25') N/A ( constant offset) N/A <6.7 m (22') edge of pavement, paving pass width, crown line & grade breaks as appropriate ( constant offset) as appropriate as appropriate as appropriate as appropriate as appropriate as appropriate Setting Tolerance (Within) 7 mm (0.02') Horizontal, also see section 2-9.2.1 herein 0.3 m (1') Horizontal 30 mm (0.1') Vertical & Horizontal 30 mm (0.1') Horizontal 30 mm (0.11) Verticals Horizontal 10 mm CVe") Horizontal & 7 mm (1/4") Vertical 10 mm (V) Horizontal & 7 mm Ck") Vertical 1 0 mm ("Vs") Horizontal & 7 mm (V) Vertical 10 mm (V) Horizontal & 7 mm (V) Vertical 1 0 mm (J/8") Horizontal & 7 mm (1/4") Vertical 10 mm (V) Horizontal & 7 mm (V) Vertical 10 mm (J/8") Horizontal & when depth cannot be measured from existing pavement 7 mm ( /4") Vertical 1 0 mm ("/a") Horizontal & 7 mm (V) Vertical (when vertical data needed) 30 mm (0.1') Verticals Horizontal 7 mm CU") Horizontal & 7 mm (V) Vertical 10/08/03 Contract No. 39561-A Page 58 of 82 Pages Major Structure ® Footings, Bents, Abutments & Wingwalls Superstructures Miscellaneous ® Contour Grading ® Utilities ®, © Channels, Dikes & Ditches ® Signs CD Subsurface Drains ® Overside Drains ® Markers ® Railings & Barriers ® AC Dikes ® Box Culverts Pavement Markers® Stake RP + Marker Stake + Line Point +Guard Stake RP RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake + Line Point +Guard Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP & wall height 3 m to 10 m (10' to 33') as required by the Engineer, BC & EC, transition points & at beginning & end. Elevation points on footings at bottom of columns 3 m to 10 m (10' to 33') sufficient to use string lines, BC & EC, transition points & at beginning & end. Elevation points on footings at bottom of columns < 15m (50') < 15 m (50') on tangents & curves when R> 300m (1000') & < 7.5m (25') on curves when R <, 300m (1000') or where grade < 0.30% intervisible & < 30 m (1 00'), BC & EC of facilities, Grade breaks, Alignment breaks, Junctions, Inlets & similar facilities At sign location intervisible & < 15m (50'), BC & EC of facilities, Grade breaks, Alignment breaks, Junctions, Inlets & similar facilities, Risers & similar facilities longitudinal location for asphalt street surfacing <, 15 m (50') on tangents & curves when R> 300m (1000') & < 7.5m (251) on curves when R < 300m (1000'). At beginning & end and < 15 m (50') on tangents & curves when R > 300m (1000') & < 7.5m (25') on curves when R < 300m (10001 At beginning & end 3 m to 10 m (10' to 33') as required by the Engineer, BC & EC, transition points & at beginning & end. Elevation points on footings & at invert 60 m (200') on tangents, 15m (50') on curves when R > 300m (1000') & 7.5m (25') on curves when R < 300m (1000') For PCC surfaced streets lane cold joints will suffice as appropriate as appropriate along contour line as appropriate as appropriate Line point as appropriate At beginning & end At marker location (s) at railing & barrier location(s) as appropriate as appropriate at pavement marker location(s) 10 mm (Va") Horizontal & 7 mm (1/4") Vertical 10 mm (V) Horizontal & 7 mm (V4") Vertical 30 mm (0.1') Verticals Horizontal 1 0 mm (V) Horizontal & 7 mm (V) Vertical 30 mm (0.1') Horizontal & 7 mm (1/4") Vertical 30 mm (0.1') Verticals Horizontal 30 mm (0.1') Horizontal & 7 mm (V4") Vertical 30mm (0.1') Horizontal & 7 mm (V4") Vertical 7 mm (n/4") Horizontal 10 mm C/e") Horizontal & Vertical 30 mm (0.1') Hon'zontal & Vertical 10mm (J/8") Horizontal & 7 mm (1/4") Vertical 7 mm (V) Horizontal ® Staking for feature may be omitted when adjacent marker stakes reference the offset and elevation of those features and the accuracy requirements of the RP meet the requirements for the feature CD Reference points shall be sufficiently durable and set securely enough to survive with accuracy intact throughout the installation & inspection of the features or adjacent facilities for which they provide control. RP means reference point for the purposes of this table ® Perpendicular to centerline. ® Some features are not necessarily parallel to centerline but are referenced thereto CD Multi-plane surfaced features shall be staked so as to provide line & grade information for each plane of the feature ® > means greater than, or equal to, the number following the symbol. ^ means less than, or equal to, the number following the symbol. © The cut datum for storm drainage & sanitary sewer pipes & similar structures shall be their invert. The cut datum for all other utilities shall be the top of their pipe or conduit. All guard stakes, line stakes and lath shall be fagged. Unless otherwise approved by the Engineer flagging, paint and marking cards shall be the color specifed in TABLE 2-9.2.2(6) Revised: 10/08/03 Contract No. 39561-A Page 59 of 82 Pages TABLE 2-9.2.2(B) Survey Stake Color Code for Construction Staking Type of Stake Horizontal Control Vertical Control Clearing Grading Structure Drainage, Sewer, Curb Right-of-Way Miscellaneous Description Coordinated control points, control lines, control reference points, centerline, alignments, etc. Bench marks Limits of clearing Slope, intermediate slope, abutment fill, rough grade, contour grading, final grade, etc. Bridges, sound and retaining walls, box culverts, etc. Pipe culverts, junction boxes, drop inlets, headwalls, sewer lines, storm drains, slope protection, curbs, gutters, etc. Fences, R/ W lines, easements, property monuments, etc. Signs, railings, barriers, lighting, etc. Color* White/Red White/Orange Yellow/Black Yellow White Blue White/Yellow Orange * Flagging and marking cards, if used. Add the following section: 2-9.2.3 Payment for Survey, Payment for work performed to satisfy the requirements of Sections 2- 9.1 through 2-9.3.2 shall be included in the actual bid items requiring the survey work and no additional payment will be made. Extension of unit prices for extra work shall include full compensation for attendant survey work and no additional payment will be made. Payment for the replacement of disturbed monuments and the filing of records of survey and/or corner records, including filing fees, shall be incidental to the work necessitating the disturbance of said monuments and no additional payment will be made. 2-10 AUTHORITY OF BOARD AND ENGINEER. Add the following section: 2-10.1 Availability of Records, The Contractor shall, at no charge to the Agency, provide copies of all records in the Contractor's or subcontractor's possession pertaining to the work that the Engineer may request. Add the following section: 2-10.2 Audit And Inspection, Contractor agrees to maintain and/or make available, to the Engineer, within San Diego County, accurate books and accounting records relative to all its activities and to contractually require all subcontractors to this Contract to do the same. The Engineer shall have the right to monitor, assess, and evaluate Contractor's and its subcontractors performance pursuant to this Agreement, said monitoring, assessments, and evaluations to include, but not be limited to, audits, inspection of premises, reports, contracts, subcontracts and interviews of Contractor's staff and the staff of all subcontractors to this contract. At any time during normal business hours and as often as the Engineer may deem necessary, upon reasonable advance notice, Contractor shall make available to the Engineer for examination, all of its, and all subcontractors to this contract, records with respect to all matters covered by this Contract and will permit the Engineer to audit, examine, copy and make excerpts or transcripts from such data and records, and to make audits of all invoices, materials, payrolls, records of personnel, and other data relating to all matters covered by this Contract. However, any such activities shall be carried out in a manner so as to not unreasonably interfere with Contractor's ongoing business operations. Contractor and all subcontractors to this contract shall maintain such data and records for as long as may be required by applicable laws and regulations. Revised: 10/08/03 Contract No. 39561-A Page 60 of 82 Pages SECTION 3 - CHANGES IN WORK 3-2 CHANGES INITIATED BY THE AGENCY. 3-2.2.1 Contract Unit prices, add the following: In the case of an increase or decrease in quantity of a minor bid item in excess of 25 percent of the original quantity bid the adjustment of contract unit price for such items will be limited to that portion of the change in excess of 25 percent of the original quantity listed in the Contractor's bid proposal for this contract. Adjustments in excess of 25 percent may, at the option of the Engineer, be paid pursuant to section 3-3, Extra Work. 3-3 EXTRA WORK. 3-3.2.2 (c) Tool and Equipment Rental, second paragraph, modify as follows: Regardless of ownership, the rates and right-of-way delay factors to be used in determining rental and delay costs shall be the edition of the, "Labor Surcharge and Equipment Rental Rates" published by CALTRANS, current at the time of the actual use of the tool or equipment. The right-of-way delay factors therein shall be used as multipliers of the rental rates for determining the value of costs for delay to the Contractor and subcontractors, if any. The labor surcharge rates published therein are not a part of this contract. 3-3.2.3 Markup, Delete sections 3-3.2.3 (a) and (b) and replace wth the following: (a) Work by Contractor. The following percentages shall be added to the Contractor's costs and shall constitute the markup for all overhead and profits: 1) Labor 20 2) Materials 15 3) Equipment Rental 15 4) Other Items and Expenditures .. 15 To the sum of the costs and markups provided for in this section, 1 percent shall be added as compensation for bonding. (b) Work by Subcontractor. When all or any part of the extra work is performed by a Subcontractor, the markup established in section 3-3.2.3(a) shall be applied to the Subcontractor's actual cost of such work. A markup of 10 percent on the first $5,000 of the subcontracted portion of the extra work and a markup of 5 percent on work added in excess of $5,000 of the subcontracted portion of the extra work may be added by the Contractor. 3-3.3 Daily Reports by Contractor, add the following after the second sentence: Payment for extra work will not be made until such time that the Contractor submits completed daily reports and all supporting documents to the Engineer. 3-4 CHANGED CONDITIONS. Delete the second sentence of paragraph three, delete paragraph five (5), and add the following: The Contractor shall not be entitled to the payment of any additional compensation for any act, or failure to act, by the Engineer, including failure or refusal to issue a change order, or for the happening of any event, thing, occurrence, or other cause, unless the Contractor shall have first given the Engineer due written notice of potential claim as hereinafter specified. Compliance with this section shall not be required as a prerequisite to notice provisions in Section 6-7.3 Contract Time Accounting, nor to any claim that is based on differences in measurement or errors of computation as to contract quantities. The written notice of potential claim for changed conditions shall be submitted by the Contractor to the Engineer upon their discovery and prior to the time that the Contractor performs the work giving rise to the potential claim. The Contractor's failure to give written notice of potential claim for changed conditions to the agency upon their discovery and before they are disturbed shall constitute a waiver of all claims in connection therewith. oRevised: 10/08/03 Contract No. 39561-A Page 61 of 82 Pages The Contractor shall provide the City with a written document containing a description of the particular circumstances giving rise to the potential claim, the reasons for which the Contractor believes additional compensation may be due and nature of any and all costs involved within 20 working days of the date of service of the written notice of potential claim for changed conditions. Verbal notifications are disallowed. The potential claim shall include the following certification relative to the California False Claims Act, Government Code Sections 12650-12655. "The undersigned certifies that the above statements are made in full cognizance of the California False Claims Act, Government Code sections 12650-12655. The undersigned further understands and agrees that this potential claim, unless resolved, must be restated as a claim in response to the City's proposed final estimate in order for it to be further considered." By: Title: Date: Company Name: The Contractor's estimate of costs may be updated when actual costs are known. The Contractor shall submit substantiation of its actual costs to the Engineer within 20 working days after the affected work is completed. Failure to do so shall be sufficient cause for denial of any claim subsequently filed on the basis of said notice of potential claim. It is the intention of this section that differences between the parties arising under and by virtue of the contract be brought to the attention of the Engineer at the earliest possible time in order that such matters be settled, if possible, or other appropriate action promptlytaken. 3-5 DISPUTED WORK. Add the following: The Contractor shall give the agency written notice of potential claim prior to commencing any disputed work. Failure to give said notice shall constitute a waiver of all claims in connection therewith. Delete second sentence of paragraph one and add the following: Prior to proceeding with dispute resolution pursuant to Public Contract Code provisions specified hereinafter, the contractor shall attempt to resolve all disputes informally through the following dispute resolution chain of command: 1. Project Inspector 2. Construction Manager 3. Deputy City Engineer, Construction Management & Inspection 4. City Engineer 5. City Manager The Contractor shall submit a complete report within 20 working days after completion of the disputed work stating its position on the claim, the contractual basis for the claim, along with all documentation supporting the costs and all other evidentiary materials. At each level of claim or appeal of claim the City will, within 10 working days of receipt of said claim or appeal of claim, review the Contractor's report and respond with a position, request additional information or request that the Contractor meet and present its report. When additional information or a meeting is requested the City will provide its position within 10 working days of receipt of said additional information or Contractor's presentation of its report. The Contractor may appeal each level's position up to the City Manager after which the Contractor may proceed under the provisions of the Public Contract Code. Revised: 10/08/03 Contract No. 39561-A Page 62 of 82 Pages The authority within the dispute resolution chain of command is limited to recommending a resolution to a claim to the City Manager. Actual approval of the claim is subject to the change order provisions in the contract. All claims by the contractor for $375,000 or less shall be resolved in accordance with the procedures in the Public Contract Code, Division 2, Part 3, Chapter 1, Article 1.5 (commencing with Section 20104) which is set forth below: ARTICLE 1.5 RESOLUTION OF CONSTRUCTION CLAIMS 20104. (a)(1) This article applies to all public works claims of three hundred seventy-five thousand dollars ($375,000) or less which arise between a contractor and a local agency (2) This article shall not apply to any claims resulting from a contract between a contractor and a public agency when the public agency has elected to resolve any disputes pursuant to Article 7.1 (commencing with Section 10240) of Chapter 1 of Part 2. (b)(1) "Public work" has the same meaning as in Sections 3100 and 3106 of the Civil Code, except that "public work" does not include any work or improvement contracted for by the state or the Regents of the University of California. (2) "Claim" means a separate demand by the contractor for (A) a time extension, (B) payment of money or damages arising from work done by, or on behalf of, the contractor pursuant to the contract for a public work and payment of which is not otherwise expressly provided for or the claimant is not otherwise entitled to, or (C) an amount the payment of which is disputed by the local agency. (c) The provisions of this article or a summary thereof shall be set forth in the plans or specifications for any work which may give rise to a claim under this article. (d) This article applies only to contracts entered into on or after January 1,1991. 20104.2. For any claim subject to this article, the following requirements apply: (a) The claim shall be in writing and include the documents necessary to substantiate the claim. Claims must be filed on or before the date of final payment. Nothing in this subdivision is intended to extend the time limit or supersede notice requirements otherwise provided by contract for the filing of claims. (b)(1) For claims of less than fifty thousand dollars ($50,000), the local agency shall respond in writing to any written claim within 45 days of receipt of the claim, or may request, in writing, within 30 days of receipt of the claim, any additional documentation supporting the claim or relating to defenses to the claim the local agency may have against the claimant. (2) If additional information is thereafter required, it shall be requested and provided pursuant to this subdivision, upon mutual agreement of the local agency and the claimant. (3) The local agency's written response to the claim, as iirther documented, shall be submitted to the claimant within 15 days after receipt of the further documentation or within a period of time no greater than that taken by the claimant in producing the additional information, whichever is greater. (c)(1) For claims of over fifty thousand dollars ($50,000) and less than or equal to three hundred seventy-five thousand dollars ($375,000), the local agency shall respond in writing to all written claims within 60 days of receipt of the claim, or may request, in writing, within 30 days of receipt of the claim, any additional documentation supporting the claim or relating to defenses to the claim the local agency may have against the claimant. (2) If additional information is thereafter required, it shall be requested and provided pursuant to this subdivision, upon mutual agreement of the local agency and the claimant. (3) The local agency's written response to the claim, as farther documented, shall be submitted to the claimant within 30 days after receipt of the further documentation, or within a period of time no greater than that taken by the claimant in producing the additional information or requested documentation, whichever is greater. evised: 10/08/03 Contract No. 39561-A Page 63 of 82 Pages (d) If the claimant disputes the local agency's written response, or the local agency fails to respond within the time prescribed, the claimant may so notify the local agency, in writing, either within 15 days of receipt of the local agency's response or within 15 days of the local agency's failure to respond within the time prescribed, respectively, and demand an informal conference to meet and confer for settlement of the issues in dispute. Upon a demand, the local agency shall schedule a meet and confer conference within 30 days for settlement of the dispute. (e) Following the meet and confer conference, if the claim or any portion remains in dispute, the claimant may file a claim as provided in Chapter 1 (commencing with Section 900) and Chapter 2 (commencing with Section 910) of Part 3 of Division 3.6 of Title 1 of the Government Code. For purposes of those provisions, the running of the period of time within which a claim must be filed shall be tolled from the time the claimant submits his or her written claim pursuant to subdivision (a) until the time that claim is denied as a result of the meet and confer process, including any period of time utilized by the meet and confer process. (f) This article does not apply to tort claims and nothing in this article is intended nor shall be construed to change the time periods for filing tort claims or actions specified by Chapter 1 (commencing with Section 900) and Chapter 2 (commencing with Section 910) of Part 3 of Division 3.6 of Title 1 of the Government Code. 20104.4. The following procedures are established for all civil actions filed to resolve claims subject to this article: (a) Within 60 days, but no earlier than 30 days, following the filing or responsive pleadings, the court shall submit the matter to non-binding mediation unless waived by mutual stipulation of both parties. The mediation process shall provide for the selection within 15 days by both parties of a disinterested third person as mediator, shall be commenced within 30 days of the submittal, and shall be concluded within 15 days from the commencement of the mediation unless a time requirement is extended upon a good cause showing to the court or by stipulation of both parties. If the parties fail to select a mediator within the 15-day period, any party may petition the court to appoint the mediator (b)(1) If the matter remains in dispute, the case shall be submitted to judicial arbitration pursuant to Chapter 2.5 (commencing with Section 1141.10) of Title 3 of Part 3 of the Code of Civil Procedure, notwithstanding Section 1141.11 of that code. The Civil Discovery Act of 1986 (Article 3 (commencing with Section 2016) of Chapter 3 of Title 3 of Part 4 of the Code of Civil procedure) shall apply to any proceeding brought under the subdivision consistent with the rules pertaining to judicial arbitration. (2) Notwithstanding any other provision of law, upon stipulation of the parties, arbitrators appointed for purposes of this article shall be experienced in construction law, and, upon stipulation of the parties, mediators and arbitrators shall be paid necessary and reasonable hourly rates of pay not to exceed their customary rate, and such fees and expenses shall be paid equally by the parties, except in the case of arbitration where the arbitrator, for good cause, determines a different division. In no event shall these fees or expenses be paid by state or county funds. (3) In addition to Chapter 2.5 (commencing with Section 1141.10) Title 3 of Part 3 of the Code of Civil Procedure, any party who after receiving an arbitration award requests a trial de novo but does not obtain a more favorable judgment shall, in addition to payment of costs and fees under that chapter, pay the attorneys fees of the other party arising out of the trial de novo. (c) The court may, upon request by any party, order any witnesses to participate in the mediation or arbitration process. 20104.6. (a) No local agency shall fail to pay money as to any portion of a claim which is undisputed except as otherwise provided in the contract. (b) In any suit filed under Section 20104.4, the local agency shall pay interest at the legal rate on any arbitration award or judgment. The interest shall begin to accrue on the date the suit is filed in a court of law. 10/08/03 Contract No. 39561-A Page 64 of 82 Pages SECTION 4 - CONTROL OF MATERIALS 4-1 MATERIALS AND WORKMANSHIP. 4-1.3.1 General, add the following: The Contractor shall provide the Engineer free and safe access to any and all parts of work at any time. Such free and safe access shall include means of safe access and egress, ventilation, lighting, shoring, dewatering and all elements pertaining to the safety of persons as contained in the State of California, California Code of Regulations, Title 8, Industrial Relations, Chapter 4, Division of Industrial Safety, Subchapter 4, Construction Safety Orders and such other safety regulations as may apply. Contractor shall furnish Engineer with such information as may be necessary to keep the Engineer fully informed regarding progress and manner of work and character of materials. Inspection or testing of the whole or any portion of the work or materials incorporated in the work shall not relieve Contractor from any obligation to fulfill this Contract. 4-1.4 Test of Materials, delete the phrase, "and a reasonable amount of retesting", from the third sentence of the first paragraph. add the following: Except as specified in1 these Supplemental Provisions, the Agency will bear the cost of testing of locally produced materials and/or on-site workmanship where the results of such tests meet or exceed the requirements indicated in the Standard Specifications and the Supplemental Provisions. The cost of all other tests shall be borne by the Contractor. At the option of the Engineer, the source of supply of each of the materials shall be approved by the Engineer before the delivery is started. All materials proposed for use may be inspected or tested at any time during their preparation and use. If, after incorporating such materials into the Work, it is found that sources of supply that have been approved do not furnish a uniform product, or if the product from any source proves unacceptable at any time, the Contractor shall furnish approved material from other approved sources. If any product proves unacceptable after improper storage, handling or for any other reason it shall be rejected, not incorporated into the work and shall be removed from the project site all at the Contractor's expense. Compaction tests may be made by the Engineer and all costs for tests that meet or exceed the requirements of the specifications shall be borne by the Agency. Said tests may be made at any place along the work as deemed necessary by the Engineer. The costs of any retests made necessary by noncompliance with the specifications shall be borne by the Contractor. 4-1.6 Trade names or Equals add the following: The Contractor is responsible for the satisfactory performance of substituted items. If, in the sole opinion of the Engineer, the substitution is determined to be unsatisfactory in performance, appearance, durability, compatibility with associated items, availability of repair parts and suitability of application the Contractor shall remove the substituted item and replace it with the originally specified item at no cost to theAgency. Add the following section: 4-2 MATERIALS TRANSPORTATION, HANDLING AND STORAGE. The Contractor shall order, purchase, transport, coordinate delivery, accept delivery, confirm the quantity and quality received, prepare storage area(s), store, handle, protect, move, relocate, remove and dispose excess of all materials used to accomplish the Work. Materials shall be delivered to the site of the work only during working hours, as defined in section 6-7.2, and shall be accompanied by bills of lading that shall clearly state for each delivery: the name of the Contractor as consignee, the project name and number, address of delivery and name of consignor and a description of the material(s) shipped. Prior to storage of any materials which have been shipped to or by the Contractor to any location within the Agency's boundaries the Contractor shall provide the €5^f^Revised: 10/08/03 Contract No. 39561-A Page 65 of 82 Pages Engineer a copy of lease agreements for each property where such materials are stored. The lease agreement shall clearly state the term of the lease, the description of materials allowed to be stored and shall provide for the removal of the materials and restoration of the storage site within the time allowed for the Work. All such storage shall conform to all laws and ordinances that may pertain to the materials stored and to preparation of the storage site and the location of the site on which the materials are stored. Loss, damage or deterioration of all stored materials shall be the Contractor's responsibility. Conformance to the requirements of this section, both within and outside the limits of work are a part of the Work. The Engineer shall have the right to verify the suitability of materials and their proper storage at anytime during the Work. SECTION 5 - UTILITIES 5-1 LOCATION. Delete the first paragraph and substitute the following: The Agency and affected utility companies have, by a search of known records, endeavored to locate and indicate on the Plans, all utilities which exist within the limits of the work. However, the accuracy and/or completeness of the nature, size and/or location of utilities indicated on the Plans is not guaranteed. 5-4 RELOCATION. Add the following: In conformance with section 5-6 the Contractor shall coordinate the work with utility agencies and companies. Prior to the installation of any and all utility structures within the limits of work by any utility agency or company, or its contractor, the Contractor shall place all curb or curb and gutter that is a part of the work and adjacent to the location where such utility structures are shown on the plans and are noted as being located, relocated or are otherwise shown as installed by others. In order to minimize delays to the Contractor caused by the failure of other parties to relocate utilities that interfere with the construction, the Contractor, upon the Engineer's approval, may be permitted to temporarily omit the portion of work affected by the utility. If such temporary omission is approved by the Engineer the Contractor shall place survey or other physical control markers sufficient to locate the curb or curb and gutter to the satisfaction of the utility agency or company. Such temporary omission shall be for the Contractor's convenience and no additional compensation will be allowed therefore or for additional work, materials or delay associated with the temporary omission. The portion thus omitted shall be constructed by the Contractor immediately following the relocation of the utility involved unless otherwise directed by the Engineer. SECTION 6 -- PROSECUTION, PROGRESS AND ACCEPTANCE OF THE WORK 6-1 CONSTRUCTION SCHEDULE AND COMMENCEMENT OF WORK. Delete section 6-1 and substitute the following: Except as otherwise provided herein and unless otherwise prohibited by permits from other agencies as may be required by law the Contractor shall begin work within 14 calendar days after receipt of the "Notice to Proceed". Revised: 10/08/03 Contract No. 39561-A Page 66 of 82 Pages Add the following section: 6-1.1 Pre-Construction Meeting. After, or upon, notification of contract award, the Engineer will set the time and location for the Preconstruction Meeting. Attendance of the Contractor's management personnel responsible for the management, administration, and execution of the project is mandatory for the meeting to be convened. Failure of the Contractor to have the Contractor's responsible project personnel attend the Preconstruction Meeting will be grounds for default by Contractor per section 6-4. No separate payment will be made for the Contractor's attendance at the meeting. The notice to proceed will only be issued on or after the completion of the preconstruction meeting. Add the following section: 6-1.1.1 Baseline Construction Schedule Submittal. The Contractor shall submit the Baseline Construction Schedule per the submittal requirements of section 2-5.3. The submittal of the Baseline Construction Schedule shall include each item and element of sections 6-1.2 through 6-1.2.9 and shall be on hard (paper) copy and electronic media conforming to section 6-1.3.3 Electronic Msdia. Add the following section: 6-1.2 Preparation and Review of the Baseline Construction Schedule. The Contractor shall prepare the Baseline Construction Schedule as a Critical Path Method (CPM) Schedule in the precedence diagram method (activity-on-node) format. The Baseline Construction Schedule shall depict a workable plan showing the sequence, duration, and interdependence of all activities required to represent the complete performance of all project work as well as periods where work is precluded. The Baseline Construction Schedule shall begin with the projected date of issuance of the notice to proceed and conclude with the date of final completion per the contract duration. The Baseline Construction Schedule shall include detail of all project phasing, staging, and sequencing, including all milestones necessary to define beginning and ending of each phase or stage. Add the following section: 6-1.2.1 Time-Scaled Network Diagram. As a part of the Baseline Construction Schedule the Contractor shall prepare and submit to the Engineer a complete time-scaled network diagram showing ail of the activities, logic relationships, and milestones comprising the schedule. Add the following section: 6-1.2.2 Tabular Listing. As a part of the Baseline Construction Schedule the Contractor shall prepare and submit to the Engineer a tabular listing of all of the activities, showing for each activity the identification number, the description, the duration, the early start, the early finish, the late start, the late finish, the total float, and all predecessor and successor activities for the activity described. Add the following section: 6-1.2.3 Bar Chart. As a part of the Baseline Construction Schedule the Contractor shall prepare and submit to the Engineer a chart showing individual tasks and their durations arranged with the tasks on the vertical axis and duration on the horizontal axis. The bar chart shall use differing texture patterns or distinctive line types to show the critical path. 10/08/03 Contract No. 39561-A Page 67 of 82 Pages Add the following section: 6-1.2.4 Schedule Software. The Contractor shall use commercially available software equal to the Windows 2000 compatible "Suretrak" program by Primavera or "Project" program by Microsoft Corporation to prepare the Baseline Construction Schedule and all updates thereto. The Contractor shall submit to the Agency a CD-ROM data disk with all network information contained thereon, in a format readable by a Microsoft Windows 2000 system. The Agency will use a "Suretrak", "Project" or equal software program for review of the Contractor's schedule. Should the Contractor elect to use a scheduling program other than the "Suretrak" program by Primavera or "Project" program by Microsoft Corporation the Contractor shall provide the Engineer three copies of the substituted program that are fully licensed to the Agency and 32 class hours of on-site training by the program publisher for up to eight Agency staff members. The classes shall be presented on Mondays through Thursdays, inclusive, between the hours of 8:00 a.m. and 5:00 p.m. The on-site training shall be held at 1635 Faraday Avenue, Carlsbad, California. The dates and times of the on-site training shall be submitted to the Engineer for approval five working days before the start of the on-site training. The on-site training shall be completed prior to the submittal of the first Baseline Construction Schedule. Add the following section: 6-1.2.5 Schedule Activities. Except for submittal activities, activity durations shall not be shorter than 1 working day nor longer than 15 working days, unless specifically and individually allowed by the Engineer. The Baseline Construction Schedule shall include between 100 and 500 activities, including submittals, interfaces between utility companies and other agencies, project milestones and equipment and material deliveries. The number of activities will be sufficient, in the judgment of the Engineer, to communicate the Contractor's plan for project execution, to accurately describe the project work, and to allow monitoring and evaluation of progress and of time impacts. Each activity's description shall accurately define the work planned for the activity and each activity shall have recognizable beginning and end points. Add the following section: 6-1.2.6 Float. Float or slack time within the schedule is available without charge or compensation to whatever party or contingency first exhausts it. Add the following section: 6-1.2.7 Restraints to Activities. Any submittals, utility interfaces, or any furnishing of Agency supplied materials, equipment, or services, which may impact any activity's construction shall be shown as a restraint to those activities. Time periods to accommodate the review and correction of submittals shall be included in the schedule. Add the following section: 6-1.2.8 Late Completion. A Baseline Construction Schedule showing a project duration longer than the specified contract duration will not be acceptable and will be grounds for determination of default by Contractor, per section 6-4. Revised: 10/08/03 Contract No. 39561-A Page 68 of 82 Pages Add the following section: 6-1.2.9 Early Completion. The Baseline Construction Schedule will show the Contractor's plan to support and maintain the project for the entire contractual time span of the project. Should the Contractor propose a project duration shorter than contract duration, a complete Baseline Construction Schedule must be submitted, reflecting the shorter duration, in complete accordance with all schedule requirements of section 6-1. The Engineer may choose to accept the Contractor's proposal of a project duration shorter than the duration specified; provided the Agency is satisfied the shortened Baseline Construction Schedule is reasonable and theAgency and all other entities, public and private, which interface with the project are able to support the provisions of the shortened Baseline Construction Schedule. The Agency's acceptance of a shortened duration project will be confirmed through the execution of a contract change order revising the project duration and implementing all contractual requirements including liquidated damages in accordance with the revised duration. Add the following section: 6-1.2.10 Engineer's Review. The Construction Schedule is subject to the review of the Engineer. The Engineer's determination that the Baseline Construction Schedule proposed by the Contractor complies with the requirements of these supplemental provisions shall be a condition precedent to issuance of the Notice to Proceed by the Engineer. If the Engineer determines that the Construction Schedule does not meet the requirements of these specifications the Contractor shall correct the Construction Schedule to meet these specifications and resubmit it to the Engineer. Failure of the Contractor to obtain the Engineer's determination that the initial Construction Schedule proposed by the Contractor complies with the requirements of these supplemental provisions within thirty (30) working days after the date of the preconstruction meeting shall be grounds for termination of the contract per section 6-4. Days used by the Engineer to review the initial Construction Schedule will not be included in the 30 working days. The Engineer will review and return to the Contractor, with any comments, the Baseline Construction Schedule within 15 working days of submittal. The Baseline Construction Schedule will be returned marked as per sections 6-1.2.10.1 through 6-1.2.10.3. Add the following section: 6-1.2.10.1 "Accepted." The Contractor may proceed with the project work upon issuance of the Notice to Proceed, and will receive payment for the schedule in accordance with section 6-1.8.1. Add the following section: 6-1.2.10.2 "Accepted with Comments." The Contractor may proceed with the project work upon issuance of the Notice to Proceed. The Contractor must resubmit the schedule incorporating the comments prior to receipt of payment per section 6-1.8.1. Add the following section: 6-1.2.10.3 "Not Accepted." The Contractor must resubmit the schedule incorporating the corrections and changes of the comments prior to receipt of payment per section 6-1.8.1. The Notice to Proceed will not be issued by the Engineer if the changes of the comments are not submitted as required hereinbefore and marked "Accepted" or "Accepted with Comments" by the Engineer. The Contractor, at the sole option of the Engineer, may be considered as having defaulted the contract under the provisions of section 6-4 DEFAULT BY CONTRACTOR if the changes of the comments are not submitted as required hereinbefore and marked "Accepted" by the Engineer. Revised: 10/08/03 Contract No. 39561-A Page 69 of 82 Pages Add the following section: 6-1.3 Preparation of Schedule Updates and Revisions. The Contractor shall meet with the Engineer during the last week of each month to agree upon each activity's schedule status and shall submit monthly updates of the Baseline Construction Schedule confirming the agreements no later than the fifth working day of the following month. The monthly update will be submitted on hard (paper) copy and electronic media conforming to section 6-1.3.3 Electronic Media per the submittal requirements of section 2-5.3 and will include each item and element of sections 6-1.2 through 6- 1.2.9 and 6-1.3.1 through 6-1.3.7. Add the following section: 6-1.3.1 Actual Activity Dates. The actual dates each activity was started and/or completed during the month. After first reporting an actual date, the Contractor shall not change that actual date in later updates without specific notification to the Engineer with the update. Add the following section: 6-1.3.2 Activity Percent Complete. For each activity underway at the end of the month, the Contractor shall report the percentage determined by the Engineer as complete for the activity. Add the following section: 6-1.3.3 Electronic Media. The schedule data disk shall be a CD-ROM, labeled with the project name and number, the Contractor's name and the date of preparation of the schedule data disk. The schedule data disk shall be readable by the software specified in section 6-1.2.4 "Schedule Software" and shall be free of file locking, encryption or any other protocol that would impede full access of all data stored on it. Add the following section: 6-1.3.4 List of Changes. A list of all changes made to the activities or to the interconnecting logic, with an explanation for each change. Add the following section: 6-1.3.5 Change Orders, Each monthly update will include the addition of the network revisions reflecting the change orders approved in the previous month. The network revisions will be as agreed upon during the review and acceptance of the Contractor's change orders. Add the following section: 6-1.3.6 Bar Chart. Each monthly update will include a chart showing individual tasks and their durations arranged with the tasks on the vertical axis and duration on the horizontal axis. The bar chart shall use differing texture patterns or distinctive line types to show the critical path. Add the following section: 6-1.4 Engineer's Review of Updated Construction Schedule. The Engineer will review and return the Updated Construction Schedule to the Contractor, with any comments, within 5 working days of submittal. The Updated Construction Schedule will be returned marked as per sections 6-1.4.1 through 6-1.4.3. Any Updated Construction Schedule marked "Accepted with Comments" or "Not Accepted" by the Engineer will be returned to the Contractor for correction. Upon resubmittal the Engineer will review and return the resubmitted Updated Construction Schedule to the Contractor, with any comments, within 5 working days. Failure of the Contractor to submit a monthly updated construction schedule will invoke the same consequences as the Engineer returning a monthly updated construction schedule marked "Not Accepted". Devised: 10/08/03 Contract No. 39561-A Page 70 of 82 Pages Add the following section: 6-1.4.1 "Accepted." The Contractor may proceed with the project work, and will receive payment for the schedule in accordance with section 6-1.8.2. Add the following section: 6-1.4.2 "Accepted with Comments." The Contractor may proceed with the project work. The Contractor must resubmit the Updated Construction Schedule to the Engineer incorporating the corrections and changes noted in the Engineer's comments prior to receipt of payment per section 6-1.8.2. Add the following section: 6-1.4.3 "Not Accepted." The Contractor must resubmit the Updated Construction Schedule to the- Engineer incorporating the corrections and changes noted in the Engineer's comments prior to receipt of payment per section 6-1.8.2. The Contractor, at the sole option of the Engineer, may be considered as having defaulted the contract under the provisions of section 6-4 DEFAULT BY CONTRACTOR if the changes of the comments are not submitted and marked "Accepted" by the Engineer before the last day of the month in which the Updated Construction Schedule is due. If the Contractor fails to submit the corrected Updated Construction Schedule as required herein the Contractor may elect to proceed with the project at its own risk. Should the Contractor elect not to proceed with the project, any resulting delay, impact, or disruption to the project will be the Contractor's responsibility. Add the following section: 6-1.5 Late Completion or Milestone Dates. Should the Schedule Update indicate a completion or contractually required milestone date later than the properly adjusted contract or milestone duration, the Agency may withhold Liquidated Damages for the number of days late. Should a subsequent "Accepted" Schedule Update remove all or a portion of the delay, all or the allocated portion of the previously held Liquidated Damages shall be released in the monthly payment to the Contractor immediately following the "Accepted" schedule. Add the following section: 6-1.6 Interim Revisions. Should the actual or projected progress of the work become substantially different from that depicted in the Project Schedule, independently of and prior to the next monthly update, the Contractor will submit a revised Baseline Construction Schedule, with a list and explanation of each change made to the schedule. The Revised Construction Schedule will be submitted per the submittal requirements of section 2-5.3 and per the schedule review and acceptance requirements of section 6-1, including but not limited to the acceptance and payment provisions. As used in this subsection "substantially different" means a time variance greater than 5 percent of the number of days of duration for the project. Add the following section: 6-1. 7 Final Schedule Update. The Contractor shall prepare and submit a final schedule update when one hundred percent of the construction work is completed. The Contractor's Final Schedule Update must accurately represent the actual dates for all activities. The final schedule update shall be prepared and reviewed per sections 6-1.3 Preparation of Schedule Updates and Revisions and 6-1. 4 Engineer's Review of Updated Construction Schedule. Acceptance of the final schedule update is required for completion of the project and release of any and all funds retained per section 9-3.2. Add the following section: 6-1.1 Measurement And Payment Of Construction Schedule. The Contractor's preparation, revision and maintenance of the Construction Schedule are incidental to the work and no separate payment will be made therefore. Revised: 10/08/03 Contract No. 39561-A Page 71 of 82 Pages 6-2 PROSECUTION OF WORK. Add the following section: 6-2.2.5 Night Work. Night work shall be performed by the Contractor for the duration of the project. Add the following section: 6-2.3 Project Meetings. The Engineer will establish the time and location of weekly Project Meetings. The Contractor's Representative shall attend each Project Meeting. The Project Representative shall be the individual determined under section 7-6, "The Contractor's Representative", SSPWC. No separate payment for attendance of the Contractor, the Contractor's Representative or any other employee or subcontractor or subcontractor's employee at these meetings will be made. 6-6 DELAYS AND EXTENSIONS OF TIME. 6-6.4 Written Notice and Report. Modify as follows: The Contractor shall provide written notice to the Engineer within two hours of the beginning of any period that the Contractor has placed any workers or equipment on standby for any reason that the Contractor has determined to be caused by the Agency or by any organization that the Agency may otherwise be obligated by. The Contractor shall provide continuing daily written notice to the Engineer, each working day, throughout the duration of such period of delay. The initial and continuing written notices shall include the classification of each workman and supervisor and the make and model of each piece of equipment placed on standby, the cumulative duration of the standby, the Contractor's opinion of the cause of the delay and a cogent explanation of why the Contractor could not avoid the delay by reasonable means. Should the Contractor fail to provide the notice(s) required by this section the Contractor agrees that no delay has occurred and that it will not submit any claim(s) therefore. 6-7 TIME OF COMPLETION. Add the following: The Contractor shall diligently prosecute the work to completion within two hundred fifty (250) working days after the starting date specified in the Notice to Proceed. 6-7.2 Working Day. Add the following: Unless otherwise approved in writing by the Engineer, the hours of work shall be between the hours of 8:30 p.m. and 5:30 a.m. on Mondays through Fridays, excluding Agency holidays. The Contractor shall obtain the written approval of the Engineer if the Contractor desires to work outside said hours or at any time during weekends and/or holidays. This written permission must be obtained at least 48 hours prior to such work The Engineer may approve work outside the hours and/or days stated herein when, in his/her sole opinion, such work conducted by the Contractor is beneficial to the best interests of the Agency. The Contractor maybe permitted to perform daytime work on certain portions of the project, if the Contractor can ensure minimal traffic disruption and agrees to provide and install K-Rail in accordance with a traffic control plan prepared by the Contractor and approved by the City of San Marcos. Requests for working hours between 7:30am and 3:30pm Monday through Fridays for work, which does not require any traffic control, lane closures or signal modifications will be approved subject to notice requirements above. The Contractor shall incorporate the work hours, dates, areas and types of work prohibited in this section in the Construction Schedule required by section 6.1. No additional payment, adjustment of bid prices or adjustment of contract time of completion will be allowed as a consequence of the prohibition of work being performed within the dates, areas and/or types of work prohibited in this section. 10/08/03 Contract No. 39561-A Page 72 of 82 Pages 6-8 COMPLETION AND ACCEPTANCE. Delete the second paragraph and add the following: The Engineer will not accept the Work or any portion of the Work before all of the Work is completed and all outstanding deficiencies that may exist are corrected by the Contractor and the Engineer is satisfied that all the materials and workmanship, and all other features of the Work, meet the requirements of all of the specifications for the Work. Use, temporary, interim or permanent, of all, or portions of, the Work does not constitute acceptance of the Work. If, in the Engineer's judgment, the Work has been completed and is ready for acceptance the Engineer will so certify to the Board. Upon such certification by the Engineer the Board may accept the completed Work. Upon the Board's acceptance of the Work the Engineer will cause a "Notice of Completion" to be filed in the office of the San Diego County Recorder. The date of recordation shall be the date of completion of the Work. Delete the first sentence of the third paragraph and substitute the following two sentences: All work shall be warranted for one (1) year after recordation of the "Notice of Completion" and any faulty work or materials discovered during the warranty period shall be repaired or replaced by the Contractor, at its expense. Twenty-five percent of the faithful performance bond shall be retained as a warranty bond for the one year warranty period. 6-9 LIQUIDATED DAMAGES. Modify the last sentence of the first paragraph and the first sentence of the second paragraph and add the following: For each consecutive calendar day in excess of the time specified for completion of Work, as adjusted in accordance with 6-6, the Contractor shall pay the Agency, or have withheld monies due it, the sum of One Thousand Dollars ($1,000.00). Execution of the Contract shall constitute agreement by the Agency and Contractor that One Thousand Dollars ($1,000.00) per day is the minimum value of costs and actual damages caused by the Contractor to complete the Work within the allotted time. Any progress payments made after the specified completion date shall not constitute a waiver of this paragraph or of any damages. SECTION 7 -- RESPONSIBILITIES OF THE CONTRACTOR 7-3 LIABILITY INSURANCE. Modify as follows: All insurance is to be placed with insurers that have a rating in Best's Key Rating Guide of at least A-:V arid are admitted and authorized to conduct business in the state of California and are listed in the official publication of the Department of Insurance of the State of California. 7-4 WORKERS'COMPENSATION INSURANCE. Add the following: All insurance is to be placed with insurers that are admitted and authorized to conduct business in the state of California and are listed in the official publication of the Department of Insurance of the State of California. Policies issued by the State Compensation Fund meet the requirement for workers' compensation insurance. 7-5 PERMITS. Delete the first sentence and add the following four sentences: Except as specified herein the Contractor will obtain, at no cost to the Contractor all City of San Marcos encroachment, right-of-way, grading and building permits necessary to perform work for this contract on Agency property, streets, or other rights-of-way. Contractor shall not begin work until all permits incidental to the work are obtained. The Contractor shall obtain and pay for all permits for the disposal of all materials removed from the project. The cost of said permit(s) shall be included in the price bid for the appropriate bid item and no additional compensation will be allowed therefore. 10/08/03 Contract No. 39561-A Page 73 of 82 Pages 7-7 COOPERATION AND COLLATERAL WORK. Add the following section: 7-7.1 Coordination. The Contractor shall coordinate and cooperate with all the utility companies during the relocation or construction of their lines. The Contractor may be granted a time extension if, in the opinion of the Engineer, a delay is caused by the utility company. No additional compensation will be made to the Contractor for any such delay. 7-8 PROJECT SITE MAINTENANCE. 7-8.1 Cleanup and Dust Control. Add the following: Cleanup and dust control required herein shall also be executed on weekends and other non-working days when needed to preserve the health safety or welfare of the public. The Contractor shall conduct effective cleanup and dust control throughout the duration of the Contract. The Engineer may require increased levels of cleanup and dust control that, in his/her sole discretion, are necessary to preserve the health, safety and welfare of the public. Cleanup and dust control shall be considered incidental to the items of work that they are associated with and no additional payment will be made therefore. 7-8.5 Temporary Light, Power and Water. Add the following: The Contractor shall obtain a construction meter for water used for the construction, plant establishment, maintenance, cleanup, testing and all other work requiring water related to this contract. The Contractor shall contact the appropriate water agency for requirements. The Contractor shall pay all costs of temporary light, power and water including hookup, service, meter and any, and all, other charges, deposits and/or fees therefore. Said costs shall be considered incidental to the items of work that they are associated with and no additional payment will be made therefore. 7-8.6 Water Pollution Control. Add the following: Contractor shall comply with the California State Water Resources Control Board (SWRCB) Order Number 99-08-DWQ, National Pollutant Discharge Elimination System (NPDES) General Permit Number CAS000002, Waste Discharge Requirements (WDR's) for Discharges of Stormwater Runoff associated with Construction Activity (General Permit) and subsequent adopted modifications and with all requirements of the Storm Water Pollution Prevention and Monitoring Plans for this project in accordance with these regulations. Add the following section: 7-8.8 Noise Control. All internal combustion engines used in the construction shall be equipped with mufflers in good repair when in use on the project with special attention to the City Noise Control Ordinance, Carlsbad Municipal Code Chapter 8.48. 7-10 PUBLIC CONVENIENCE AND SAFETY. 7-10.1 Traffic and Access, add the following: The Contractor shall schedule the work so as to prevent damage by all traffic, including but not limited to mail delivery. The Contractor shall not schedule work so as to conflict with trash pickup. The trash hauling schedule can be obtained by calling the City's contracted waste disposal company, Coast Waste Management at 929-9417. : 10/08/03 Contract No. 39561-A Page 74 of 82 Pages During overlay operations, the Contractors schedule for overlay application shall be designated to provide residents and business owners whose streets are to be overlaid sufficient paved parking within an 800 foot distance from their homes or businesses. Seventy-two hours prior to the start of any construction in the public right-of-way that affects vehicular traffic and/or parking or pedestrian routes, the Contractor shall give written notification of the impending disruption. For a full street closure, all residences and/or businesses on the affected street or alley shall be notified. For partial street closures, or curb, sidewalk and driveway repairs, the residences and/or businesses directly affected by the work shall be notified. The notification shall be hand delivered and shall state the date and time the work will begin and its anticipated duration. The notification shall list two telephone numbers that may be called to obtain additional information. One number shall be the Contractor's permanent office or field office and the other number shall be a 24-hour number answered by someone who is knowledgeable about the project. At least one of the phone numbers shall be in the (760) area code. An answering machine shall not be connected to either number. The notification shall also give a brief description of the work and simple instructions to the home or business owner on what they need to do to facilitate the construction. The Contractor shall submit the contents of the notification to the Engineer for approval. Notices shall not be distributed until approved by the Engineer. For residences, the notification shall be pre-cut in a manner that enables it to be affixed to a doorknob without adhesives. It shall be a minimum size of 3-1/2 inches by 8-1/2 inches and shall be brightly colored with contrasting printing. The material shall be equivalent in strength and durabilityto 65 Ib. card stock. The printing on the notice shall be no smaller than 12 point. An example of such notice is provided in Appendix "A". In addition to the notifications, the contractor shall post no parking signs 48 hours in advance of the work being performed. The no parking signs shall state the date and time of parking restriction for a duration not to exceed the time necessary to complete the work at that location. Failure of the contractor to meet the posted date requires re-posting the no parking signs 48 hours in advance of the rescheduled work. If the work is delayed or rescheduled the no parking signs shall be removed and re-posted 48 hours in advance of the rescheduled work. The preparation, materials, printing and distribution of the notifications shall be included in the contract price bid for traffic control and the Contractor will not be entitled to any additional compensation for printing and distributing these notices. 7-10.3 Street Closures, Detours, Barricades. Add the following: Traffic controls shall be in accordance with the plans, Federal Highway Administration (FHWA) Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement and these Supplemental Provisions. If any component in the traffic control system is damaged, displaced, or ceases to operate or function as specified, from any cause, during the progress of the work, the Contractor shall immediately repair said component to its original condition or replace said component and shall restore the component to its original location. In the event that the Contractor fails to install and/or maintain barricades or such other traffic signs, markings, delineation or devices as may be required herein, the Engineer may, at his/her sole option, install the traffic signs, markings, delineation or devices and charge the Contractor twenty dollars ($25.00) per day per traffic sign or device, or the actual cost of providing such traffic control facility, whichever is the greater. Revised: 10/08/03 Contract No. 39561-A Page 75 of 82 Pages Add the following section: 7-10.3.1 Construction Area Signs and Control Devices. All construction traffic signs and control devices shall be maintained throughout the duration of work in good order and according to the approved traffic control plan. All construction area signs shall conform to the provisions of section 206-7.2 et seq. All temporary reflective pavement markers shall conform to the provisions of section 214-5.Let seq. All temporary reflective channelizers shall conform to the provisions of section 214- 5.2 et seq. All paint for temporary traffic striping, pavement marking, and curb marking shall conform to the provisions of section 210-1.6 et seq. except that all temporary paint shall be rapid dry water borne conforming to section 210-1.6for materials and section 310-5 et seq. For workmanship. Warning and advisory signs, lights and devices installed or placed to provide traffic control, direction and/or warning shall be furnished, installed and maintained by the Contractor. Warning and advisory signs, lights and devices shall be promptly removed by the Contractor when no longer required. Warning and advisory signs that remain in place overnight shall be stationary mounted signs. Stationary signs that warn of non-existent conditions shall be removed from the traveled way and from the view of motorists in the traveled way or shielded from the view of the traveling public during such periods that their message does not pertain to existing conditions. Care shall be used in performing excavation for signs in order to protect underground facilities. All excavation required to install stationary construction area signs shall be performed by hand methods without the use of power equipment. Warning and advisory signs that are used only during working hours may be portable signs. Portable signs shall be removed from the traveled way and shielded from the view of the traveling public during non-working hours. During the hours of darkness, as defined in Division 1, Section 280, of the California Vehicle Code, portable signs shall be illuminated or, at the option of the Contractor, shall be in conformance with the provisions in section 206-7.2 et seq. If illuminated traffic cones rather than post-type delineators are used during the hours of darkness, they shall be affixed or covered with reflective cone sleeves as specified in CALTRANS "Standard Specifications", except the sleeves shall be 180 mm (7") long. Personal vehicles of the Contractor's employees shall not be parked within the traveled way, including any section closed to public traffic. Whenever the Contractor's vehicles or equipment are parked on the shoulder within 1.8 m (6') of a traffic lane, the shoulder area shall be closed with fluorescent traffic cones or portable delineators placed on a taper in advance of the parked vehicles or equipment and along the edge of the pavement at not less than 7.6 m (25') intervals to a point not less than 7.6 m (25') past the last vehicle or piece of equipment. A minimum of nine (9) cones or portable delineators shall be used for the taper. A C23 (Road Work Ahead) or C24 (Shoulder Work Ahead) sign shall be mounted, as required herein, on a signpost or telescoping flag tree with flags. The signpost or flag tree shall be placed where directed by the Engineer. Add the following section: 7-10.3.2 Maintaining Traffic. The Contractor's personnel shall not work closer than (insert minimum acceptable lateral safety buffer distance, eg. 1.8 m (6')), nor operate equipment within 0.6 m (2') from any traffic lane occupied by traffic. For equipment the than (insert minimum acceptable shy distance, eg. 0.6 m (2')) shall be measured from the closest approach of any part of the equipment as it is operated and/or maneuvered in performing the work. This requirement may be waived when the Engineer has given written authorization to the reduction in clearance that is specific to the time, duration and location of such waiver, when such reduction is shown on the traffic control plans included in these contract documents, when such reduction is shown on the traffic control plans prepared by the Contractor and approved by the Engineer or for the work of installing, maintaining and removing traffic control devices. As a condition of such waiver the Engineer may require the Contractor to detour traffic, adjust the width of, or realign the adjacent traffic lane, close the adjacent traffic lane or provide barriers. 10/08/03 Contract No. 39561-A Page 76 of 82 Pages Add the following section: 7-10.3.3 Traffic Control System for Lane Closure. A traffic control system consists of closing traffic lanes or pedestrian walkways in accordance with the details shown on the plans, Federal Highway Administration (FHWA) Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement and provisions under "Maintaining Traffic" elsewhere in these Supplemental Provisions. The provisions in this section will not relieve the Contractor from its responsibility to provide such additional devices or take such measures as may be necessary to maintain public safety. When lanes are closed for only the duration of work periods, all components of the traffic control system, except portable delineators placed along open trenches or excavation adjacent to the traveled way, shall be removed from the traveled way and shoulder at the end work period. If the Contractor so elects, said components may be stored at selected central locations, approved by the Engineer, within the limits of the right-of-way. Add the following section: 7-10.3.4 Traffic Control for Permanent and Temporary Traffic Striping. During traffic stripe operations, traffic shall be controlled with lane closures, as provided for under "Traffic Control System for Lane Closure" of these Supplemental Provisions or by use of an alternative traffic control plan proposed by the Contractor and approved by the Engineer. The Contractor shall not start traffic striping operations using an alternative plan until the Contractor has submitted its plan to the Engineer and has received the Engineer's written approval of said plan. Add the following section: 7-10.3.5 Temporary Pavement Delineation. Temporary pavement delineation shall be furnished, placed, maintained and removed in accordance with the minimum standards specified in Chapter 5 of the "Traffic Manual", 1996 edition published by CALTRANS. Whenever the work causes obliteration of pavement delineation, temporary or permanent pavement delineation shall be in place prior to opening the traveled way to public traffic. Lane line or centerline pavement delineation shall be provided at all times for traveled ways open to public traffic. All work necessary, including any required lines or marks, to establish the alignment of temporary pavement delineation shall be performed by the Contractor. When temporary pavement delineation is removed, all lines and marks used to establish the alignment of the temporary pavement delineation shall be removed by grinding. Surfaces to receive temporary pavement delineation shall be dry and free of dirt and loose material. Temporary pavement delineation shall not be applied over existing pavement delineation or other temporary pavement delineation. Temporary pavement delineation shall be maintained until superseded or replaced with permanent pavement delineation. Temporary pavement delineation shall be removed when, as determined by the Engineer, the temporary pavement delineation conflicts with the permanent pavement delineation or with a new traffic pattern for the area and is no longer required for the direction of public traffic. When temporary pavement delineation is required to be removed, all lines and marks used to establish the alignment of the temporary pavement delineation shall be removed. OR,evised: 10/08/03 Contract No. 39561-A Page 77 of 82 Pages Add the following section: 7-10.3.6 Preparation of New, or Modifications and Additions to Existing, Traffic Control Plan Sheets. If no traffic control plans (TCP) or Traffic Control Staging plans (TCP) are included in the project plans, or if the Contractor elects to modify TCP included in the project plans, the Contractor shall have such new or modified TCP prepared and submitted as a part of the Work for any and all construction activities that are located within the travelled way. The Contractor shall have TCP prepared and submitted as a part of the Work for any construction activities that are a part of this project that are not included in the project plans. The Contractor must submit the TCP for the Engineer's review in conformance with the requirements of section 2-5.3, et seq. and obtain the Engineer's approval of the TCP prior to implementing them. The minimum 20-day review period specified in section 2-5.3.1 for shop drawings and submittals shall pertain to each submittal of TCP, new, modified or added to, for the Engineer's review. New or revised TCP submittals shall include all TCP needed for the entire duration of the Work. Each phase of the TCP shall be shown in sufficient scale and detail to show the lane widths, transition lengths, curve radii, stationing of features affecting the traffic control plan and the methodology proposed to transition to the subsequent TCP phase. When the vertical alignment of the travelled surface differs from the finished pavement elevation vertical curves must also be shown. The Contractor may choose to modify, add to or supplement the TCP shown on drawings Nos. IP-4693 and 425-1 of the contract documents or substitute TCP to further its own interests. Such substitution shall be prepared in type and kind as sheets of Drawing. The level of detail, format, and graphics shall be of quality and size no less than shown on sheets of Drawing. Such modifications, supplements and/or new design of TCP shall meet the requirements of the Engineer and Chapter 5 of the "Traffic Manual", 1996 Edition as published by CALTRANS. Such modification, addition, supplement, and/or new design of TCP shall be prepared by a registered professional engineer appropriately registered in the State of California. The Engineer shall be the sole judge of the suitability and quality of any such modifications, supplements, and/or new designs to TCP. The Engineer may approve any such modifications, supplements, and/or new designs to the TCP when, in the Engineer's sole opinion, such modifications, supplements, and/or new designs to the TCP prepared by the registered professional engineer retained by the Contractor will be beneficial to the best interests of the Agency. Such modification, addition, supplement, and/or new design shall not be implemented and no work shall be commenced that is contingent on such approval until the changed TCP are approved by the Engineer. The preparation of such modification, addition, supplement, and/or new designs of TCP shall not presuppose their approval or obligate the Agency in any fashion. Submittal and review requirements for such modifications, supplements, and/or new designs to TCP shall conform to the requirements of section 2-5.3 Shop Drawings and Submittals. Add the following section: 7-10.3.7 PaymentThe Contractor shall provide traffic control at the contract lump sum price bid. The contract lump sum price paid for "traffic control" shall include full compensation for furnishing all labor (including flagging costs), materials (including signs), tools, equipment and incidentals, and for doing all the work involved in preparation, reproduction and changing of traffic control plans, placing, applying traffic stripes and pavement markers with bituminous adhesive, removing, storing, maintaining, moving to new locations, replacing, and disposing of the components of the traffic control system as shown on the plans and approved additions and modifications, as specified in these supplemental provisions, and as directed by the Engineer. All expenses and time to prepare and review modifications, additions, supplements and/or new TCP designs shall be included in the lump sum bid for traffic control and no additional payment will be made therefore. Flagging costs will be paid for as a part of the Lump Sum Amount for "Traffic Control." The cost of labor and material for portable concrete barriers will be paid for at the unit price bid. When there is no bid item the cost of labor and material for portable concrete barriers they will be paid as an incidental to the work being performed and no additional payment will be made therefore. Progress payments for "Traffic Control" will be based on the percentage of the improvement work completed. Revised: 10/08/03 Contract No. 39561-A Page 78 of 82 Pages The Contractor shall prepare and implement traffic control plans and shall furnish all labor and materials to perform, install, maintain, replace and remove all traffic control as incidentals to the work with which they are associated and no other compensation will be allowed therefore. Add the following section: 7-10.4.4 Safety and Protection of Workers and Public. The Contractor shall take all necessary precautions for the safety of employees on the work and shall comply with all applicable provisions of Federal, State and Municipal safety laws and building codes to prevent accidents or injury to persons on, about, or adjacent to the premises where the work is being performed. The Contractor shall erect and properly maintain at all times, as required by the conditions and progress of the work, all necessary safeguards for the protection of workers and public, and shall use danger signs warning against hazards created by such features of construction as protruding nails, hoists, well holes, and falling materials. 7-13 LAWS TO BE OBSERVED. Add the following: Municipal ordinances that affect this work include Chapter 11.06. Excavation and Grading. If this notice specifies locations or possible materials, such as borrow pits or gravel beds, for use in the proposed construction project which would be subject to Section 1601 or Section 1603 of the Fish and Game Code, the conditions established pursuant to Section 1601 et seq. of the Fish and Game Code shall become conditions of the contract. SECTION 8 - FACILITIES FOR AGENCY PERSONNEL 8-2 FIELD OFFICE FACILITIES. Add the following: Contractor shall furnish the Engineer a "Class A" Field Office. The field office shall be for the exclusive use of the Engineer and such other individuals that the Engineer may designate. The field office shall be a separate structure from any other office facility. The Contractor shall maintain the field office throughout the entire duration of the contract unless the Engineer shall otherwise direct. 8-2.1 Class "A" Field Office. Add the following: Additionally the "Class A" Field Office shall be provided with: one (1) additional standard 1.5 m (5') double pedestal desk with two chairs, one (1) electrostatic copier and supplies, copier shall be Xerox Model Document Centre 545, or equal, one (1) FAX machine, Canon Model Faxphone B640 Bubble Jet Facsimile, or equal, one (1) refn'gerator, one (1) microwave oven, and one (1) additional plan rack shall be provided. Water cooler to have hot and chilled water. The integral sanitary facilities may be separate enclosed toilets per Section 7-8.4. Furnishings are subject to agency approval. The field office shall be located at a site satisfactory to the Engineer and within or immediately adjacent to the limits of work. Access and three parking spaces for the exclusive use of the Engineer and his/her designees that are convenient and satisfactory to the Engineer shall be provided by the Contractor. The field office shall have a 600 mm by 900 mm (24" by 36") sign affixed near the entry door. The sign text shall be proportioned as shown below. The Contractor shall affix a City and CMWD seal to the sign in a centered location. The seals will be supplied by the Engineer. Revised: 10/08/03 Contract No. 39561-A Page 79 of 82 Pages CARLSBAD MUNICIPAL WATER DISTRICT CITY OF SAN MARCOS ENGINEERING INSPECTION 8-6 BASIS OF PAYMENT. Add the following: Payment for field office will be made at the lump sum price bid and will include full compensation for installing and removing the field office, relocating it as may be necessary to facilitate the project, obtaining all permits, property rental, providing utilities including, but not limited to, high speed internet service, electrical, telephone, potable water and sanitary facilities, and maintenance. Payments to the contractor will be based on a monthly rate, (lump sum price divided by the contract duration) will be paid for each full calendar month throughout the duration of the contract that the field office, complete with all facilities and utilities, is available to the Engineer and on the project excepting when the Engineer has ordered that the field office be removed from the project. SECTION 9 - MEASUREMENT AND PAYMENT 9-1 MEASUREMENT OF QUANTITIES FOR UNIT PRICE WORK 9-1.4 Units of Measurement, modify as follows: The system of measure for this contract shall be the U.S. Standard Measures. 9-3 PAYMENT. 9-3.1 General. Delete the eighth paragraph and substitute the following: Guarantee periods shall not be affected by any payment but shall commence on the date of recordation of the "Notice of Completion" 9-3.2 Partial and Final Payment. Delete the second paragraph and substitute the following: Each month, the Engineer will make an approximate measurement of the work performed to the closure date as basis for making monthly progress payments. The estimated value will be based on contract unit prices, completed change order work and as provided for in Section 9-2 of the Standard Specifications (SSPWC). Progress payments shall be made no later than thirty (30) calendar days after the closure date. Five (5) working days following the closure date, the Engineer shall complete the detailed progress pay estimate and submit it to the Contractor for the Contractor's information. Should the Contractor assert that additional payment is due, the Contractor shall within ten (10) days of receipt of the progress estimate, submit a supplemental payment request to the Engineer with adequate justification supporting the amount of supplemental payment request. Upon receipt Revised: 10/08/03 Contract No. 39561-A Page 80 of 82 Pages of the supplemental payment request, the Engineer shall, as soon as practicable after receipt, determine whether the supplemental payment request is a proper payment request. If the Engineer determines that the supplemental payment request is not proper, then the request shall be returned to the Contractor as soon as practicable, but not later than seven (7) days after receipt. The returned request shall be accompanied by a document setting forth in writing the reasons why the supplemental payment request was not proper. In conformance with Public Contract Code Section 20104.50, the City shall make payments within thirty (30) days after receipt of an undisputed and properly submitted supplemental payment request from the Contractor. If payment of the undisputed supplemental payment request is not made within thirty (30) days after receipt by the Engineer, then the City shall pay interest to the Contractor equivalent to the legal rate set forth in subdivision (a) of Section 685.010 of the Code of Civil Procedure. Add paragraph 6 et seq. as follows: After final inspection, the Engineer will make a Final Payment Estimate and process a corresponding payment. This estimate will be in writing and shall be for the total amount owed the Contractor as determined by the Engineer and shall be itemized by the contract bid item and change order item with quantities and payment amounts and shall show all deductions made or to be made for prior payments and amounts to be deducted under provisions of the contract. All prior estimates and progress payments shall be subject to correction in the Final Payment Estimate. The Contractor shall have 30 calendar days from receipt of the Final Payment Estimate to make written statement disputing any bid item or change order item quantity or payment amount. The Contractor shall provide all documentation at the time of submitting the statement supporting its position. Should the Contractor fail to submit the statement and supporting documentation within the time specified, the Contractor acknowledges that full and final payment has been made for all contract bid items and change order items. If the Contractor submits a written statement with documentation in the aforementioned time, the Engineer will review the disputed item within 30 calendar days and make any appropriate adjustments on the Final Payment. Remaining disputed quantities or amounts not approved by the Engineer will be subject to resolution as specified in subsection 3-5, Disputed Work. The written statement filed by the Contractor shall be in sufficient detail to enable the Engineer to ascertain the basis and amount of said disputed items. The Engineer will consider the merits of the Contractor's claims. It will be the responsibility of the Contractor to furnish within a reasonable time such further information and details as may be required by the Engineer to determine the facts or contentions involved in its claims. Failure to submit such information and details will be sufficient cause for denying payment for the disputed items. 9-3.2.1 Payment for Claims. Add the following: Except for those final payment items disputed in the written statement required in subsection 9-3.2 all claims of any dollar amount shall be submitted in a written statement by the Contractor no later than the date of receipt of the final payment estimate. Those final payment items disputed in the written statement required in subsection 9-3.2 shall be submitted no later than 30 days after receipt of the Final Payment estimate. No claim will be considered that was not included in this written statement, nor will any claim be allowed for which written notice or protest is required under any provision of this contract including sections 3-4 Changed Conditions, 3-5 Disputed Work, 6-6.3 Payment for Delays to Contractor, 6-6.4 Written Notice and Report, or 6-7.3 Contract Time Accounting, unless the Contractor has complied with notice or protest requirements. Revised: 10/08/03 Contract No. 39561-A Page 81 of 82 Pages The claims filed by the Contractor shall be in sufficient detail to enable the Engineer to ascertain the basis and amount of said claims. The Engineer will consider and determine the Contractor's claims and it will be the responsibility of the Contractor to furnish within a reasonable time such further information and details as may be required by the Engineer to determine the facts or contentions involved in its claims. Failure to submit such information and details will be sufficient cause for denying the claims. Payment for claims shall be processed within 30 calendar days of their resolution for those claims approved by the Engineer. The Contractor shall proceed with informal dispute resolution under subsection 3-5, Disputed Work, for those claims remaining in dispute. Add the following section: 9-3.3.1 Delivered Materials. The cost of materials and equipment delivered but not incorporated into the work will not be included in the progress estimate. Add the following section: 9-3.4.1 Mobilization and Preparatory Work. Payment for mobilization and preparatory Work will be made at the stipulated lump-sum price bid therefore in the bid schedule and shall not exceed sixty thousand dollars ($60,000.00) for each bid schedule, and includes full compensation for furnishing all insurance, bonds, licenses, labor, materials, utilities, tools, equipment and incidentals, and for doing all the work involved in mobilization and preparatory work and operations, including, but not limited to, those necessary for the movement of personnel, equipment, supplies, and incidental to preparing to conduct work on and off the project site and other offsite facilities necessary for work on the project; for all other facilities, sureties, work and operations which must be performed or costs incurred prior to beginning work on various contract items on or off the project site, excepting those specifically paid for under separate sections of these specifications. The Contractor hereby agrees that the stipulated lump sum amount is sufficient for Mobilization and Preparatory Work, as described in this section, and that the Contractor shall have no right to additional compensation for Mobilization and Preparatory Work. Progress payments for Mobilization and Preparatory Work will be made as follows: For the first progress payment (after the issuance of the Notice to Proceed), forty percent (40%) of the amount bid for Mobilization And Preparatory Work will be allowed. For the second progress payment, an additional sixty percent (60%) of the amount bid for mobilization and preparatory work will be allowed therefore. :evised: 10/08/03 Contract No. 39561-A Page 82 of 82 Pages ft TABLE OF CONTENTS PART 2, CONSTRUCTION MATERIALS 4 SECTION 200 - ROCK MATERIALS 4 200.1 ROCK PRODUCTS... . . ...................... ............................. .. ..................................................................................4 200-2 UNTREATED BASE MATERIALS _ 5 SECTION 201 - CONCRETE, MORTAR, AND RELATED MATERIALS 6 201-1 PORTLAND CEMENT CONCRETE 6 201-3 EXPANSION JOINT FILLER AND JOINT SEALANTS. 8 SECTION 203 - BITUMINOUS MATERIALS 9 203-6 ASPHALT CONCRETE. _. 9 203-11 ASPHALT RUBBER HOT MIX (ARHM) WET PROCESS 10 203-13 ASPHALT PAVEMENT CRACK SEALANTS .. . 10 SECTION 204 - LUMBER AND TREATMENT WITH PRESERVATIVES 11 204-1 LUMBER AND PLYWOOD ...................... ................................ . 11 SECTION 205 - PILES „ - 11 205-3 CONCRETE PILES.™....™..........™......™.. . ......................................... ........ ™.............™........™....ll SECTION 206 - MISCELLANEOUS METAL ITEMS 11 206-7 TRAFFIC SIGNS 11 206-8 LIGHT GAGE STEEL TUBING AND CONNECTORS .. 14 SECTION 207 - PIPE — 15 207-2 REINFORCED CONCRETE PIPE 15 207-25 UNDERGROUND UTILITY MARKING TAPE . .. 15 SECTION 209 - ELECTRICAL COMPONENTS 16 209 ELECTRICAL COMPONENTS ™ .. . ™.™..™™. .™....™... „ ......... 16 SECTION 209 - SIGNALS, LIGHTING AND TRAFFIC ELECTRICAL SYSTEMS 17 209-1 GENERAL .. ™... 17 209-2 MATERIALS AND INSTALLATION 21 209-3 CONTROLLER ASSEMBLIES , .. 40 209-4 TRAFFIC SIGNAL FACES AND FITTINGS ™ „ 41 209-5 DETECTORS 57 209-6 LIGHTING 66 209-7 REMOVING, REINSTALLING OR SALVAGING ELECTRICAL EQUIPMENT 71 209-8 PAYMENT 71 SECTION 210 - PAINT AND PROTECTIVE COATINGS 72 210-1 PAINT „ „ „ ™™..72 210-3 GALVANIZING 73 SECTION 212 - LANDSCAPE AND IRRIGATION MATERIALS 73 212-1 LANDSCAPE MATERIALS - 73 212-2 IRRIGATION SYSTEM MATERIALS „ - 78 212-3 ELECTRICAL MATERIALS. 80 July 2005 Page 1 of 115 SECTION 213 - ENGINEERING FABRICS 81 213-2 GEOTEXTILES. - .. 81 213-3 EROSION CONTROL SPECIALTIES. 81 SECTION 214 PAVEMENT MARKERS 82 214-5 REFLECTIVE PAVEMENT MARKERS 82 PART 3, CONSTRUCTION METHODS 83 SECTION 300 - EARTHWORK 83 300-1 CLEARING AND GRUBBING 83 300-2 UNCLASSIFIED EXCAVATION :. 83 300-3 STRUCTURE EXCAVATION AND BACKFILL. 85 300-4 UNCLASSIFIED FILL.... „.„.„. . _...„ „ ............................. ...............™......_..........85 300-5 BORROW EXCAVATION. 86 300-9 GEOTEXTILES FOR EROSION CONTROL AND WATER POLLUTION CONTROL 87 300-11 STONEWORK FOR EROSION CONTROL 87 300-12 ROCK SLOPE PROTECTION FABRIC. 88 300-13 STORM WATER POLLUTION PREVENTION PLAN ; .. 88 SECTION 301 - TREATED SOIL, SUBGRADE PREPARATION & PLACEMENT OF BASE MATERIALS.... 92 301-1 SUBGRADE PREPARATION. . 92 SECTION 302 - ROADWAY SURFACING „ 92 302-5 ASPHALT CONCRETE PAVEMENT ......92 302-11 ASPHALT PAVEMENT REPAIRS AND REMEDIATION . 93 SECTION 303 CONCRETE AND MASONRY CONSTRUCTION 95 303-1 CONCRETE STRUCTURES 95 303-5 CONCRETE CURBS, WALKS, GUTTERS, CROSS GUTTERS, ALLEY INTERSECTIONS, ACCESS RAMPS, AND DRIVEWAYS _..................„.„...„.„.„„ _95 303-6 STAMPED CONCRETE .. . 95 303-7 CONCRETE RETAINING WALL 96 SECTION 304 - METAL FABRICATION AND CONSTRUCTION 96 304-1 STRUCTURAL STEEL 96 304-3 CHAIN LINK FENCE . ........... ... ................................................................... _™96 SECTION 306 - UNDERGROUND CONDUIT CONSTRUCTION 96 306-1 OPEN TRENCH OPERATIONS 96 SECTION 307 - STREET LIGHTING AND TRAFFIC SIGNALS 100 307-3 STREET LIGHTING CONSTRUCTION 100 307-4 TRAFFIC SIGNAL CONSTRUCTION 100 SECTION 308 LANDSCAPE AND IRRIGATION INSTALLATION 100 308-2 EARTHWORK AND TOPSOIL PLACEMENT 100 308-4 PLANTING 101 308-5 IRRIGATION SYSTEM INSTALLATION 104 308-6 MAINTENANCE AND PLANT ESTABLISHMENT 105 308-7 GUARANTEE _ 106 308-8 MEASUREMENT AND PAYMENT 108 July 2005 Page 2 of 115 SECTION 310 - PAINTING 108 310-5 PAINTING VARIOUS SURFACES „ „ „. 108 SECTION 312 - PAVEMENT MARKER PLACEMENT AND REMOVAL 109 312-1 PLACEMENT................. «™.......................™....._............................™................................™............™.....™. 109 SECTION 313 - TEMPORARY TRAFFIC CONTROL DEVICES 109 313-1 TEMPORARY TRAFFIC PAVEMENT MARKERS 109 313-2 TEMPORARY TRAFFIC SIGNING . 110 313-4 MEASUREMENT AND PAYMENT „... . ................................... .._ .„„. 112 PART 6, MODIFIED ASPHALTS, PAVEMENTS AND PROCESSES ....113 600-3 RUBBERIZED EMULSION - AGGREGATE SLURRY . 113 APPENDIX "B" 115 July 2005 Page 3 of 115 SUPPLEMENTAL PROVISIONS TO "GREEN BOOK" STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART 2, CONSTRUCTION MATERIALS (Pertaining to City of San Marcos IP-4693 and Bid Schedule 'A') July 2005 SECTION 200 - ROCK MATERIALS 200.1 ROCK PRODUCTS Add the following section: 200-1.2.2 Permeable Material. Permeable material shall consist of hard, durable, clean sand, gravel, or crushed stone, and shall be free from organic material, clay balls, or other deleterious substances. Class 1 and Class 2 permeable material shall have a Durability Index of not less than 40. Class 2 Permeable material shall have a Sand Equivalent value of not less than 75. Class 1 permeable material shall conform to the requirements in this section and Table 200-1.2.2(A). Class 2 permeable material shall conform to the requirements in this section and Table 200-1.2.2(8). When permeable material is required and the class or kind is not specified, Class 1 permeable material shall be used. The alternative grading within Class 1 permeable material are identified by types. Unless otherwise shown on the plans the Contractor will be permitted to furnish and place any one of the types provided for this class. The percentage composition by mass of permeable material in place shall conform to the grading in Tables 200-1.2.2(A) and 200-1.2.2(B). TABLE 200-1.2.2(A) CLASS 1 PERMEABLE MATERIAL Sieve Sizes 50-mm (2") 37.5-mm(l'/2") 19-mm(V) 12.5-mm (V2") 9.5-mm (V) 4.75-mm (No. 4) 2.36-mm (No. 8) 75-um (no. 200) Percent: Type A — —100 95-100 70-100 0-55 0-10 0-3 ige Passing TypeB 100 95-100 50-100 • 15-55 0-25 0-5 0-3 TABLE 200-1.2.2(8) CLASS 2 PERMEABLE MATERIAL Sieve Sizes 25-mm(l") 19-mm(3/4") 9.5-mm (V) 4.75-mm (No. 4) 2.36-mm (No. 8) 600-um (No. 30) 300-um (No. 50) 75-um (no. 200) Percentage Passing 100 90-100 40-100 25-40 18-33 5-15 0-7 0-3 July 2005 Page 4 of 1 1 5 200-2 UNTREATED BASE MATERIALS 200-2.1 General. Add the following: Aggregate base shall be Class 2 Aggregate Base per Standard Specification, July 2002, Section 26: Aggregate Bases, Subsection 26-1.02A Class 2 Aggregate and as specified herein. Add the following section: 200-2.7 Class 2 Aggregate Base. Aggregate for Class 2 aggregate base shall be free from organic matter and other deleterious substances, and shall be of such nature that it can be compacted readily under watering and rolling to form a firm, stable base. Aggregate may include material processed from reclaimed asphalt concrete, portland cement concrete, lean concrete base, cement treated base or a combination of any of these materials. Aggregate shall conform to the grading and quality requirements shown in the following tables. At the option of the Contractor, the grading for either the 11/2-inch maximum or 3/4 inch maximum shall be used, except that once a grading is selected it shall not be changed without the Engineer's written approval. AGGREGATE GRADING REQUIREMENTS Percentage Passing 11/2" Maximum 3/4" Maximum Sieve Sizes 2" 11/2"r 3/4" No. 4 No. 30 No. 200 Operating Range 100 90-100 50-85 25-45 10-25 2-9 Operating Range 100 90-100 35-60 10-30 2-9 QUALITY REQUIREMENTS Operating Tests Range Resistance (R-value) 78 Min. Sand Equivalent 25 Min. Durability Index 35 Min. The aggregate shall not be treated with lime, cement or other chemical material before the Durability Index test is performed. If the results of either or both the aggregate grading and Sand Equivalent tests do not meet the requirements specified for "Operating Range" but meet the "Contract Compliance" requirements, placement of the aggregate base may be continued for the remainder of that day. However, another day's work may not be started until tests, or other information, indicate to the satisfaction of the Engineer that the next material to be used in the work will comply with the requirements specified for "Operating Range." If the results of either or both the aggregate grading and Sand Equivalent tests do not meet the requirements specified for "Contract Compliance," the aggregate base which is represented by these tests shall be removed. However, if requested by the Contractor and approved by the Engineer, the aggregate base may remain in place and the Contractor shall pay to the Agency $2.25 per cubic yard for such aggregate base left in place. The Agency may deduct this amount from any moneys due, or that may become due, the Contractor under the contract. If both the aggregate grading and Sand Equivalent do not conform to the "Contract Compliance" requirements, only one adjustment shall apply. No single aggregate grading or Sand Equivalent test shall represent more than 500 cubic yards or one day's production, whichever is smaller. July 2005 Page 5 of 115 SECTION 201 - CONCRETE, MORTAR, AND RELATED MATERIALS 201-1 PORTLAND CEMENT CONCRETE TABLE 20M.1.2(A) Modify as follows: TABLE 201-1.1.2(A) (3) PORTLAND CEMENT CONCRETE Type of Construction All Concrete Used Within the Right-of-Way Trench Backfill Slurry Street Light Foundations and Survey Monuments Traffic Signal Foundations Concreted-Rock Erosion Protection Concrete Class 330-C-23 (560-C-3250) (1) 115-E-3 (190-E-400) 330-C-23 (560-C-3250) 350-C-27 (590-C-3750) 310-C-17 (520-C-2500P) Maximum Slump mm (Inches) (2) 200 (8") 100 (4") 100 (4") per Table 300-1 1.3.1 (1) Except that concrete required to be of higher strength by Table 201-1.1.2(A) SSPWC shall be as per Table 201-1.1.2(A) SSPWC. (2) As per Table 201-1.1.2(A) SSPWC. (3) Portions of Table 201-1.1.2(A) of the Standard Specifications for Public Works Construction not shown herein as changed are not affected by this table. 201-1.2 Materials. 201-1.2.4(a) Integral Colored Concrete. Add the following: Proposed retaining wall shall be poured with integral-colored concrete (color to be approved by City Planning Division). Architectural treatment shall conform to the San Marcos Ledger Stone Texture used on the Las Posas/SR 78 Interchange retaining walls (sample panel to be approved by Construction Manager). Integral color shall consist of colored admixtures developed for use in ready mixed concrete. The product shall be made of the highest quality pigments, as well as other ingredients designed to enhance the color and improve the pigment dispersion, workability and finishing performance of the concrete. Integral color pigments shall meet or exceed ASTM-C-979. The coloring method shall be designed for concrete flatwork applications (salt finished, broom finishes, rotary finishes), as well as vertical surfaces, and other types of architectural concrete. Pigment shall be a permanent coloration, uniform throughout the concrete surface and interior, and shall be highly UV and fade resistant. Integral colored concrete shall be cured with QC Color Cure color matched to the concrete (see product information bulletin). Provide sample panel submittals of all colors to be used in the installation on identical surfaces for approval by Resident Engineer. Contractor shall provide a maintenance schedule for integral colored concrete. July 2005 Page 6 of 115 Admixture for all integral colored concrete paving in medians and other integral colored concrete shall be the following: NOTES TO THE CONTRACTOR FOR SUPPLEMENTAL PROVISION 201-^ 1.2.4 and 201-1.2.6 Proposed retaining wall shall be poured with integral-colored concrete (color to be approved by City Planning Division). Architectural treatment shall conform to the San Marcos Ledger Stone Texture used on the Las Posas/SR 78 Interchange retaining walls (sample panel to be approved by Construction Manager). Admixture products and procedures for installation shall be in strict accordance with the manufacturer's specifications and recommendations, and those published by the American Concrete Institute (ACI) and the Portland Cement Association (PCA). 201-1.2.4 Chemical Admixtures, (e) Air-Entraining Admixtures. Substitute the following: The air content shall not deviate from the percentage specified or permitted by more than 1-1/2 percentage points. The air content of freshly mixed concrete will be determined by California Test Method No. 504. Add the following: 201-1.6 Finish: Random stone stamped pattern with heavy sandblast to match existing median paving. Add the following: 201-1.7 Miscellaneous Concrete Finishing Products. 201-1.7.1 Water Base Penetrating Sealer for Integral Colored Concrete. (Scofield Colorcure Concrete Sealer or approved equal) Water base penetrating sealer shall be a sealer designed for the protection of imprinted and natural concrete. Water base penetrating sealer shall be a sealer designed for the protection of imprinted, colored and natural concrete, and other masonry surfaces to preserve the natural appearance of the masonry without darkening or adding gloss to the surface. It shall preserve the natural slip resistance of the concrete, etc. Sealer shall repel spills and soils, minimizing staining and maintenance. Seal shall leave no visible material on the surface and shall be absorbed and locked into the pores of the masonry, repelling liquids and soils but leaving the top surface natural in appearance. Install per manufacturer's directions. Seal shall be compatible with the surfaces and materials which it is applied. Concrete sealer shall conform to the following specifications: Color: As specified Odor: Mild Flash Point:None (C.O.C. method) Specific Grav.: 1.03 Density: 8.6 pounds per gallon Drying Tune: 30 minutes to 60 minutes Cure Time: 24 to 48 hours VOC Content: None (0 g/1) excluding water Polymer Type: Proprietary Reactive Resin System Coverages (approximate): Smooth Concrete: 300 to 400 square feet per gallon Rough Concrete: 200 to 300 square feet per gallon Note: Coverages vary depending on porosity and condition of surface and method of application. Method of: Airless sprayer. Application Manufacturer: Scofield Chromix Admixtures for color-conditioned concrete, or approved equal L.M. Scofield Company, 6533 Bandini Boulevard, Los Angeles, CA 90040 1-800-800-9900 July 2005 Page 7 of 115 All materials shall be furnished, prepared, applied, cured, and stored according to the product manufacturer's direction. 201-1.2.4 Chemical Admixtures. (e) Air-entraining Admixtures. Substitute the following: The air content shall not deviate from the percentage specified or permitted by more than 1-1/2 percentage points. The air content of freshly mixed concrete will be determined by California Test Method No. 504. 201-3 EXPANSION JOINT FILLER AND JOINT SEALANTS. Add the following: 201-3.4 Type "A" Sealant (Two-Part Polyurethane Sealant). Add the following: All finished concrete surfaces shall have a '/£" continuous expansion joint at locations indicated on the plans and notes and shall be located either parallel to perpendicular to the curb line. When not otherwise indicated, all expansion joints located adjacent to colored concrete shall be sealant Type "A" and colored to match the color of the concrete surface. Contractor shall provide joint sealants that have been produced and installed to establish and to maintain watertight and airtight continuous seals without causing staining or deterioration of joint substrates. Contractor shall submit product data from the manufacturer of each joint sealant product required, including instructions for joint preparation and joint sealer application. Contractor shall also submit samples for initial selection purposes in form of manufacturer's standard bead samples, consisting of strips of actual products showing full range of colors available, for each product exposed to view. Samples shall be submitted to Engineer. Submit complete schedule of type (and location where type is to be used) of each sealant. Contractor shall engage an experienced installer who has completed joint sealant applications similar in material, design and extent to that indicated for Project that have resulted in construction with a record of successful in-service performance. Provide joint sealants, joint fillers, and other related materials that are compatible with one another and with joint substrates under conditions of service and application, as demonstrated by sealant manufacturer based on testing and field experience. Provide color selections made by Engineer from manufacturer's full range of standard colors for products of type indicated. Sealant color parallel to curbline shall match color of Paving Treatment Type "A" as specified in Section 201-1.2.4(a) of these Special Provisions. Joint sealants shall be multi-component polyurethane sealant. Except as otherwise indicated, provide manufacturer's standard, non-modified, 2-or-more-part, polyurethane-based, elastomeric sealant; complying with either ASTM-C-920-87, Type M, Grade P, Class 25, or FS TT-S 0227E Class A, non-sag, Type II. Acceptable Products: "Sonneborn NPH"; Sonnebom Building Products Division; "Scofield Lithoseal Trafficalk 3-G", L.M. Scofield Company; or equivalent, as approved by the Engineer. Provide sealant backings of material and type that are nonstaining; are compatible with joint substrates, sealants, primers and other joint fillers; and are approved for applications indicated by sealant manufacturer based on field experience and laboratory testing. Plastic foam joint fillers shall be preformed, compressible, resilient, nonstaining, nonwaxing, nonextruding strips of flexible plastic foam either open-cell polyurethane foam or closed-cell polyethylene foam, subject to approval of sealant manufacturer, for cold-applied sealants only. Polystyrene foam is not acceptable. July 2005 Page 8 of 115 SECTION 203 - BITUMINOUS MATERIALS 203-6 ASPHALT CONCRETE. DELETE sections 203-6.2 and 203-6.3.2 and ADD the following: 203-6.1 General. Add the following: The Contractor shall submit a design mix report and verification data for review by the Engineer for each source of supply and type of mixture specified. The design mix report shall indicate the results of all testing requirements identified in sections 203-1.2 and 203-6.3 of the standard specifications for public works construction and these special provisions. 203-6.2 Materials. Add the following: Asphalt concrete shall be class C2-AR-4000 for surface course, and B- AR-4000 for base course. Asphalt concrete shall be class D2-AR-8000 for dikes and class E-AR-8000 ditches. 203-6.3.2 Composition and Grading. Add the following: Evaluation of asphalt concrete shall be determined from samples of asphalt concrete taken after completion of all processing (Wet Mix) or by core sample analysis of the in-place asphalt concrete or by direct central plant inspection that confirms the production of a particular mix design and verifies using samples of aggregate taken before the addition of asphalt and mineral1 filler (Bin). All samples shall be taken in accordance with Calif. Test 125. When Wet Mix or Core samples of asphalt concrete are to be used for evaluation, sufficient size samples shall be taken to ensure representative and adequate quantity of material for: 1. Asphalt Content and Gradation of Extraction using Calif. Test 382 or ASTM 2172, and Calif. Test 202. 2. Stability1 using: a. Stabilometer Value2 using Calif. Test 366 and shall be the average of three individual Stabilometer Values And/or b. Marshall Stability in accordance with the Asphalt Institute's MS-2 fabricated and tested for traffic volume and shall be the average of three specimens. 'Stability will be waived provided the extracted asphalt concrete is within +/-.S of mix design and the extracted gradation complies with Table 203-6.3.2 (A). 2Use Marshall Stability when the deviation between individual Stabilometer Values are greater than +/-4. When using core sample analysis, the samples must be properly prepared to safeguard against influx of outside contaminates and so that the cut surfaces do not influence the test results. The amount of asphalt binder used in asphalt concrete placed in dikes, gutters, gutter flares, overside drains and aprons at the ends of drainage structures shall be increased one percent by mass of the aggregate over the amount of asphalt binder determined for use in asphalt concrete placed on the traveled way. 203-6.3.3 Acceptance. Wet Mix or Core sampled asphalt concrete will be considered in conformance with the mix design when the asphalt content is within +/-.S of the design mix and the gradation conforms to the grading as shown hi Table 203-6.3.2 (A). Deviations in gradation may be considered in conformance with the mix design provided the stability of the completed mix complies with the requirements for Stabilometer Value per Table 203-6.3.2 (A) Marshall Stability using Asphalt Institute MS-2. Plant inspected asphalt concrete will be considered in conformance with the mix design when visually inspected and the combined gradation of the Bin samples show conformance to the grading as shown in Table 203-6.3.2 (A). J uly 2005 Page 9 of 115 203-6.6.2, Batch Plant Method, modify as follows: Third paragraph, last sentence, delete "and from the Engineer's field laboratory". Last paragraph, add after D 2172: "method A or B." 203-6.7 Asphalt Concrete Storage, add the following: Open graded asphalt concrete stored in excess of 2 hours, and any other asphalt concrete stored in excess of 18 hours, shall not be used in the work. 203-11 ASPHALT RUBBER HOT MIX (ARHM) WET PROCESS 203-11.3 Composition and Grading. Add the following: Asphalt Rubber Hot Mix shall be class ARHM- GG-C. Add the following section: 203-13 ASPHALT PAVEMENT CRACK SEALANTS 203-13.1 Elastomeric Sealant. Elastomeric sealant shall be a polyurethane material of a composition that will, within its stated shelf life, cure only in the presence of moisture. No elastomeric sealant shall be incorporated into any portion of the work that is beyond the shelf life recommended by its manufacturer. No elastomeric sealant shall be incorporated into any portion of the work that has been stored under conditions not recommended by its manufacturer. Sealant shall be suitable for use in both asphalt concrete and portland cement concrete. The cured sealant shall have the performance characteristics in Table 203-13(A). TABLE 203-13.1(A) ELASTOMERIC SEALANT CHARACTERISTICS Property Hardness (indentation) Tensile Strength Elongation Flex at -40°C Weathering Resistance Salt-Spray Resistance Dielectric Constant Measuring Standard (ASTM Designation) ASTM D 2240 Rex. Type A, Model 1700 ASTM D 41 2 Die C, ASTM D 41 2 Die C, 0.6 mm (25 mil) Free Film Bend (180°) ASTM D 822 Weatherometer 350 h ASTMB 117 28 days at 38°C ASTM D 150 Results 65-85 3.45 MPa, minimum 400%, minimum No cracks Slight chalking 3.45 MPa, minimum tensile; 400% minimum Elongation Less than 25% change Conditions 25°C @ 50% relative humidity pulled at 508 mm (20") per minute pulled at 508 mm (20") per minute over 13 mm (V2") Mandrel Cured 7 days at 25°C @ 50% relative humidity 5% NaCl, Die C, pulled at 508 mm (20") per minute over a temperature range of - 30-^C to 5Q~*>C 203-13.2 Asphaltic Emulsion Sealant. Asphaltic emulsion sealant shall conform to the State of California Specification 8040-41A-15 and shall be used only for filling slots in asphalt concrete pavement. This material shall not be used in slots which exceed 16 mm (5/8") hi width or where the slope causes the material to run from the slot. The material shall not be thinned in excess of the manufacturer's recommendations and shall not be placed when the air temperature is less than 7°C (45°F). 203-13.3 Hot-Melt Rubberized Asphalt Sealant. Hot-melt rubberized asphalt shall be in solid form at room temperature and fluid at an application temperature of 190°C (375°F) to 205°C (400°F). Fumes from the material shall be non-toxic. Sealant shall be suitable for use in both asphalt concrete and portland cement concrete. Performance characteristics of the cured hot-melt rubberized asphalt shall be as per Table 203-13.3(A). July 2005 Page 10 of 115 TABLE 203-13.3(A) CURED HOT-MELT RUBBERIZED ASPHALT Property Cone Penetration Flow, 60°C Resilience Softening Point, Ductility, Flash Point, COC, °C Viscosity, Brookfield Thermosel, Measuring Standard (ASTM Designation) ASTM D 3407, Sec. 5 ASTM D 3407, Sec. 6 ,ASTM D 3407, Sec. 8 ASTM D 36 ASTM D 113 ASTM D 92 ASTM D 4402 Results 3.5 mm, max. 5 mm, max. 25%, min. 82 °C, min. 300 mm, min. 288 °C, min. 2.5-3.5 Pa-s Conditions 25°C, 150g, 5s 25°C 25°C, 50 mm/min No. 27 Spindle, 20 rpm, 190°C, SECTION 204 - LUMBER AND TREATMENT WITH PRESERVATIVES 204-1 LUMBER AND PLYWOOD TABLE 204-1.2(A) add the following: TABLE 204-1.2(A) USES Headers for bituminous pavement up to 50 mm x 1 00 mm (2"x4") Headers for bituminous pavement larger than 50 mm x 100mm (2"x4") GRADES Construction grade Redwood or preservative treated construction grade Douglas Fir Number 1 grade Redwood, or preservative treated number 1 grade Douglas Fir SECTION 205 - PILES 205-3 CONCRETE PILES 205-33.2 Piles Cast in Drilled Holes, add the following: The borings for this project encountered a massive hard rock or rock-like material (see Borings B-l and B-2 by GEOCON Inc.) between Elevations 575'± and 579'±. The Contractor shall bring drilling equipment of proper size and type capable of drilling or coring this material and maintain a stable hole to the design pile tip elevations shown on the plans. SECTION 206 - MISCELLANEOUS METAL ITEMS Add the following section: 206-7 TRAFFIC SIGNS. Add the following section: 206-7.1 Permanent Traffic Signs Permanent traffic signs shall consist of 10-gage and 12-gage cold-rolled steel perforated tubing. This includes all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic upon the completion of the Work unless otherwise shown on the plans. Add the following section: 206-7.1.1 General. Materials, legend, proportion, size, and fabrication of all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall conform to the requirements of "SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993", Sheets 1 through 5 thatoJuly 2005 Page 11 of 115 accompany "SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993" of dimensions and details, dated April 1987, and "OPAQUE COLOR CHART", dated February 1980, all published by the State of California, Department of Transportation, Division of Procurement Services, Office of Material Opera 1900 Royal Oaks Drive, Sacramento, CA 95819 and as modified herein. Where the "SPECIFICATION REFLECTIVE SHEETING SIGNS, October 1993" require the Contractor or supplier to notify the Department of Transportation or to certify compliance to said SPECIFICATIONS, to provide a quality control program or to allow testing, approval, observation of manufacturing or assembly operations by the State of California, Department of Transportation and/or its employees or officials, such rights shall be vested in the Engineer. Add the following section: 206-7.1.2 Sign Identification. Modify the "SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993" as follows: Sign identification shall be as per "SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993", except that the notation shall be "PROPERTY OF THE CITY OF SAN MARCOS". Add the following section: 206-7.13 Drawings. Modify the "Specifications For Reflective Sheeting Signs, October 1993" as follows: Standard signs shall be as per the most recently approved "Approved Sign Specification Sheets" of the State of California, Department of Transportation. The date of approval shall be the date most closely preceding the date of manufacture of the sign(s) or the date of the "Notice to Proceed" of this contract, whichever is most recent. Add the following section: 206-7.1.4 Reflective Sheeting. Modify the "Specifications For Reflective Sheeting Signs, October 1993" as follows: All advisory signs, warning signs and all regulatory signs shall be fabricated with Type HI encapsulated lens sheeting conforming to the requirements of this specification. Add the following section: 206-7.1.5 Substrate. Modify the "Specifications For Reflective Sheeting Signs, October 1993" as follows: All permanent traffic signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall use aluminum substrate. Add the following section: 206-7.1.6 Mounting Traffic Signs. Traffic signs shall be installed on 10-gage or 12-gage cold-rolled steel perforated tubing posts as shown on San Diego Regional Standard drawing M-45 or, when the sign area exceeds the maximum area allowed for on that drawing, on multiple 10-gage or 12-gage cold-rolled steel perforated tubing posts. The number of posts shall be determined by the parameters hi SDRS drawing M-45 or as approved by the Engineer. Traffic signs will be provided with back braces and mounting blocks as approved by the Engineer consisting of 10-gage or 12-gage cold-rolled steel perforated tubing when multiple posts are used. Add the following section: 206-7.1.6 Traffic Sign Posts. Posts shall be constructed of 10-gage or 12-gage cold-rolled steel perforated tubing posts as shown on San Diego Regional Standard drawing M-45. Add the following section: 206-7.2 Temporary Traffic Signs. Temporary traffic signs shall consist of all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic during the Contractor's performance of the Work. Temporary traffic signs include both stationary and portable signs. Add the following section: 206-7.2.1 General. Materials, legend, proportion, size, and fabrication of all temporary traffic signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall conform to the requirements of "Specifications For Reflective Sheeting Signs, October 1993", Sheets 1 through 5 that July 2005 Page 12 of 115 accompany "Specifications For Reflective Sheeting Signs, October 1993" of dimensions and details, dated April 1987, and "OPAQUE COLOR CHART", dated February 1980, all published by the State of California, Department of Transportation, Division of Procurement Services, Office of Material Operations, 1900 Royal Oaks Drive, Sacramento, CA 95819 and as modified herein. Where The "Specification For Reflective Sheeting Signs, October 1993" require the Contractor or supplier to notify the Department of Transportation or to certify compliance to said "Specifications For Reflective Sheeting Signs, October 1993", to provide a quality control program or to allow testing, approval, observation of manufacturing or assembly operations by the State of California, Department of Transportation and/or its employees or officials, such rights shall be vested in the Engineer. Add the following section: 206-7.2.2 Drawings. Modify the "Specifications For Reflective Sheeting Signs, October 1993" as follows: Standard temporary traffic signs shall be as per the most recently approved "Approved Sign Specification Sheets" of the State of California, Department of Transportation. The date of approval shall be the date most closely preceding the date of manufacture of the sign(s) or the date of the "Notice to Proceed" of this contract, whichever is most recent. Add the following section: 206-7.2.3 Reflective Sheeting. Modify the "Specifications For Reflective Sheeting Signs, October 1993" as follows: All advisory signs, warning signs and all regulatory signs shall be fabricated with Type in encapsulated lens sheeting conforming to the requirements of this specification. Add the following section: 206-7.2A Substrate. Modify the "Specifications For Reflective Sheeting Signs, October 1993" as follows: Excepting only construction warning signs used at a single location during daylight hours for not more than five (5) consecutive days, all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall be stationary mounted and shall use aluminum substrate. Add the following section: 206-7.2.5 Stationary Mounted Temporary Traffic Signs. Stationary mounted temporary traffic signs shall be installed on 10-gage and 12-gage cold-rolled steel perforated tubing posts in the same manner shown on the State of California, Department of Transportation "Standard Plans" 1995 edition standard plans numbers RSI, RS2, RS3 and RS4 for installation of roadside signs, except as follows: a) Wood posts shall not be used. b) Back braces and blocks for sign panels will not be required. c) The height to the bottom of the sign panel above the edge of traveled way shall be at least 2.1 m d) Unless otherwise shown on the plans traffic sign posts shall conform in materials and installation to SDRS drawing M-45 and shall have one post provided for each 0.48 m2 (5 ft2)of sign area, or the signs may be installed on existing lighting standards when approved by the Engineer. e) Sign panels mounted on temporary traffic sign posts shall conform to the requirements specified for aluminum signs in the "Specifications For Reflective Sheeting Signs, October 1993". Add the following section: 206-7.2.6 Temporary Traffic Sign Posts. Posts shall be 10-gage or 12-gage cold-rolled steel perforated tubing used for the support and stabilization of stationary mounted temporary signs. Post size and number of posts shall be as shown on the plans, except that when stationary mounted signs are installed and the type of sign installation is not shown on the plans, post size and the number of posts will be determined by the Engineer. Sign panels for stationary mounted signs shall consist of reflective sheeting applied to a sign substrate. Add the following section: 206-7.2.7 Portable Temporary Traffic Signs. Each portable temporary traffic sign shall consist of a base, standard or framework and a sign panel. The units shall be capable of being delivered to the site of use and placed in immediate operation. Sign panels for portable signs shall conform to the requirements of sign panels July 2005 Page 13 of 115 for stationary mounted signs in the "Specifications For Reflective Sheeting Signs, October 1993, or shall be cotton drill fabric, flexible industrial nylon fabric, or other approved fabric. Fabric signs shall not be used during the hours of darkness. Size, color, and legend requirements for portable signs shall be as described for, stationary mounted sign panels in section 206-7.2 of these Supplemental Provisions. The height to the bottom* of the sign panel above the edge of traveled way shall be at least 0.3-m (12"). All parts of the sign standard or framework shall be finished with 2 applications of orange enamel which will match the color of the sign panel background. Testing of paint will not be required. Add the following section: 206-8 LIGHT GAGE STEEL TUBING AND CONNECTORS. Add the following section: 206-8.1 General. This Section pertains to 10-gage and 12-gage cold-rolled steel perforated tubing used for the support and stabilization of signs. All shapes shall have a galvanized finish and shall be cold-roll-formed steel conforming to ASTM Designation A-446, Grade A. Galvanizing shall conform to ASTM A-525, Designation G-90. Galvanizing shall be performed after all forming and punching operations have been completed. Cold-rolled steel perforated tubing shall be perforated on all four faces with llmm (7/16") holes on 25 mm (1") centers. Add the following section: 206-8.2 Tolerances. Wall thickness tolerance shall not exceed +0.28 mm, -0.13 mm (+0.011", -0.005"). Convexity and concavity measured in the center of the flat side shall not exceed a tolerance of+0.25 mm (+0.010") applied to the specific size determined at the corner. Straightness tolerance variation shall not exceed 1.6 mm in 1 m (1/16 " in 3'). Tolerance for comer radius is 4.0mm (5/32"), plus or minus 0.40 mm (1/64"). Weld flash on corner-welded square tubing shall permit 3.60 mm (9/64") radius gage to be placed in the comer. Using 10-gage or 12-gage square tube, consecutive size tubes shall telescope freely for 3.1m (10'). Tolerance on hole size is plus or minus 0.40 mm (1/64") on a size. Tolerance on hole spacing is plus or minus 3.2 mm in 6.1 m (1/8" in 20')- hi addition, for the following specific sizes of light gage steel tubing, dimensional tolerances shall not exceed those listed in tables 206-8.2 (A) and 206-8.2(B). TABLE 206-8.2(A) LIGHT GAGE STEEL TUBING SIZE TOLERANCE Nominal Outside Dimensions mm (inches) 25x25 32x32 38x38 44x44 51x51 56x56 57x57 64x64 51 x76 (1x1) d'Atxl'A) (iVzxl'/z) (1% x !3/4) (2x2) (23/I6x23/16) (2'/4 x 2V4) (2'/2x2V2) (2x3) Outside Tolerance for All Sides at Corners mm (inches) 0.13 0.15 0.15 0.20 0.20 0.25 0.25 0.25 0.25 0.005 0.006 0.006 0.008 0.008 0.010 0.010 0.010 0.010 TABLE 206-8.2(8) LIGHT GAGE STEEL TUBING SQUARENESS OF SIDES AND TWIST Nominal Outside Dimension mm (Inches) 25x25 32x32 38x38 44x44 (1x1) (l-V4xl-l/4) (l-'/2xl-V2) (l-3/4Xl-3/4) Squareness'1' mm (Inches) 0.15 0.18 0.20 0.25 0.006 0.007 0.009 0.010 Twist Permissible in 900 mm (3") mm(2) (Inches)(2) 1.3 1.3 1.3 1.6 0.050 0.050 0.050 0.062 July 2005 Page 14 of 115 Nominal Outside Dimension mm (Inches) 51x51 56x56 57x57 64x64 51x76 (2x2) (2-3/16x2-V16) (2-V4 x 2-V4) (2-V2x2-V2) (2x3) Squareness(1) mm (Inches) 0.30 0.36 0.36 0.38 0.46 0.012 0.014 1.014 0.015 0.018 Twist Permissible in 900 mm (3") mm(2) (Inches)(2) 1.6 1.6 1.6 1.9 1.9 0.062 0.062 0.062 0.075 0.075 (1) (2) Tubing may have its sides failing to be 90 degrees to each other by the tolerance listed. Twist is measured by holding down the edge of one end of a square tube on a surface plate with the bottom side of the tube parallel to the surface plate, and noting the height that either corner on the opposite end of the bottom side is above the surface plate. Add the following section: 206-8.3 Fasteners. Fasteners used to assemble cold-rolled steel perforated tubing shall be steel "pull- through" electrogalvanized rivets with 9.5 mm (3/8") diameter shank, 22 mm (7/8") diameter head, and a grip range of from 5 mm (0.200") to 0.90 mm (0.356"). The fasteners shall conform to ASTM B-633, Type m SECTION 207 - PIPE 207-2 REINFORCED CONCRETE PIPE. 207-2.5 Joints. Add the following: When watertight joints are indicated on the plans they shall be of the rubber-gasketed type meeting the requirements of ASTM Standard Specification designations C 361-95 and C 443-94. Pipe designated in the plans as "pressure pipe" or with a 100-year hydraulic grade line at or above the soffit shall be bell and groove spigot joint with "O" rings conforming to ASTM C-443 and C-361 for the limits shown on the plans. Add the following section: 207-25 UNDERGROUND UTILITY MARKING TAPE. Add the following section: 207-25.1 Detectable Underground Utility Marking Tape: Detectable Underground Utility Marking Tape shall have a minimum 0.13 mm (0.005") overall thickness, with no less than a 35 gauge (AWG), 0.14 mm aluminum foil core. The foil must be visible from both sides. The layers shall be laminated together with the extrusion lamination process, not adhesives. No inks or printing shall extend to the edges of the tape. All printing shall be encased to avoid ink rub-off. Detectable Underground Utility Marking Tape shall conform to the properties listed in Tables 207-25(A) and 207-25 (B). TABLE 207-25.1(A) DETECTABLE UNDERGROUND UTILITY MARKING TAPE PROPERTD2S Property Thickness Tensile strength Elongation Printability Flexibility Inks Method ASTM D2103 ASTM D882 ASTM D882-88 ASTM D2578 ASTM D67 1-81 Manufacturing specifications Value 01 14 mm (0.0056") 4500g/cm (25 Ibs/inch) (5,500 PSI) <50 percent at break >50 dynes/square centimeter Pliable hand Heat-set Mylex July 2005 Page 15 of 115 Property Message repeat Foil Top layer Bottom layer Adhesives Bond strength Colors Method Manufacturing specifications Manufacturing specifications Manufacturing specifications Manufacturing specifications Manufacturing specifications Boiling H2O at 100 degrees Celsius APWA Code Value Every 500 mm(20") Dead soft/annealed ^ Virgin PET ™ Virgin LDPE >30 percent, solid 1.5#/R Five hours without peel See Table 207-25.1 (B) TABLE 207-25.1(B) DETECTABLE UNDERGROUND UTILITY MARKING TAPE COLORS Color Red Yellow Orange Blue Green Brown Purple Utility Marked Electric power, distribution, transmission, and municipal electric systems. Gas and oil distribution and transmission, dangerous materials, product and steam. Telephone and telegraph systems, police and fire communications, and cable television. Water systems. Sanitary and storm sewer systems, nonpotable. Force mains. Reclaimed water lines. Add the following section: 207-25.2 Materials Approvals. Detectable Underground Utility Marking Tape shall meet the requirements of each of the following agency/association publications. A. Department of Transportation, Materials Transportation Bureau, Office of Pipeline Safety. USAS code for pressure piping B31.8, paragraph 192.321(e). B. National Transportation Safety Board, Washington, DC, Special Study Prevention of Damage to Pipelines. Adopted June 7, 1974. Report NTSB-PSS-73-1. C. American Petroleum Institute (API). Recommended practice for marking buried liquid petroleum pipelines - APR RP 1109. D. General Services Administration, Washington, DC, Public Buildings Service Guide Specification for Mechanical and Electrical Equipment - PBS 4-1501, Amendment 2, Page 501-14, Paragraph 18, Subparagraph 18.1, Clause 18.1.1. E. Rural Electrification Authority (REA), U.S. Department of Agriculture, Washington, DC, National Electrical Safety Code for Underground Construction for remote and immediate hazards. SECTION 209 - ELECTRICAL COMPONENTS 209 ELECTRICAL COMPONENTS. Modify as follows: Section 209, "Signals, Lighting and Traffic Electrical Systems", herein, shall replace Section 209, "Electrical Components", of the SSPWC in all matters pertaining to the specifications for measurement, payment, warranty, and materials and methods of construction for all elements of street lighting and traffic signals. For electrical components provided and installed in systems not including street lighting and traffic signals section 209 SSPWC is unmodified except as specified in sections other than section 209, "Signals, Lighting and Electrical Systems", herein. For section 209, "Signals, Lighting and Traffic Electrical Systems", for all elements of street lighting and traffic signals both construction materials and construction methods have been combined into a single section. All work and equipment shall complywith the City of San Marcos "Traffic Signal Manual for New Signal Designs and Installation" as last updated. July 2005 Page 16 of 115 SECTION 209 - SIGNALS, LIGHTING AND TRAFFIC ELECTRICAL SYSTEMS 209-1 GENERAL 209-1.01 Description. Signals, lighting and electrical systems work shall consist of furnishing and installing, modifying or removing one or more traffic signals, traffic signal master controller assemblies and interconnection facilities, flashing beacon systems, lighting systems, sign illumination systems, traffic monitoring stations, communication systems, electrical equipment in structures, falsework lighting, provisions for future systems, or combinations thereof, all as shown on the plans, and as specified in these special provisions. The locations of signals, beacons, standards, lighting fixtures, signs, controls, services and appurtenances shown on the plans are approximate and the exact locations will be established by the Engineer in the field. All systems shall be complete and in operating condition at the time of acceptance of the contract. 209-1.015 Definitions. The following definitions pertain only to Section 209, "Signals, Lighting and Traffic Electrical Systems." Actuation. —The operation of any type of detector. Burn-In Procedure. — The procedure by which each LED signal module is energized for a minimum of 24 hours at operating voltage at a 100% duty cycle, and in an ambient temperature of 60°C (HOT). Candlepower Values. — Luminous intensity expressed in candelas (cd). Channel. — A discrete information path. Chromaticity (Color). — The color of the light emitted by a signal module, specified as x-y chromaticity coordinates on the chromaticity diagram according to the 1931 Commission Internationale d'Eclairage standard observer and coordinate system. The measured chromaticity coordinates shall fall within the limits specified in VTCSH Section 8.04 "Limits of Chromaticity Coordinates." Controller Assembly. — The complete assembly for controlling the operation of a traffic signal or other system, consisting of a controller unit, and all auxiliary equipment housed in a rainproof cabinet. Controller Unit. — That part of the controller assembly which performs the basic timing and logic functions. Detector. — A device for indicating the passage or presence of vehicles or pedestrians. Duty Cycle. — The amount of illuminated on-time a signal module is energized, expressed as a percent of signal cycle time period. Electrolier. — The complete assembly of lighting standard, luminaire, ballast and lamp. Flasher. — A device used to open and close signal circuits at a repetitive rate. Flashing Beacon Control Assembly. — A complete electrical mechanism for operating a warning beacon or intersection control beacon. Inductive Loop Vehicle Detector. — A detector capable of being actuated by the change of inductance caused by a vehicle passing over or standing over the loop. Integrating Photometer. — An instrument used in measuring the intensity of light that enables total luminous flux to be determined by a single measurement. LED Light Source. — An individual light emitting diode. LED Signal Module. — A sealed circular ball or arrow that includes the lens and utilizes LED devices as the light source. An LED signal module may directly replace an existing traffic signal lamp and lens combination. July 2005 Page 17 of 115 Lighting Standard.— The pole and mast arm which support the luminaire. Luminaire.— The assembly which houses the light source and controls the light emitted from the light source. Magnetic Vehicle Detector.— A detector capable of being actuated by the induced voltage caused by the passage of a vehicle through the earth's magnetic field. Magnetometer Vehicle Detector.— A detector capable of being actuated by the magnetic disturbance caused by the passage or presence of a vehicle. Major Street.— The roadway approach or approaches at an intersection normally carrying the major volume of vehicular traffic. Minimum Intensity. — In accordance with the values in Table 1 of the existing "Vehicle Traffic Control Signal Heads", hereinafter VTCSH standard, the minimum intensity values below which no LED signal modules will be released from the supplier. Minor Street.— The roadway approach or approaches at an intersection normally carrying the minor volume of vehicular traffic. Pedestrian Detector.— A detector, usually of the push button type, capable of being operated by hand. Plans. — For this Section (Section 209) plans shall include all documents listed in Section 2.5, "Plans and Specifications", et seq. as well as the "STANDARD PLANS", 2002 edition as promulgated by the State of California, Department of Transportation. Power Consumption. — The rms electrical power (watts) consumed by an LED signal module when operated at rated voltage. Pre-timed Controller Assembly.— A controller assembly for operating traffic signals in accordance with a pre-determined cycle length. Rated Initial Intensity. — The light intensity of a new LED signal module, operated at rated voltage, measured after the burn-in procedure with an integrating photometer. Rated Voltage. — The ac rms voltage at which light output performance and power consumption are specified (117 VAC at 60 Hz). Signal Face.— That part of a signal head provided for controlling traffic in a single direction and consisting of one or more signal sections. Signal Head.— An assembly containing one or more signal faces. Signal Indication.— The illumination of a signal section or other device, or of a combination of sections or other devices at the same time. Signal Section.— A complete unit for providing a signal indication consisting of a housing, lens, reflector, lamp receptacle and lamp. Sun Phantom. — The effect of an outside light source entering the signal assembly and being returned in such a manner as to present the appearance of the signal assembly being illuminated. Traffic-Actuated Controller Assembly. — A controller assembly for operating traffic signals in accordance with the varying demands of traffic as registered with the controller unit by detectors. Traffic Phase.— The right of way, change and clearance intervals assigned to a traffic movement or combination of movements. Vehicle.— Any motor vehicle normally licensed for highway use. VTCSH Standard. — The definitions and practices described in "Vehicle Traffic Control Signal Heads" published in the "Equipment and Materials Standards" of the Institute of Transportation Engineers. 209-1.02 Regulations and Code. All electrical equipment shall conform to the standards of the National Electrical Manufacturers Association (NEMA), the Underwriters' Laboratories Inc. (UL), the Electrical July 2005 Page 18 of 115 Testing Laboratories (ETL), the National Electrical Testing Association, Inc. (NETA), or the Electronic Industries Association (EIA), wherever applicable. In addition to the requirements of the plans, these special provisions, all materials and workmanship shall conform to the latest requirements of the National Electrical Code, hereinafter referred to as the Code; California Code of Regulations, Title 8, Chapter 4, Subchapter 5, Electrical Safety Orders; Rules for Overhead Electrical Line Construction, General Order No. 95 of the Public Utilities Commission; Standards of the American Society for Testing and Materials (ASTM); American National Standards Institute (ANSI); and any local ordinances which may apply. Wherever reference is made to any of the standards mentioned above, the reference shall be construed to mean the code, order, or standard that is in effect on the day the Notice to Contractors for the work is dated. 209-1.03 Equipment List and Drawings. Unless otherwise permitted in writing by the Engineer, the Contractor shall, within 15 days following award of the contract, submit to the Engineer for review a list of equipment and materials which the Contractor proposes to install as specified hi Section 2-5.3, "Shop Drawings and Submittals." The list shall be complete as to name of manufacturer, size and identifying number of each item. The list shall be supplemented by such other data as may be required, including schematic wiring diagrams and scale drawings of cabinets showing location and spacing of shelves, terminal blocks and equipment, including dimensioning. All of the above data shall be submitted, install as specified in Section 2- 5.3, "Shop Drawings and Submittals", for review. Where electrical equipment is constructed as detailed on the plans, the submission of detailed drawings and diagrams will not be required. The Contractor shall furnish 5 sets of controller cabinet schematic wiring diagrams made by (1) wet blueprint, white background process using iron-sensitized paper, (2) the offset lithograph process, or (3) the electrostatic process. The diagrams shall show the location of the installation and shall list all equipment installed in each controller cabinet. In addition, for each signal installation, the Contractor shall furnish an intersection sketch showing poles, detectors, field wire connection terminals and phasing as shown on the plans. All schematic wiring diagrams of the controller units and auxiliary equipment, all cabinet diagrams, and all operation manuals shall be submitted at the time the controller assemblies are delivered for testing. The schematic wiring diagram shall show in detail all circuits and parts. All parts shown thereon shall be identified by name or number and in such manner as to be readily interpreted. All diagrams, plans and drawings shall be prepared using graphic symbols shown in ANSI publication Y32.2, entitled "IEEE Standard and American National Standard Graphic Symbols for Electrical and Electronic Diagrams." 209-1.04 Warranties, Guaranties and Instruction Sheets. Manufacturers' warranties and guaranties furnished for materials used in the work and instruction sheets and parts lists supplied with materials shall be delivered to the Engineer prior to acceptance of the project. 209-1.05 Maintaining Existing and Temporary Electrical Systems. Existing electrical systems (traffic signal, street lighting, flashing beacon, traffic monitoring, sign illumination and other facilities), or approved temporary replacements thereof, shall be kept in effective operation for the benefit of the traveling public during the progress of the work, except when shutdown is permitted, to allow for alterations or final removal of the systems. The traffic signal shutdowns shall be limited to normal working hours. Lighting system shutdowns shall not interfere with the regular lighting schedule, unless otherwise permitted by the Engineer. The Contractor shall notify the Engineer prior to performing any work on existing systems. The Contractor shall notify the local traffic enforcement agency prior to any operational shutdown of a traffic signal. Where an existing system or temporary system is being modified, work not shown on the plans or specified hi these special provisions and which is considered by the Engineer as necessary to keep all or any part of the system in effective operation will be paid for as extra work as provided hi Section 3-3 "Extra Work.". The Agency will: 1) Continue the operation and maintenance of existing electrical facilities. 2) Continue to provide for electrical energy for the operation of existing electrical facilities. 3) Repair or replace existing facilities damaged by public traffic. 4) Pay the cost of electrical energy for the operation of existing or new facilities that are undergoing the functional tests described in Section 209-2.14C, "Functional Testing." The Contractor shall ascertain the exact location and depth of existing detectors, conduits, pull boxes and other electrical facilities before using any tools or equipment that may damage those facilities or interfere with any July 2005 Page 19 of 115v electrical system. Where damage is caused by the Contractor's operations, the Contractor shall, at the Contractor's expense, repair or replace damaged facilities promptly in accordance with these specifications. If any existing loop conductor, including the portion leading to the detector hand hole or termination pull box, is> damaged by the Contractor's operations, the Contractor shall immediately notify the Engineer. The affected* detectors shall be replaced at the Contractor's expense and as directed by the Engineer within 24 hours. If the Contractor fails to complete the repairs within this period, the repairs will be made by Agency forces at the Contractor's expense. Should the Contractor fail to perform the required repairs or replacements, the cost of performing the repairs or replacements will be deducted from any moneys due or to become due the Contractor. Where roadways are to remain open to traffic and existing lighting systems are to be modified, the lighting systems shall remain in operation and the final connection to the modified circuit shall be made so that the modified circuit will be in operation by nightfall of the same day. Temporary electrical installations shall be kept in effective operation until the temporary installations are no longer required for the traveling public. Removal of temporary installations shall conform to the provisions in Section 209-7, "Removing, Reinstalling or Salvaging Electrical Equipment." These provisions will not relieve the Contractor in any manner of the Contractor's responsibilities as provided in Sections 4-1.1, "General" and 4-1.2, "Protection of Work and Materials." During traffic signal system shutdown the Contractor shall place "STOP AHEAD" and "STOP" signs to direct vehicle and pedestrian traffic through the intersection. All signal faces shall be covered when the system is shut down overnight. Temporary "STOP AHEAD" and "STOP" signs shall be either covered or removed when the system is turned on. "STOP AHEAD" and "STOP" signs shall be furnished by the Contractor and shall conform to the provisions in Section 7-10.3, "Street Closures, Detours, Barricades." Minimum size of "STOP" signs shall be 750 mm (30"). One "STOP AHEAD" sign and one "STOP" sign shall be placed for each direction of traffic. For two, or more, lane approaches, two "STOP" signs shall be placed for each direction of traffic. Location of the signs shall be as directed by the Engineer. 209-1.06 Scheduling of Work. No above ground work, except service equipment, shall be performed until the Contractor has all materials on hand to complete that particular signal location or lighting circuit. Work shall be so scheduled that each traffic signal, lighting and sign illumination system shall be completed and ready for operation prior to opening the corresponding section of the roadway to traffic. Traffic signals shall not be placed in operation for use by public traffic without the written approval of the Engineer. The Contractor shall obtain the written approval of the Engineer no less than three days prior to placing any traffic signal in operation. Traffic signals shall not be placed in operation for use by public traffic without the energizing of street lighting at the intersection to be controlled if street lighting exists or is being installed in conjunction with the traffic signals. Traffic signals shall not be placed in operation until the roadways to be controlled are open to public traffic, unless otherwise directed by the Engineer. Lighting and traffic signals shall not be placed in operation, including flashing operation, prior to commencement of the functional test period specified in Section 209-2.14, "Testing," unless ordered otherwise by the Engineer. Conductors shall not be pulled into conduit until pull boxes are set to grade, crushed rock sumps installed and metallic conduit bonded. In vehicular undercrossings, soffit lights shall be placed in operation as soon as practicable after falsework has been removed from the structure. Lighting for pedestrian structures shall be placed in operation prior to opening the structure to pedestrian traffic. If the Engineer orders soffit lights or lighting for pedestrian structures placed in operation before permanent power service is available, the cost of installing and removing temporary power service will be paid for as extra work as provided in Section 3-3, "Extra Work." The initial turn-on shall be made only between the hours of 9:00 a.m. and 2:00 p.m. and Tuesday through Thursday unless otherwise approved, hi writing, by the Engineer. Prior to turn-on, all equipment as shown on the plans shall be installed and operable including pedestrian signals, pedestrian push buttons, vehicle detectors, lighting, signs and pavement delineation. All louvers, visors, and signal faces shall be directed to J uly 2005 Page 20 of 115 provide maximum visibility. Functional tests shall start on any working day except Friday, or the day preceding a legal holiday. 209-1.07 Safety Precautions. Attention is directed to Section 7-10.4.1, "Safety Orders." Before starting work on existing series street lighting circuits, the Contractor shall obtain daily a safety circuit clearance from the serving utility. By-pass switch plugs shall be pulled and "Men at Work" signs posted at switch boxes before any work is done. 209-2 MATERIALS AND INSTALLATION 209-2.01 Excavating and Backfilling. The excavations required for the installation of conduit, foundations, and other appurtenances shall be performed in such a manner as to avoid any unnecessary damage to streets, sidewalks, landscaping, and other improvements. The trenches shall not be excavated wider than necessary for the proper installation of the electrical appurtenances and foundations. Excavation shall not be performed until immediately before installation of conduit and other appurtenances. The material from the excavation shall be placed in a position that will not cause damage or obstruction to vehicular and pedestrian traffic nor interfere with surface drainage. Unless otherwise permitted in writing by the Engineer, all surplus excavated material shall be removed and disposed of, within 48 hours, outside the public right of way in accordance with the provisions in Sections 7- 8.1, "Cleanup and Dust Control", 300-1.3, "Removal and Disposal of Materials" and 302-6, "Surplus Material", depending on the origin and nature of the materials to be removed and disposed. The excavations shall be backfilled in conformance with the provisions in Sections 300-3.5, "Structure Backfill" or 306-1.3, "Backfill and Densification," depending on the nature of the structure or conduit that the excavation being backfilled accommodates. Excavations after backfilling shall be kept well filled and maintained in a smooth and well-drained condition until permanent repairs are made. All excavations shall be filled, and sidewalks, pavement, and landscaping restored at each intersection prior to excavating at any other intersection, unless otherwise permitted by the Engineer. Excavations in the street or highway shall be performed in such a manner that not more than one traffic lane is restricted at any time, unless otherwise approved by the Engineer. 209-2.02 Removing and Replacing Improvements. In addition to the requirements of sections 7-9, "Protection and Restoration of Existing Improvements" and 306-1.5, "Trench Resurfacing" Improvements such as sidewalks, curbs, gutters, portland cement concrete and asphalt concrete pavement, underlying material, lawns and plants, and any other improvements removed, broken or damaged by the Contractor's operations, shall be replaced or reconstructed with the same kind of material as found on the work or with materials of equal quality. The new work shall be left in a serviceable condition. Whenever a part of a square or slab of existing concrete sidewalk, curb, gutter, or driveway is broken or damaged, the entire square, section or slab shall be removed and the concrete reconstructed as above specified. The outline of all areas to be removed in portland cement concrete sidewalks and driveways and in pavements shall be cut to a minimum depth of 50 mm (2") with an abrasive type saw prior to removing the sidewalk, driveways and pavement material. Cuts shall be neat and true along score lines, with no shatter outside the removal area. 209-2.03 Foundations. Portland cement materials and construction methods shall conform to Section 201, "Concrete, Mortar and Related concrete Materials," for Materials and Section 303, "Concrete and Masonry Construction," for construction methods. Concrete foundations shall rest on firm ground. Except when located on structures, foundations for posts, standards, and pedestals, not shown on the plans to have mortar pads, shall be placed "in the solid" and monolithic except for the top 50 mm (2") which shall be placed after the post, standard or pedestal is in proper position. After each post, standard, or pedestal on structures, and each standard shown on the plans to have mortar pads, is in proper position, mortar shall be placed under the base plate as shown on the plans. The exposed portions shall be formed to present a neat July 2005 Page 21 of 115 appearance. Mortar shall consist of one part by volume of portland cement and 3 parts of clean sand, shall contain only sufficient moisture to permit packing and shall be cured by keeping it damp for 3 days. Reinforced cast-in-drilled-hole concrete pile foundations for traffic signal and lighting standards shall conform^ to the provisions in Section 205-3.3, "Cast-in-Place Concrete Piles," except that material resulting from drilling holes shall be disposed of as provided in Section 209-2.01, "Excavating and Backfilling." The exposed portions of the foundation shall be formed to present a neat appearance. Forms shall be true to line and grade. Tops of foundations for posts and standards, except special foundations, shall be finished to curb or sidewalk grade or as directed by the Engineer. Forms shall be rigid and securely braced in place. Conduit ends and anchor bolts shall be placed in proper position and to proper height, and shall be held in place by means of a template until the concrete sets. Anchor bars or studs and nuts, except for Type 30 and Type 31 lighting standards, shall conform to ASTM Designation: A 307. Headed anchor bolts for foundations shall conform to the specifications of ASTM Designation: A 307, Grade B with SI supplementary requirements. At the option of the Contractor, nonheaded anchor bolts for foundations shall conform either to the specifications of ASTM Designation: A 307, Grade C or to the provisions in AASHTO Designation: M 314, Grade 36 or 55 with SI supplementary requirements. When nonheaded anchor bolts conforming to the specifications of ASTM Designation: A 307, Grade C are furnished, the end of each fabricated anchor bolt shall be either coded by end stamping as required in ASTM Designation: A 307 or the end that projects from the concrete shall be permanently coded with a green color by the manufacturer. High strength anchor bolts, bars, or studs for Type 30 and Type 31 lighting standards shall conform to ASTM Designation: A 325, A325M or A 449 and shall comply with the me- chanical requirements of ASTM Designation: A 325 or A 325M after galvanizing. Nuts and washers for high strength anchor bolts shall conform to ASTM Designations: A 563 or A 563M, and F 476 or F 476M, re- spectively. In addition to the requirements of ASTM Designation: A 449, studs shall be marked on either end as required for bolt heads. All steel parts shall be galvanized in accordance with the provisions in Section 210- 3.6, "Galvanizing for Traffic Signal Facilities." The upper threaded portion of all anchor bolts shall be provided with 2 nuts and 2 washers each. Anchor bars or studs shall be provided with 3 nuts and washers each. Welding shall not be performed on any portion of the body of high-strength anchor bolts, anchor bars, or studs. Plumbing of the standards shall be accomplished by adjusting the leveling nuts before placing mortar or before the foundation is finished to final grade. Shims, or other similar devices shall not be used for plumbing or raking of posts, standards or pedestals. Both forms and ground which will be in contact with the concrete shall be thoroughly moistened before placing concrete. Forms shall not be removed until the concrete has thoroughly set. Ordinary surface finish, as specified in Section 303-1.9.2, "Ordinary Surface Finish," shall be applied to exposed surfaces of concrete. Where obstructions prevent the construction of a planned foundation, the Contractor shall construct an effective foundation as directed by the Engineer. The foundations shown on the plans shall be extended if conditions require additional depth, and the additional work, if ordered by the Engineer, will be paid for as extra work as provided in Section 3-2, "Changes Initiated By The Agency." Unless otherwise specified or shown on the plans, foundations not to be reused shall be removed. When a foundation is shown on the plans to be abandoned, the top of foundation, anchor bolts, and conduits shall be removed to a depth of not less than 1 .0 m (3 ') below surface of sidewalk or unimproved ground. The resulting hole shall be backfilled with material equivalent to the surrounding material. Unless otherwise shown on the plans, all standards to be relocated shall be provided with new foundations and anchor bolts of the proper type and size. Posts, poles, standards, pedestals, and cabinets shall not be erected until the foundation has set at least 7 days, and shall be plumbed or raked, as directed by the Engineer. In unpaved areas, a 1 .0 m (3') square, 1 00 mm (4") thick or of the size shown on the plans, whichever is the larger, raised pad of portland cement concrete shall be placed in front of each controller cabinet. July 2005 Page 22 of 1 1 5 209-2.04 Standards, Steel Pedestals and Posts. Standards for traffic signals and lighting, and steel pedestals for cabinets and other similar equipment shall be located as shown on the plans. Workmanship and finish shall be equal to the best general practice of metal fabrication shops. All welding shall conform to AWS Dl.l, "Structural Welding Code," and to the requirements in this Section 209-2.04. All welds joining the shafts of the standards and mast arms to their base plates shall be as shown on the plans, however, alternative weld joint details may be approved by the Engineer. Approval of alternative weld joint details will be contingent upon the proposed weld joint passing both weld procedure and nondestructive testing as deemed necessary by the Engineer. All costs of the supplemental testing shall be borne by the Contractor. All standards except Type 1, and all signal mast arms, shall have an aluminum identification plate, as noted on the plans, attached with stainless steel rivets or screws. Type 1 standards and steel pedestals for controller cabinets shall be constructed of 3 mm (.125") or thicker galvanized steel; or 100 mm (4") standard weight galvanized, steel pipe or Size 103, Type 1 conduit, with the top designed for post-top slip-fitter. Standard weight galvanized, steel pipe shall conform to the specifications of ASTM Designation: A 53. Materials and construction methods for all ferrous metal parts of standards, with shaft length of 4.6 m (15') and longer, shall conform to the details shown on the plans, the requirements of Sections 206, "Miscellaneous Metal Items," for Materials and Section 304, "Metals Fabrication and Construction," for construction methods except as otherwise noted, and the following requirements: Except as otherwise specified, standards shall be fabricated from sheet steel of weldable grade having a minimum yield strength, after fabrication, of 276 Mpa (40,000 psi). Certified test reports which verify conformance to the minimum yield strength requirements shall be submitted to the Engineer. The test reports may be the mill test reports for the as-received steel or, when the as-received steel has a lower yield strength than required, the Contractor shall provide supportive test data which provides assurance that the Contractor's method of cold forming will consistently increase the tensile properties of the steel to meet the specified mini- mum yield strength. The supportive test data shall include tensile properties of the steel both before and after cold forming for specific heats and thicknesses. When a single-ply 8 mm (0.3125") thick pole is specified, a 2-ply pole with equivalent section modulus may be substituted. Standards may be fabricated of full-length sheets or shorter sections. Each section shall be fabricated from not more than 2 pieces of sheet steel. Where 2 pieces are used, the longitudinal welded seams shall be directly opposite one another. When the sections are butt-welded together, the longitudinal welded seams on adjacent sections shall be placed to form continuous straight seams from base to top of standard. Butt-welded transverse joints shall be strengthened by inserting a metal sleeve at each joint. The sleeve shall be 3 mm (0.120") nominal thickness, or thicker, steel having the same chemical composition as the steel in the standard. When the sections to be joined have different specified minimum yield strengths, the steel in the sleeve shall have the same chemical composition as the higher minimum yield strength steel to be joined. The metal sleeve shall have a minimum length of 25 mm. The sleeve shall be centered at the joint and have the same taper as the standard with the outside of the sleeve in full contact with the inside of the standard throughout the sleeve length and circumference. All welds shall be continuous. The weld metal at the transverse joint shall extend to the sleeve, making the sleeve an integral part of the joint. Longitudinal welds in steel tubular sections will be tested in accordance with California Test 664. The sampling frequency shall be as determined by the Engineer. The welds may be made by the electric resistance welding process. All exposed welds, except fillet and fatigue resistant welds and welds on top of mast arms, shall be ground flush with the base metal. All exposed edges of the plates which make up the base assembly shall be finished smooth and all exposed corners of the plates shall be neatly rounded unless otherwise shown on the plans. Shafts shall be provided with slip-fitter shaft caps. Standards shall be straight, with a permissive variation not to exceed 25 mm (1") measured at the midpoint of a 9 m (30') or 11 m (36') standard and not to exceed 20 mm (3/4") measured at the midpoint of a 5 m (17') through 6 m (20') standard. Variation shall not exceed 25 mm (1") at a point 4.5 m (15') above the base plate for Type 35 and Type 36 standards. All galvanized nuts, used on assemblies with a specified preload or torque, shall be lubricated in accordance with the requirements specified for galvanized Grade DH nuts in ASTM Designation: A 563 or A 563M. July 2005 Page 23 of 115 Standards with an outside diameter of 300 mm (12") or less shall be round. Standards with an outside diameter greater than 300 mm (12") shall be round or multisided. Multisided standards shall have a minimum of 10 sides which shall be convex and shall have a minimum bend radius of 100 mm (4"). Mast arms for standards, shall be fabricated from material as specified for standards and shall conform to the dimensions shown on the plans. The cast steel option for slip bases shall be fabricated from material conforming to the requirements of ASTM Designation: A 27/A 27M, Grade 70-40. Other comparable material may be used if written permission is given by the Engineer. The casting tolerances shall be in accordance with the Steel Founder's Society of America recommendations (green sand molding). One casting from each lot of 50 castings or less shall be subject to radiographic inspection, in accordance with the provisions in ASTM Designation: E 94. The castings shall comply with the acceptance criteria severity level 3 or better for all types and categories of dis- continuities as specified in ASTM Designations: E 186 and E 446. If the one casting fails to pass the inspection, 2 additional castings shall be radiographed. Both of these castings shall pass the inspection or the entire lot of 50 will be rejected. Material certifications consisting of physical and chemical properties, and radiographic films of the castings shall be filed at the manufacturer's office. These certifications and films shall be available for inspection upon request. High-strength bolts, nuts and flat washers used to connect slip base plates shall conform to ASTM Designation: A 325 or A 325M and shall be galvanized as specified in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." Plate washers shall be fabricated by saw cutting and drilling steel plate conforming to AISI Designation: 1018, and be galvanized as specified in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." Prior to galvanizing, all burrs and sharp edges shall be removed and holes shall be chamfered sufficiently on each side to allow the bolt head to make full contact with the washer without tension on the bolt. High-strength cap screws shown on the plans for attaching mast arms to standards shall conform to ASTM Designation: A 325, A 325M or ASTM Designation: A 449 and shall comply with the mechanical requirements of ASTM Designation: A325orA325M after galvanizing. The cap screws shall be galvanized as specified in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." The threads of the cap screws shall be coated with a lubricant which is clean and dry to the touch. The galvanized faying surfaces of the connections between signal or lighting mast arms and poles shall be free of surface imperfections, such as lumps, runs, and scum, which would prevent intimate, uniform contact between the faying surfaces. Handholes in the base of standards shall conform to the details shown on the plans. All handholes shall be provided with covers. Changes in configuration of mast arms will be permitted, provided the mounting height and stability are maintained. Fabricators electing to use larger than minimum arm diameters shall adjust the details as required to permit solid seating of the cap screws. All arms shall be bent to the approximate configuration shown on the plans. A smooth curving arm is required. Pedestrian push button posts shall be constructed of 65 mm (2 V2") standard pipe conforming to the dimensions shown on the plans. Guard posts shall be constructed of 100 mm (4") nominal dimension galvanized standard pipe 1.7 m (66") long. Posts shall be set 900 mm (3') in a block of portland cement con- crete, as shown on the plans, and the pipe shall be filled with portland cement concrete. Push button posts and guard posts shall be pipe conforming to the specifications of ASTM Designation: A 53. Slip bases shall be assembled and tightened when the pole is on the ground prior to erection. The threads of the heavy hex nuts for the slip base bolts shall be coated with an additional lubricant which is clean and dry to the touch. Each high strength slip base bolt shall be tightened to within 10 N-m (10 foot-pounds), plus or minus, of values in Table 209-2.04(A): TABLE 209-2.04 (A) July 2005 Page 24 of 115 HIGH STRENGTH SLIP BASE BOLT TORQUE VALUES Standard Type 15-SB 30 31 36-20A Torque (Newton-meters) 200 200 275 225 Torque Foot- Pounds 150 150 200 165 Holes left in the shafts of existing standards, due to removal of equipment or mast arms, shall be repaired by welding in a suitable disk, grinding smooth, and painting as provided for repairing damaged galvanized surfaces in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." When directed by the Engineer, existing standards to be relocated or reused in place shall be repaired. Large dents shall be removed, shafts shall be straightened, and portions which are in poor condition due to corrosion or damage, shall be replaced. Extent of repairs or replacements will be determined by the Engineer and the repairs or replacements ordered by the Engineer will be paid for as extra work as provided in Section 3-2, "Changes Initiated By The Agency." Anchor bolts or bars and nuts required for relocating existing standards shall be furnished by the Contractor. When a standard or mast arm is relocated, or when a used standard or mast arm is Agency-furnished, new nuts, bolts, cap screws and washers shall be provided and, if the standard has a slip base, a new keeper plate shall be provided. New hardware shall conform to the requirements for hardware used with new standards. New standards, mast arms, posts and other ferrous materials shall be galvanized as provided in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." 209-2.05 Conduit. All conductors shall be run in conduit, except overhead and temporary installations, and where conductors are run inside poles. Conduit shall be of the sizes shown on the plans and as specified in this Section 209-2.05. hi addition, the Contractor may, as an option at the Contractor's expense, use conduit of a larger size than that shown or specified, provided the larger size is used for the entire length of the run from outlet to outlet. Reducing couplings will not be permitted. New conduit shall not pass through foundations for standards. 209-2.05A Materials. Conduit and conduit fittings shall be UL or ETL listed and shall conform to the following: Type 1. Hot-dip galvanized rigid steel conduit conforming to the requirements in UL Publication UL 6 for Rigid Metallic Conduit. The zinc coating will be tested in accordance with ASTM Designation: A 239. Type 2. Hot-dip galvanized rigid steel conduit conforming to Type 1 above and coated with polyvinyl chloride or polyethylene. The exterior thermoplastic coating shall have a minimum thickness of 0.9 mm (35 mils). Type 3. Rigid non-metallic conduit conforming to the requirements in the UL Standard for Rigid Non-Metallic Conduit (Publication UL 651). Type 3 conduit shall be installed at all underground locations. Type 4. Liquid tight flexible metal conduit shall consist of conduit with a liquid tight, non-metallic, sunlight- resistant jacket over an inner flexible metal core. Type 4 conduit shall be UL listed for use as the grounding conductor. Type 5. Intermediate steel conduit (IMC) conforming to the requirements in UL Publication 1242 for Intermediate Metallic Conduit. Type 5 conduit shall only be used when specified. Bonding bushings to be installed on metal conduit shall be insulated and shall be the galvanized or zinc alloy type. All conduit installed underground shall be Type 3, rigid non-metallic conduit. Type 3 conduit shall be installed at underground locations only. July 2005 Page 25 of 115 209-2.05B Use. Exposed conduit installed on a painted structure shall be painted the same color as the structure. Unless otherwise indicated, the minimum metric trade size of conduit shall be: 1) From an electrolier to the adjacent pull box shall be Size 41 (1V2" dia). 2) From a pedestrian push button post to the adjacent pull box shall be Size 27 (1" dia). 3) From a signal standard to the adjacent pull box shall be Size 53 (2" dia). 4) From a controller cabinet to the adjacent pull box shall be Size 78 (3" dia). 5) For detector runs shall be Size 41 (lV2" dia). 6) Not otherwise specified shall be Size 41(1 V2" dia). 209-2.05C Installation. Conduit shall be installed hi conformance with the codes and regulations listed in Section 209-1.02, "Regulations and Code." Conduit runs shown on the plans may be changed to avoid under- ground obstructions with written approval by the Engineer. The ends of all conduits, whether shop or field cut, shall be reamed to remove burrs and rough edges. Cuts shall be made square and true. Slip joints or running threads will not be permitted for coupling conduit. When a standard coupling cannot be used for coupling metal type conduit, a UL or ETL listed threaded union coupling shall be used. All couplings for metal type conduit shall be tightened to provide a good electrical connection throughout the entire length of the conduit run. Conduit shall be tightened into couplings or fittings using strap wrenches or approved groove joint pliers. Conduit threads and damaged surfaces on metal conduit shall be painted with 2 applications of approved unthinned zinc-rich primer (organic vehicle type) conforming to the requirements in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." Aerosol cans shall not be used. The ends of conduit shall be threaded and shall be capped with standard pipe caps or "pennies" to protect the raceway against dirt and concrete until wiring is started. When caps or "pennies" are removed, the ends of conduit and conduit fittings shall be provided with conduit bushings. Conduit terminating hi pull boxes or foundations shall be provided with insulated bonding bushings Conduit bends, except factory bends, shall have a radius of not less than 6 times the inside diameter of the conduit. Where factory bends are not used, conduit shall be bent, without crimping or flattening, using the longest radius practicable. A No. 12 copper pull wire or a pull rope shall be installed in all conduits which are to receive future conductors. The pull rope shall be nylon or polypropylene with a minimum tensile strength of 2225 N (500 pounds). At least 0.6 m (2') of pull wire or rope shall be doubled back into the conduit at each termination. Existing underground conduit to be incorporated into a new system shall be cleaned with a mandrel or cylindrical wire brush and blown out with compressed air. Conduit shall be laid to a depth of not less than 460 mm (18") below grade in portland cement concrete sidewalk areas and curbed paved median areas, and not less than 750 mm (30") below finished grade hi all other areas. Conduit may be laid on top of the existing pavement within new curbed medians being constructed on top of the existing pavement. Conduit couplings shall be located at least 150 mm (6") from face of foundation. 209-2.05D Expansion Fittings. Expansion fittings shall be installed where the conduit crosses any expansion joint in the structure. Each expansion fitting for metal conduit shall be provided with a copper bonding jumper having the ampacity required by the Code. Each expansion-deflection fitting for expansion joints of 38 mm (1V2") movement rating shall be watertight and shall consist of a molded neoprene sleeve, a bonding jumper and 2 silicon bronze or zinc-plated iron hubs. Each fitting shall permit a minimum of 19 mm (3/4") expansion and contraction and a minimum of 19 mm (3/4") lateral deflection. Details of expansion- deflection fittings for joints of movement rating of more than 38 mm (lV2") shall be as shown on the plans and specified hi these special provisions. July 2005 Page 26 of 115 209-2.06 Pull Boxes. Pull boxes shall be installed at the locations shown on the plans or as specified. The Contractor may, as an option, at the Contractor's expense, use pull boxes of a larger standard size than that shown or specified. 209-2.06A Materials. Pull boxes, covers and extensions for installation in the ground or in sidewalk areas shall be of the sizes and details shown on the plans and shall be precast of reinforced portland cement concrete (PCC) material Pull boxes and covers for installation in structures shall be of the sizes and details shown on the plans. Each No. 7 ceiling pull box located near a flush soffit fixture and to be used to house the ballast for the fixture shall be provided with mounting brackets for the ballast and any required capacitors. Covers, except covers for ceiling pull boxes, shall be secured with 9 mm (3/8") bolts, cap screws, or studs, and nuts which shall be of brass, stainless steel or other non-corroding metal material. Stainless steel holddown bolts, cap screws or studs, and nuts and washers shall have a chromium content of not less than 18 percent and a nickel content of not less than 8 percent. All ferrous metal parts shall be galvanized in accordance with the provisions in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." 209-2.06B Cover Marking. Covers for pull boxes, except covers for ceiling pull boxes, shall be marked as shown on the plans. Marking shall be clearly defined and uniform in depth and may be placed parallel to either the long or short sides of the cover. Marking letters shall be between 25 mm (1") and 75 mm (3") high. Marking shall be applied to each steel or cast iron cover prior to galvanizing by one of the following methods: (a) Cast iron strips, at least 6 mm (V4") thick, with the letters raised a minimum of 1.5 mm (Vi6"). Strips shall be fastened to covers with 6 mm (V4") flathead stainless steel machine bolts and nuts. Bolts shall be peened after tightening. (b) Sheet steel strips at least 0.7 mm (22 ga.) with the letters raised a minimum of 1.5 mm (Vis") above the surrounding surface of the strips. Strips shall be fastened to covers by spot welding, tack welding or brazing, with 6 mm (V/') stainless steel rivets, or with 6 mm (V^') roundhead stainless steel machine bolts and nuts. Bolts shall be peened after tightening. (c) Bead welding the letters on the covers. The letters shall be raised at least 2 mm (3/32"). 209-2.06C Installation and Use. Pull boxes shall be installed at the locations shown on the plans and, in conduit runs exceeding 60 m(200'), shall be spaced at not over 60 m (200') intervals, except as otherwise noted on the plans. The Contractor may, at the Contractor's expense, install additional pull boxes to facilitate the work. The bottoms of pull boxes installed in the ground or in sidewalk areas, shall be bedded in crushed rock as shown on the plans. 209-2.08 Conductors. Conductors shall be copper of the gage shown on the plans, unless specified otherwise. Copper wire shall conform to the specifications of ASTM Designations: B 3 and B 8. Wire sizes, other than conductors used in loop detector lead-in cable, shall be based on American Wire Gage (AWG), except that conductor diameter shall be not less than 98 percent of the specified AWG diameter. Conductors for branch circuits shall be sized to prevent a voltage drop exceeding 3 percent at the furthest connected load, while drawing the combination of all connected loads capable of simultaneous operation. The maximum voltage drop for both feeders and branch circuits shall not exceed 5 percent at the furthest connected load, while drawing the combination of all connected loads capable of simultaneous operation. Conductors used in loop detector lead-in cable shall conform to the specifications of ASTM Designation: B 286. A Certificate of Compliance conforming to the provisions in Section 4-1.5, "Certification," shall be submitted by the manufacturer with each type of cable to be used on a project. 209-2.08A Conductor Identification. All single conductors in cables, except detector lead-in cables, shall have clear, distinctive and permanent markings on the outer surface throughout the entire length showing the manufacturer's name or trademark, insulation type letter designation, conductor size, voltage rating and the number of conductors if a cable. Conductor insulation shall be of a solid color or of basic colors with a July 2005 Page 27 of 115 permanent colored stripe as detailed in the following table unless otherwise specified. Solid or basic colors shall be homogeneous through the full depth of insulation. Identification stripes shall be continuous over the entire length of the conductor. For conductor sizes No. 2 and larger, the insulation may be black and the ends, of the conductors shall be taped with electrical insulating tape of the required color for a minimum of 500 mm* (20"). All single conductors in cables shall be marked as shown in Table 209-2.08A (A): July 2005 Page 28 of 115 TABLE 209-2.08A (A) CONDUCTORS Circuit Vehicle Signals (Note 4) Pedestrian Signals (Note 4) Pedestrian Push Buttons (Note 4) Traffic Signal Controller Cabinet Highway Lighting Pull Box to Luminaire (Note 9) Multiple Highway Lighting Lighting Control Multiple Service Sign Lighting (Note 8) Flashing Beacons (Note 7) Grounded & Common Interconnect Railroad Pre-Emption Spares Signal Phase or Function '6 .... 18 1 5 5 7 >n 60 In 80 lD5n ip,7p • ?n 60 .. . . In gn In 5n ?P,7p Jngrounded between Service Switch & Cabinet Jngrounded-Line 1 Jngrounded-Line 2 Grounded Jngrounded-Line 2 Jngrounded to Photoelectric Unit (PEU) ... Switching leg from PEU unit or SM transformer Jngrounded-Line 1 (Signals) Jngrounded-Line 2 (Lighting) Jngrounded-Line 1 Jngrounded-Line 2 Ungrounded between Flasher and Beacons 'edestrian Push Buttons Signals & Multiple Lighting . •lashing Beacons & Sign Lighting sighting Control Multiple Service Common •lash )ia!2 )ial 3 Dffset Identification Insulation Colors Base Red, Yellow, Brown Red, Yellow, Brown Red, Yellow, Brown Red, Yellow, Brown Red, Brown Red, Brown Red, Brown Red, Brown Blue Blue Blue Blue Black Red Black Red White Black Red Black Red Black Red (Note 10) Black Red Red or Yellow White White White White White White Orange Orange Orange Orange Black Black Stripe (Note 1) Black Orange None Purple Black Orange None Purple Black Orange None Purple None None None None None None None None None None None None None None Black None None None None None None None None None None None Band Symbols (Note 6) 2,6 4,8 1 5 3,7 2p,6p 4p,8p lp,5p 3p,7p P-2.P-6 P-4.P-8 P-1J-5... P-3.P-7 CON-1 .... CON-2 No band require* No band require* No band requirec ML1 ML2 pi C2 No band require< Except per Note SL-1 SL-2 F-Location No. (See Note 3) No band required No band required No band required C-3 . No band required I I-F I-D2 I-D3 I-O R No band required Minimum Size (Note 11) 14 14 14 14 14 14 14 14 14 14 14 14 6 6 14 14 14 10 10 14 14 6 8 10 10 14 14 10 12 14 14 14 14 14 14 14 14 14 Notes: 1. On overlaps, insulation is striped for first phase in designation, for example, a phase (2+3) conductor is striped as for phase 2. 2. Band for overlap and special phases as required. 3. Flashing beacons having separate service do not require banding. 4. These requirements do not apply to signal cable. 5. "S" if circuit is switched on line side of service equipment by utility. 6. Band conductors in each pull box and near ends of termination points. On signal light circuits, a single band may be placed around 2 or 3 ungrounded conductors comprising a phase. 7. Ungrounded conductors between service switch and flasher mechanism shall be black and banded as indicated in this column. 8. Conductors between ballasts and sign lighting lamps shall be No. 16 and color shall correspond to that of the ballast leads. 9. Both conductors between external H.I.D. ballast and lamp socket shall be black. 10. Black acceptable for size No. 2 and larger. Tape ends for 500 mm (20") with indicated color. 11. Wire sizes listed are minimums. Ampacity requirements of specific circuits or voltage drop may necessitate larger conductors. July 2005 Page 29 of 115 209-2.08B Multiple Circuit Conductors. Conductors for multiple circuits shall be UL or ETL listed and rated for 600-volt operation. The insulation for No. 14 through No. 4 conductors shall be one of the following: Type TW polyvinyl chloride conforming to the requirements of ASTM Designation: D 2219. Type THW polyvinyl chloride. Type USE, Type RHH or Type RHW cross-linked polyethylene. At any point, the minimum thickness of any Type TW, THW, USE, RHH or RHW insulation shall be 1.0 mm (40 mils) for conductor sizes No. 14 to No. 10, inclusive, and 1.3 mm (54 mils) for No. 8 to No. 2, inclusive. The insulation for No. 2 and larger conductors shall be one of the types listed above or shall be Type THWN. Conductors for wiring wall luminaires shall be stranded copper, with insulation rated for use at temperatures up to 125°C. Overhead lighting conductors shall be No. 8, or larger, medium hard drawn copper with weatherproof covering. 209-2.08C Series Circuit Conductors. Conductors for series circuits shall be No. 8, shall be rated for 5000-volt operation and shall be insulated with 3.7 mm (150 mils) minimum thickness polyvinyl chloride compound conforming to the specifications of ASTM Designation: D 2219, or polyethylene conforming to the specifications of ASTM Designation: D 1351. 209-2.08D Signal Cable. Signal cable shall be installed. Individual conductors are not allowed. Signal cable shall conform to the following: The cable jacket shall be black polyethylene with an inner polyester binder sheath, and shall be rated for 600- volt and 75°C. All cables shall have clear, distinctive, and permanent markings on the outer surface throughout the entire length of the cable showing the manufacturer's name or trademark, insulation designation, number of conductors, conductor sizes, and the voltage rating of the jacket. Filler material, if used, shall be polyethylene material. Individual conductors in the cable shall be solid copper with Type THWN insulation, and shall conform to the requirements in Section 209-2.08, "Conductors," and ASTM Designation: B 286. The minimum thickness of Type THWN insulation, at any point, shall be 0.3 mm (13 mils) for conductor sizes No. 14 and No. 12, and 0.4 mm (18 mils) for conductor size No. 10. The minimum thickness of the nylon jacket shall be 0.1 mm (4 mils) at any point. Three-Conductor Cable (3CSC). The 3-conductor signal cable shall consist of three No. 14 conductors. The cable jacket shall have a minimum average thickness of 1.1 mm (45 mils) and a minimum thickness at any point of 0.9 mm (36 mils). The nominal outside diameter of the cable shall not exceed 10 mm (0.40"). The color code of the conductors shall be blue/black stripe, blue/orange stripe, and white/black stripe. The 3 conductor cable shall be used for pedestrian push buttons and a spare. FiveConductor Cable (5CSC). The 5-conductor signal cable shall consist of five No. 14 conductors. The cable jacket shall have a minimum average thickness of 1.1 mm (45 mils) and shall have a minimum thickness at any point of 0.9 mm (36 mils). The nominal outside diameter of the cable shall not exceed 13 mm (0.50"). The color code of the conductors shall be red, yellow, brown, black, and white. Nine-Conductor Cable (9CSC). The 9-conductor cable shall consist of eight No. 14 conductors and one No. 12 conductor. The cable jacket shall have a minimum average thickness of .5 mm (60 mils) and shall have a minimum thickness at any point of 1.2 mm (48 mils). The nominal outside diameter of the cable shall not exceed 17 mm (0.70"). The color code for the No. 12 conductor shall be white. The color code for the No. 14 conductors shall be as Table 209-2.08D(A): July 2005 Page 30 of 115 TABLE 209-2.08D(A) NINE-CONDUCTOR CABLE SIGNAL CABLE Insulation Colors red yellow brown red/black stripe yellow/black stripe brown/black stripe black white/black stripe Twelve-Conductor Cable (12CSC). The 12-conductqr signal cable shall consist of eleven No. 14 conductors and one No. 12 conductor. The cable jacket shall have a minimum average thickness of 1.5 mm (60 mils) and shall have a minimum thickness at any point of 1.2 mm (48 mils). The nominal outside diameter of the cable shall not exceed 17 mm (0.70"). The color code for the No. 12 conductor shall be white. The color code and functional connections for the No. 14 conductors shall be as Table 209-2.08D(B), unless otherwise approved by the Engineer: TABLE 209-2.08D(B) TWELVE -CONDUCTOR CABLE SIGNAL CABLE Color Code red yellow brown red/black stripe yellow/black stripe brown/black stripe black/red stripe black/white stripe black red/white stripe brown/white stripe Termination vehicle signal red vehicle signal yellow vehicle signal green vehicle signal red vehicle signal yellow vehicle signal green spare, or use as required for red or Don't Walk spare, or use as required for yellow spare, or use as required for green or Walk ped signal Don't Walk ped signal Walk Phase 2, 4, 6 or 8 2,4,6or8 2, 4, 6 or 8 1,3, 5 or 7 1,3, 5 or 7 1,3, 5 or 7 The 12-conductor cable shall be used for vehicle signals, pedestrian signals, spares and the signal common. Twenty Eight-Conductor Cable (28CSC). The 28-conductor signal cable shall consist of 27 No. 14 conductors and one No. 10 conductor. The cable jacket shall have a minimum average thickness of 2 mm (80 mils) and shall have a minimum thickness at any point of 1.6 mm (64 mils). The nominal outside diameter of the cable shall not exceed 23 mm (0.90"). The color code for the No. 10 conductor shall be white. The color code and functional connections for the No. 14 conductors shall be as Table 209-2.08D(C) July 2005 Page 31 of 115 TABLE 209-2.08D(C) TWENTY EIGHT - CONDUCTOR CABLE SIGNAL CABLE Color Code red/black stripe yellow/black stripe brown/black stripe red/orange stripe yellow/orange stripe brown/orange stripe red/silver stripe yellow/silver stripe brown/silver stripe red/purple stripe yellow/purple stripe brown/purple stripe red/2 black stripes brown/2 black stripes red/2 orange stripes brown/2 orange stripes red/2 silver stripes brown/2 silver stripes red/2 purple stripes brown/2 purple stripes blue/black stripe blue/orange stripe blue/silver stripe blue/purple stripe white/black stripe black/red stripe black Termination vehicle signal red vehicle signal yellow vehicle signal green vehicle signal red vehicle signal yellow vehicle signal green vehicle signal red vehicle signal yellow vehicle signal green vehicle signal red vehicle signal yellow vehicle signal green ped signal Don't Walk ped signal Walk ped signal Don't Walk ped signal Walk overlap A, C red overlap A, C green overlap B, D red overlap B, D green ped push button ped push button overlap A, C yellow overlap B, D yellow ped push button common railroad pre-emption spare Phase ^ 2 or 6 ^1 2 or 6 2 or 6 4 or 8 4 or 8 4 or 8 Ior5 lor 5 Ior5 3 or 7 3 or 7 3 or 7 2or6 2 or 6 4 or 8 4 or 8 OLA, OLC OLA, OLC OLE, OLD OLE, OLD 2 or 6 4 or 8 OLA(y), OLC(y) 4 OLB(y), OLD(y) V 1) The signal commons in each 28-conductor cable shall be kept separate except at the signal controller. 2) Each 28-conductor cable shall be labeled in each pull box "Cl" or "C2",. 3) The cable identified "Cl" shall be used for signal Phases 1, 2, 3 and 4. The cable identified "C2" shall be used for signal Phases 5, 6, 7 and 8. 4) Each signal cable, except 28-conductor, shall be marked, in each pull box, showing the signal standard to which it is connected. 209-2.08E Signal Interconnect Cable (SIC). Signal Interconnect Cable shall consist of six or twelve No. 20, minimum, stranded tinned copper conductors as shown on the plans or required herein. Each conductor shall be insulated with 0.33 mm (0.013"), minimum nominal thickness, color coded, polypropylene material. Conductors shall be in twisted pairs. Color coding shall distinguish each pair. Each pair shall be wrapped with an aluminum polyester shield and shall have a No. 22 or larger, stranded, tinned copper drain wire inside the shielded pair. The cable jacket shall be black, high density polyethylene, rated for a minimum of300- volts and 60°C, and shall have a nominal wall thickness of 1.0 mm (40 mils), minimum. The cable jacket or the moisture-resistant tape directly under the outer jacket shall be marked with the manufacturer's name, insulation type designation, number of conductors and conductor size, and voltage and temperature ratings. Splices shall be made only where shown on the plans or in controller cabinets. A minimum of one meter (3') of slack shall be provided at each splice and 2 m (6') at each controller cabinet. Splices of conductors shall be insulated with heat-shrink tubing of the appropriate size and shall overlap the conductor insulation at least 15 mm (0.5"). The overall cable splice shall be covered with heat-shrink tubing, with at least 40 mm (1V2") of overlap of the cable jacket. July 2005 Page 32 of 115 209-2.09 Wiring. All conductors shall be run in conduit, except overhead and temporary installations and where conductors are run inside poles. Wiring shall be done in conformance with the regulations and code listed in Section 209-1.02, "Regulations and Code," and the following additional requirements: 209-2.09A Circuitry. Sufficient traffic signal light conductors shall be provided to perform the functional operation of the signal and, in addition thereto, 3 spare conductors shall be provided in all conduits containing traffic signal light conductors, unless shown otherwise on the plans. Traffic signal light conductors shall not run to a terminal block on a standard unless they are to be connected to a signal head that is mounted thereon. Connection to each terminal of a pedestrian push button shall be by a single conductor. The common for pedestrian push button circuits shall be separate from the traffic signal light circuit grounded conductors. Where ballasts or transformers are used, series conductors shall be run from ballast to ballast, transformer to transformer, and from ballast or transformer to service. 209-2.09B Installation. A UL or ETL listed inert lubricant shall be used in placing conductors in conduit. Conductors shall be pulled into conduit by hand and the use of winches or other power actuated pulling equipment will not be permitted. All conductors shall be pulled directly from the spool into the conduit and shall not be dragged on the ground as to cause damage to the conductors. When new conductors are to be added to existing conductors in a conduit, all conductors shall be removed; the conduit shall be cleaned as provided in Section 209-2.05C, "Installation"; and both old and new conductors shall be pulled into the conduit as a unit. Where traffic signal light conductors are run in lighting standards containing street lighting conductors from a different service point, either the traffic signal light conductors or the lighting conductors shall be encased in flexible or rigid metal conduit, to a point where the 2 types of conductors are no longer in the same raceway. Temporary conductors less than 3 m (10') above grade shall be enclosed in flexible or rigid metal conduit. At least 0.3 m (1 ') of slack shall be left for each conductor at each signal or lighting standard, or combined standard, and at least one meter (3') of slack at each pull box. At least one meter (3') of slack shall be left for each conductor at each splice. Ends of spare conductors or conductors terminated in pull boxes shall be taped to provide a watertight seal. Conductors within fixtures or service cabinets shall be neatly arranged and shall be cabled together with self- clinching nylon cable ties, or other method approved by the Engineer. Traffic signal light conductors, interconnect conductors, service conductors, detector conductors and cables in controller cabinets and flashing beacon cabinets shall be neatly arranged, and shall be cabled together with self-clinching nylon cable ties, or enclosed in plastic tubing or raceway. Conductor identification shall be provided under the following conditions: Where signal phase or circuit are not clearly indicated by conductor insulation color and stripe as detailed in the conductor table in Section 209-2.08, "Conductors," or when identification stripes are not available, marking shall be as detailed in the conductor table for special and overlap phases. Where metered and unmetered conductors occupy the same pull box, the unmetered circuit conductors shall be identified, "UNMETERED-STREET LTG," "UNMETERED-COUNT STATION," or as appropriate to describe the unmetered circuit. Conductors shall be permanently identified as to function. Identification shall be placed on each conductor, or each group of conductors comprising a signal phase, in each pull box and near the end of terminated conductors. Identification shall be by direct labeling, tags or bands fastened to the conductors in such a manner that they will not move along the conductors. Labeling shall be by mechanical methods. July 2005 Page 33 of 115 209-2.09C Connectors and Terminals. Conductors shall be joined by the use of UL or ETL listed crimp type connectors as shown on the plans. Connectors and terminals shall be applied with the proper type tool as recommended by the manufacturer of the connector or terminal being used. Finished connections and terminals shall comply with the requirements of Military Specification MIL-T-7928. All stranded conductors smaller than No. 14 shall be terminated in crimp style terminal lugs. All connectors and terminal lugs for conductor sizes No. 8 and smaller shall be soldered by the hot iron, pouring or dipping method. Open flame soldering will not be permitted. 209-2.09D Splicing and Terminations. Unless specified otherwise or permitted by the Engineer, splices shall conform to the details shown on the plans and will be permitted only in the following types of circuits at the following locations: Grounded conductors in pull boxes. Pedestrian push button conductors in pull boxes. Multiple or series lighting conductors in the pull box adjacent to each electrolier or luminaire location or in the bases of Type 21 standards. Where electroliers are more than 120 m (400') apart, splices will be permitted in pull boxes at 120 m (400'), or greater, intervals. When traffic signals are being modified, ungrounded traffic signal light conductors may be spliced in pull boxes at locations shown on the plans. Ungrounded traffic signal light conductors to a terminal compartment or signal head on a standard may be spliced to through conductors of the same phase in the pull box adjacent to the standard. All splices and terminal lugs for conductor sizes No. 8 and smaller shall be soldered by the hot iron, pouring or dipping method. Open flame soldering will not be permitted. 209-2.09E Splice Insulation. All splices shall be capable of satisfactory operation under continuous submersion in water. Multi-conductor cables shall be spliced and insulated to provide a watertight joint and to prevent absorption of moisture by the cable. Where more than one conductor enters the sleeve of a ballast installed in a pull box, the insulation and taping shall be applied between the conductors in such a manner as to provide a watertight joint. Splice insulation shall conform to the details shown on the plans. Low-voltage tape shall be UL or ETL listed and shall be the following types: Self-fusing, oil and flame-resistant, synthetic rubber. Pressure-sensitive, adhesive, polyvinyl chloride, 0.15 mm (0.007") minimum thickness. Tape for insulating splices in high-voltage (over 600 V) circuits shall be designed for use on 5-kvolt circuits and shall be resistant to ozone, corona and water. Insulating pad shall be composed of a laminate of 2 mm (0.085") thickness of electrical grade polyvinyl chloride and a 3 mm (0.125") thickness of butyl splicing compound with removable liner. . Heat-shrink tubing shall be medium or heavy wall thickness, irradiated polyolefin tubing containing an adhesive mastic inner wall. Minimum wall thickness prior to contraction shall be one millimeter (39 mils). When heated, the inner wall shall melt and fill all crevices and interstices of the object being covered while the outer wall shrinks to form a waterproof insulation. Each end of the heat shrink tube or the open end of the end cap of heat-shrink tubing shall, after contraction, overlap the conductor insulation at least 38 mm (1 Vi"). Heat- shrink tubing shall conform to the requirements of UL Standard 468D and ANSI Cl 19.1, for extruded insulated tubing at 600-V. All heat-shrink tubing shall also meet the requirements of Table 209-2.09E(A): July 2005 Page 34 of 115 TABLE 209-2.09E(A) HEAT-SHRINK TUBING Property Shrinkage Ratio Dielectric Strength Resistivity Tensile Strength Operating Temperature Water Absorption Requirement 33 percent, maximum, of supplied diameter when heated to allowed to cool to 25°C. 125°C and 140 kV per 10 mm, minimum. 10*3 E • mm, minimum. 14 MPa, minimum. -40°C to 90°C (1 35°C Emergency). 0.5 percent, maximum. When three or more conductors are to be enclosed within a single splice using heat-shrink tubing, mastic shall be placed around each conductor, prior to being placed inside the heat-shrink tubing. The mastic shall be the type recommended by the manufacturer of the heat-shrink tubing. After contraction, the ends and seams of heat-shrink tubing shall be painted with electrical insulating coating. Heat-shrink tubing shall not be heated with an open flame. A heating device designed for the purpose is required. The Contractor may, at the Contractor's option, use either of the following splice insulation methods: 1) "Method B" as shown on the plans. A minimum of 2 thicknesses of electrical insulating pad shall be used. Pads shall be applied to the splice in accordance with the manufacturer's recommendations. 2) Heat-shrink tubing as provided above. 209-2.095 Fused Splice Connectors. In the pull box adjacent to each luminaire a fused disconnect splice connector shall be installed in each ungrounded conductor between the line and the ballast. The connector shall be readily accessible in the pull box regardless of whether the ballast is remote or is integral with the luminaire. For 240-volt and 480-volt circuits, each connector shall be designed so that both ungrounded conductors are disconnected simultaneously. The connector shall have no exposed metal parts, except the head of a stainless steel assembly screw may be exposed. The head of the metal assembly screw shall be recessed a minimum of 0.8 mm ('/32") below the top of a plastic boss which surrounds the head. The splice connector shall completely enclose the fuse and shall protect the fuse against damage from water and weather. The contact between the fuse and fuse holder shall be by spring pressure. The terminals of the splice connector shall be rigidly crimped, using a tool of the type recommended by the manufacturer of the fused splice connector, onto the line conductors and the conductors to the ballasts and shall be insulated and made waterproof in accordance with the splice connector manufacturer's recommendations. Fused splice connectors shall not be used in series circuits. Fuses shall be standard midget, ferrule type, with "Non-Time- Delay" feature, and shall be 10 mm (13/32") x 38 mm (1V2"). 209-2.10 Bonding and Grounding. Metallic cable sheaths, metal pull box covers, metal conduit, equipment grounding conductors, ballast and transformer cases, service equipment, sign switches, and metal poles and pedestals shall be made mechanically and electrically secure to form a continuous system, and shall be effectively grounded. Bonding jumpers shall be copper wire or copper braid of the same cross sectional area as No. 6 for series lighting systems and No. 8 or larger for all other systems. The jumper size shall be increased to match the load or the circuit breaker size, or shall be as shown on the plans. Equipment ground- ing conductors shall be color coded to Code requirements or shall be bare. The bonding jumper in standards with handholes shall be attached by a 4.5 mm (3/]6") or larger brass bolt and shall be run to the conduit or bonding wire in the adjacent pull box. Standards without handholes shall be bonded by a jumper attached to all anchor bolts, and shall be run to the conduit or bonding wire in the adjacent pull box. Grounding jumper shall be visible after cap has been placed on foundation. Where slip base standards or slip base inserts are installed, the bonding jumper shall not intrude into the slip plane. Bonding July 2005 Page 35 of 115 shall be accomplished by a bonding strap to all anchor bolts or a 4.5 mm (Vig") or larger brass bolt installed in the bottom slip base plate. One side of the secondary circuit of series-multiple and step-down transformers shall be grounded. Grounding of metal conduit, service equipment and the grounded conductor at service point shall be accomplished as required by the Code and the serving utility, except that grounding electrode conductor shall be No. 6, or larger. For equipment grounding purposes in Type 3 conduit, a No. 6 copper wire shall be run continuously in circuits used for series lighting, and a No. 8, minimum, copper wire shall be run continuously in all other circuits. The bonding wire size shall be increased to match the circuit breaker size, or shall be as shown on the plans. Where Type 3 conduit is to be installed for future conductors, the copper wire may be omitted. Equipment bonding and grounding conductors are not required in conduits which contain only loop lead-in cable or signal interconnect cable or both. At each multiple service disconnect location, a ground electrode shall be furnished and installed. Ground electrodes shall be one-piece lengths of galvanized steel rod or pipe not less than 19 mm (3/4") in diameter, or of copper clad steel rod not less than 15 mm (5/g") in diameter. Ground electrodes shall be installed in accor- dance with the provisions of the Code. The service equipment shall be bonded to the ground electrode by use of a ground clamp or exothermic weld and No. 6 or larger copper wire, enclosed in a size 16 or larger diameter conduit. Ground clamp for service grounding and for grounding of equipment on wood poles shall be Size 16 galvanized, malleable iron conduit hub with swivel feature. On wood poles, all metallic equipment mounted less than 2.4 m (8') above ground surface shall be grounded. Bonding of metallic conduit in non-metallic pull boxes shall be by means of bonding bushings and bonding junipers. Bonding of metallic conduit in metal pull boxes shall be by means of locknuts, one inside and one outside of the box. 209-2.11 Service. Electrical service installation and materials shall conform to the requirements of the serving utility. When the service equipment is to be installed on a utility-owned pole, the Contractor shall furnish and install conduit, conductors and all other necessary material to complete the installation of the service. The position of the riser and equipment will be determined by the utility. Service conduit shall conform to the requirements of the serving utility and shall be not less than Size 41 (1V2" dia.). Where a kilowatt-hour meter is required, a meter socket with sealing ring, as approved by the serving utility, shall be furnished and installed. Where a meter socket is installed, the meter enclosure shall be provided with factory installed test bypass facilities as required by the serving utility. Service equipment shall be installed as soon as possible to enable the utility to schedule its work well in advance of the completion of the project. Each service shall be provided with a circuit breaker which shall simultaneously disconnect all ungrounded service entrance conductors. All circuit breakers shall be quick-break on either automatic or manual operation. The operating mechanism shall be enclosed and shall be trip-free from the operating handle on overload. Circuit breakers shall be trip-indicating, shall have frame size plainly marked and shall have trip rating clearly indicated on the operating handle. Overload tripping of breakers shall not be influenced by an ambient temperature range of from -18°C to 50°C. Multiple-pole breakers shall be the internal trip type. All circuit breakers shall be listed by UL or ETL. Current rating of breakers shall be as shown on the plans. Circuit breakers used as service disconnect equipment shall have a minimum interrupting capacity of 10 000 A, rms. Circuit breakers shall be enclosed in a NEMA rain tight enclosure with dead-front panel and hasp with a 11 mm (7/i6") hole for a padlock. The padlock will be furnished by others. Service equipment enclosures, except Types II and III, shall be galvanized. Types II and III service equipment enclosures shall be fabricated from galvanized sheet steel or fabricated from sheet steel and zinc or cadmium plated after fabrication, or shall be fabricated from aluminum. Fabrication of service equipment enclosures shall conform to the requirements of Section 209-3.04A, "Cabinet Construction." Steel enclosures shall be painted in accordance with the provisions in Section 209-2.16, "Painting." All overlapping exterior seams and doors shall meet the requirements for Type 3R enclosures specified in the NEMA Enclosure Standards. July 2005 Page 36 of 115 Except for falsework lighting and power for the Contractor's operations, upon written request by the Contractor, the Engineer will arrange with the serving utility to complete service connections for both tempo- rary and permanent installations and the Agency will pay all costs and fees required by the utility. The request shall be submitted not less than 15 days before service connections are required. Except for falsework lighting and power for the Contractor's operations, upon written request by the Contractor, the Engineer will arrange for furnishing electrical energy. Energy used prior to completion of the contract will be charged to the Contractor, except that the cost of energy used for public benefit, when an operation is ordered by the Engineer, will be at the expense of the Agency. 209-2.13 Sign Control. Each sign illumination installation shall be provided with a disconnect circuit breaker mounted on the sign standard or structure, as shown on the plans. Where the sign lighting is served from a series lighting circuit through a series-multiple transformer, the circuit breaker shall be installed in the secondary circuit. Where the sign lighting is served through a multiple-multiple transformer, the circuit breaker shall be installed in the primary circuit. Circuit breakers shall meet the requirements for circuit breakers in Section 209-2.11, "Service." Enclosure for the circuit breaker shall be NEMA Type 3R, shall be galvanized or shall be cadmium plated, and shall be provided with dead front panel and a hasp with all mm (7/i6") diameter hole for a padlock. Padlocks will be furnished by others. When the sign structure is to be painted, the circuit breaker or sign switch enclosure shall be painted the same color as the sign structure on which it is mounted. 209-2.14 Testing. Attention is directed to Section 4-1.4, "Test of Materials." Testing shall conform to the following: 209-2.14A Materials Testing. Material and equipment to be tested shall be delivered to a testing location designated by the Engineer. Testing will be performed by the Agency. Testing and quality control procedures for Model 170 and Model 2070 controller assemblies shall conform to the requirements in "Transportation Electrical Equipment Specifications," and "Traffic Signal Control Equipment Specifications," issued by the State of California, Department of Transportation, and to all addendums thereto current at the time of project advertising. Testing and quality control procedures for all other traffic signal controller assemblies shall conform to the requirements in the NEMA TS Standards for Traffic Control Systems. In the event equipment submitted for testing does not comply with specifications, the Contractor shall remove the equipment for repair within 5 working days after notification that the equipment is rejected. In the event the equipment is not removed within that period, it may be shipped to the Contractor at the Contractor's expense. The Contractor shall allow 30 days for Agency testing from the time the material or equipment is delivered to the Agency test site. When equipment being tested has been rejected for failure to comply with the specifications, the Contractor shall allow 30 days for Agency retesting. The retesting period shall begin when the corrected equipment is made available at the test site. All testing subsequent to rejection of the equipment for failure to comply with specification requirements will be at the expense of the Contractor. Deductions to cover the cost of that testing will be made from any moneys due or which may become due the Contractor under the contract. The Contractor will be notified when testing of the equipment has been completed and it shall be the Contractor's responsibility to deliver the equipment to the site of the work or, at the Contractor's request and the Agency's convenience, the Agency will pack and ship the equipment to the Contractor or to the site of work. The sum of $100 or the actual cost of packing and shipping, whichever amount is greater, will be deducted, for each unit of equipment shipped by the Agency, from any moneys due to the Contractor under the contract. 209-2.14B Field Testing. Prior to start of functional testing, the Contractor shall perform the following tests on all circuits, in the presence of the Engineer. July 2005 Page 37 of 115 209-2.14B(1) Continuity. Each circuit shall be tested for continuity. 209-2.14B(2) Ground. Each circuit shall be tested for grounds. 209-2.14B(3) Insulation Resistance. An insulation resistance test at 500 volts DC shall be made on each circuit between the circuit and a ground. The insulation resistance shall not be less than 10 MQ on all circuits, except for inductive loop detector circuits which shall have an insulation resistance value of not less than 100MH. The insulation resistance test shall not be performed on magnetometer sensing elements. Splices in the pull box adjacent to the magnetometer sensing elements shall not be made prior to performing the test on the lead- in conductors between the pull box and the controller cabinet field terminals. 209-2.14C Functional Testing. Attention is directed to Section 209-1.06, "Scheduling of Work," regarding requirements for test periods. A functional test shall be made in which it is demonstrated that each and every part of the system functions as specified. The functional test for each new or modified system shall consist of not less than 5 days of continuous, satisfactory operation. If unsatisfactory performance of the system develops, the condition shall be corrected and the test shall be repeated until the 5 days of continuous, satisfactory operation is obtained. Turn-on of new or modified traffic signals shall be made only after all traffic signal circuits have been thoroughly tested as specified above. Except for new or modified portions of existing lighting circuits and sign illumination systems, The Agency will maintain the system or systems during the test period and will pay the cost of electrical energy for the operation of all of the facilities that are undergoing testing. The cost of any necessary maintenance performed by the Agency on new circuits or on the portions of existing circuits modified under the contract, except electrical energy, shall be at the Contractor's expense and will be deducted from any moneys due, or to become due, the Contractor. A shutdown of the electrical system resulting from damage caused by public traffic, from a power interruption or from unsatisfactory performance of Agency-furnished materials shall not constitute discontinuity of the functional test. 209-2.15 Galvanizing. Galvanizing shall be in accordance with the provisions in Section 210-3.6, "Galvanizing for Traffic Control Facilities," except that cabinets may be constructed of material galvanized prior to fabrication in conformance with the specifications of ASTM Designation: A 525 or A 525M, Coating Designation G 90, in which case all cut or damaged edges shall be painted with at least 2 applications of approved unthinned zinc-rich primer (organic vehicle type) conforming to the requirements in Section 210-3.5, "Repair of Damaged Zinc Coating." Aerosol cans shall not be used. Other types of protective coating shall be approved by the Engineer prior to installation. Iron or steel pipe standards and pipe mast arms shall be hot-dip galvanized after fabrication in conformance with the specifications of ASTM Designation: A 53. Galvanized surfaces shall have spurs removed. Tie-rods, bolts, nuts, washers, clamps and other miscellaneous ferrous parts shall be hot-dip galvanized after fabrication in accordance with the provisions in Section 210-3.6, "Galvanizing for Traffic Control Facilities." Not less than 250 mm (10") of the upper end of the anchor bolts, anchor bars, or studs, and all nuts and washers shall be galvanized in accordance with the provisions in Section 210-3.6, "Galvanizing for Traffic Control Facilities." After galvanizing, the bolt threads shall accept galvanized standard nuts without requiring tools or causing removal of protective coatings. July 2005 Page 38 of 115 Galvanizing of existing materials in an electrical installation will not be required. 209-2.16 Painting. Painting of electrical equipment and materials shall conform to the provisions in Section 310, "Painting," with the following additions and modifications. Paint materials for electrical installations, unless otherwise specified, shall conform to the provisions in Section 210, "Paint and Protective Coatings." Factory or shop cleaning methods for metals will be acceptable if equal to the methods specified herein. In lieu of the temperature and seasonal restrictions for painting as provided in Section 310, "Painting," paint may be applied to equipment and materials for electrical installations at any time permitted by the Engineer. All ungalvanized ferrous surfaces to be painted shall be cleaned prior to applying the prime coat. Blast cleaning will not be required. If an approved prime coat has been applied by the manufacturer, and it is in good condition, the first primer application by the Contractor will not be required. Existing equipment to be painted in the field, including Agency-furnished equipment, shall be washed with a stiff bristle brush using a solution of water containing 7.5 ml. of heavy duty detergent powder per liter (2 tablespoons per gallon). After rinsing, all surfaces shall be wire brushed with a coarse, cup shaped, power- driven brush to remove all poorly bonded paint, rust, scale, corrosion, grease or dirt. Any dust or residue remaining after wire brushing shall also be removed prior to priming. Immediately after cleaning, all galvanized surfaces and all non-ferrous metal surfaces shall be coated with one application of Primer (Wash) Pre-Treatment, Section 210-1.5 or wash primer conforming to the requirements of Military Specification MIL- P-15328D. The wash primer shall be applied by spraying or brushing to produce a uniform wet film on the surface. Galvanized equipment and wood poles for traffic signal or flashing beacon installations shall not be painted. New galvanized metal surfaces to be painted in the field shall be cleaned as specified for existing equipment before applying the prime coats specified. Wire brushing of new galvanized surfaces will not be required. After erection, all exterior surfaces shall be examined for damaged primer and the damaged surfaces shall be cleaned and spot coated with primer. Galvanized metal guard posts shall not be painted. Painting of Agency- furnished controller cabinets will not be required. Types II and ffl steel service equipment enclosures shall be painted with a polymeric or an enamel coating system conforming to Color No. 14672 (light green) of Federal Standard 595B. All coatings shall be commercially smooth, substantially free of flow lines, paint washout, streaks, blisters, and other defects that would impair serviceability or detract from general appearance. The coatings shall comply with the following requirements: 1) Coating Hardness - The finish shall have a pencil lead hardness of HB minimum using an Eagle Turquoise pencil. 2) Salt Spray Resistance - The undercutting of the film of the coating system shall not exceed 3 mm (V8") average, from lines scored diagonally and deep enough to expose the base metal, after 250 hours exposure in a salt spray cabinet in accordance with ASTM Designation: B 117. 3) Adherence - There shall be no coating loss when tested by California Test 645. Compliance of the coating system to the above requirements may be determined by the application of the coating, to 100 mm (4") x 200 mm (8") x 0.6 mm (0.0236") test specimens of the same material as the cabinets, in the same manner as applied to the cabinets. A Certificate of Compliance shall be furnished in accordance with the provisions of Section 4-1.5, "Certification," certifying that the coating system furnished complies in all respects with these requirements. Interior of metal signal visors, louvers and front faces of back plates shall be finished with 2 applications of lusterless black exterior grade latex paint formulated for application to properly prepared metal surfaces, except that factory finish in good condition will be acceptable. Metal signal sections, signal head mountings, brackets and fittings, outside of visors, pedestrian push button housings, pedestrian signal sections and visors, and back faces of back plates, shall be finished with 2 applications of lusterless black or dark olive green exterior grade latex paint formulated for application to July 2005 Page 39 of 115 properly prepared metal surfaces. Dark olive green color shall match Color Chip No. 68 on file at the CALTRANS Transportation Laboratory. Conduit and conduit fittings above ground shall be prepared and finished in the same manner as the adjacent' standard or post. Relocated, reset or modified equipment previously finished as specified hi this Section 209- 2.16, except for galvanized standards previously finished with traffic signal yellow enamel, shall be given a spot finishing application on newly primed areas, followed by one finishing application over the entire surface. If any signal faces or mounting brackets are required to be painted under this Section, all signal faces and mounting brackets on the same mounting shall be repainted. Small rusted or repaired areas of relocated or reset galvanized equipment shall be cleaned and painted as provided in Section 210-3.6, "Galvanizing for Traffic Control Facilities,"for repairing damaged galvanized surfaces. Equipment number shall be neatly stenciled on the standard or adjacent structure. The number designation will be determined by the Engineer. All paint shall be applied either by hand brushing or by spraying machines hi the hands of skilled operators. The work shall be done hi a neat and workmanlike manner. The Engineer reserves the right to require the use of brushes for the application of paint, should the work done by the paint spraying machine prove unsatisfactory or objectionable, as determined by the Engineer. 209-3 CONTROLLER ASSEMBLIES 209-3.01 Controller Assembly. A controller assembly shall consist of a complete mechanism for controlling the operation of traffic signals or other systems, including the controller unit and all necessary auxiliary equipment, mounted hi a cabinet. All equipment required to provide the operation shown on the plans and as specified shall be provided. All field conductors No. 12 and smaller shall terminate with spade type terminals. All field conductors No. 10 and larger shall terminate hi spade type or ring type terminals. 209-3.02 Type 90 Controller Assembly. Deleted 209-3.03 Model 170 and Model 2070 Controller Assemblies. Model 170 and Model 2070 (Model 170/2070) controller assemblies shall consist of a Model 170, 170E or 2070 controller unit, a wired cabinet and all auxiliary equipment required to control the system as shown on the plans, and as specified hi these special provisions. Model 170/2070 controller assemblies shall conform to the requirements in "Transportation Electrical Equipment Specifications," (TEES) and 'Traffic Signal Control Equipment Specifications" (TSCES), issued by the State of California, Department of Transportation, and to all ad- dendums thereto current at the tune of project advertising. Unless otherwise specified or shown on the plans, controller assembly cabinets (housing) shall be Type 1 as shown hi the TSCES. In addition to the requirements found in TEES and TSCES, Model 170/2070 controller assemblies shall conform to the following: 209-3.04 Controller Cabinets. Unless otherwise specified, controller cabinets for Model 170/2070 controllers shall conform to the following: 1) Controller cabinets shall be fabricated from aluminum sheet per the TSCES. 2) Controller cabinets shall have a single front door equipped with a Best Company lock core and lock. No other manufacturers shall be accepted. 209-3.05 Cabinet Accessories. The following accessories shall be furnish with each cabinet assembly for Model 170/2070 controllers: 1) Controller cabinets shall have a pull-out type document tray. 2) Each cabinet shall be provided with a fluorescent lighting fixture mounted on the inside top of the cabinet near the front edge. Fixture shall be provided with an Fl 5T8, cool white lamp operated July 2005 Page 40 of 115 from a normal power factor UL or ETL listed ballast. The "on-off' switch for the lighting fixture shall be a door-actuated switch that turns the light on when either door is open and off when ei- ther door is closed. 3) An uninterruptible power system (UPS) shall be installed in each cabinet using a swing-away type mounting. The UPS shall be Clary SP 1000 series or approved equal and shall provide a minimum of eight (8) hours of continuous red flash operation at intersections using red LED sig- nal indications and provide power conditioning to the controller. Batteries for the UPS shall be housed in a NEMA 3R rated cabinet mounted to the side of the Model 332 cabinet per Caltrans specifications. 209-3.06 Back-Up Cabinet and Accessories. The back-up battery cabinet shall: 1) Be a City of San Marcos approved cabinet per the 'Traffic signal Manual for New signal Design and Installation." 2) Be at a location approved by the City of San Marcos Public works Department. 3) The battery back-up system shall be the Clary Corporation SP Series 1000 Traffic UPS or approved equal. The Traffic UPS must be a true on-line, power conditioner and battery back- up/uninterruptible power system and shall consist of three (3) major components: the Electronic Module, the Power Interface Module, and the Battery System consisting of 6 Outpost OPB-1241, or approved equal, batteries. The system must be capable of operating in two (2) modes: flash mode (red LEDs) and full normal operation mode (all LED indications). System shall include a timing circuit allowing automatic switching from full operation to all red flash at a selectable time interval. The UPS shall have two (2), continuously conditioned, true on-line, 5-15 receptacles for connecting the controller and other sensitive electronic equipment. The UPS shall include two (2) front panel LCD displays. One to count the number of times the UPS operates on battery and one to count the total elapsed time in battery mode. Enclosures constructed of material anodized prior to fabrication shall have all cut edges repaired for abraded or damaged anodized surfaces. 4) Auxilliary generator plug shall be installed. 209-4 TRAFFIC SIGNAL FACES AND FITTINGS 209-4.01 Vehicle Signal Faces. Each vehicle signal face shall be of the adjustable type conforming to the provisions in Institute of Traffic Engineers (ITE) Publication: ST-008B, "Vehicle Traffic Control Signal Heads." Plastic signal sections shall meet the requirements of California Test 605. Any fracture within the housing assembly, or a deflection of more than 10 degrees in either the vertical or horizontal plane after the wind load has been removed from the front of the signal face, or a deflection of more than 6 degrees in either the vertical or horizontal plane after the wind load has been removed from the back of the signal face will be considered structural failure. Vehicle signal faces, except arrow and "X" faces, shall meet the requirements of California Test 604. Adjustment shall permit rotation of 360 degrees about a vertical axis. The number and type of sections shall be as specified herein or as shown on the plans. Each vehicle signal face shall be installed at the location and mounted in the manner shown on the plans. Unless otherwise shown on the plans, all vehicle signal faces shall contain 3 sections arranged vertically; red-top, yellow-center, green- bottom. All new vehicle signal faces, except programmed visibility type, installed at any one intersection shall be of the same manufacture and of the same material. 209-4.01A Optical Units. Each optical unit for green, yellow and red sections, circular ball or arrow, shall conform to the provisions in Section 209-4.02, "Light Emitting Diode Signal Module". July 2005 Page 41 of 115 209-4.01B Signal Sections. Each signal section housing and backplate shall be made from aluminum. Signal sections shall conform to the following: 1. Maximum height of a signal section shall be 375 mm (143/V') for each 300 mm (12") section. 2. The housing of each signal section shall be provided with a one-piece, hinged, square-shaped door' designed to permit access to the section for relamping without the use of tools. 3. The door shall be secured by a method that will hold the door closed during the loading tests specified in this Section. 4. The lens shall be mounted in the door in a watertight manner. 5. All exposed hardware, such as hinge pins and door latching devices, shall be Type 304 or 305 stainless steel. 6. All interior screws and fittings shall be stainless steel. 7. An opening shall be provided in the top and bottom of each signal section to receive 40 mm (11/2") pipe. 8. The 300 mm (12") signal sections of an individual manufacturer shall be capable of joining to form a signal face in any combination. This interchangeability is not required between metal and plastic signal sections. 9. All gaskets, including those for the door, lens, reflector and lamp holder, shall be made of a material that is not affected when installed in a signal section with a metal or plastic housing that is operated continuously for 336 hours. 209-4.01C Electrical Components. Lamp receptacles and wiring shall conform to ITE Publications: ST- 008B. The metal portion of the medium base lamp socket shall be brass, copper or phosphor bronze. Each lamp receptacle shall be wired with a conductor, connected to the shell of the receptacle, with black insulation or with insulation color-coded. These conductors shall, in turn, be connected to a terminal block mounted inside at the back of the housing. The terminal block shall have sufficient screw type terminals or NEMA type tab connectors to terminate all field conductors and lamp conductors independently. The terminals to which field conductors are attached shall be permanently identified or conductors shall be color coded to facilitate field wiring. Lamp receptacle conductors shall be No. 18 or larger, 600-V, appliance wiring material (AWM), with 0.75 mm (30 mil) thickness insulation rated 105°C or with insulation that conforms to the requirements in Military Specification MIL-W-16878D, Type B, with vinyl nylon jacket rated 115°C. The manufacturer's name or trademark, conductor size, insulation type letter designation and temperature rating shall be marked on the insulation or a Certificate of Compliance conforming to the provisions in Section 6-1.07, "Certification of Compliance", shall be submitted by the manufacturer with each shipment of traffic signal faces. 209-4.01D Visors. Each signal section shall be provided with a removable visor conforming to ITE Publication: ST-008B. Visors are classified, on the basis of lens enclosure, as full circle, runnel (bottom open), or cap (bottom and lower sides open). Unless otherwise specified, visors shall be the tunnel type. The visor shall be a minimum of 240 mm (9V2") in length for nominal 300 mm (12") round lenses, with a downward tilt between 3 degrees and 7 degrees. Plastic visors shall conform to the following: 1. Visors shall be either formed from sheet plastic or assembled from one or more injection, rotational or blow molded plastic sections. 2. Sections shall be joined using thermal, chemical or ultrasonic bonding or with aluminum rivets and washers permanently colored to match the visor. 3. Visors shall be of black homogeneous colored material with a lusterless finish. 4. Each visor shall be secured to its door in a manner that will prevent its removal or permanent deformation when the wind load specified in California Test 605 for plastic visors is applied to the side of the visor for 24 hours. 209-4.02 Light Emitting Diode Signal Modules. Each light emitting diode (LED) signal module shall be Type 1 and consist of an assembly that utilizes light emitting diodes as the light source in lieu of an incandescent lamp for use in traffic signal sections and conform to the following: July 2005 Page 42 of 115 1. Each Type 1 LED signal module shall be designed to mount in the standard lamp socket normally used with an incandescent lamp. When a Type 1 LED signal module is used, a standard traffic signal lens in the doorframe shall be used or, at the option of the Contractor, the standard lens may be replaced with a translucent or clear lens to seal the signal section from weather. The installation of a Type 2 LED signal module shall not require any modification to the standard lamp socket or reflector. 2. LED signal modules shall be from the same manufacturer, and each size shall be the same model. 3. Type 1 LED signal modules shall be a sealed unit containing all components necessary for operation except, at the option of the Contractor, use of a corresponding lens mounted in the doorframe will be allowed. 4. Type 1 LED signal modules shall not require a specific mounting orientation or have a variance in light output, pattern or visibility for any mounting orientation. 5. The LEDs utilized in the modules shall be GELcore or City of San Marcos approved equal. 12" Red Ball D12RA4 12" Red Arrow D12RA7 12" Yellow Ball D12RY4 12" Yellow Arrow D12YA7 12" Green Ball D12GA4 12" Green Arrow D12GA7 6. The individual LEDs shall be wired such that a catastrophic failure of one LED will result in the loss of not more than 5 percent of the signal module light output. The failure of an individual LED in a string shall only result in the loss of that LED, not the entire string or indication. 209-4.02A Physical and Mechanical Requirements. LED traffic signal modules shall be designed as retrofit replacements for existing optical units of signal lamps and shall not require special tools for installation. LED signal modules shall fit into existing traffic signal section housings without any modification to the housing. Installation of a LED signal module shall only require the removal of the optical unit components, i.e., lens, lamp module, gaskets, and reflector; shall be weather tight and fit securely in the housing; and shall connect directly to electrical wiring. The arrow modules shall meet or exceed specifications stated in Section 9.01 of the ITE Publication: Equipment and Materials Standards, Chapter 2 (Vehicle Traffic Control Signal Heads) for arrow indications. The LEDs shall be spread evenly across the illuminated portion of the arrow area. 209-4.02A(1) LED Signal Module Lens. The LED signal module shall be capable of replacing the optical unit. The lens may be tinted or may use transparent film or materials with similar characteristics to enhance ON/OFF contrasts. The use of tinting or other materials to enhance ON/OFF contrasts shall not affect chromaticity and shall be uniform across the face of the lens. If a polymeric lens is used, a surface coating or chemical surface treatment shall be used to provide front surface abrasion resistance. 209-4.02A(2) Environmental Requirements. The LED signal module shall be rated for use in the operating temperature range of-40°C (-40°F) to +74°C (+165°F). The LED signal module shall be protected against dust and moisture intrusion per the requirements of NEMA Standard 250-1991 for Type 4 enclosures to protect all internal components. The LED signal module lens shall be UV stabilized and shall be capable of withstanding ultraviolet (direct sunlight) exposure for a minimum period of 60 months without exhibiting evidence of deterioration. 209-4.02A(3) Construction. The LED signal module shall be a single, self-contained device, not requiring on-site assembly for installation into an existing traffic signal housing. The power supply for the LED signal module shall be integral to the unit. The assembly and manufacturing process for the LED signal assembly July 2005 Page 43 of 115 shall be designed to assure all internal components are adequately supported to withstand mechanical shock and vibration from high winds and other sources. 209-4.02A(4) Materials. Material used for the lens and signal module construction shall conform to ASTMl specifications for the materials where applicable. Enclosures containing either the power supply or electronic components of the signal module shall be made of UL94VO flame retardant materials. The lens of the signal module is excluded from this requirement. 209-4.02A(5) Module Identification. Each LED signal module shall have the manufacturer's name, trademark, and other necessary identification permanently marked on the back of the module. Each individual LED signal module shall be identified with serial number for warranty purposes. The following operating characteristics shall be identified: rated voltage, power consumption, and volt-ampere. 209-4.02B Photometric Requirements. The minimum initial luminous intensity values for the modules shall be as stated in Table 209-4.028(1) and Table 209-4.028(3) at 25°C. The modules shall meet or exceed the illumination values as shown in Table 209-4.02B(2) and Table 209^1.028(4), throughout the useful life based on normal use in a traffic signal operation over the operating temperature range. The measured chromaticity coordinates of the modules shall conform to the chromaticity requirements of Table 209-4.028(5), throughout the useful life over the operating temperature range. The LED signal modules tested or submitted for testing shall be representative of typical average production units. Circular modules shall be tested according to California Test No. 604. All optical testing shall be performed with the module mounted in a standard traffic signal section but without a visor or hood attached to the signal section. The LEDs shall be spread evenly across the illuminated portion of the arrow area. Arrow modules shall be tested according to California Test No. 3001. All optical testing shall be performed with the module mounted in a standard traffic signal section but without a visor or hood attached to the signal section. Each LED arrow signal section indication shall provide a minimum average luminous intensity as listed in Table 209-4.028(3). All measurements shall be performed at rated operating voltage of 120 VAC. J uly 2005 Page 44 of 115 Table 209-4.028(1) Minimum Initial Intensities for Circular Indications (in cd) Angle (v,h) 2.5, ±2.5 2.5, ±7.5 2.5, ±12.5 2.5, ±17.5 7.5, ±2.5 7.5, ±7.5 7.5, ±12.5 7.5, ±17.5 7.5, ±22.5 7.5, ±27.5 12.5, ±2.5 12.5, ±7.5 12.5, ±12.5 12.5, ±17.5 12.5, ±22.5 12.5, ±27.5 17.5, ±2.5 17.5, ±7.5 17.5, ±12.5 17.5, ±17.5 17.5, ±22.5 17.5, ±27.5 -..»- ••-'.-;,' • 30dmm(12**>^-»'t^*-'u;.-4^%*.;Jt^ Red 399 295 166 90 266 238 171 105 45 19 59 57 52 40 26 19 26 26 26 26 24 19 - -" YeOfffirA.i^e^^ 798 589 333 181 532 475 342 209 90 38 119 114 105 81 52 38 52 52 52 52 48 38 July 2005 Page 45 of 115 Table 209-4.026(2) Maintained Minimum Intensities for Circular Indications (in cd) Angle (v,h) 2.5, ±2.5 2.5, ±7.5 2.5, ±12.5 2.5, ±17.5 7.5, ±2.5 7.5, ±7.5 7.5, ±12.5 7.5, ±17.5 7.5, ±22.5 7.5, ±27.5 12.5, ±2.5 12.5, ±7.5 12.5, ±12.5 12.5, ±17.5 12.5, ±22.5 12.5, ±27.5 17.5, ±2.5 17.5, ±7.5 17.5, ±12.5 17.5, ±17.5 17.5, ±22.5 17.5, ±27.5 300 mm (12") Red 339 251 141 77 226 202 145 89 38 16 50 48 44 34 22 16 22 22 22 22 20 16 Yellow & Green 678 501 283 154 452 404 291 178 877 32 101 97 89 69 44 32 44 44 44 44 41 32 Table 209-4.02B(3) Minimum Initial Intensities for Arrow Indications (in cd/m2) Arrow Indication Red 5,500 Yellow & Green 11,000 Table 209-4.023(4) Minimum Maintained Intensities for Arrow Indications (in cd/m2) Arrow Indication Red 5,500 Yellow & Green 11,000 Table 209-4.02B(5) Chromaticity Standards (CIE Chart) Red Yellow Green Y: not greater than 0.308, or less than 0.998-x Y: not less than 0.41 1, nor less than 0.995-x, nor less than 0 452 Y: not less than 0.506-0. 519x, nor less than 0.150+1. 068x, nor more than 0.730-x oJuly 2005 Page 46 of 115 209-4.02C Electrical. Maximum power consumption requirements for LED signal modules shall be as listed in Table 209-4.02C. Table 209-4.02C Maximum Power Consumption (in Watts) Temperature 300 mm circular 300 mm arrow Red 25°C 11 9 74°C 17 12 Yellow 25°C 22 10 74°C 25 12 : • Green '••': '••' '•: 'V 25°C 12 13 74°C 12 13 LED signal modules shall operate from a 60 Hz ±3 Hz AC line over a voltage ranging from 80 volts to 135 volts. The LED circuitry shall prevent perceptible flicker over the voltage range specified above. The fluctuations of line voltage shall have no visible effect on the luminous intensity of the indications. Rated voltage for all measurements shall be 120 volts. The signal module on-board circuitry shall include voltage surge protection to withstand high-repetition noise transients as stated in Section 2.1.6 of NEMA Standard TS- 2, 1992. LED signal modules shall be operationally compatible with currently used controller assemblies (solid state load switches, flashers, and conflict monitors). When a current of 20 ma AC (or less) is applied to the unit, the voltage read across the two leads shall be 15 VAC or less. LED signal modules and associated on-board circuitry must meet Federal Communications Commission (FCC) Title 47, SubPart B, Section 15 regulations concerning the emission of electronic noise. The LED signal module shall provide a power factor of 0.90 or greater. Total harmonic distortion (current and voltage) induced into an AC power line by an LED signal module shall not exceed 20 percent. 209-4.02D Quality Assurance. LED signal modules shall be manufactured in accordance with a vendor quality assurance (QA) program. The QA program shall include two types of quality assurance: (1) design quality assurance and (2) production quality assurance. The production quality assurance shall include statistically controlled routine tests to ensure minimum performance levels of LED signal modules built to meet this specification. QA process and test results documentation shall be kept on file for a minimum period of seven years. LED signal module designs not satisfying design qualification testing and the production quality assurance testing performance requirements described below shall not be labeled, advertised, or sold as conforming to this specification. 209-4.02D(1) Manufacturer's Serial Numbers. Identification of the component and sub-assembly level may be required if the reliability and performance of the module must be traceable to the original item manufacturers of the module components and subassemblies. 209-4.02D(2) Production Quality Assurance Testing. The following Production Quality Assurance tests shall be performed on each new LED signal module prior to shipment. Failure to meet requirements of any of these tests shall be cause for rejection. The manufacturer for warranty purposes shall retain test results for seven years. Each LED signal module shall be tested for rated initial intensity after burn-in. Burn-in period shall consist of each signal module being energized at rated voltage for a 30 minutes stabilization period before the measurement is made. A single point measurement with a correlation to the intensity requirements of Table 209-4.02B(1) for circular modules may be used. The ambient temperature for this measurement shall be +25°C (+77°F). Each LED signal module not meeting minimum luminous intensity requirements per Table 209-4.028(1) or Table 209-4.02B(3) shall be a cause for rejection. Each LED signal module shall be tested for required power factor after bum-in. July 2005 Page 47 of 115 Each LED signal module shall be measured for current flow in amperes after bum-in. The measured current values shall be compared against current values resulting from design qualification measurements under "Design Qualification Testing". The current flow shall not exceed the rated value. The measured amperet values with rated voltage shall be recorded as volt-ampere (VA) on the product labels. Each LED signal modules shall be visually inspected for any exterior physical damage or assembly anomalies. Careful attention shall be paid to the surface of the lens to ensure there are no scratches (abrasions), cracks, chips, discoloration, or other defects. Any such defects shall be cause for rejection. 209-4.02D(3) Design Qualification Testing. Design Qualification testing shall be performed on new LED signal module designs, and when a major design change has been implemented on an existing design. The minimum sample quantity of LED signal modules shall be as stated for each test. Failure to meet requirements for any of these tests shall be cause for rejection. A random sample of six LED signal modules shall be energized for a minimum of 24 hours, at 100 percent on-time duty cycle, in a temperature of 74°C (+165°F) before performing any design qualification testing. Any failure within an LED signal module after bum-in shall be cause for rejection. 209-4.02D(4) Rated Initial Luminous Intensity. After burn-in, a sample of six LED signal modules shall be tested for rate initial intensity per the requirements of "Photometric Requirements". Before measurement, each LED signal module shall be energized at rated voltage, with 100 percent on-time duty cycle, for a time period of 30 minutes. The ambient temperature for this measurement shall be 25°C (77°F). The test results for this test shall have recorded the current voltage, total harmonic distortion (THD), and power factor (PF) associated with each measurement. 209-4.02D(5) Chromaticity (Color). A sample of two LED signal modules shall be measured for chromaticity (color) per the requirements of "Chromaticity requirements under "Photometric Requirements." A spectra radiometer shall be used for this measurement. The ambient temperature for this measurement shall be 25°C(77°F). 209-4.02D(6) Electrical. A sample of six LED signal modules shall be measured for current flow in amperes. The measured current values shall be used for quality comparison of Production Quality Assurance current measurement on production modules. A sample of six LED signal modules shall be measured for power factor. A commercially available power factor meter may be used to perform this measurement. A sample of six LED modules shall be measured for total harmonic distortion. A commercially available total harmonic distortion meter may be used to perform this measurement. A sample of six LED signal modules shall be tested per the requirements of "Electrical", with reference to Class A emission limits referenced in Federal Communications Commission (FCC) Title 47, SubPart B, Section 15. July 2005 Page 48 of 115 A sample of six LED signal modules shall be tested for compatibility with the controller unit, conflict monitor, and load switch. Each signal module shall be connected to any AC voltage supply between the values of 80 and 135 VAC. The AC voltage developed across each LED signal module so connected shall not exceed 10 volts rms as the input AC voltage is varied from 80 volts to 135 volts rms. A sample of six LED modules shall be tested for transient immunity per "Electrical" using the procedure described in NEMA Standard TS-1992. Mechanical vibration testing shall be performed on a sample of three LED signal modules per MEL-STD-883, Test Method 2007, using three 4 minute cycles along each x, y, and z axis, at a force of 2.5 Gs, with a frequency sweep from 2 Hz to 120 Hz. The loosening of the lens, of any internal components, or other physical damage shall be cause for rejection. Temperature cycling shall be performed on a sample of three LED signal modules per MIL-STD-883, Test method 1010. The temperature range shall be per "Environmental Requirements". A minimum of 20 cycles shall be performed with a 30 minute transfer time between temperature extremes and a 30 minute dwell time at each temperature. Signal under test shall be non-operating. Failure of a module to function properly or any evidence of cracking of the module lens or housing after temperature cycling shall be cause for rejection. Moisture resistance testing shall be performed on a sample of three LED signal modules per NEMA Standard 250-1991 for Type 4 enclosures. Any evidence of internal moisture after testing shall be cause for rejection. 209-4.02D(7) Certificate of Compliance. The Contractor shall provide the Engineer a Certificate of Compliance from the manufacturer in accordance with the provisions of Section 6-1.07, "Certificates of Compliance," of the Caltrans Standard Specifications. The certificate shall certify that the LED signal modules comply with the requirements of these specifications. The certificate shall also include a copy of all applicable test reports on the LED signal modules. LED signal modules shall be guaranteed by the Contractor for a period of one year starting on the day after the project is accepted by the Engineer. Modules that fail during this period shall be replaced at no cost to the City, except that City forces will change out the modules in the field. The replacement modules shall be delivered to the Public Works Department at 405 Oak Avenue within five working days after notification. The failed modules will be made available to the Contractor at the above address at the same time as the replacement is delivered. The manufacturer shall provide a written warranty against defects in materials and workmanship for the LED signal modules for a period of 36 months after installation of the modules. Replacement modules shall be provided promptly after receipt of modules that have failed at no cost to the State except cost of shipping of the failed modules. All warranty documentation shall be given to the Engineer prior to installation. The replacement modules shall be delivered to the Public Works Department at 405 Oak Avenue. 209-4.03 Directional Louvers. Where shown on the plans, directional louvers shall be furnished and installed in signal visors. Directional louvers shall be so constructed as to have a snug fit in the signal visors. The outside cylinder shall be constructed of 0.75 mm (0.030") nominal thickness, or thicker, sheet steel and the vanes shall be constructed of 0.4 mm (0.016") nominal thickness, or thicker, sheet steel or the cylinder and vanes shall be constructed of 5052-H32 aluminum alloy of equivalent thickness. Dimensions of louvers and arrangements of vanes shall be as shown on the plans. July 2005 Page 49 of 115 209-4.04 Backplates. One piece metal backplates shall be furnished and installed on all signal faces. 209-4.05 Programmed Visibility Vehicle Signal Faces. Each programmed visibility signal face and ti installation thereof shall conform to the provisions in Sections 209-4.01, "Vehicle Signal Faces," 209-4.03,' "Backplates," and 209-4.06, "Signal Mounting Assemblies," except that the provisions in Section 209-4.01A, "Optical Units," shall not apply. Each programmed visibility signal section shall provide a nominal 300 mm (12") diameter circular or arrow indication. Color and arrow configuration shall conform to ITE Publication: ST-008B. Each section shall be provided with a cap visor. Each signal section shall be provided with an adjustable connection that permits incremental tilting from 0 to 10 degrees above or below the horizontal while maintaining a common vertical axis through couplers and mountings. Terminal connection shall permit external adjustment about the mounting axis in 5 degree increments. The signal shall be mountable with ordinary tools and capable of being serviced without tools. Adjustment shall be preset at 4 degrees below the horizontal, unless otherwise specified. The visibility of each programmed visibility signal face shall be capable of adjustment or programming within the face. When programmed, each signal face's indication shall be visible only in those areas or lanes to be controlled, except that during dusk and darkness a faint glow to each side will be permissible. Prior to programming, each signal section with a yellow indication shall provide a minimum luminous intensity of 2500 cd on the optical axis, and a maximum intensity of 100 cd at 15 degrees horizontal from the axis. Each signal section with a yellow indication shall be capable of having its visibility programmed to achieve the following luminous intensities: a minimum of 2500 cd on the optical axis, a maximum of 100 cd at from 0.5 to 2 degrees horizontal from the axis and a maximum of 10 cd at from 2 to 15 degrees horizontal from the axis. Under the same conditions, the intensities of the red indication and the green indication shall be at least 19 and 38 percent, respectively, of the yellow indication. Each signal face or each signal section shall include integral means for regulating its luminous intensity between limits in proportion to the individual background luminance. Lamp intensity shall not be less than 97 percent of uncontrolled intensity at lOOOOlx, and shall reduce to 15 ±2 percent of maximum intensity at less than 10 Ix. The dimming device shall operate over an applied voltage range of 95 to 130 V, 60 Hz and a temperature range of -40°C to 74°C. The Contractor shall program the head as recommended by the manufacturer and as directed by the Engineer. 209-4.06 Pedestrian Signal Faces. Message symbols for pedestrian signal faces shall be white WALKING PERSON and Portland orange UPRAISED HAND conforming to the requirements of the Institute of Transportation Engineers Standards: "Pedestrian Traffic Control Signal Indications" and the "Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement". The height of each symbol shall be not less than 250 mm (10") and the width of each symbol shall be not less than 165 mm (6V2"). The luminance of the UPRAISED HAND symbol shall be 3750 cd/m2 (1,100 foot-lamberts), minimum, and the luminance of the WALKING PERSON symbol shall be 5300 cd/m2 (1,550 foot-lamberts), minimum, when tested in accordance with California Test 606. The uniformity ratio of an illuminated symbol shall not exceed 4 to 1 between the highest luminance area and the lowest luminance area. The luminance difference between a nonilluminated symbol and the background around the symbol shall be less than 30 percent when viewed with the front screen in place and at a low sun angle. Brightness measurements for signals designed for an incandescent lamp will be made when the signal is equipped with an A-21 traffic signal lamp operated at a voltage to produce 665 lumens. Each housing, including the front screen, shall have maximum overall dimensions of 470 mm (18'/2") width, 483 mm (19") height and 292 mm (11V2") depth. All new pedestrian signal faces installed at any one intersection shall be the same make and type. Each pedestrian signal face shall be installed at the location and mounted in the manner shown on the plans. 209-4.06A Types. Pedestrian signal faces shall be Type A and shall conform to the following: Each Type A signal shall consist of a housing, two-color message plate, a reflector assembly, two light emitting diode modules conforming to the provisions in Section 209-4.07, "Light Emitting Diode Pedestrian Signal Modules", with sockets and a front screen. Each message plate shall be one piece and shall be made 4.7 mm (3/I6") tempered glass. The symbols shall be applied to the inside smooth surface of the message plate. Each reflector assembly shall consist of a double reflector or 2 single reflectors. Each reflector shall be made July 2005 Page 50 of 115 of either aluminum or plastic. All reflectors shall conform to the provisions in Institute of Traffic Engineers Publication: ST-008B, "Vehicle Traffic Control Signal Heads." Plastic reflectors shall consist of molded or vacuum-formed plastic with a vacuum-deposited aluminum reflecting surface. The plastic material shall not distort when the reflector is used with the lamp of the wattage normally furnished with the signal. In addition, the UL nonmechanical loading temperature of the material shall exceed, by at least 10°C, the maximum temperature in the signal section with the lamp "ON" and measured in an ambient air temperature of 25°C in accordance with UL Publication UL 746B. Each completed reflector shall, when operated with the appropriate lamp and lens, provide the message brightness specified. 209-4.06B Front Screen. The front screen provided on each Type A signal shall have a 38 mm (1V2") deep eggcrate or Z-crate type screen of 0.8 mm (0.03") nominal thickness polycarbonate. The screening shall be mounted in a frame constructed of 1.0 mm (0.04") minimum thickness polycarbonate. The screen shall be installed parallel to the face of the message plate and shall be held in place by the use of stainless steel screws. The front screen shall not fracture, separate at the welds, or compress more than 3 mm (V8") when a 75 mm (3") diameter, 1.8-kg (41b.) steel ball is dropped onto the screen from a height of 1.2 m (4') above the screen. The screen will be lying in a horizontal position and supported on its edges for this test. The message plate will be removed from the pedestrian signal housing, when the pedestrian housing is used to support the front screen during the test, so there will be no back support for the screen. The screen and frame shall be fabricated from aluminum anodized flat black, or finished with lusterless black exterior grade latex paint formulated for application to properly prepared metal surfaces, or shall be fabricated from flat black plastic. Alternate methods of screening may be substituted for the above screens provided that the results are at least equal to those obtained with the above specified screens as determined by the Engineer. 209-4.06C Housing. Pedestrian signal housings shall conform to the provisions in Section 209-4.0IB, "Signal Sections." 209-4.06E Finish. The exterior of each housing and visor and the interior of visors shall be painted in accordance with the provisions in Section 209-2.16, "Painting." 209-4.06F Controls. All pedestrian signals shall be capable of being controlled by the solid-state switching devices specified for traffic signal controller assemblies. 209-4.06G Terminal Blocks. Each pedestrian signal face shall be provided with a light duty terminal block conforming to the provisions in Section 209-4.01C, "Electrical Components." All field wiring shall connect to this terminal block. 209-4.07 Light Emitting Diode Pedestrian Signal Modules For Type A pedestrian signal faces, the pedestrian signal face "Upraised Hand" & "Walking Person" module shall utilize light emitting diode. Each light emitting diode (LED) pedestrian signal face "Upraised Hand" & "Walking Person" module shall consist of an assembly that utilizes light emitting diodes as the light source in lieu of an incandescent lamp for use in pedestrian signal faces and shall conform to the following: 1. LED Pedestrian signal face "Upraised Hand" & "Walking Person" module shall be designed to mount in the standard existing Type "A" Housing. Pedestrian signal face modules shall be designed to mount behind or replace the existing face plate of existing Type "A" housing as specified by the requirements of the ITE Standards: "Pedestrian Traffic Control Signal Indications" and the "Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Sup- plement". The design of the modules shall require a specific mounting orientation. 2. LED pedestrian signal module used on this project shall be from the same manufacturer. July 2005 Page 51 of 115 3. The circuit board and power supply shall be contained inside the module. Circuit boards shall conform to Chapter 1, Section 6 of the "Transportation Electrical Equipment Specifications". 4. LED pedestrian signal modules shall fit into the existing type "A" housing and shall not require a specific mounting orientation or have a variance in light output, pattern or visibility for any mounting orientation. 5. The LEDs for "Upraised Hand" symbol shall utilize AllnGaP technology and shall be the ultra bright type rated for 100,000 hours of continuous operation from -40°C to 74°C. 6. The individual LEDs shall be wired such that a catastrophic failure of one LED will result in the loss of not more then 5 percent of the signal module light output. The failure of an individual LED in a string shall only result in the loss of that LED, not the entire string or indication. 7. The LED ped modules tested or submitted for testing shall be representative of typical average production units. LED ped modules shall be tested according to California Test No. 610 and as described herein. All optical testing shall be performed with the module mounted in a standard Type "A" Pedestrian Housing but without a visor or hood attached to the housing. 8. The luminance of the UPRAISED HAND symbol shall be 3750 cd/m2 minimum. The color of UPRAISED HAND should be Portland orange conforming to the requirements of the institute of Transportation Engineers Standards: "Pedestrian Traffic Control Signal Indications" and the "Manual on Uniform Traffic Control Devices." The height of each symbol shall be not less than 250 mm and the width of each symbol shall not be less than 165 mm. 9. The luminance of the WALKING PERSON symbol shall be 5300 cd/m2 minimum. The color of WALKING PERSON should be White conforming to the requirements of the Institute of Transporta- tion Engineers Standards: "Pedestrian Traffic Control Signal Indications" and the "Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Sup- plement". The height of each symbol shall be not less than 250 mm and the width of each symbol shall not be less than 165 mm. 10. The uniformity ratio of an illuminated symbol shall not exceed 4 to 1 between the highest luminance area and the lowest luminance area. 11. LED ped module shall be rated for a minimum useful life of 48 months and shall maintain not less than 85 percent of 3750 cd/m2 for UPRAISED HAND & 5300 cd/m2 for WALKING PERSON after 48 months of continuous use in a traffic signal operation over the temperature range of -40°C to +74°C. 209-4.07A Physical And Mechanical Requirements. LED ped module traffic signal modules shall be designed as retrofit replacements for existing optical units of signal lamps and shall not require special tools for installation. LED ped module shall fit into existing traffic signal section housings built to the VTCSH without modification to the housing. Installation of an LED ped module shall require the removal of the lens, reflector and lamps. 209-4.07A(l) Environmental Requirements. LED ped modules shall be rated for use in the operating temperature range of-40°C (-40T) to +74°C (+165°F). 209-4.07A(2) Construction. LED ped modules shall be a single, self-contained device, not requiring on-site assembly for installation into an existing Type "A" housing. The power supply for the LED ped module shall be integral to the unit. The assembly and manufacturing process for the LED ped module assembly shall be designed to assure all internal components are adequately supported to withstand mechanical shock and vibration from high winds and other sources. A•^ July 2005 Page 52 of 115 209-4.07A(3) Materials. Material used for the LED ped module construction shall conform to ASTM specifications for the materials where applicable. Enclosures containing either the power supply or electronic components of the LED ped module shall be made of UL94VO flame retardant materials. 209-4.07A(4) Module Identification. Each LED ped module shall have the manufacturer's name, trademark, and other necessary identification permanently marked on the back of the module. Each individual LED ped module shall be identified for warranty purposes. The following operating characteristics shall be identified: rated voltage, power consumption, and volt-ampere. If a specific mounting orientation is required, each module shall have prominent and permanent marking(s) for correct indexing and orientation within a signal housing. The marking shall consist of an up arrow, or the word "UP" or "TOP". Type A Pedestrian Signal Face (Combination Raised Hand/Walking Person section) housing without the reflector shall be utilized for LED combo modules. 209-4.07B Photometric Requirements. An LED ped module shall meet at least 85 percent of the minimum 3750 cd/m2 for UPRAISED HAND & 5300 cd/m2 for WALKING PERSON while operating throughout the operating temperature range of -40°C to 74°C. The minimum initial luminous intensity values for UPRAISED HAND LED ped modules shall be 3750 cd/m2 at 25°C. The minimum initial luminous intensity values for WALKING PERSON LED ped modules shall be 5300 cd/m2 at 25°C. The measured chromaticity coordinates of LED ped modules shall conform to the chromaticity requirements of Section 5.3.2.1 and Figure C of the VTCSH standards. 209-4.07C Electrical. Maximum power consumption requirements for LED signal modules shall be as follows: LED Signal Module UPRAISED HAND WALKING PERSON POWER CONSUMPTION 25°C 10.0W 12.0W POWER CONSUMPTION 74°C 12.0W 15.0W LED pedestrian signal modules shall operate from a 60 ±3 Hz AC line over a voltage ranging from 95 V to 135 V. The LED ped module circuitry shall prevent perceptible flicker over the voltage range specified above. The fluctuations of line voltage shall have no visible effect on the luminous intensity of the indications. Rated voltage for all measurements shall be 120 V. The LED ped module on-board circuitry shall include voltage surge protection to withstand high-repetition noise transients as stated in Section 2.1.6 of NEMA Standard TS- 2, 1992. The LED circuitry shall prevent perceptible flicker to the unaided eye over the voltage range specified above. All wiring and terminal blocks shall meet the requirements of Section 13.02 of ITE Publication: Equipment and Material Standards, Chapter 2 (Vehicle Traffic Control Signal Heads). LED ped modules shall be operationally compatible with currently used controller assemblies (solid state load switches, flashers, and conflict monitors). When a current of 20 ma AC (or less) is applied to the unit, the voltage read across the two leads shall be 15 VAC or less. LED ped modules and associated on-board circuitry must meet Federal Communications Commission (FCC) Title 47, SubPart B, Section 15 regulations concerning the emission of electronic noise. The LED ped module shall provide a power factor of 0.90 or greater. Total harmonic distortion (current and voltage) induced into an AC power line by an LED ped module shall not exceed 20 percent. 209-4.07D Quality Assurance. LED ped modules shall be manufactured in accordance with a vendor quality assurance (QA) program. The QA program shall include two types of quality assurance: (1) design quality assurance and (2) production quality assurance. The production quality assurance shall include statistically controlled routine tests to ensure minimum performance levels of LED ped modules built to meet this specification. QA process and test results documentation shall be kept on file for a minimum period of seven years. LED ped module designs not satisfying design qualification testing and the production quality assurance testing performance requirements described below shall not be labeled, advertised, or sold as conforming to this specification. m& July 2005 Page 53 of 115 209-4.07D(1) Manufacturer's Serial Numbers. Identification of the component and sub-assembly level may be required if the reliability and performance of the module must be traceable to the original item manufacturers of the module components and subassemblies. ^t 209-4.07D(2) Production Quality Assurance Testing. The following Production Quality Assurance tests shall be performed on each new LED ped module prior to shipment. Failure to meet requirements of any of these tests shall be cause for rejection. The manufacturer for warranty purposes shall retain test results for seven years. Each LED ped module shall be tested for rated initial intensity after burn-in. Burn-in period shall consist of each signal module being energized at a rated voltage for a 30 minute stabilization period before the measurement is made. Each LED ped module not meeting 3750 cd/m2 for UPRAISED HAND & 5300 cd/m2 for WALKING PERSON luminous intensity requirements shall be cause for rejection. Each ped module shall be tested for required power factor after burn-in. Each LED ped module shall be measured for current flow in amperes after burn-in. The measured current values shall be compared against current values resulting from design qualification measurements under "Design Qualification Testing". The current flow shall not exceed the rated value. The measured ampere values with rated voltage shall be recorded as volt-ampere (VA) on the product labels. Each LED ped module shall be visually inspected for any exterior physical damage or assembly anomalies. Careful attention shall be paid to the surface of the lens to ensure there are no scratches (abrasions), cracks, chips, discoloration, or other defects. Any such defects shall be cause for rejection. 209-4.07D(3) Design Qualification Testing- Design qualification testing shall be performed on new LED ped module designs, and when a major design change has been implemented on an existing design. The minimum sample quantity of LED ped modules shall be as stated for each test. Failure to meet requirements for any of these tests shall be cause for rejection. A random sample of six LED ped modules shall be energized for a minimum of 24 hours, at 100 percent on-time duty cycle, in a temperature of 74°C (+165°F) before performing any design qualification testing. Any failure within an LED ped module after burn-in shall be cause for rejection. 209-4.07D(4) Rated Initial Luminous Intensity. After bum-in, a sample of six LED ped modules shall be tested for rated initial intensity per the requirements of "Photometric Requirements". Before measurement, each LED ped module shall be energized at rated voltage, with 100 percent on-time duty cycle, for a time period of 30 minutes. The ambient temperature for this measurement shall be 25°C (77°F). The test results for this test shall have recorded the current voltage, total harmonic distortion (THD), and power factor (PF) associated with each measurement. 209-4.07D(5) Chromaticity (Color). A sample of two LED ped modules shall be measured for chromaticity (color) per the requirements of "Chromaticity requirements under "Photometric Requirements." A spectraradiometer shall be used for this measurement. The ambient temperature for this measurement shall be 25°C (77°F). 209-4.07D(6) Electrical. A sample of six LED ped modules shall be measured for current flow in amperes. The measured current values shall be used for quality comparison of Production Quality Assurance current measurement on production modules. A sample of six LED ped modules shall be measured for power factor. A commercially available power factor meter may be used to perform this measurement. A sample of six LED ped modules be measured for total harmonic distortion. A commercially available total harmonic distortion meter may be used to perform this measurement. A sample of six LED ped modules shall be tested per the requirements of "Electrical", with reference to Class A emission limits referenced in Federal Communications Commission (FCC) Title 47, SubPart B, Section 15. A sample of six LED ped modules shall be tested for compatibility with the controller unit, conflict monitor, and load switch. Each signal module shall be connected to any AC voltage supply between the values of 80 and 135 VAC. The AC voltage developed across each LED ped module so connected shall not exceed 10 volts rms as the input AC voltage is varied from 80 V rms to 135V rms. July 2005 Page 54 of 115 A sample of six LED ped modules shall be tested for transient immunity per "Electrical" using the procedure described in NEMA Standard TS-1 992. Mechanical vibration testing shall be performed on a sample of three LED ped modules per MIL-STD-883, Test Method 2007, using three 4 minute cycles along each x, y, and z axis, at a force of 2.5 g, with a frequency sweep from 2 Hz to 120 Hz. The loosening of the lens, of any internal components, or other physical damage shall be cause for rejection. Temperature cycling shall be performed on a sample of three LED ped modules per MIL-STD-883, Test method 1010. The temperature range shall be per "Environmental Requirements". A minimum of 20 cycles shall be performed with a 30 minute transfer time between temperature extremes and a 30 minute dwell time at each temperature. Signal under test shall be non-operating. Failure of a module to function properly or any evidence of cracking of the module lens or housing after temperature cycling shall be cause for rejection. Moisture resistance testing shall be performed on a sample of three LED ped modules per NEMA Standard 250-1991 for Type 4 enclosures. Any evidence of internal moisture after testing shall be cause for rejection. 209-4.07D(7) Certificate of Compliance. The Contractor shall provide the Engineer a Certificate of Compliance from the manufacturer in accordance with the provisions of Section 6-1.07, "Certificates of Compliance," of the Standard Specifications. The certificate shall certify that the LED ped modules comply with the requirements of these specifications. The certificate shall also include a copy of all applicable test reports on the LED ped modules. 209-4.07D(8) Guarantee. The Contractor shall guarantee LED ped modules for a period of one year starting on the day after the Engineer accepts the project. Modules that fail during this period shall be replaced at no cost to the State, except that State forces will change out the modules in the field. The replacement modules shall be delivered to the Engineer, or to the Public Works Department at 405 Oak Avenue, within five working days after notification. The failed modules will be made available to the Contractor at the above address at the same time as the replacement is delivered. 209-4.07D(9) Warranty. The manufacturer shall provide a written warranty against defects in materials and workmanship for the LED ped modules for a period of 36 months after installation of the modules. Replacement modules shall be provided promptly after receipt of modules that have failed at no cost to the State except cost of shipping of the failed modules. All warranty documentation shall be given to the Engineer prior to installation. 209-4.08 Signal Mounting Assemblies. Signal mounting assemblies shall consist of 40 mm (lV2") standard weight steel galvanized pipe conforming to the specifications of ASTM Designation: A 53, necessary fittings, slip-fitters and terminal compartments. Pipe fittings shall be ductile iron, galvanized steel, aluminum alloy Type AC-84B No. 380, or bronze. Mast arm slip-fitters shall be cast bronze or hot-dip galvanized ductile iron. Post top slip-fitters and terminal compartments shall be cast bronze, Type 356-T6 aluminum or hot-dip galvanized ductile iron. After installation, any exposed threads of galvanized pipe brackets and all areas of the brackets damaged by wrench or vise jaws shall be cleaned with a wire brush and painted with 2 applications of approved unthinned zinc-rich primer (organic vehicle type) conforming to the requirements in Section 210, "Paint and Protective Coatings." Aerosol cans shall not be used. Each terminal compartment shall be fitted with a terminal block containing a minimum of 12 poles, each with 2 screw type terminals. Each terminal shall be designed to accommodate at least 5 No. 14 conductors. A cover shall be provided on the compartment to give ready access to the terminal block. Where used to bracket mount signals, the terminal compartment shall be designed to bolt securely to a pole or standard. The horizontal dimension of mounting assembly members between the vertical centerline of the terminal compartment or slip-fitter and the vertical centerline of each signal face, shall not exceed 280mm (11"), except where required to provide proper signal face alignment or permit programming of programmed visibility signal faces or when otherwise directed by the Engineer. Each mounting assembly shall be oriented to provide maximum horizontal clearance to the adjacent roadway. All mounting assembly members shall be either plumb or level, symmetrically arranged and securely assembled. Construction shall be such as to permit July 2005 Page 55 of 1 1 5 all conductors to be concealed. Mounting assemblies shall be watertight and free of sharp edges or protrusions which might damage conductor insulation. For post-top mounting of signals, a slip-fitter shall be used. Slip-fitter shall fit over a 115 mm (4'/2") outsider diameter pipe or tapered standard end. Each slip-fitter shall be provided with cadmium-plated steel set screws, arranged as shown on the plans. Each slip-fitter used to post-top mount signals with brackets shall be provided with an integral terminal compartment. Each mounting assembly shall be provided with positive locking, ser- rated fittings, which when mated with similar fittings on the signal faces shall prevent faces from rotating. Fittings shall permit fastening at increments of not more than 7 degrees. Signal faces shall not be installed at any intersection until all other signal equipment, including the complete controller assembly, is in place and ready for operation at that intersection, except that the signal faces may be mounted if they are not directed toward traffic or if they are covered. 209-4.09 Flashing Beacons. Each beacon shall consist of a single section traffic signal face, conforming to the provisions in Section 209-4.01, "Vehicle Signal Faces," with yellow or red lens as shown on the plans. The beacon flasher unit shall be independent of the intersection flasher unit. Reflective sheeting for W41 "Signal Ahead" signs, mounted on flashing beacons, shall be prismatic lens reflective sheeting (Diamond Grade or equal). 209-4.09A Backplates. Each beacon shall be provided with a backplate conforming to the requirements in Section 209-4.03, "Backplates." 209-4.09B Visors. Each beacon shall be provided with a full circle type visor conforming to the requirements in Section 209-4.01D, "Visors." 209-4.09C Flashing Beacon Control Assembly. Each flashing beacon control assembly shall consist of switches, circuit breakers, terminal blocks, flasher, dimming relay, wiring and electrical components necessary to provide proper operation of the beacons, all housed in a single enclosure. 209-4.09C(1) Enclosure. The enclosure shall be NEMA Type 3R, and shall be provided with dead front panel and a hasp to permit padlocking of the cover. The padlock will be furnished by others. The enclosure shall be hot-dip galvanized or, at the option of the Contractor, shall be provided with a factory applied rust resistant prime coat and finish coat. 209-4.09C(2) Circuit Breakers and Switches. A 15-A circuit breaker shall be installed to control each ungrounded conductor entering the enclosure. A switch to permit manual operation of the sign lighting circuit shall be provided. Switches shall be of the single-hole-mounting toggle type, single-pole, single-throw, rated at 12 A, 120 V. Switches shall be furnished with an indicating nameplate reading "Auto - Test" and shall be connected in parallel with the load contacts of the photoelectric control circuit. A 15-A circuit breaker may be used in place of the toggle switch. 209-4.09C(3) Flasher. The flasher shall meet the requirements of Section 8, "Solid-State Flashers," of NEMA Standards Publication No. TS 1. The flasher shall be a solid-state device with no contact points or moving parts. The flasher shall provide 2 output circuits to permit alternate flashing of signal faces and shall be capable of carrying a minimum of 10 A per circuit at 120 V. 209-4.09C(4) Wiring. Conductors and wiring in the enclosure shall conform to the requirements in Section 209-3.04C, "Cabinet Wiring." July 2005 Page 56 of 115 209-4.09C(5) Terminal Blocks. Terminal blocks shall be rated at 25 A, 600 V, shall be molded from phenolic or nylon material and shall be the barrier type with plated brass screw terminals and integral type marking strips. 209-4.09C(6) Dimming Relay. A heavy duty dimming relay shall be provided to reduce the voltage to the lamps at night. Heavy duty relays shall be designed for continuous duty. Relays shall operate during ambient temperatures from-18°C to 71 °C (0° to 160°F). Each relay shall operate in the 8-pin Jones-type socket shown on the plans. Relays shall be provided with double-pole, double-throw contacts. Contact points shall be of fine silver, silver-alloy, or superior alternative material. Contact points and contact arms shall be capable of operation for 250,000 cycles with 20 A of tungsten load per contact at 120 V, 60 Hz AC. Coils shall have a power consumption of 10 V-A or less and shall be designed for continuous duty on 120 volts AC. Heavy duty relays shall be enclosed with a removable, clear plastic cover. 209-5 DETECTORS 209-5.01 Vehicle Detectors. Vehicle detectors shall be the type or types shown on the plans. All sensor units, control units, and amplifiers shall meet the requirements of California Test 675. The units shall not be affected by transient voltages when tested in accordance with California Test 667. After a power interruption the units shall return to normal operation within one minute. Each unit shall be provided with a light or meter, for each output circuit, to indicate when the detector is detecting a vehicle. Each detector shall operate over the range of voltages from 100 volts to 135 volts at 60 Hz. Circuitry shall be solid-state except relays with normally closed contacts may be used for the output circuit. Units shall be designed to provide ease of maintenance with easily accessible electronic components. Each detector shall provide vehicle detection without readjustment from -18°C to 71°C (0° to 160°F). Units shall use printed circuit boards designed to facilitate identification of components. This shall be done by either part identification markings or by providing a pictorial diagram showing physical location and identification of each component. Each printed circuit board shall have the following minimum quality requirements: NEMA FR-4 glass cloth base epoxy resin board, 1.5 mm (Vi6") minimum thickness, organic solder masking and gold plated contacts. Intercomponent wiring shall be copper track with a minimum mass of 600 g/m2 (2 oz/ft2). Printed circuit design shall be such that components may be removed and replaced without permanent damage to boards or tracks. Splices shall conform to the provisions in Section 209-2.09, "Wiring." 209-5.01 A Inductive Loop Detectors. Inductive loop detectors shall conform to the following: 209-5.01 A(l) General. The term "inductive loop detector" applies to a complete installation consisting of a loop or group of loops installed in the roadway, as shown on the plans, lead-in cable and a sensor unit with power supply installed in a controller cabinet. 209-5.01A(3) Sensor Unit Construction. "Card" type sensor units shall conform to the requirements in "Traffic Signal Control Equipment Specifications," issued by the State of California, Department of Transportation, and to all addendums thereto current at the time of project advertising. Shelf mounted sensor units shall conform to the requirements in Section 11 of the NEMA Standards Publication No. TS 1. Capacitors or inductors necessary for loop tuning shall not be mounted external to the sensor unit. 209-5.01A(4) Construction Materials. Conductor for each inductive loop detector shall be continuous and unspliced and shall conform to one of the following: Type 1 loop wire shall be Type RHW-USE neoprene-jacketed or Type USE cross-linked polyethylene insulated, No. 12, stranded copper wire. The minimum insulation thickness at any point shall be 1.0 mm (40 mils). Type 2 loop wire shall consist of a conductor inside of plastic tubing. The conductor shall be Type THWN or Type XHHW, No. 14, stranded copper wire. The tubing shall be polyethylene or vinyl, rated for use at 105°C, July 2005 Page 57 of 115 and shall be resistant to oil and gasoline. The tubing shall have a maximum outside diameter of 7 mm (0.27") and a minimum wall thickness of 0.71 mm (0.028"). The conductors shall not be spliced inside the tubing. Conductors for loop detector lead-in cable shall be 2 No. 16 (19 x 29) stranded tinned copper. Loop detector lead-in cable shall conform to the calculated cross sectional area of ASTM Designation: B 286, Table 1. The lead-in cable shall conform to one of the following: Type B lead-in cable shall be insulated with 0.5 mm (20 mils) of high-density polyethylene. The conductors shall be twisted together with at least 6 turns per meter and the twisted pair shall be protected with a copper or aluminum polyester shield. A No. 20, minimum, copper drain wire shall be provided and connected to the equipment ground within the cabinet. The cable shall be provided with a high-density polyethylene or high- density polypropylene outer jacket with a nominal thickness of 0.8 mm (35 mils). An amorphous interior moisture penetration barrier of nonhydroscopic polyethylene or polypropylene fillers shall be provided. Type C lead-in cable shall conform to International Municipal Signal Association (IMSA) Specification No. 50-2. A No. 20, minimum, copper drain wire shall be provided and connected to the equipment ground within the cabinet. 209-5.01A(5) Installation Details. Installation and tests shall conform to the details and notes shown on the plans. Unless shown otherwise each loop shall consist of 3 turns of conductor as specified in Section 209- 5.01 A(4), "Construction Materials." Slots cut in the pavement shall be washed clean, blown out and thoroughly dried before installing conductors. Residue resulting from slot cutting operations shall not be permitted to flow across shoulders or lanes occupied by public traffic and shall be removed from the pavement surface before any residue flows off of the pavement surface. Residue from slot cutting operations shall be disposed of outside the highway right of way in accordance with Section 7-8.1, "Cleanup and Dust Control." After conductors are installed in the slots cut in the pavement, the slots shall be filled with sealant to within 3 mm (V8") of the pavement surface. The sealant shall be at least 25 mm (1") thick above the top conductor in the saw cut. Before setting, surplus sealant shall be removed from the adjacent road surfaces without the use of solvents. The sealant for filling slots shall conform to the following: 1. Hot-Melt Rubberized Asphalt Sealant.— Hot-melt rubberized asphalt shall be in solid form at room temperature and fluid at an application temperature of 190°C (375°F) to 205°C (400°F). Fumes from the material shall be non-toxic. Sealant shall be suitable for use in both asphalt concrete and portland cement concrete. Performance characteristics of the cured hot-melt rubberized asphalt shall be as per Table 209-5.01A(5)(B). July 2005 Page 58 of 115 TABLE 209-5.01A(5)(B) CURED HOT-MELT RUBBERIZED ASPHALT Property Cone Penetration Flow, 60°C Resilience Softening Point, Ductility, Flash Point, COC, °C Viscosity, Brookfield Thermosel, Measuring Standard (ASTM Designation) ASTM D 3407, Sec. 5 ASTM D 3407, Sec. 6 ,ASTM D 3407, Sec. 8 ASTM D 36 ASTM D 113 ASTM D 92 ASTM D 4402 Results 3.5 mm, max. 5 mm, max. 25%, min. 82 °C, min. 300 mm, min. 288 °C, min. 2.5-3.5 Pa-s Conditions 25°C, 150g,5s 25°C 25°C, 50 mm/min No. 27 Spindle, 20 rpm, 190°C, The hot-melt rubberized asphalt shall be melted in a jacketed, double boiler type melting unit. Temperature of the heat transfer medium shall not exceed 245°C (475°F). Application of the hot-melt sealant shall be made with a pressure feed applicator or pour pot. Sealant shall be applied when the pavement surface temperature is greater than 4°C (40°F), Hot-melt sealant shall be packaged in containers clearly marked "Detector Loop Sealant" and specifying the batch and lot number of the manufacturer. Loop conductors shall be installed without splices and shall terminate in the nearest pull box. The loops shall be joined in the pull box in combination of series and parallel so that optimum sensitivity is obtained at the sensor unit. Final splices between loops and lead-in cable shall not be made until the operation of the loops under actual traffic conditions is approved by the Engineer. All loop conductors for each direction of travel for the same phase of a traffic signal system, in the same pull box, shall be spliced to a detector lead-in cable which shall be run from the pull box adjacent to the loop detector to a sensor unit mounted in the controller cabinet. All loop conductors for traffic monitoring shall terminate in a pull box or terminal strip in the traffic monitor station cabinet when a cabinet of that type is installed. Conductors for inductive loop traffic signal and traffic monitoring installations shall be identified and banded, in pairs, by lane, in the pull box adjacent to the loops and near the termination of the conductors in the controller or traffic monitoring station cabinet. Bands shall conform to the provisions in Section 209-2.09, "Wiring." If asphalt concrete surfacing is to be placed, the loop conductors shall be installed prior to placing the uppermost layer of asphalt concrete. The conductors shall be installed, as shown on the plans, in the compacted layer of asphalt concrete immediately below the uppermost layer. Installation details shall be as shown on the plans, except the sealant shall fill the slot flush to the surface. 209-5.01B Emergency Vehicle Pre-Emption Detector System. Each emergency vehicle pre-emption detector system shall conform to the details shown on the plans and these special provisions and shall consist of an optical emitter assembly or assemblies located on the appropriate vehicle and an optical detector/discriminator assembly or assemblies located at the traffic signal. Each system shall permit detection of Class II emergency vehicles. Class II emergency vehicles shall be capable of being detected at any range up to 2,500 feet from the optical detector. 209-5.016(1) Optical Emitter Assembly. Each optical emitter assembly shall consist of an emitter unit, an emitter control unit and connecting cables and shall conform to the following: July 2005 Page 59 of 115 Each optical emitter assembly, including lamp, shall be designed to operate over an ambient temperature range of -34 °C to 74 °C at both modulation frequencies and to operate continuously at the higher frequency for a minimum of 3,000 hours at 25 ° C ambient before failure of lamp or any other component. Each emitter unit shall be controlled by a single, maintained-contact switch on the respective emitter control unit. The switch shall be capable of being positioned in a readily accessible location to the vehicle driver. The control unit shall contain a pilot light to indicate that the emitter power circuit is energized and shall be capable of generating only Class II modulating code. Functional Requirements. Each emitter unit shall transmit optical energy in one direction only. The signal from each emitter unit shall be capable of being detected at a distance of 2,500 feet when used with a standard optical detection/discriminator assembly. The modulation frequency for Class n signal emitters shall be 14.035 Hz ± 0.003 Hz. The standard optical detection/discriminator assembly to be used in conducting the range tests shall be available from the manufacturer of the system. A certified performance report shall be furnished by the contractor with each assembly. The emitter unit shall be configured with a grating to provide precise directionality control. Electrical Requirements. Each optical emitter assembly shall be capable of providing full light output with input voltages between 10 and 16 volts DC. An optical emitter assembly shall not be damaged by input voltages up to 7.5 volts DC about the supply voltage. The optical emitter assembly shall not generate voltage transient, on the input supply, which exceeds the supply voltage by more than 4 volts. Each optical emitter assembly shall not consume more than 100 watts at 17.5 volts DC and shall have a power input circuit breaker rated at 10 to 12 amperes, 12 volts DC. The design and circuitry of each emitter unit shall permit its use on vehicles with either negative or positive ground without disassembly or rewiring of the unit. Mechanical Requirements. Each emitter unit shall be housed in a weatherproof, corrosion-resistant housing. The housing shall be provided with facilities to permit mounting on various types of vehicles and shall have provision for proper alignment of the emitter unit and for locking of the emitter unit into proper alignment. Each emitter control unit shall be provided with appurtenant hardware to permit its mounting in or on an emergency vehicle or mass transit vehicle. Where required for certain emergency vehicles, the emitter control unit and all exposed controls shall be weatherproof. Each emitter shall include a multi-purpose port compliant with the SAE J1708 communication standard to enable unit configuration to be set into the emitter and read from the emitter. 209-5.01B(2) Optical Detection/Discriminator Assembly. Optical detection/discriminator assembly shall consist of one or more optical detectors, connecting cable and a discriminator module and conform to the following: Each such assembly, when used with standard emitters, shall have a range of up to 2,500 feet for Class II signals. Standard emitters for Class II signals shall be available from the manufacturer of the system. Range measurements shall be taken with all range adjustments on the discriminator module set to "maximum". 209-5.0 1B(3) Optical Detector. Each optical detector shall be a waterproof unit capable of receiving optical energy from one or two separately aimable directions. The horizontal angle between the two directions shall be variable from 5 degrees to 1 80 degrees. The reception angle for each photocell assembly shall be a maximum of 8 degrees in all directions about the aiming axis of the assembly. Measurements of reception angle will be taken at a range of 2,500 feet for a Class II emitter. July 2005 Page 60 of 115 All internal circuitry shall be solid state and electrical power shall be provided by the associated discriminator module. Each optical detector shall be contained in a housing, which shall include one or two rotatable photocell assemblies, an electronic assembly and a base. The base shall have an opening to permit its mounting on a mast arm. Each optical detector shall weigh no more than 2.5 pounds and shall present a maximum wind load area of 36 square inches. The housing shall be provided with weep holes to permit drainage of condensed moisture. Each optical detector shall be installed, wired and aimed as specified by the manufacturer. 209-5.01B(4) Optical Detector Cable. Optical detector cable shall meet the requirements of IPCEA- S-61 -402/NEMA WC 5, Section 7.4, 600 volt control cable, 75 ° C, Type B and the following: The cable shall contain three conductors, each of which shall be AWG #20 (7x28) stranded, tinned copper with low-density polyethylene insulation. Minimum average insulation thickness shall be 25 mils. The insulation of individual conductors shall be color coded as follows: Yellow - Detector Signal #1 Blue - Detector Signal #2 Orange - Power (+) Bare (Drain) - Common or Ground The shield shall be either tinned copper braid or aluminized polyester film with a nominal 20 percent overlap. Where the film is used, a AWG #20 (7x28) standard, tinned, bare drain wire shall be place between the insulated conductors and the shield and in contact with the conductive surface of the shield The jacket shall be black polyvinyl chloride with a minimum rating of 600 volts and 80 °C and a minimum average thickness of 45 mils. The jacket shall be marked as required by IPCEA/NEMA. The finished outside diameter of the cable shall not exceed 0.3 inches. The capacitance of the optical detector cable, as measured between any conductor and the other conductors and the shield, shall not exceed 14.3 microfarads per 1000 feet. The characteristic impedance of the optical detector cable shall be 0.6 ohms per 1000 feet. 209-5.01B(5) Discriminator Module. Each discriminator module shall be designed to be compatible and usable with Model 170 controller unit and to be mounted in the input file of a Model 332 controller cabinet, and shall conform to the requirements of Chapter 1 of the State of California, Department of Transportation, "Traffic Signal Control Equipment Specifications", dated January 1989, and to all addenda thereto current at the time of project advertisement. Each discriminator module shall be capable of operating one or two channels and shall be capable of: 1. Receiving Class II signals at a range of up to 2,500 feet. 2. Decoding the signal on the basis of frequency at 14.035 Hz + 0.003 Hz for Class n signals. 3. Establishing the validity of received signals on the basis of frequency and length of time received. A signal shall be considered valid only when received for more than 0.50 seconds. No combination of Class 1 signals shall be recognized as a Class II signal regardless of the number of signals being received, up to a maximum often signals. Once a valid signal has been recognized, its effect shall be held by the module in the event of temporary loss of the signal for a period adjustable from 4.5 seconds to 11 seconds in at least 2 steps at 5 ± 0.5 seconds and 10 + 0.5 seconds. 4. Providing an output for each channel that will result in "low" or grounded condition of the appropriate input of a Model 170 controller unit. For Class II signals the output shall be steady. Each discriminator module shall be powered from 115 volt (95 volts AC to 135 volts AC), 60 Hz mains and will contain an internal, regulated power supply that supports up to twelve optical detectors. Electric power, July 2005 Page 61 of 115 one detector input for each channel and one output for each channel, shall terminate at the printed circuit board edge connector pins listed below. Board edge connector pin assignments shall be as follows: Pins Function A Ground D Channel A primary detector input E Detector 24 VDC power output F Channel A output, collector (+) H Channel A output, emitter (-) J Channel B primary detector input K Detector ground L Earth ground M AC - (in) N AC + (in) Pins Function P Not used R Detector 24 VDC power output S Not used T Not used U Not used V Detector ground W Channel B output collector (+) X Channel B output emitter (-) Y Not used Z Not used PinTwo auxiliary inputs for each channel shall enter each module through the front panel connector, assignment for the connector shall be as follows: Pins Function 13 Auxiliary detector 2 input, Channel A 14 Auxiliary detector 1 input, Channel B 15 Auxiliary detector 2 input, Channel B 28 Auxiliary detector 1 input, Channel A Each channel output shall be an optically isolated NPN open collector transistor capable of sinking 50 milliamperes at 30 volts and shall be compatible with Model 170 controller unit inputs. Each discriminator module shall be provided with means of preventing transients received by the detector from affecting the Model 170 controller assembly. Each discriminator module shall have a single connector board, shall be capable of being inserted into the input file of a Model 332 cabinet and shall occupy one slot width of the input file. The front panel of each module shall have a handle to facilitate withdrawal and the following controls and indicators for each channel: 1. A Command (High) and Advantage (Low) solid-state LED indicator for each channel to display active calls. 2. A test switch for each channel to test proper operation of Command or Advantage priority. 3. A single confirmation light control output for each channel. These outputs shall be user configurable through software for a variety of confirmation light sequences. The front panel shall be provided with a single circular, bayonet-captured, multi-pin connector for two auxiliary detector inputs for each channel. Connector shall be a mechanical configuration equivalent to a D- Shell 44-Pin front panel. Wiring for a Model 332 cabinet shall conform to the following: Slots 12 and 13 of the input file 'T' shall be wired to accept a two-channel module. Field wiring for the primary detectors, except 24-volt DC power, shall terminate on either terminal board TB-9 in the controller cabinet or on the rear of input file "J", depending on cabinet configuration. Where TB-9 is used, position assignments shall be as follows: Position Assignment 4 Channel A detector input, 1st module (Slot J-l 2) 5 Channel B detector input, 1st module (Slot J-l2) 7 Channel A detector input, 2nd module (Slot J-13) 8 Channel B detector input, 2nd module (Slot J-13) July 2005 Page 62 of 115 The 24 volt cabinet DC power shall be available at Position 1 of terminal board TB-1 in the controller cabinet. All field wiring for the auxiliary detectors shall terminate on terminal board TB-0 in the controller cabinet. Position assignments are as follows: Position Assignment 7 +24VDCfrom(J-13E) 8 Detector ground from (J-13K) 9 Channel A auxiliary detector input 1 10 Channel A auxiliary detector input 2 11 Channel B auxiliary detector input 1 12 Channel B auxiliary detector input 2 The contractor shall demonstrate that all of the components of the system will perform satisfactorily as a system. Satisfactory performance shall be determined using the following test procedure: 1. Each system to be used for testing shall consist of an optical emitter assembly, an optical detector, at least 200 feet of optical detector cable and a discriminator module. 2. The discriminator modules shall be installed in the proper input file slot of Model 332 controller cabinet. The controller cabinet, together with a Model 170 controller unit with the appropriate operating program, a Model 210 monitor unit and 120 volt AC power, will be available as shown on the plans and as indicated elsewhere in these special provisions. 3. One test shall be conducted using a Class n signal emitter and a distance of 2,500 feet between the emitter and the detector. All range adjustments on the module shall be set to "Maximum" for each test. 4. Each test shall be conducted for a period of one hour, during which the emitter shall be operated for 30 cycles, each consisting of a one minute "on" interval and a one minute "off interval. During the total test period: (A) the emitter signal shall cause the proper response from the Model 170 controller unit during each "on" interval and (B) there shall be no improper operation of either the Model 170 controller unit or the monitor during each "off' interval. 209-5.01C Video Detection System. The video detection system shall consist of one (1) video camera and one (1) video detection processor (VDP) for each vehicle approach. A video monitor and a pointing device shall be housed in the controller cabinet. The system shall include software that detects vehicles in multiple lanes using only the video image. Detection zones shall be defined using only a video menu and a pointing device to place zones on a video image. A minimum of 24 detection zones per camera shall be available. 209-5.01C(1) Functional Requirements. The VDP shall process video from a single source. The source can be a video camera or a video tape player. The video shall be input to the VDP in RSI70 format and shall be digitized and analyzed in real time. The VDP shall detect the presence of vehicles in up to 24 detection zones per camera. A detection zone shall be approximately the width and length of one car. Detection zones shall be programmed via a menu displayed on a video monitor and a pointing device connected to the VDP. The menu shall facilitate placement of the detection zones and setting of zone parameters. A separate computer shall not be required for programming detection zones or to view system operations. The VDP shall store up to three different detection zone patterns. The VDP shall be able to switch to any one of the three different detection zone patterns within one second of user request via menu selection with the pointing device. The VDP shall detect vehicles in real time as they travel across each detection zone. The VDP shall have an RS-232 port for communications with an external computer. The VDP shall accept new detector patterns from an external computer through the RS-232 port when that computer uses the appropriate communications protocol for downloading detector patterns. The VDP shall send its detector patterns to an external computer through the RS-232 port when requested when that computer uses the appropriate communications protocol for uploading detector patterns. A Windows-based software program designed for local or remote connection and providing video capture, real-time detection indication and detection zone modification capability shall be provided with the system. The camera system shall be able to transmit an NTSC video signal, with minimal signal degradation, up to 300m (1000 ft). The VDP shall default to a safe condition, such as a constant call to each active detection channel, in the event of unacceptable interference in the video signal. July 2005 Page 63 of 115 The system shall be capable of automatically detecting a low visibility condition such as fog and respond by placing all defined detection zones in a constant call mode. A user-selected output shall be active during the low visibility condition that can be used to modify the controller operation if connected to the appropriate controller input modifiers). The system shall automatically revert to normal detection mode when the lowf visibility condition no longer exists. 209-5.01 C(2) Operational Requirements. A minimum of 24 detection zones per-camera shall be supported and each detection zone can be sized to suit the conditions and the desired vehicle detection region. A single detection zone shall be capable of replacing multiple loops and the detection zone may be AND'ed or OR'ed together to indicate vehicle presence on a single phase of traffic movement. Placement of detection zones shall be done by using a pointing device and a graphical interface built into the VDP and displayed on a video monitor. No separate computer shall be required to program the detection zones. Up to three detection zone patterns shall be saved within the VDP memory and this memory shall be preserved during power outages. The selection of the detection zone pattern for current use shall be done through a menu system. It shall be possible to activate a detection zone pattern for a camera from VDP memory and have the detection zone pattern displayed within one second of activation; When a vehicle is detected crossing a detection zone, the detection zone will flash a symbol on the screen to confirm the detection of the vehicle. Detection shall be at least 98% accurate in good weather conditions and at least 96% accurate under adverse weather conditions (rain, snow or fog). Detector placement shall not be more distant from the camera than a distance of fifteen times the mounting height of the camera. The VDP shall provide up to eight channels of vehicle presence detection through a NEMA TS1 port. The VDP shall provide dynamic zone reconfiguration (DZR) to enable normal detector operation of existing zones except the one being added or modified during the setup process. The VDP shall output a constant call on any detection channel when the corresponding zone is being modified. Detection zone outputs shall be configurable to allow the selection of presence, pulse, extend and delay outputs. Timing parameters of pulse, extend, and delay outputs shall be user definable between 0.1 and 25.0 seconds. Up to six detection zones shall be capable of counting the number of vehicles detected. The count value shall be internally stored for later retrieval through the RS-232 port. The data collection interval shall be user definable in periods of five, fifteen, thirty or sixty minutes. 209-5.01C(3) Hardware Requirements. The VDP shall be housed in a durable metal enclosure suitable for shelf mounting in the side rails of the controller cabinet. The VDP enclosure shall not exceed 180mm (7.1 in) in length and 157mm (6.2 in) in depth. The VDP shall operate satisfactorily in a temperature range of-34°C to +74°C (-29°F to +165°F) and a humidity range of 0%RH to 95% RH, non-condensing. The VDP shall be powered by 24 volts DC. VDP power consumption shall not exceed 10 watts. The VDP shall include an RS- 232 port for serial communications with a remote computer. This port shall be a 9-pin "D" subminiature connector on the front of the VDP. The front of the VDP shall include one BNC video input connection suitable for RSI70 video inputs. The video input shall include a switch-selectable 75-ohm or high impedance termination to allow camera video to be routed to other devices, as well as input to the VDP for vehicle detection. The front of the VDP shall include one BNC video output providing real time video output that can be routed to other devices. 209-5.01C(4) Video Detection Camera. The video camera shall be furnished by the VDP supplier and shall be qualified by the supplier to ensure proper system operation. The camera shall produce useable video image of the bodies of vehicles under all roadway lighting conditions, regardless of time of day. The minimum range of scene luminance over which the camera shall produce a useable video image shall be the minimum range of night time to day time but not less than the range of 0.1 lux to 10,000 lux. The camera shall use a CCD sensing element and shall output monochrome video with resolution of not less than 380 lines vertical and 380 lines horizontal. The camera shall include an electronic shutter control based upon average scene luminance and shall be equipped with a factory adjusted manual iris. The camera shall include a variable focal length lens with variable focus that can be adjusted, without opening the camera housing, to suit the site geometry by means of a portable interface device designed for that purpose and manufactured by the detection system supplier. The horizontal field of view shall be adjustable from 8.1° to 45.9°. A single camera configuration shall be used for all approaches in order to minimize setup time and spares required by the user. The camera electronics shall include AGC to produce a satisfactory image at night. July 2005 Page 64 of 115 The camera shall be housed in a weather-tight sealed enclosure. The camera enclosure shall be able to rotate to allow proper alignment between the camera and the traveled road surface. The camera enclosure shall be equipped with a sun shield. The sun shield shall include a provision for water diversion to prevent water from flowing in the camera's field of view. The camera enclosure with sun shield shall be less than 170mm (6 in) in diameter, less than 380mm (15 in) long, and shall weigh less than 13.3kg (6 pounds) when the camera and lens are mounted inside the enclosure. The camera enclosure shall include a thermostatically controlled heater to assure proper operation of the lens at low temperatures and to prevent moisture condensation on the optical faceplate of the enclosure. When mounted outdoors in the enclosure, the camera shall operate satisfactorily in a temperature range of — 34°C to +60°C (-29°F to +140°F) and a humidity range of 0% RH to 100% RH. The camera shall be powered by 120/240 VAC, 50/60 Hz. Power consumption shall be 15 watts or less under all conditions. Recommended camera placement height shall be 10m (33 ft) above the roadway, and over the traveled way on which vehicles are to be detected. For optimum detection, the camera should be centered above the traveled roadway. The camera shall view approaching vehicles at a distance not to exceed 100m (350 ft) for reliable detection (height:distance ration of 10:100). Camera placement and field of view shall be unobstructed and as noted in the installation documentation provided by the supplier. The camera enclosure shall be equipped with separate, weather-tight connections for power and video cables at the rear of the enclosure. These connections may also allow diagnostic testing and viewing of the video signal at the camera while the camera is installed, using a lens adjustment module supplied by the VDP supplier. Video and power shall not be connected within the same connector. The video signal output by the camera shall be black and white in RSI70 or CCIR format. The video signal shall be fully isolated from the camera enclosure and power cabling. 209-5.01C(5) Installation Requirements. The coaxial cable to be used between the camera and the VDP in the controller cabinet shall be Belden 8281 or a 75 ohm, precision video cable with 20 gauge solid bare copper conductor (9.9 ohms/M), solid polyethylene insulating dielectric, 98% (min) tinned copper double-braided shield and black polyethylene outer covering. The signal attenuation shall not exceed 0.78 dB per 30m (100 ft) at 10 MHz. Nominal outside diameter shall be 8mm (0.304 in). The coaxial cable shall be a continuous, unbroken run from the camera to the VDP. This cable shall be suitable for installation in conduit or overhead with appropriate span wire. 75 ohm BNC plug connectors shall be used at both the camera and controller. The coaxial cable, BNC connector and crimping tool shall be approved by the supplier of the video detection system, and the manufacturer's instructions must be followed to ensure proper connection. The power cabling shall be 16 AWG three conductor cable. The cabling shall comply with the National Electric Code, as well as local electrical codes. Cameras may acquire power from the luminaire if necessary. The video detection system shall be installed by supplier factory certified installers and as recommended by the supplier and documented in the installation materials provided by the supplier. Proof of factory certification shall be provided. 209-5.01C(6) Warranty. The supplier shall provide a limited two year warrant on the video detection system. See supplier's standard warranty included in the Terms and Conditions of Sale documentation. During the warranty period, technical support shall be available from the supplier via telephone within four hours of the time a call is made by the user. This support shall be made available from factory certified personnel or factory certified installers. During the warranty period, updates to the VDP software shall be made available from the supplier without charge. 209-5.01C(7) Maintenance and Support. The supplier shall maintain an adequate inventory of parts to support maintenance and repair of the video detection system. These parts shall be made available for delivery within 30 days of placement of an acceptable order at the supplier's current pricing and terms of sale for said parts. The supplier shall maintain an ongoing program of technical support for the video detection system. This technical support shall be available via telephone, or via personnel sent to the installation site upon placement of an acceptable order at the supplier's current pricing and terms of sale for on site technical support services. Installation or training support shall be provided by a factory authorized representative. All product documentation shall be written in the English language. The contractor shall ensure the presence of a factory authorized representative at the time of traffic signal turn-on. July 2005 Page 65 of 115 209-5.02 Pedestrian Push Button Assemblies. Where shown on the plans, pedestrian push button assemblies of substantial tamper-proof construction and signs shall be furnished and installed. The housing shall be either die-cast or permanent mold cast aluminum, or when specified shall be ultraviolet stabilized,, self-extinguishing structural plastic. Plastic housings shall be black matching Color No. 17038, 27038 on 37038 of Federal Standard No. 595B, and shall be colored throughout. The assembly shall be rainproof and shall be shockproof in any weather condition. The pedestrian push button switch shall be a phenolic enclosed precision snap-acting type, single-pole, double-throw, switching unit, with screw type terminals, rated 15 A at 125 volts AC, and shall have the following characteristics: 1 . Switching unit shall have a stainless steel plunger actuator and shall be provided with U-frame to permit recessed mounting in push button housing. 2. Switch shall have an operating force of 2.5 N (9 oz.) to 3.6 N (13 oz.) and a minimum release force of one newton (4 oz.). 3. Pretravel shall be 0.4 mm C/M") maximum. 4. Over travel shall be 6 mm (7/3a") minimum. 5. Differential travel shall be 0.01 mm (0.0004") to 0.05 mm (0.002"). 6. Actuator shall have a minimum diameter of 50 mm (2"). Where a pedestrian push button is attached to a pole, the housing shall be shaped to fit the curvature of the pole and secured to provide a rigid installation. Saddles shall be provided to make a neat fit when required. Where a pedestrian push button is to be mounted on top of a Size 65 (2V2") diameter post, the housing shall be provided with a slip-fitter fitting and screws for securing rigidly to the post. Pedestrian push button signs shall be porcelain enameled metal or structural plastic. Push button and sign shall be installed on the crosswalk side of the pole. Arrows on push button signs shall point in the same direction as the corresponding crosswalk. Where Type A push buttons are specified, each push button assembly shall be equipped with red and green indicator lamps. Lamps shall be so connected that, when the push button has been activated, the red lamp shall be energized and continue so until the next pedestrian walk interval, at which time the green lamp shall be energized in lieu of the red lamp. At the termination of the pedestrian walk interval, the lamps shall be de- energized until the next actuation of the push button. Lenses for the lamps shall have a visible diameter of approximately 32 mm (I1//') and a length of approximately 22 mm (7/g"). On the Type A or TypeB push button assembly, the sign shall attach to and be securely supported by the framework. With Type C pedestrian push buttons, the instruction sign shall be mounted, using 2 straps and saddle brackets, on the same standard as the push button assembly. Straps and saddle brackets shall be as shown on the plans and shall be corrosion- resisting chromium nickel steel conforming to the specifications of ASTM Designation: A 167, Type 302. Bolts shall be stainless steel with a chromium content of at least 17 percent and a nickel content of at least 8 percent. Bolts shall NOT be theft-proof. 209-6 LIGHTING 209-6.01 Low Pressure Sodium Luminaires. Low pressure sodium luminaires shall be the enclosed type with a horizontal burning lamp. Luminaires shall be the cutoff type. Each luminaire shall consist of a housing, a reflector, a refractor or a lens, a lamp socket, an integral ballast, a terminal strip and a lamp. Housings shall be fabricated from aluminum. Housings that are painted shall withstand a 1000-hour salt spray test as specified in ASTM Designation: B 117. All other metal parts of the housing shall be fabricated from metal at least equal in corrosion resistance and finish to the metal in the housing. Each housing shall be provided with a slip-fitter capable of mounting on a 50 mm (2") pipe tenon and of being adjusted 5 degrees from the axis of the tenon. The clamping brackets of the slip-fitter shall not bottom out on the housing bosses when adjusted within the ±5 degree range. No part of the slip-fitter mounting brackets on the luminaires shall develop a permanent set in excess of 0.5 mm (0.020") when the four 10 mm (3/8") diameter cap screws used for mounting are tightened to 13 N-m (10 ft/lbs.). All luminaires to be mounted on horizontal mast arms, when tested in accordance with California Test 611, shall be capable of withstanding cyclic loading in (G = Acceleration of Gravity): 1 . a vertical plane at a minimum peak acceleration level of 3.0 G peak-to-peak sinusoidal loading (same as 1 .5 G peak) with the internal ballast removed, for a minimum of 2 million cycles without failure of any luminaire parts. J uly 2005 Page 66 of 1 1 5 2. a horizontal plane perpendicular to the direction of the mast arm at a minimum peak acceleration level of 1.5 G peak-to-peak sinusoidal loading (same as 0.75-G peak) with the internal ballast installed, for a |^ minimum of 2 million cycles without failure of any luminaire parts. ^F 3. a vertical plane at a minimum peak acceleration level of 1.0 G peak-to-peak sinusoidal loading (same as 0.5-G peak) with the internal ballast installed, for a minimum of 2 million cycles without failure of any luminaire parts. Each mast arm mounted luminaire shall be furnished with a photoelectric unit receptacle. If a photoelectric unit receptacle is included and the plans call for the omission of a photoelectric unit, a raintight shorting cap shall be installed. The surface of each reflector shall be specular and shall be protected by either an anodized finish or a silicate film. The reflector shall be shaped so that a minimum of light is reflected through the arc tube of the lamp. Each refractor or lens shall be mounted in a frame that is hinged to the housing and secured with a spring-loaded latch. Each refractor shall be made of glass or polycarbonate plastic. Each lens shall be made of heat and impact resistant glass. The optical system, consisting of the reflector, refractor or lens, lamp socket and lamp, shall be in a sealed chamber. Sealing shall be provided by a gasket between the reflector and refractor or lens and a gasket between the reflector and lamp socket. The chamber shall have provision for filtered flow of air in and out of the chamber due to lamp heat. Filtering shall be accomplished by either a separate filter or a filtering gasket. Each lamp socket shall be a porcelain enclosed mogul-multiple type. The shell shall contain integral lamp grips to assure electrical contact under conditions of normal vibration. The socket shall be mounted in the luminaire in a manner to permit pre-setting a variety of specified light distribution patterns. The socket shall be rated for 1500 W and 600 V, and shall be rated for a 4-kV pulse. When the components are mounted on a down-opening door, the door shall be hinged and secured to the luminaire housing separately from the refractor or flat lens frame. The door shall be easily removable and replaceable. The door shall be secured to the housing in a manner to prevent its accidental opening when the refractor or flat lens frame is opened. Field wires connected to the luminaire shall terminate on a barrier type terminal block secured to the housing. The terminal screws shall be captive and equipped with wire grips for „ conductors up to No. 6. Each terminal position shall be clearly identified. The minimum light distribution for • each luminaire shall be as shown on the isolux diagrams on the plans. 209-6.01A Low Pressure Sodium Lamp Ballasts. Each ballast shall be designed for the type, characteristics and wattage of the lamp it is to operate and it shall provide the proper starting and operating waveforms, voltage and current. Ballasts shall provide reliable lamp starting and operation at ambient temperature down to -30°C for the rated life of the lamp. Ballasts shall be designed for continuous operation at ambient air temperatures from -20°C to 25°C without reduction in ballast life. Ballasts shall have a design life of not less than 100,000 hours. Ballasts shall be designed to operate for at least 180 cycles of 12 hours on and 12 hours off, with the lamp circuit in an open or short-circuited condition and without measurable reduction in the operating requirements. Ballasts shall be tested in accordance with the requirements of ANSI C82.6-1980, "Methods of Measurement of High-Intensity-Discharge Lamp Ballasts." Starting aids for ballasts of a given lamp wattage shall be interchangeable between ballasts of the same wattage and manufacturer without adjustment. A Certificate of Compliance conforming to the provisions in Section 4-1.5, "Certification," shall be submitted by the manufacturer with each lot of integral ballast lurninaires and with each lot of ballasts designed for use outside of lurninaires. The certificate shall state that the lot of ballasts meets, in every respect, the above requirements and the lamp-ballast specifications of the lamp manufacturer. The input voltage for ballasts shall be as shown on the plans or as specified in these special provisions. Each integral ballast shall consist of separate components, each of which shall be capable of being easily replaced. A starting aid which is encapsulated will be considered as a single component. Each component shall be provided with screw terminals, NEMA tab connectors or a single multi-circuit connector. All conductor terminals shall be>identified as to the component terminal to which they connect. Heat-generating components shall be mounted so as to use the portion of the luminaire upon which they are mounted as a heat sink. Capacitors shall be located as far as practicable from heat-generating components or shall be thermally shielded to limit the case temperature to 75°C. July 2005 Page 67 of 115 Transformers and inductors shall be resin-impregnated for protection against moisture. Capacitors, except those in starting aids, shall be metal cased and hermetically sealed. Ballasts to be located remote from the luminaire shall be the submersible type and shall conform to the requirements in Section 209-6.09C, "Submersible Type Transformers." All components, including starting aid, shall be enclosed in a single housing. Ballast leads shall extend a minimum of 300 mm (12") from the case. Steel housings shall be galvanized or painted. Ballast housings shall be clearly labeled to indicate lamp type, lamp wattage and input voltage. Ballasts for high-pressure sodium lamps shall have a ballast characteristic curve which will intersect both of the lamp-voltage limit lines between the wattage limit lines and remain between the wattage limit lines throughout the full range of lamp voltage. This requirement shall be met not only at the rated input voltage of the ballast, but also at the lowest and highest input voltage for which the ballast is rated. Throughout the lifetime of the lamp, the ballast curve shall fall within the specified limits of lamp voltage and wattage. Ballasts for luminaires to be mounted on mast arms, brackets or lowering assemblies shall be located within the luminaire housing. 209-6.01A(1) Regulator Type Ballasts. Regulator type ballasts shall conform to the following: For nominal input voltage and lamp voltage, the ballast design center shall not vary more than 7.5 percent from rated lamp watts. The ballast shall be designed so that a capacitance variance of ±6 percent will not cause more than a ±8 percent variation in lamp wattage regulation throughout rated lamp life for nominal input voltage. The lamp current crest factor shall not exceed 1.8 for input voltage variation of ±10 percent at any lamp voltage from initial through life. Regulator type ballasts shall be lag-type or lead-type conforming to the following: Lag-Type Regulator Ballasts.— Each lag-type regulator ballast shall have the primary and secondary windings electrically isolated and, when operated with the appropriate lamp, shall have the following characteristics and shall maintain the following lamp operation: The power factor shall be not less than 90 percent throughout the life of the lamp at nominal line voltage with a nominally rated reference lamp. Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 18 percent for ±10 percent input voltage variation. Lead-Type Regulator Ballasts.— Each lead-type regulator ballast (CWA-constant wattage auto-regulator) shall, when operated with the appropriate lamp, have the following characteristics and shall maintain the following lamp operation: The power factor shall be not less than 90 percent when the ballast is operated at nominal line voltage with a nominally rated reference lamp. Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 30 percent for ±10 percent input voltage variation. 209-6.01A(2) Autotransformer or Reactor Type Ballasts. Each nonregulating reactor, autotransformer, or high reactance ballast shall, when operated with the appropriate lamp, have the following characteristics and shall maintain the following lamp operations: The power factor shall be not less than 90 percent when the ballast is operated at nominal line voltage with a nominally rated reference lamp. Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 25 percent for ±5 percent input voltage variation. July 2005 Page 68 of 115 For nominal input voltage and lamp voltage, the ballast design center shall not vary more than 7.5 percent from rated lamp watts. •t The lamp current crest factor shall not exceed 1.8 for input voltage variation of ±5 percent at any lamp voltage from initial through life. 209-6.02 Photoelectric Controls. Photoelectric controls, as specified in these special provisions or as shown on the plans, shall be capable of switching multiple lighting systems directly. Type IV photoelectric control shall be used unless otherwise shown on the plans or required by these special provisions and shall be installed in a receptacle integral with the luminaire. 1. Type I photoelectric control shall consist of a remote photoelectric unit and a test switch housed in an enclosure. 2. Type II photoelectric control shall consist of a remote photoelectric unit, a separate contactor located in a service equipment enclosure, and a test switch located in the service equipment enclosure unless shown otherwise. 3. Type in photoelectric control shall consist of a remote photoelectric unit, and a separate contactor and a test switch housed in an enclosure. 4. Type IV photoelectric control shall consist of a photoelectric unit which plugs into an EEI-NEMA twist lock. 209-6.02A Types. The types of photoelectric controls shall be as follows: receptacle integral with the luminaire. Type V photoelectric control shall consist of a photoelectric unit, contactor and test switch located in a service equipment enclosure. A switch to permit manual operation of the lighting circuit shall be provided for each Type I, Type II, Type HI, and Type V photoelectric control. Switches shall be of the single-hole mounting toggle type, single-pole, single-throw, rated at 12 A and a voltage rating to match the circuit. Switches shall be furnished with an indicating nameplate reading "Auto-Test" and shall be connected in parallel with the load contacts of the photoelectric unit. Test switch shall not have an "OFF" position. Photoelectric units for Types I, n and HI photoelectric controls, shall be pole-top mounted unless otherwise specified. 209-6.02B Equipment Details. Equipment details shall conform to the following: 209-6.028(1) Photoelectric Unit. The photoelectric unit shall provide an output in response to changing light levels. Components of the unit shall not require periodic replacement. Units shall have a "turn-on" between 10 and 50 lux (one and 5 footcandles) and a "turn-off' at between 1.5 and 5 times "turn-on." Measurements shall be by the procedures set forth in EEI-NEMA Standards for Physical and Electrical Interchangeability of Light-Sensitive Control Devices Used in the Control of Roadway Lighting. Photoelectric controls, except Type IV and Type V, shall be furnished with a 100 mm (4") minimum inside diameter pole- top mounting adaptor containing a terminal block and with cable supports or clamps to support pole wires. The photoelectric unit receptacle shall be the EEI-NEMA type. Mounting brackets shall be used where pole- top mounting is not possible. Photoelectric controls shall be installed at the locations shown on the plans and oriented as directed by the Engineer. For switching 480 V, 60 Hz circuits, a 100 V'A, minimum, 480/120-volt transformer shall be installed in the contactor enclosure to provide 120 volts for the photoelectric control unit. Where more than one photoelectric unit is to be installed at the same location, a single transformer, with a volt-ampere rating capable of handling the total controlled load, may be used. Photoelectric units shall be screened to prevent artificial light from causing cycling. July 2005 Page 69 of 115 The photoelectric unit shall also conform to the following: The supply voltage rating shall be 60 Hz, 105-130 V, 210-240 V, or 105-240 V, as specified. The load rating shall be 800 W minimum, incandescent, mercury or fluorescent. The operating temperature range shall be from -29°C (-20°F) to 65°C (150°F). The power consumption shall be less than 10 W. The unit shall be housed in a weatherproof enclosure. The base of the unit shall be provided with a 3-prong, EEI-NEMA standard, twist-lock plug mounting. 1. Units shall be provided with a "fail-on" feature. 209-6.028(2) Contactor. The contactor shall have contacts rated to switch the specified lighting load and shall be normally open, unless otherwise specified. The contactor shall be either the mechanical armature type or the mercury displacement type. The contacts of the mechanical armature type contactor shall be either fine silver, silver alloy, or superior alternative material. The contactor shall have a miriirnum rating of 30 A, per contact, inductive load. 209-6.02B(3) Contactor and Test Switch Housing. The enclosure for Type I and Type m photoelectric controls shall be NEMA Type 3R. The enclosure shall be provided with a factory applied rust resistant prime coat and finish coat. Two applications of paint to match the color of the standard shall be applied as specified in Section 209-2.16, "Painting." The enclosure may be hot-dip galvanized in lieu of painting. A minimum of 65 mm (2V2") shall be provided between contactor terminals and end of enclosure for wiring connections. The enclosure shall be mounted on the same standard as the photoelectric unit at a height of approximately 1.8 m (6') above the base. 209-6.026(4) Wiring. Conductors between the photoelectric unit and an external contactor shall be No. 14 and shall be run inside the lighting standard, or in conduit, unless otherwise shown on the plans. 209-6.028(5) Terminal Blocks. Terminal blocks shall be rated at 25 A, 600 V, shall be molded from phenolic or nylon material and shall be the barrier type with plated brass screw terminals and integral type marking strips. 209-6.03 Transformers. Multiple to multiple and series to multiple transformers shall be of the single- phase, dry type designed for operation on a 60 Hz supply. 209-6.03A Electrical Requirements. Transformer ratings shall be 120/480 volts, 240/480 volts or 480/120 volts for multiple to multiple units and 6.6 A/120 volts or 6.6 A/480 volts for series to multiple units or other ratings as shown on the plans. Secondary 480-volt windings shall be center tapped. Volt-ampere ratings shall be as shown on the plans. Transformer efficiency shall exceed 95 percent for multiple to multiple units and 80 percent for series to multiple units. Secondary voltage regulation and tolerance shall be ±3 percent from half load to full load for multiple to multiple units and +10 percent (maximum) at no load to ±3 percent at full load for series to multiple units. Transformers shall have a decal showing a connection diagram. The diagram shall show either color coding or tagging of wires with primary (HI, H2) or secondary (XI, X2) markers, and shall also show the primary and secondary voltage and volt-ampere rating. 209-6.038 Physical Requirements. External leads for multiple to multiple and series to multiple secondary connections shall be Type USE, No. 10, rated 600 volts AC. Primary conductors for series to multiple transformers shall be rated for use on 5000-volt AC circuits. Transformer leads shall extend a minimum of 300 mm (12") from the case. Transformer insulation shall be NEMA 185°C or better. Series to multiple transformers shall withstand the application of 12 000 volts AC from core to primary coil and from coil to coil for a one minute period. Series to multiple transformer secondaries and multiple to multiple transformers shall withstand the application of 2200 volts AC from core to coils and, for multiple units only, from coil to coil for July 2005 Page 70 of 115 a one minute period. The above tests shall be made immediately after operation of the transformer at full load for 24 hours. Non-submersible transformers shall be provided with metal half-shell coil protection, shall have moisture resistant, synthetic varnish impregnated windings and shall be suitable for outdoor operation in a raintight enclosure. Each transformer to be installed in a pull box shall be the submersible type and shall be provided with a handle and a hanger. 209-6.03C Submersible Type Transformers. Submersible type transformers shall be securely encased in a rugged corrosion resistant, watertight case and shall withstand a 5-day test submerged in 600 mm (2') of salt water (2 percent salt by mass) with 12-hour on and off periods. The operating periods shall be at full load. Leads of submersible transformers shall be brought out through one or more sealed hubs and shall be secured in a manner which will withstand a 450-N (100 Ib) static pull without loosening or leaking. 209-7 REMOVING, REINSTALLING OR SALVAGING ELECTRICAL EQUIPMENT 209-7.01 Removing Electrical Equipment. Attention is directed to Section 7-9, "Protection and Restoration of Existing Improvements." Existing electrical equipment shown on the plans or specified in these special provisions to be removed and not reused or salvaged, and pull boxes, conduit and detector frames not reused, shall become the property of the Contractor and shall be removed from the street right of way in accordance with the provisions in 300-1, "Clearing and Grubbing," except, if not interfering with other construction, underground conduit may be abandoned in place after all conductors have been removed. Care shall be exercised in salvaging equipment so that it will not be damaged or destroyed and will remain in its existing condition whenever possible. Mast arms shall be removed from standards. Luminaires, signal heads, and signal mounting assemblies shall be removed from standards and mast arms. Attention is directed to the provisions in Section 7-9, "Protection and Restoration of Existing Improvements" and 300-1.2, "Preservation of Property." The Contractor will be required to repair or replace, at the Contractor's expense, any electrical equipment to be salvaged which, as determined by the Engineer, has been damaged or destroyed by reason of the Contractor's operations. Attention is directed to the provisions in Section 209-2.03, "Foundations," regarding foundations to be abandoned or removed. Holes resulting from removing pull boxes and detector frames shall be filled with material equivalent to the surrounding material. 209-7.02 Reinstalling Removed Electrical Equipment. When removed electrical equipment is to be reinstalled, the Contractor shall furnish and install all necessary materials and equipment, including signal mounting assemblies, anchor bolts, nuts, washers and concrete as required to complete the new installation. All traffic signal and flashing beacon faces to be reinstalled or to be part of a modified system shall be cleaned and relamped. All luminaires and sign lighting fixtures to be reinstalled shall be cleaned and relamped. Existing materials required to be relocated and found to be unsatisfactory by the Engineer shall be replaced by new material and the cost therefore will be paid for as extra work as provided in Section 3-3, "Extra Work." 209-8 PAYMENT 209-8.01 Payment. The contract lump sum price or prices paid for signal, flashing beacon, lighting, sign illumination, traffic monitoring station, closed circuit television systems, or combinations thereof; for modifying or removing those systems; for temporary systems; or the lump sum or unit prices paid for various units of those systems; or the lump sum or per meter price paid for conduit of the various sizes, types and installation methods listed in the Engineer's Estimate shall include full compensation for furnishing all labor, materials, tools, equipment and incidentals, and for doing all the work involved in furnishing and installing, modifying, or removing the systems, combinations or units thereof, as shown on the plans, as specified in these special provisions, and as directed by the Engineer, including any necessary pull boxes (except when the type required is shown as a separate contract item); excavation and backfill; concrete foundations (except when shown as a separate contract item); pedestrian barricades; furnishing and installing illuminated street name signs; installing Agency-furnished sign panels on pedestrian barricades, on flashing beacon standards, and on traffic signal mast arms; restoring sidewalk, pavement and appurtenances damaged or destroyed during construction; salvaging existing materials; and making all required tests. July 2005 Page 71 of 115 Full compensation for all additional materials and labor, not shown on the plans or specified, which are necessary to complete the installation of the various systems, shall be considered as included in the prices pa for the systems, or units thereof, and no additional compensation will be allowed therefore, except as provided in Section 209-1.05, "Maintaining Existing and Temporary Electrical Systems." When shown as a contract item, the contract price paid per meter for cast-in-drilled-hole concrete pile (signal foundation) shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in constructing reinforced concrete pile foundations of the size shown on the Engineer's Estimate, including drilling holes, disposing of the material resulting from drilling holes, furnishing and placing anchor bolt assemblies and reinforcing steel, complete in place, as shown on the plans, and as specified in these special provisions and as directed by the Engineer. When shown as a contract item, non-reinforced portland cement concrete foundations will be measured and paid for in the manner as provided in Section 303-1.11, "Payment." When shown as a separate contract item by the lump sum or per bid item linear measurement, interconnection conduit and conductor shall include all interconnection conductors, but shall only include conduit and pull boxes containing interconnection conductors and no other conductors. The quantity of interconnection conduit and conductor to be paid for by the lump sum bid or the bid item linear measurement shall be the length of that conduit. Compensation for conduit containing interconnection conductors and other conductors shall be considered as included in the contract price paid for the item requiring the other conductors. Full compensation for furnishing, installing, maintaining and removing falsework lighting equipment shall be considered as included in the contract prices paid for the items of work involved in the structure which requires the falsework lighting and no additional compensation will be allowed therefore. SECTION 210 - PAINT AND PROTECTIVE COATINGS 210-1 PAINT. 210-1.5 Paint Systems. Add the following to Table 210-1.5(A) TABLE 210-1.5 (A) Surface to be Painted Temporary Railing type (K) Pre-reatment / Surface Preparation Abrasive Blast Cleaning to a Roughened, Textured Appearance Primer None Finish Coats Two coats white Acrylic Emulsion Paint (1) (1) acrylic emulsion paint designed for use on exterior masonry. This paint shall comply in all respects to Federal Specification TT-P-19 (latest revision), Paint, Acrylic Emulsion, Exterior. This paint may be tinted by using "universal" or "all purpose" concentrates. 210-1.6 Paint for Traffic Striping, Pavement Marking, and Curb Marking. Modify as follows: Paint for traffic lane lines, turn pocket lines, edge lines, channelizing lines, bike lane lines, chevrons, and curbs shall be rapid dry water borne conforming to CALTRANS Specification No. PTWB-01. Paint for pavement legends, pavement symbols, pavement arrows, cross walks, parking stall markings and stop bars shall be alkyd thermoplastic conforming to CALTRANS Specification No. 8010-19A. Glass beads shall be applied to the surface of the rapid dry water borne paint and the molten thermoplastic material and shall conform to the requirements of CALTRANS Specification No. 8010-004 (Type IT). CALTRANS Specifications for water borne paint, thermoplastic material and glass beads may be obtained from the CALTRANS Transportation Laboratory, P.O. Box 19128, Sacramento, CA 95819, telephone number (916) 227-7000. 0July 2005 Page 72 of 115 210-3 GALVANIZING Add the following section: 210-3.6 Galvanizing for Traffic Signal Facilities. The requirements of this section shall pertain only to the preparation and galvanizing of traffic signal facilities. Galvanizing of products fabricated from rolled, pressed and forged steel shapes, plates, bars and strip 3.2 mm (V8") thick or thicker, shall conform to the specifications of ASTM Designation: A 123, except that complete seal welding of tightly contacting surfaces of these products prior to galvanizing is required only where seal welding is shown on the plans or specified in these special provisions. Except for pre-galvariized standard pipe, galvanizing of material 3.2 mm (Vg") thick or thicker shall be performed after fabrication into the largest practical sections. At the option of the Contractor, material thinner than 3.2 mm (Vg") shall be galvanized either before fabrication in conformance with the requirements of ASTM Designation: A 525M, Coating Designation Z600, or after fabrication in conformance with the requirements of ASTM Designation: A 123, except that the weight of zinc coating shall average not less than 365 g per square meter (1.2 oz. per ft2) of actual surface area with no individual specimen having a coating weight of less than 305 g per square meter (1.0 oz. per ft2). Galvanizing of standard pipe shall conform to the requirements of ASTM Designation: A 53. Galvanizing will not be required for stainless steel, monel metal and similar corrosion resistant parts. Fabrication shall include all operations such as shearing, cutting, punching, forming, drilling, milling, bending, welding and riveting. All welded areas shall be thoroughly cleaned prior to galvanizing to remove all slag or other material that would interfere with the adherence of the zinc. When it is necessary to straighten any sections after galvanizing, the work shall be performed without damage to the zinc coating. Galvanizing of iron and steel hardware and nuts and bolts, when specified or shown on the plans, shall conform to the specifications of ASTM Designation: A 153, except whenever threaded studs, bolts, nuts, and washers are specified to conform to ASTM Designation: A 307, A 325, A 325M, A 449, A 563, A 563M, or F 436 and zinc coating is required, they shall be hot-dip zinc coated or mechanically zinc coated in accordance with the requirements of the ASTM Designations. Unless otherwise specified, galvanizing shall be performed after fabrication. Components of bolted assemblies shall be galvanized separately before assembly. Tapping of nuts or other internally threaded parts to be used with zinc coated bolts, anchor bars or studs shall be done after galvanizing and shall conform to the requirements for thread dimensions and overlapping allowances in ASTM Designation: A 563 or A 563M. When specified, painting of zinc coated surfaces shall be in accordance with the procedures in Section 210-1, "Paint." Galvanized surfaces that are abraded or damaged at any time after the application of the zinc coating shall be repaired by thoroughly wire brushing the damaged areas and removing all loose and cracked coating, after which the cleaned areas shall be painted with 2 applications of unthinned zinc-rich primer (organic vehicle type) conforming to the provisions in Section 210- 3.5, "Repair of Damaged Zinc Coating." Aerosol cans shall not be used. SECTION 212 - LANDSCAPE AND IRRIGATION MATERIALS 212-1 LANDSCAPE MATERIALS. 212-1.2.3 Commercial Fertilizer. add the following: Preplant fertilizer shall be granular commercial fertilizer 7-7-7 or approved equal. Postplant fertilizer shall be 12-4-6 or approved equal with Ca, Fe, Zn, and Mn and with the majority of nitrogen in nonammoniac form to prevent acidification of soil. Planting tablets shall be compressed fertilizer tablets with a 20-10-5 analysis. 212-1.2.4 Organic Soil Amendment. Add the following: For all types of Organic Soil Amendment mulch materials produced from pine trees grown in Alameda, Monterey, Santa Clara, Santa Cruz or San Mateo Counties shall not be used in the Work. Type 1A Organic Soil Amendment shall conform to the requirements for type 1 Organic Soil Amendment except as modified hereinafter. Type 1A Organic Soil Amendment shall •^ July 2005 Page 73 of 115 be a wood or rice residual product derived from the bark of pine, white fir, or red fir or cedar or redwood shavings or rice hulls. Type 1A Organic Soil Amendment shall be manufactured from clean wood, free from clods coarse objects and rocks and shall conform to the properties shown in Table 212-1.2.4(B): Table 212-1.2.4(B) SOIL AMENDMENT PROPERTIES Property Dry Weight Nitrogen Dry Weight Passing 25 mm (1") Sieve Dry Weight Passing #4 Sieve Dry Weight Passing #16 Sieve Dry Weight Passing #30 Sieve Dry Weight Passing #50 Sieve Dry Weight Passing #100 Sieve Salinity Iron ( Dilute acid soluble on dry weight basis) Ash (dry weight basis) PH Wettability Minimum (1) 100% 95% 45% 30% 0% 0% (1) 0.08% 0% 6.0 (1) Maximum (1) 100% 100% 65% 40% 10% 2% (1) —6.0% 7.0 (1) (1) (As Required by Table 212-1.2.4(A) SSPWC) For all types of Organic Soil Amendment the Contractor shall supply the Engineer a sample of the proposed amendment accompanied by an analytical analysis from a qualified agricultural laboratory certifying compliance to the requirements herein. Qualified agricultural laboratories shall have an on-going quality assurance program that fulfills the requirements of the most recent version of the "Western States Laboratory Proficiency Testing Program Soil and Plant Analytical Methods". Certificates of compliance shall contain a statement attesting that the organic soil amendment meets the requirements of these specifications and that the testing agricultural laboratory does fulfill the requirements of "Western States Laboratory Proficiency Testing Program Soil and Plant Analytical Methods". Said submittal shall be hi accordance with Section 2-5.3.3. 212-1.2.5 Mulch for Hydraulic Method Seed Lawn Planting. Add the following: The terms Hydroseeding and Hydroseed shall be synonymous with Hydraulic for the purposes of Section 212. Disturbed Areas, planting areas shall be mulched, fertilized and seeded using method B. Mulch shall be manufactured from virgin wood cellulose fiber mulch and shall not contain growth or germination inhibitors. When mixed with water, the mulch shall remain in uniform suspension and when blended with the seed, fertilizer, and other approved additives, shall form a homogeneous slurry. When applied, the fibers shall form a moisture absorbing membrane with adequate percolation properties sufficient to allow one hundred percent of water applied at the rate of 3.1 liters per minute per square meter (0.075 gallons per minute per square foot) onto a surface inclined at a 2:1 (horizontal: vertical) slope to pass through the membrane. A non-phyto-toxic wetting agent shall be added to the slurry mixture. A water soluble, non-toxic green dye shall be added in sufficient quantity to clearly delineate the planted areas. When required, binder shall be added to the slurry mixture and shall be "CPA 4000", "AZTAC", "Ecology Control", "M-Binder", or approved equal. Add the following section: 212-1.2.5.1 Disturbed Area Mulch Fertilizer and Additives. hi addition to the seed mix shown in the table for Disturbed Areas the slurry mixture shall be applied at the rates shown in Table 212-1.2.5.1 (A) July 2005 Page 74 of 115 Table 212-1.2.5.1(A) DISTURBED AREA MULCH FERTILIZER AND ADDITIVES Component Virgin Wood Cellulose Fiber Mulch Binder (1) Fertilizer (16-20-0) Ammonium Phosphate Sulfate, Plus 15% Soil Sulfur Wetting Agent Green Colorant Applicati grams per sq. meter 225 7 35 on Rate (pounds per acre) (2000) (60) (300) Per Mfg. Recommendation Per Mfg. Recommendation (1) Required to be incorporated only when applied between the months of Nov. through Feb. Add the following section: 212-1.2.6 Herbicides and Pesticides. Shall be used in their appropriate applications with strict adherence to manufacturer's specifications and instructions. Postemergent herbicide for all areas shall be Glyphosate, N- (phosphonomethyl) glycine, in the form of its isopropylamine salt such as Roundup Pro, Diquat, Montar, or approved equal. Preemergent herbicide for shrubs and groundcover areas planted from flats shall be Treflan, Surflan, Eptan, or approved equal. Add the following section: 212-1.2.7 General Soil Conditioners. Agricultural-grade gypsum shall be a calcium sulfate (CaSO4 H20) product - 94.3 percent. 90 percent shall pass a 50-mesh screen. Control of dust during application is mandatory. Iron Sulfate shall be ferrous sulfate in pelletized or granular form containing not less than 20.0 percent iron expressed as metallic iron. Iron Sulfate pellets shall be of size and gradation such that 98 percent is retained on a 10-mesh screen. Add the following section: 212-1.2.8 Stabilizing Emulsion. Stabilizing emulsion shall be a concentrated liquid chemical that forms a plastic film upon drying and allows water and air to penetrate. The film shall be nonflammable and shall have an effective life of at least one year. Stabilizing emulsion shall be nontoxic to plant and animal life and nonthinking to concrete or painted surfaces. In the cured state the stabilizing emulsion shall not be re- emulsifiable. The material shall be registered with, and licensed by the California, Department of Food and Agriculture, as an "auxiliary soil chemical". Stabilizing emulsion shall be miscible with water at time of mixing and application. 212-1.3 Seed. Add following: The quantity of pure live seed supplied shall meet or exceed the quantity shown in the specified mixes. Seed shall not contain more than 0.5 percent weed seed by volume Seed types shall be as specified on the plans and planting legends, and shall be applied at the rates indicated. All brand-name, patented seed must be received by Contractor in original manufacturer's bag. Seed shall be received by Contractor in separate containers specifying kind, quantity, purity, and germination. Contractor shall provide the Engineer with each seed bag label used in the Work. Add the following section: 212-1.3.1 Seed for Disturbed Areas. Hydroseeding mix for Disturbed Areas shall consist of no less than the seed varieties shown in Table 212-1.3.1 (A). July 2005 Page 75 of 115 Table 212-1 J.1 SEED FOR DISTURBED AREAS Seed Variety Rose Clover Festuca Megalura, Zorro Fescue Eschscholzia Californica Achillea Millefolia Alyssum (Carpet Of Snow) Dimorpholeca Applicat grains per sq. meter 2.5 2.5 0.35 0.45 0.35 0.25 on Rate (pounds per acre) 20(1) 20 3 4 3 2 (1) Rose Clover shall be inoculated with a nitrogen fixing bacteria and be applied dry either by drilling or broadcasting immediately before hydraulic application of the remaining seed mix and mulch. Add the following section: 212-1.3.2 Seed for Southern Willow Scrub and Riparian Scrub Areas. Hydroseeding mix for the Southern Willow Scrub and Riparian Scrub area shall consist of no less than the seed varieties shown in Table 212-1.3.2(A). Table 212-1.3.2(A) SEED FOR SOUTHERN WILLOW SCRUB AND RIPARIAN SCRUB AREAS Seed Variety Ambrosia Psilostachya Artemesia Douglasiana Artemesia Dracunculus Atriplex Patula SSP, Hastata Halberd Leaf Saltbrush Encelia Californica, California Sunflower Festuca Megalura, Zorro Fescue Isocoma Venetus, Coastal Goldenbrush Leymus Condensatus, Giant Wild Rye Oenothera Hookerii, Hooker's Primrose Applicat grams per sq. meter 0.35 0.35 0.25 0.25 0.25 0.25 0.45 0.45 0.10 on Rate (pounds per acre) 3 3 2 2 2 2 4 4 1 Add the following section: 212-1.33 Seed for Riparian Scrub and Upland Transition Zone Areas. Hydroseeding mix for the Riparian Scrub and Upland Transition Zone area shall consist of not less than the seed varieties shown in Table 212-1.3.2(A). Table 212- SEED FOR RIPARIAN SCRUB AND UPLAND TRANSITION ZONE AREAS Seed Variety Encelia Californica Eschscholzia Californica, California Poppy Festuca Megalura, Zorro Fescue Isocoma Venetus, Coastal Goldenbrush Leymus Condensatus, Giant Wild Rye Lotus Scoparius, Deerweed Lupinus Succulentus, Arroyo Lupine Phacelia Tanacetifolia Applicati grams per sq. meter 0.45 0.25 0.25 0.45 0.45 0.45 0.35 0.25 on Rate (pounds per acre) 4 2 2 4 4 4 3 2 July 2005 Page 76 of 115 212-1.4.1 General. Add the following: Plants shall be the variety and size shown on the plans or in the special provisions and shall conform to the requirements of these specifications. Contractor shall notify the Engineer 48 hours before each plant delivery so that the Engineer can inspect the plants. The scientific and common names of plants herein specified shall conform to the approved names given in "A Checklist of Woody Ornamental Plants in California, Oregon and Washington" published by the University of California, Division of Agriculture Sciences, Publication 4091 (1979). Each group of plant materials delivered on site shall be labeled clearly as to species and variety. All patented plants (cultivars) required by the plant list shall be delivered with a proper plant patent attached. The Contractor shall obtain clearance from the County Agricultural Commissioner, as required by law, before planting plants delivered from outside the County in which they are to be planted. Evidence that clearance has been obtained shall be filed with the Engineer. All plants furnished by the Contractor shall be true to type or name as shown on the plans and shall be tagged identifying the plants by species or variety; however, determination of plant species or variety will be made by the Engineer and the Engineer's decision shall be final. Plants shall be individually tagged or tagged in groups by species or variety. Carpobrorus cuttings need not be tagged. All plants shall comply with Federal and State laws requiring inspection for plant diseases and infestations. Inspection certificates required by law shall accompany each shipment of plants, and certificates shall be delivered to the Engineer. Plants furnished by the Contractor shall be healthy, shapely, and well-rooted, and roots shall show no evidence of having been restricted or deformed at any time. Plants shall be well-grown, free from insect pests and disease, and shall be grown in nurseries which have been inspected by the State Department of Food and Agriculture and have complied with the regulations thereof. The Engineer is the sole judge as to acceptability of each plant. Vigorous, healthy, well-proportioned plants are the intent of this specification. Plants which are even moderately "overgrown", or are showing signs of decline or lack of vigor, are subject to rejection. The size of the plants will be as shown on the plans. Plants larger in size than specified may be used with the approval of the Engineer, but the use of larger plants will make no change in contract price. If the use of larger plants is approved, soil amendments shall be increased proportionately. All plants not conforming to the requirements herein specified shall be considered defective and such plants, whether in place or not, shall be marked as rejected, and immediately removed from the site and replaced with new plants by the Contractor at the Contractor's expense. The Engineer reserves the right to change the species, variety, and/or sizes of plant material to be furnished, provided that the cost of such plant changes do not exceed the cost of plants in the original bid, and with the provision that the Contractor shall be notified in writing, at least 60 days before the planting operation has commenced. No plant shall be transported to the planting area that is not thoroughly wet throughout the ball of earth surrounding the roots. Any plant that, in the opinion of the Engineer, has a damaged root ball or is dry or in a wilted condition when delivered to the planting area will not be accepted, and shall be replaced by the Contractor at the Contractor's expense. Each plant shall be handled and packed in the approved manner for that species or variety, and all necessary precautions shall be taken to ensure that the plants will arrive at the site of the work in proper condition for successful growth. Trucks used for transporting plants shall be equipped with covers to protect plants from windburn. Root condition of plants furnished by the Contractor in containers will be determined by removal of earth from the roots of not less than 2 plants nor more than 2 percent of the total number of plants of each species or variety, except when container-grown plants are from several sources, the roots of not less than 2 plants of each species or variety from each source will be inspected by the Engineer. In case the sample plants inspected are found to be defective, the Agency reserves the right to reject the entire lot or lots of plants represented by the defective samples. Any plants rendered unsuitable for planting because of this inspection will be considered as samples and will not be paid for. The Contractor shall notify the Engineer when plants are to be shipped to the project site. The notification shall be given not less than 10 days prior to the actual shipment date. Carpobrotus cuttings shall be 250 mm (10") or more in length and shall not be rooted. Delosperma cuttings July 2005 Page 77 of 115 shall be 150 mm (6") or more in length and shall not be rooted. Cuttings shall be tip cuttings from healthy, vigorous and strong-growing plants and shall be insect and disease free. Mature or brown-colored stem growths or cuttings which have been trimmed will not be accepted. Cuttings shall be planted not more than 2 days after cutting and shall not be allowed to dry or wither. Carpobrotus cuttings shall not be taken from any plants that indicate the presence of ice plant scale (Pulvinaria species). The Contractor shall notify the Engineer of the location where cuttings are to be taken at least 10 days prior to taking the cuttings and shall be responsible for all permit and inspection fees involved in obtaining cuttings. 212-1.5.3 Tree Stakes. Modify as follows: Tree stakes shall be 50mm (2") diameter turned lodgepole pine, pointed on their driven end. Add the following section: 212-1.6 Erosion Control Matting. Erosion control matting shall be made of 100-percent-biodegradable, weed-free wheat straw of thickness and density yielding 270 grams per square meter (0.50 lb./sy) with photodegradable polypropylene netting with a density of 0.89 grams per square meter (1.64 lb/1000 sy) having an approximate mesh interval of 50 mm x 50 mm (2" x 2") on each face of the straw mat. The straw mat shall be sewn together with unidirectional lines of cotton or polypropylene thread spaced approximately 50 mm (2") apart. Erosion control matting shall be "North American Green, DS150", "BonTerra S2", or approved equal. Add the following section: 212-1.7 Erosion Control Mat Staples. Erosion control mat staples shall be 25 mm x 150 mm (1" x 6"), U-shaped 11-gauge mild steel staples. Add the following section: 212-1.8 Root Barriers. Root barriers shall be no less than 1m (39") in width. Root barriers shall be "Biobarrier", as manufactured by Reemay, Inc., 70 Old Hickory Boulevard, Old Hickory, TN 97138, Phone 615-847-7000, no substitutes will be accepted. 212-2 IRRIGATION SYSTEM MATERIALS. 212-2.1.3 Plastic Pipe for Use with Solvent Weld Socket or Threaded Fittings, add the following: Except as provided in this section, all buried piping in the irrigation system shall be installed with underground utility marking tape conforming to the requirements of section 207-21 and identifying it as reclaimed water. Intermittent pressure lines (lines on the downstream side of a controller valve that will not be subject to constant pressure) will not require underground utility marking tape. All PVC pipe used for irrigation systems shall be colored purple by the addition of a dye integral to the PVC. Painted pipe will not be accepted. Pressure mainline piping for sizes 50 mm (2") and larger shall be PVC having a pressure rating of 2170 kPa (315 PSI), S.D.R. 13.5. Stenciled pipe is required for all irrigation system piping including portions not required to be marked with underground utility marking tape. All pipe shall have stenciling appearing on both sides of the pipe with the marking "Reclaimed Water" in 16 mm ( /g") high letters repeated every 300 mm (12"). PVC non-pressure buried lateral line piping shall be PVC Schedule 40. Add the following section: 212-2.1.7 Brass Pipe and Fittings. Brass pipe shall be IPS standard weight 125 LB 85 percent copper and 15 percent zinc, trade designation seamless red brass pipe conforming to the requirements of ASTM B43-91. Brass pipe fittings and connections shall be Standard 125 LB class 85 percent red brass fittings and connections. 212-2.2.7 Valve Boxes. Add the following: All valve boxes shall be marked "RCV", "BV" or "QC", "PB" respectively. Remote control valves shall be marked with station numbers embossed on the valve cover with a brass tag. (RCV boxes shall have locking covers.) Other boxes such as pull boxes, etc., shall be marked with appropriate identification. July 2005 Page 78 of 115 Add the following section: 212-2.2.8 Ball Valves. Ball valves shall have bottom-loaded pressure-retaining stems, glass-reinforced seats, and reinforced TFE stem packing seals. Valves sizes 13 mm (%") to 50 mm (2") shall be pressure rated at 4140 kPa (600 PSI) WOG and 1030 kPa (150-PSI) saturated steam. Each valve shall be tested, air under water, in the opened and closed position by the manufacturer. Ball valve must conform to Federal Specification WW-V-35B, Type U, Class A, Style 3, End Connection A or C. Add the following section: 212-2.2.9 Pressure Regulator Valve. Pressure regulator valve shall be bronze body with screw fitting. Add the following section: 212-2.2.9 Wye Strainers. Wye strainers shall have a cast iron or all-bronze body with a removable stainless steel or monel strainer. Wye strainers shall be capable of withstanding a cold water working pressure of 1034 kPa (150 psi). Wye strainers at backflow preventer assemblies shall be equipped with a gate valve at the outlet. All other wye strainers shall be equipped with a garden valve at the outlet. The strainer screen for the wye strainer in a backflow preventer assembly shall have an open area equal to at least 3 times the cross-sectional area of the pipe based on an iron pipe size and shall be woven wire fabric with 850-jj.m mesh or perforated sheet with 1.14 mm (0.045") diameter holes. All other wye strainers shall be equipped with 425-um strainer screens. 212-2.4 Sprinkler Equipment. Add the following: All sprinkler heads are to have factory built-in check valves or a check valve under each head. Drip assemblies shall meet the following requirements: The drip emitter shall be Pepco Quadra or Rainbird XERI-Bird-8 or approved equal as called on drawings, with four ports. Drip tubing for emitter outlets shall be Rainbird (RBT-160V), Salco, or approved equal. Drip tubing stakes shall be Rainbird No. RS-13, Salco, or approved equal. Bug cap for drip tubing shall be manufactured by Rainbird, Pepco, or approved equal. The drip pressure regulator shall be Rainbird, Netafim PVR, or approved equal. Drip emitter filter shall be Amiad, Rainbird, or approved equal. Drip emitter access boxes shall be Rainbird No. SEB-6X, Salco Subterranean Emitter Box, or approved equal. Check valves shall be of heavy-duty virgin PVC construction with FIP thread inlet and outlet. Internal parts shall be stainless steel and neoprene. Antidrain valves shall be field adjustable against drain out from 1.5 m to 12 m (5' to 40') of head. All sprinkler heads that are without valves in the heads are to have an antidrain valve feature and shall have an excess flow feature, which will automatically stop the flow of water when it exceeds the GPM preset by the manufacturer. Check valves shall be King Bros., Rainbird, or approved equal. 212-2.3 Backflow Preventer Assembly. Add the following: Backflow preventers shall be one of the approved reduced pressure principle devices listed by the California Department of Health Services, Division of Drinking Water and Environmental Management, 601 North 7th Street, Mailing Station (MS) 92, P.O. Box 942732, Sacramento, CA 94234-7320. Backflow preventers shall be factory assembled and shall include 2 check valves, one pressure differential relief valve, 2 shut-off valves and 4 test cocks. Backflow preventer and valves shall be the same size as the pipeline in which they are installed, unless otherwise shown on the plans. Backflow preventer shut-off valves shall be manufactured from iron or bronze and shall be either resilient wedged gate valves, resilient seated and fully ported ball valves, or resilient seated butterfly valves. Threaded type shut-off valves shall be provided with a union on one side of each valve. Unions shall be brass or malleable iron. Add the following section: 212-2.4.1 Additional Equipment. Contractor shall provide the following items to the Engineer: 1. Two control valve keys. 2. Two wrenches for removing each different type of sprinkler head. 3. Two quick coupler keys. The keys and hose ells shall be of the same manufacturer as 4. the coupling valve. 5. Five keys for opening and locking each automatic controller and enclosure. July 2005 Page 79 of 115 Add the following section: 212-2.5 Flexible Hose.— Flexible hose shall be nonrigid polyvinyl chloride (nonrigid PVC) hose conforminj to the specifications of ASTM Designation: D 2287, Cell-type 6464500. Wall thicknesses of nonrigid PVC hose shall conform to Table 212-2.5(A) when determined in accordance with ASTM Designation: D2122. TABLE 212-2.5(A) FLEXIBLE HOSE Hose! (Millimeters) 15 20 25 Size-Nominal (Inches) 5/8 3/4 1 Minimum W: (Millimeters) 3.73 3.91 4.55 ill Thickness* (Inches) 0.147 0.154 0.179 Range (Percent) 12 12 12 *as measured at any point on the cross section. The hose shall provide leak-free, non-separating connections suitable for the purpose intended when connected to the fittings specified herein. Fittings for flexible hose shall be injection molded PVC, Schedule 40, conforming to the specifications of ASTM Designation: D 2466. Fittings shall be solvent cemented type. Solvent cement for flexible hose and fittings shall be of commercial quality specifically manufactured for use with nonrigid PVC hose. Primer for flexible hose fittings shall be the same as specified for plastic pipe supply line fittings. 212r3 ELECTRICAL MATERIALS. 212-3.1 General. Add the following: All electrical materials shall conform to the requirements of the 1996 National Electrical Code. 212-3.2.2 Conductors. Add the following: Low voltage electric wiring running from controller to the automatic control valves shall be no smaller than No. 14 solid single conductor, copper wire, 0.015 mm (60 mil) insulation, 0.015 mm (60 mil) neoprene jacket, style UF (Direct Burial), or equal, color code wires to each valve. Neutral wires shall be white, no smaller than No. 12 solid single conductor wire, 0.015 mm (60 mil) insulation, 0.015 mm (60 mil) neoprene jacket, style UF (Direct Burial). 212-33 Controller Unit. Add the following: All controllers shall be grounded by one 19 mm (5/8") diameter by 3 m (10') long stainless steel grounding rod and a 50-ohm resistance lightning arrester. Electrical service equipment shall Add the following section. 212-3.4 Irrigation Electrical Service Equipment and Enclosures. incorporate the following elements: 1. One 100-amp, 120/240-volt, single-phase load center, as approved by the Engineer; 2. One 100-amp rated commercial meter socket suitable for the San Diego Gas and Electric Company meter, with provision for test block bypass having a UL listing and EUSERC approval; 3. One 15-amp circuit breaker for each irrigation controller energized by the service; 4. One 20-amp circuit breaker for the duplex receptacle. 5. The design, assembly, grounding, wiring, and components of the irrigation electrical service equipment and enclosure shall meet the requirements of the 1996 edition of the National Electrical Code. 6. Electrical service equipment shall be enclosed in a cabinet constructed entirely of 14-gage, or heavier, 304 stainless steel. The cabinet shall be of welded construction with a brushed finish; anchoring points shall be inside the enclosure. 7. The cabinet shall be HYDROSAFE Model No. HS9, Strong Box, or approved equal. 8. The cabinet shall have a 304 stainless steel interior bulkhead separating the 120/240-volt electrical service section from the irrigation controller section. 9. No wood components shall be used in the enclosure. July 2005 Page 80 of 115 10. Each section of the cabinet shall have full front opening doors with piano hinges, integral keylock and hasp and staple, or other provision, for padlock. 11. The cabinet shall be provided with cross-flow ventilation. Ventilation openings shall be located and designed to preclude rain, irrigation splash, vermin, and insects from entering the cabinet. 12. The controller side door shall have provision for mounting control schematics without the use of adhesives or fasteners. The service side door shall have a clear acrylic plastic window to allow the electrical meter to be read. 13. The cabinet shall have a duplex 15-amp, 120-volt receptacle with ground fault interrupter protection mounted on the interior service side. 14. Concrete footings and pads supporting the Electrical service equipment shall be 560-C-3250 and shall be no less than 150 mm (6") thick. 15. Anchor bolts to secure the service equipment to the concrete pad shall be 10 mm (3/8") diameter by 150 mm (6") long hot dip galvanized or stainless steel headed bolts with washers, without sleeves, conform- ing to section 304-1.7. Anchor bolts to secure the service equipment to the concrete pad shall be embedded in the concrete slab between 65 mm and 100 mm (214" and 4"). SECTION 213 - ENGINEERING FABRICS 213-2 GEOTEXTILES. 213-2.1 General. Add the following: Geotextile types shall be used for the applications listed in Table 213- Table 213-2.1(A) GEOTEXTILE APPLICATIONS Application of Geotextile Separation of Soil and Street Structural Section Separation of Soil and Subsurface Aggregate Drain Reinforcement of Street Structural Section Remediation and Separation of Soil Reinforcement of Soil Drainage at the Interface of Soil Structures Drainage at the Interface of Soil and Structures Rock Slope Protection Fabric for Rock Sizes Below 225 kg (!4 Ton) Rock Slope Protection Fabric for Rock Sizes Including and Above 225 kg ({4 Ton) Plant Protection Covering Erosion Control Fence with 14 AWG - 150 mm x 150 mm (6"x6") Wire and 3m (10') Post Spacing Erosion Control Fence with 1 .8 m (6') Post Spacing and No Wire Fencing Type Designation 90WS 180N 200WS 270WS 270WS N/A N/A 180N 250N 90N 90WS 200WS Add the following section: 213-3 EROSION CONTROL SPECIALTIES. Add the following section: 213-3 Gravel bags. Gravel bags for the use of temporary erosion control shall be burlap type, filled with no less than 23kg (50 Ibs) of 19 mm (3/4") crushed rock and securely tied closed. Plastic bags are not acceptable. July 2005 Page 81 of 115 SECTION 214 PAVEMENT MARKERS 214-5 REFLECTIVE PAVEMENT MARKERS Add the following section: 214-5.1 Temporary Reflective Pavement Markers. Temporary pavement markers shown on the plans and required in the specifications shall be one of the types shown in Table 214-5.1 (A), or equal thereto. TABLE 214-5.1(A) TEMPORARY REFLECTIVE PAVEMENT MARKERS Type TFPM Manufacturer of Distributor DAPCO Davidson Plastics Company, 18726 East Valley Highway, Kent, Washington 98032, Telephone (206) 251-8140. Add the following section: 14-5.2 Permanent Reflective Channelizer. Reflective Channelizer shall be new surface-mounted type and shall be furnished, placed, and maintained at the locations shown on the plans. Reflective Channelizer posts shall be orange in color. Reflective channelizers shall have affixed white reflective sheeting as specified hi the special provisions. The reflective sheeting shall be 75 mm x 300 mm in size. The reflective sheeting shah1 be visible at 300 m at night under illumination of legal high beam headlights, by persons with vision of or corrected to 20/20. Reflective Channelizer shall be one of the types shown in Table 214-5.2(A), or equal thereto. TABLE 214-5.2(A) REFLECTIVE CHANNELIZER Type Safe-Hit SH236MA Carsonite "Super Duck" SDF-436 Repo "The Replaceable Post" Manufacturer of Distributor Safe-Hit Corporation 1930 West Winton Avenue, Building #1 1 Hayward, CA 94545 Telephone (415) 783-6550 Carsonite International Corporation 2900 Lockheed Way Carson City, NV 89701 Telephone (702) 883-5 104 Western Highway Products P.O. Box 7 Stanton, CA 90680 Telephone (800) 422-4420 The Contractor shall provide the Engineer with a Certificate of Compliance in accordance with the provisions of Section 2-5.3.3 "Submittals". Said certificate shall certify that the permanent reflective channelizers comply with the plans and specifications and conform to the prequalified design and material requirements approved by the engineer and were manufactured in accordance with the approved quality control program. July 2005 Page 82 of 115 SUPPLEMENTAL PROVISIONS TO STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART 3, CONSTRUCTION METHODS (Pertaining to City of San Marcos IP-4693 and Bid Schedule 'A') SECTION 300 - EARTHWORK 300-1 CLEARING AND GRUBBING. 300-1.1 General, add the following to the third paragraph: During surface clearing operations, the Contractor shall not cover or bury any plant growth or other objectionable materials. If the Contractor cannot successfully separate the plant growth from the surface soil and advertently or inadvertently mixes organic or other objectionable materials with the soil, the soil so contaminated shall be removed from the site by the Contractor. All costs, if any, associated with removing the soil mixed with organic or other objectionable materials and importing soil to replace said contaminated soil shall be borne by the Contractor and no additional payment therefore shall be made to the Contractor. 300-1.3 Removal and Disposal of Materials, add the following: Also included in clearing and grubbing shall be removal and disposal of existing street poles and lights, metal guard rail, fences, asphalt concrete and aggregate base, concrete curb and gutter, concrete sidewalk, existing gate, existing headwalls, existing retaining wall, rip-rap, traffic signs, and other existing features which interfere with the work. Whether or not such items are shown on the plans they shall be removed as a part of clearing and grubbing. Existing underground pipes and conduits that are shown on the plans and designated to be removed shall be removed by the Contractor as a part of clearing and grubbing. 300-1.4 Payment, modify as follows: Payment for clearing and grubbing shall be made at the contract lump sum price based on percent completed for clearing and grubbing within the project limits and at stockpile locations and no other payments will be made. Unless otherwise noted on plans, the Contractor shall remove all existing abandoned pipelines and conduits of any type, or use, and pipelines and conduits of any type, or use, that are abandoned during the course of the work and shall replace said pipelines and conduits with properly compacted soils. Payment for removal and disposal of abandoned utilities shall be included in the lump-sum bid for Clearing and Grubbing, and no additional payment will be made. 300-2 UNCLASSIFIED EXCAVATION. 300-2.1 General, add the following: Unclassified excavation shall include removal and stockpile of suitable material, recompaction, mixing, grading for mitigation work, trenching and backfilling of storm drains, sewers, other utilities, disposal of unsuitable materials not included in the bid item for clearing and grubbing, all cut and fill including salvaging clean excavated material and filling areas to the required grades and cross section. Unclassified excavation shall be utilized onsite to make all fills shown on the plans. Unclassified excavation shall also include scarification and moisture adjustment and compaction of the top 300 mm (!') of the subgrade in the roadway prism in cut areas to 95 percent relative compaction, wetland mitigation grading and attendant work, export of remaining excess material to a disposal site or spoil area acquired by the Contractor and pumping and disposal of storm and ground water. 300-2.2.1 General, add the following: Alluvial and colluvial removal and recompaction shall consist of excavating, blending and recompacting loose soils in areas that are designated to receive fills. The existing ' July 2005 Page 83 of 115 loose soils shall be removed by the Contractor until a firm unyielding surface is exposed or to a depth determined by the Engineer. If the excavated material contains 4%, or more, water than the optimum moisture content the Contractor shall blend the wet soil with soils having a lower moisture content and/or spread excavated material in a manner that enables the material to dry to optimum moisture content. The cost spreading and/or drying shall be included hi the contract unit price for removal and recompaction. The excavated material shall be placed and compacted in accordance with section 300-4 of the specifications except that section 300-4.9, Measurement and Payment, shall not apply. 300-2.2.1 General, add the following to the first paragraph: Such direction may include, but is not limited to, directing the Contractor to blend, adjust moisture content of, rework, and place unsuitable soils at specific locations or elevations on the site. Add the following section: 300-2.23 Compressible Soil. Compressible soils such as existing uncontrolled or unacceptable fill, alluvium, and colluvium may exist within portions of the Project site. Where required by the Engineer, the Contractor shall remove such compressible soils from areas to receive fill or from areas upon which surface improvements are to be placed. The removal and disposal of such compressible soils shall be paid for at the Contract Unit Price for unclassified excavation unless it is considered otherwise unsuitable by the Engineer in which case it may be paid for in accordance with section 300-2.2.1. 300-2.2.4 Instability of Cuts. Add the following: The Contractor shall remove additional material as directed by the Engineer to improve the stability of excavated cuts. The removal of such excavated material shall be paid for at the Contract Unit Price for unclassified excavation unless it is considered otherwise unsuitable by the Engineer, in which case it will be paid for in accordance with Subsection 300-2.2.1. 300-2.5 Slopes, add the following: The hinge points (the top and bottom) of slopes shall be located within 75 mm (0.25') of the locations shown on the plans. 300-2.5 Slopes, add the following: after the first sentence of the first paragraph: A slope shall be defined as any area steeper than three horizontal to one vertical. 300-2.6 Surplus Material, add the following: The Contractor shall haul and dispose of all surplus material from the project. The Contractor shall utilize highway legal haul trucks for this export of material from the project site and to a site secured by the Contractor. No earth moving equipment or special construction equipment, as defined in section 565 of the California Vehicle Code, will be allowed for hauling material on public streets. 300-2.8 Measurement, delete the second paragraph relating to materials removed from stockpiles and add the following: Unclassified Excavation shall be measured based on the volume it occupies in its original position before excavating. The measurement shall be from the original ground contours after clearing and grubbing and the bottom of areas of excavation to the design elevations shown on the plans or actual ground contours existing in borrow sites after excavation or those for removal and recompaction of alluvial and colluvial materials or those for materials excavated to improve the stability of cuts, whichever is lower in elevation. No excavated material which is re-excavated will be measured for payment. Materials excavated or otherwise removed as all or part of any other bid item shall not be measured as Unclassified Excavation. 300-2.8 Measurement, delete the second paragraph relating to materials removed from stockpiles and add the following: Unclassified Excavation shall be measured based on the volume it occupies in its original position before excavating. The measurement shall be from the original ground contours after clearing and grubbing and the bottom of areas of excavation to the design elevations shown on the plans or actual ground contours existing in borrow sites after excavation. No excavated material which is re-excavated will be measured for payment. Materials excavated or otherwise removed as all or part of any other bid item shall not be measured as Unclassified Excavation. The measurement of work performed under sections 300-2.2.1 and 300-2.2.2, 300-2.2.3 and 300-2.2.4 when the Engineer determines that the soils are unsuitable shall be the actual labor, materials and equipment used to accomplish the work as per section 3-3 EXTRA WORK of the specifications. July 2005 Page 84 of 115 300-2.9 Payment, add the following: Payment for work performed under sections 300-2.2.1, 300-2.2.2, 300- 2.2.3 and 300-2.2.4, when the Engineer determines that the soils are unsuitable, shall be made for the actual labor, materials and equipment used to accomplish the work as per section 3-3 EXTRA WORK of the specifications. 300-2.9 Payment substitute the following: Payment for Unclassified Excavation will be made at the unit price bid hi the proposal. Only the quantity of unclassified excavation measured shall be paid for. No excavated material which is re-excavated will be paid for. For progress payments, the quantity of unclassified excavation shall be estimated by the Engineer . The Engineer's calculations shall be considered the definitive determinant for quantities for final payment. Payment for Unclassified Excavation shall include costs of surveying, staking, preparation of earthwork quantity reports, placement, compaction, soil remediation, moisture adjustment and water therefore, rework of compressible soils, slope rounding, grading, stockpiling, access road, temporary detour roads, earthen swales and drainage channels as shown on the drawings or required by the contract documents. Add the following section: 300-2.10 Grading Tolerance. The Contractor shall finish excavated areas other than slopes and subgrade below structures, within the roadway and sidewalk areas within 30 mm (0.1') of the grades shown on the plans. Subgrade tolerances shall conform to the requirements of section 301-1.4 SSPWC. 300-3 STRUCTURE EXCAVATION AND BACKFILL 300-3.1 General, add the following: The Contractor shall excavate to the lines and levels required and/or shown on the Drawings. The Contractor shall provide all shoring, bracing, cribbing, pumping, and planking required. The Contractor shall excavate and maintain the bottom of all trenches in a condition that is level, firm, clean and free from all debris or foreign matter. Excavations shall be kept free from water at all tunes. The Contractor shall remove any unsuitable material encountered below grade as directed by the Engineer 300-3.2 General, add the following: The Contractor shall submit to the Engineer working drawings, including design calculations, and a construction sequence for the proposed method of soldier pile wall construction for the site hi conformance with the provisions in Section 2-5.3.2, "Working Drawings," of the Standard Specifications. The drawings and calculations shall be signed by an engineer who is registered as a Civil Engineer hi the State of California. One set of the drawings and construction sequence, and one copy of the design calculations, shall be furnished to the Engineer. The working drawings and construction sequence shall include, but not be limited to, defining order of work, traffic control, method of installation of soldier piles, method of placing lagging, limits of structure excavation lifts, and type of drilling and excavation equipment to be used. The Contractor shall allow one week after complete drawings and support data are submitted for the review and approval of the proposed method of soldier pile wall construction. Excavation and construction of the soldier pile wall shall proceed in lifts from the top down. Care shall be taken in performing structure excavation for placement of lagging such that a minimal void behind the lagging is required to be backfilled. At the end of the work shift, lagging shall be in place the full height of the exposed excavation face. Structure backfill behind lagging shall be compacted by hand tamping, mechanical compaction, or other means approved by the Engineer. Structure backfill in fill areas behind the lagging shall be keyed into the existing or excavated back slope. 300-3.6 Payment, add the following: Dewatering shall be paid for as an incidental to unclassified excavation and no additional compensation will be made therefore. Except for unsuitable materials removed as part of the clearing and grubbing item unsuitable material encountered below grade will be paid for at the unit price bid for unclassified excavation. 300-4 UNCLASSIFIED FELL 300-4.2 Preparation of Fill Areas, add the following: Except as provided in section 300-4.7, "Compaction", areas proposed for improvements all fill (including backfill and scarified ground surfaces) shall be compacted July 2005 Page 85 of 115 by the Contractor to no less than 90 percent of maximum dry density as determined in accordance with ASTM Test Procedure D1557-91 . 300-4.5 Placing Materials for Fills, add the following: The Contractor shall perform grading such that the' upper 900 mm (3') of fill placed in the roadway pavement area is composed of properly compacted low expansive soils. The more highly expansive soils shall be placed in the deeper fill areas and properly compacted or exported from the site. Low expansive soils are defined as those soils that have an Expansion Index of 50 or less when tested in accordance with 1994 UBC Standard 18-2 as published by the International Conference of Building Officials. Should insufficient soils meeting the requirement of an expansion index of 50 or less be present within the limits of work, soils of the least expansion index that are available within the limits of work shall be incorporated in the upper 900 mm (3') of fill placed in the roadway. The Contractor shall break rock encountered in the excavation into particles of less than 75 mm (3"). Particles with dimensions greater than 75 mm (3") shall be uniformly distributed over the area to be filled so that construction equipment can be operated in such a manner that the larger pieces will be broken into smaller particles and become incorporated with the other materials in the layer. This requirement for particle size reduction does not apply to cobbles, small boulders, and small hard rocks found within the surface soils and formational materials. Rocks having any dimension greater than 460mm (18") shall not be incorporated into the fill. Rock exceeding 150 mm (6") in diameter shall not be placed in the upper 900 mm (3') of any fill. When there are large quantities of rock to be placed in the fill, rocks shall not be nested, but shall be spread with sufficient room between them so that intervening voids can be adequately filled with fine material to form a dense, compact mass. Oversize material which cannot be utilized for erosion mitigation or landscaping onsite shall be broken to acceptable sizes or removed from the site by the Contractor. If disposed of within the City of Carlsbad, a separate grading permit will be required for disposal of rock. 300-4.6 Application of Water, add the following: The Contractor shall place all fill soil at a moisture content no less than one (1) percent below optimum moisture as determined by ASTM test D-1557-91. 300-4.7 Compaction, add the following: The Contractor shall compact all fill soils placed within the top 1m (3 ') of roadway subgrade to a minimum of 95 percent relative compaction. On all areas to receive planting, the top 1 50 mm (6") shall be compacted to 85%, +2% -5%, to allow for plant growth. 300-4.8 Slopes, add the following: Feathering of fill over the tops of slopes will not be permitted. The Contractor shall compact the faces of fill slopes with a sheep's foot roller at vertical intervals no greater than 600 mm (2') or shall be built and cut back to finish grade. In addition, if not over built and cut back, the face of the slope shall be track walked upon completion. 300-4.9 Measurement and Payment, delete and substitute the following: Unclassified fill, grading, shaping, compacting or consolidating, slope rounding, construction of transitions and all work included in and incidental to Section 300-4, "Unclassified Fill" will be paid for as a part of unclassified excavation, and no additional payment will be made therefore. 300-5 BORROW EXCAVATION. Add the following section: 300-5.2.1 Imported Borrow Properties. The Contractor shall provide imported borrow that is clean well graded soil consisting of material conforming to all of the requirements in Table 300-5.2.1 (A) and the following requirements. Rock included in the top 1 m (3') of imported borrow shall be particles of less than 75 mm (3"). Rock included below the top 1 m (3') of imported borrow shall be particles of less than 150 mm (6"). TABLE 300-5.2.1(A) _ _ IMPORTED BORROW PROPERTIES _ Tests | Test Method No. | Requirements July 2005 Page 86 of 115 R-Value Expansion Index Plasticity Index Sieve Analysis Calif. 301 UBC Standard 18-2 ASTM D 424 ASTM D 422 40 Min. 10 Max. 4 Max. Percent Passing 75u (No. 200)15 Max. 300-9 GEOTEXTILES FOR EROSION CONTROL AND WATER POLLUTION CONTROL. Add the following section: 300-9.2 General. The Contractor shall provide erosion control and water pollution control conforming to the requirements shown on the plans, as specified herein, and as elsewhere required by the Contract Documents. Erosion control and water pollution control shall include the work specified herein, and such additional measures, as may be directed by the Engineer, to meet Best Management Practices, as defined herein, and to properly control erosion and storm water damage of the limits of work and construction impacts upon areas receiving drainage flows from within the limits of work. Add the following section: 300-9.2.1 Grading Controls. The Contractor shall protect all areas that have been graded and/or cleared and grubbed as well as areas that have not been graded and/or cleared and grubbed within the limits of work from erosion. The Contractor shall provide temporary earth berms, gravel bags, silt fences, stabilized construction entrances and similar measures, coordinated with its construction procedures, as necessary and as shown on the plans to control on site and off site erosion during the construction period. The Contractor will be required to protect areas which have been cleared and grubbed prior to excavation or embankment operations, and which are subject to runoff during the duration of the contract. The criteria used to determine the appropriate erosion control measures shall be the "Best Management Practices", hereinafter BMP, defined and described in the, "Stormwater Best Management Practices Handbook, Construction", March 2003 edition as published by the California Stormwater Quality Association. The Contractor shall maintain a copy of the "Stormwater Best Management Practices Handbook, Construction", March 2003 edition on the project site and shall conduct its operations in conformity to said Handbook. Temporary erosion control measures provided by the Contractor shall include, but not be limited to, the following: a) Embankment areas, while being brought up to grade and during periods of completion prior to final roadbed construction, shall be graded so as to direct runoff into impoundment areas within the limits of work where such runoff shall have pollutants removed by BMP methods . b) The Contractor shall provide protection by BMP measures to eliminate erosion and the siltation of downstream facilities and adjacent areas. These measures shall include, but shall not be limited to: temporary down drains, either in the form of pipes or paved ditches with protected outfall berms; graded berms around areas to eliminate erosion of embankment slopes by surface runoff; confined ponding areas to desilt runoff; and to desilt runoff. c) Excavation areas, while being brought to grade, shall be protected from erosion and the resulting siltation of downstream facilities and adjacent areas by the use of BMP measures. These measures shall include, but shall not be limited to, methods shown on the plans and described herein. Add the following section: 300-9.2.2 Payment. Full compensation for performing erosion control and water pollution control, conforming to the operational requirements herein, of the BMP and conforming to the requirements of the Federal Water Pollution Control Act, including the latest amendments thereto, which is not a part of the planned permanent work or included as a separate bid item shall be considered as included in the contract price bid for unclassified excavation, and no additional compensation will be allowed therefore. 300-11 STONEWORK FOR EROSION CONTROL. July 2005 Page 87 of 115 300-11.4 Payment, delete and replace as follows: Rock protection will be paid for at the lump sum contract Price Bid for rock protection, complete and in place, in accordance with the details and requirements of the plans and specifications. 300-12 ROCK SLOPE PROTECTION FABRIC. Add the following section: 300-12.1 Preparation of Subgrade. Prior to placing rock slope protection fabric the Contractor shall clear the surfaces upon or against which rock slope protection fabric is to be placed of loose or extraneous material and sharp objects that may damage the fabric during installation. Equipment or vehicles shall not be operated or driven directly on the rock slope protection fabric. Rock slope protection fabric damaged during placement shall be replaced or repaired by the Contractor at its expense as directed by the Engineer. Add the following section: 300-12.2 Placement. The Contractor shall place rock slope protection fabric prior to placing rock slope protection. The Contractor shall grade surfaces to be covered by rock slope protection so as to provide full support for the fabric. Rock slope protection fabric shall conform to the provisions in Section 213-2, "Geotextiles," and shall be placed by the Contractor in accordance with the details shown on the plans and as specified herein. The Contractor shall handle rock slope protection fabric with care that it is not torn or stretched and place it in accordance with the manufacturer's recommendations, these specifications and as directed by the Engineer. The Contractor shall place and fit rock slope protection fabric loosely upon or against the surface to receive the fabric so that the fabric conforms to the surface without damage when the cover material is placed. Rock slope protection fabrics shall be joined, at the option of the Contractor, either with overlapped joints or stitched seams. When fabric is joined with overlapped joints, all adjacent borders of the fabric shall be overlapped not less than 610 mm (24"). The fabric shall be placed such that the fabric being placed shall overlap the adjacent section of fabric in the direction the cover material is being placed. When the fabric is joined by stitched seams, the fabric shall be stitched with yarn of a contrasting color. The size and composition of the yarn shall be as recommended by the fabric manufacturer. The number of stitches per 25 mm (1") of seam shall be 6 ± 1. The strength of stitched seams shall be the same as specified for the fabric, except when stitched seams are oriented up and down a slope the strength shall be a minimum of 80 percent of that specified for the fabric. Fabric damaged beyond repair, as determined by the Engineer, shall be replaced by the Contractor and no additional payment will be made therefore. Repairing damaged fabric shall consist of placing new fabric over the damaged area. The minimum fabric overlap from the edge of the damaged area shall be 1 m (3') for overlap joints. If the new fabric joints at the damaged areas are joined by stitching, the stitched joints shall conform to the requirements specified herein. Damaged fabric that is suitable for repair, as determined by the Engineer, shall be repaired by the Contractor and no additional payment will be made therefore. Add the following section: 300.12.3 Measurement and Payment. Payment for rock slope protection fabric will be included in the unit and/or lump sum prices for items which have said fabric in their design and no additional payment will be made therefore. 300-13 STORM WATER POLLUTION PREVENTION PLAN Add the following section: 300-13.1 Storm Water Pollution Prevention Plan. As part of the storm water pollution prevention work, the Contractor shall prepare and submit Storm Water Pollution Prevention Plan, hereafter referred to as the "SWPPP,". The SWPPP shall conform to the requirements of the "Greenbook" Standard Specifications for Public Works Construction, the requirements in the California Storm Water Quality Association, Stormwater Best Management Practice Handbook, Construction ("Handbook"), the requirements of the Permit, the requirements in the plans and these supplemental provisions. July 2005 Page 88 of 115 300-13.1.1 SWPPP Document Within 15 calendar days after the execution of the contract, the Contractor shall submit 3 copies of the SWPPP to the Engineer, in accordance with Section 2-5.3.3 of these Special Provisions. Contractor will be provided the digital format for SWPPP to complete required sections. If revisions are required, as determined by the Engineer, the Contractor shall revise and resubmit the SWPPP within 15 days of receipt of the Engineer's comments and shall allow 5 days for the Engineer to review the revisions. Upon the Engineer's acceptance of the SWPPP, 3 additional copies of the SWPPP, incorporating the required changes, shall be submitted to the Engineer. In order to allow construction activities to proceed, the Engineer may conditionally approve the SWPPP while minor revisions are being completed. The objectives of the SWPPP shall be to identify pollution sources that may adversely affect the quality of storm water discharges associated with the project and to identify, construct, implement and maintain storm water pollution prevention measures, hereafter referred to as control measures, to reduce to the extent feasible pollutants in storm water discharges from the construction site both during and after construction is completed under this contract. The SWPPP shall incorporate control measures in the following categories: 1 . Soil stabilization practices; 2. Sediment control practices; 3. Wind erosion control practices; and 4. Non-storm water management and waste management and disposal control practices. Specific objectives and minimum requirements for each category of control measures are contained in the Handbook. The Contractor shall designate a Water Pollution Control Manager who will have the responsibilities outlined in the SWPPP. The SWPPP shall include, but not be limited to, the following items as described in the SWPPP: 1 . Source Identification; 2. Erosion and Sediment Controls; 3. Non-Storm Water Management; 4. Waste Management and Disposal; 5. Maintenance, Inspection and Repair; 6. Training; 7. List of Contractors and Subcontractors; 8. Post-Construction Storm Water Management; 9. Preparer; 10. Copy of the local permit; 1 1 . BMP Consideration Checklist; 12. SWPPP Checklist; 13. Schedule of Values; and 14. Storm Water Pollution Prevention Drawings. The Contractor shall amend the SWPPP, graphically and in narrative form, whenever there is a change in construction activities or operations which may affect the discharge of significant quantities of pollutants to surface waters, ground waters, municipal storm drain systems, or when deemed necessary by the Engineer. The SWPPP shall also be amended if it is in violation of any condition of the Permit, or has not effectively achieved the objective of reducing pollutants in storm water discharges. Amendments shall show additional control measures or revised operations, including those in areas not shown in the initially accepted SWPPP, which are required on the project to control water pollution effectively. Amendments to the SWPPP shall be submitted for review and acceptance by the Engineer in the same manner specified for the initially accepted SWPPP. Accepted amendments shall be dated and logged in the SWPPP. Upon acceptance of the amendment, the Contractor shall implement the additional control measures or revised operations. July 2005 . Page 89 of 115 The Contractor shall keep a copy of the accepted SWPPP and accepted amendments at the project site. The SWPPP shall be made available upon request of a representative of the Regional Water Quality Control Board, State Water Resources Control Board, U.S. Environmental Protection Agency or local storm water^ management agency. Requests by the public shall be directed to the Engineer. By June 15 of each year, the Contractor shall submit an annual certification to the Engineer stating compliance with the requirements governing the Permit. If the project is in non-compliance at any time, the Contractor shall make a written report to the Engineer within 15 days of identification of non-compliance. Add the following section: 300-13.13 Payment. Preparation, implementation and management of SWPPP shall be considered incidental to the items of work and no additional payment will be made therefore. Add the following section: 300-13.1.4 SWPPP Implementation. Upon acceptance of the SWPPP, the Contractor shall be responsible throughout the duration of the project for installing, constructing, inspecting and maintaining the control measures included in the SWPPP and any amendments thereto and for removing and disposing of temporary control measures. Unless otherwise directed by the Engineer or specified in these supplemental provisions, the Contractor's responsibility for SWPPP implementation shall continue throughout any temporary suspension of work ordered in accordance with Section 6-3, "Suspension of Work". Requirements for installation, construction, inspection, maintenance, removal and disposal of control measures are specified in the "Handbook" and these supplemental provisions. Soil stabilization practices and sediment control measures, including minimum requirements, shall be provided throughout the winter season, defined as between October 1 and April 30. Implementation of soil stabilization practices and sediment control measures for soil-disturbed areas of the project site shall be completed, except as provided for below, no later than 20 days prior to the beginning of the winter season or upon start of applicable construction activities for projects which begin either during or within 20 days of the winter season. The Contractor shall implement, year-round and throughout the duration of the project, control measures included in the SWPPP for sediment tracking, wind erosion, non-storm water management and waste management and disposal. The Engineer may order the suspension of construction operations, at the Contractor's cost, which create water pollution if the Contractor fails to conform to the requirements of this section as determined by the Engineer. Add the following section: 300-13.1.5 Maintenance. To ensure the proper implementation and functioning of control measures, the Contractor shall regularly inspect and maintain the construction site for the control measures identified in the SWPPP. The Contractor shall identify corrective actions and time frames to address any damaged measures or reinitiate any measures that have been discontinued. The construction site inspection checklist provided in the "Handbook" shall be used to ensure that the necessary measures are being properly implemented, and to ensure that the control measures are functioning adequately. The Contractor shall submit one copy of each site inspection record to the Engineer, within two days of the inspection. July 2005 Page 90 of 115 During the winter season, inspections of the construction site shall be conducted by the Contractor to identify deficient measures, as follows: 1. When the five-day rain probability forecast exceeds forty percent (40%). 2. After any precipitation which causes runoff capable of carrying sediment from the construction site; 3. At 24 hour intervals during extended precipitation events; and 4. Routinely, at a minimum of once every week. If the Contractor or the Engineer identifies a deficiency in the deployment or functioning of an identified control measure, the deficiency shall be corrected by the Contractor immediately, or by a later date and time if requested by the Contractor and accepted by the Engineer in writing, but not later than the onset of subsequent precipitation events. The correction of deficiencies shall be at no additional cost to the City. July 2005 Page 91 of 115 SECTION 301 - TREATED SOIL, SUBGRADE PREPARATION & PLACEMENT OF BASE MATERIALS 301-1 SUBGRADE PREPARATION. 301-1.2 Preparation of Subgrade. Modify the second and third paragraphs as follows: Change each instance reading "150mm (6 inches)" to "300 mm (12")". Add the following: Sub base shall be constructed in accordance with the provisions of Section 301 "Treated Soil, Subgrade Preparation and Placement of Base Materials" and Section 303 "Concrete and Masonry Construction" of these Supplemental Provisions and Standard Specifications For Public Works Construction. The existing sub base may be used if approved by the engineer. If existing sub base is used, it must be checked and re-leveled if required and cannot deviate from correct level by more than 0.4" and should reflect final profile of the paving. Sand leveling course shall be per Section 202-3 of the Supplemental Provisions. Thickness of sand laying course shall be uniform to insure an even surface. The Contractor shall saturate sand thoroughly with water, then the sand bed shall be compacted completely smooth, level, and to the profile required for proper installation. 301-1.3 Relative Compaction. Delete the first paragraph and substitute the following: The Contractor shall compact the upper 300 mm (12") of subgrade beneath areas to be paved, have base or subbase material placed on them, or curb, gutter, curb and gutter, alley pavement, driveway or sidewalk constructed over them to no less than 95 percent maximum dry density as determined by ASTM test D-1557-91. 301-1.7 Payment. Modify the first paragraph as follows: Payment for subgrade preparation shall be included in the contract bid price for which the subgrade is prepared and shall include all labor, materials; including water, operations and equipment to scarify, adjust moisture, compact or recompact the subgrade, both in cut areas and in fill areas, and no further compensation will be allowed. SECTION 302 - ROADWAY SURFACING 302-5 ASPHALT CONCRETE PAVEMENT. 302-5.1 General, add the following: The Contractor shall treat all vegetation within the limits of the paved area to receive asphalt concrete paving with a post emergent herbicide. Herbicide shall be applied at least 2 (two) working days prior to paving the area. Allowance for the two day period shall be shown in the schedule required per section 6-1. 302-5.2.2 Equipment, add the following: The machine shall be capable of grinding Asphalt Concrete so that the finished surface shall not vary from true plane enough to permit a .01 foot thick shim .25 feet wide to pass under a 12 foot long straight edge when the straight edge is laid on the finished surface parallel to the centerline. The transverse slope of the finished surface shall be uniform to a degree such that a .02 foot shim .25 feet wide will not pass under 12 foot long straight edge when the straight edge is laid on the finished surface in a direction transverse to the centerline and extending from edge to edge of a traffic lane. 302-5.2.5 Pavement Transitions, add the following: The Contractor shall ramp the approaches and termini to all structures and vertical joints in the cold-milled area which are transverse to through traffic with temporary asphalt concrete pavement as specified in section 306-1.5.1. Ramps shall be constructed the same day as cold milling and removed the same day as permanent paving. Ramp dimensions and compaction shall be as July 2005 Page 92 of 115 approved by the Engineer. 302-5.4 Tack Coat, add the following: The Contractor shall place a tack coat between the successive interfaces of existing pavement and new pavement when, in the opinion of the engineer, the Contractor has failed to maintain or prepare each existing or previously laid course of asphalt receiving the subsequent course of asphalt in a sufficiently clean state and the asphalt receiving the new pavement course is dirty enough to impair bonding between the next lift of asphalt. 302-5.5 Distribution and Spreading, modify as follows: After second sentence of sixth paragraph, add: The Contractor shall provide the spreading and finishing machine used to construct the asphalt concrete surface course with an automatic screed control for surface course paving. The automatic screed control shall be 9 m (30') minimum length. The paving machine shall be operated by an operator and two full-time screed men during all paving. Delete the second sentence of paragraph 7 and the subsequent subsections A. thru E. which reference windrow operations. Add the following sentence in place of the deleted sentence and subsequent subsections: The use of windrow operations shall not be allowed. 302-5.6.1 General, modify as follows: Second paragraph, Part (2), add: Pinched joint rolling procedures shall be required, and vibratory rollers shall be limited to breakdown, unless otherwise directed by the Engineer. modify as follows: After last paragraph, add: Unless directed otherwise by the Engineer, the initial breakdown rolling shall be followed by a pneumatic-tired roller as described in this section. 302-5.8 Manholes (and other structures), delete the first paragraph and replace with the following: When placing the AC overlay the Contractor shall pave over appurtenances in the roadway which includes sanitary and storm access covers, water valve boxes, air vents, sewer dead end boxes and survey monument boxes. Each appurtenance shall be treated or covered to prevent adhesion of the overlay. Each appurtenance shall be located immediately after the overlay is placed and shall be thoroughly cleaned of any and all construction debris which may have entered due to the Contractor's operation. The contractor shall adjust all water valve boxes per CMWD Standard Drawing No. Wll or CMWD Standard Drawing No. W13. All sanitary sewer access covers shall be adjusted per CMWD Drawing No. SI. All storm sewer access covers shall be adjusted per SDRSD D-10. Riser rings or extensions shall not be used for the adjustment of these appurtenances. Raising and adjusting to grade all appurtenances in the roadway shall be paid for at the contract unit price per each as shown in the Bid. Such price shall constitute full compensation for all labor, materials, and equipment necessary for completing the work as described in these specifications and plans. 302-5.9 Measurement and Payment, add the following: Payment for asphalt concrete shall be at the unit price bid per ton. No additional payment shall be made for any tack coat. Add the following section: 302-11 ASPHALT PAVEMENT REPAIRS AND REMEDIATION Add the following section. 302-11.1 General. Asphalt pavement Repairs and Remediation shall consist of the repair and restoration of existing asphalt pavement. Repair of asphalt pavement shall consist of the saw cutting, removal and disposal of existing asphalt pavement in conformance with section 300-1.3, compaction of existing subgrade in conformance with section 301-1, grading and compaction of base material in conformance with section 301-2, application of grade SS-lh emulsified asphalt and the placement of asphalt concrete base and wearing courses as specified herein Add the following section. July 2005 Page 93 of 115 302-11.2 Full Depth Asphalt Concrete Patch. Full depth asphalt concrete patch shall consist of removing asphalt concrete and/or aggregate base/subgrade to 300 mm (!') below existing asphalt surface and placing replacing the material so removed with asphalt concrete. The area shown on the plans or set forth in the bid, item are for estimating purposes only, final quantity will be as measured in the field. The Engineer willf designate and mark the final limits of the asphalt patch area by outlining the area to be patched. The Contractor shall cut such areas to straight lines in square or rectangular areas as marked. The area so cut shall have two of the sides at right angles to the direction of traffic. The excavated faces of the base/subgrade shall be straight and vertical. The Contractor shall compact the upper 300mm (1') of subgrade to 95% relative compaction. A tack coat of SS-lh emulsified asphalt shall be applied uniformly to all asphalt to asphalt contact surfaces at a rate of 0.25 L/m2 to 0.45 L/m2 (0.05 to O.lOgallons per square yard) in accordance with subsection 302-5.4, SSPWC. The Contractor shall fill and compact areas designated to be removed with 300 mm (1.0') full depth asphalt concrete. Asphalt concrete for full depth asphalt concrete patch shall be B-AR-4000. The asphalt concrete so constructed shall have a finish surface and density conforming to subsection 302-5.6.2 SSPWC. Add the following section. 302-113 Crack Sealing The Contractor shall wash, blow out and thoroughly dry all cracks designated to be sealed before installing elastomeric sealant material. The Contractor shall dispose debris from crack cleaning outside the public way in accordance with Section 7-8.1, "Cleanup and Dust Control." The hot-melt rubberized asphalt shall be melted in a jacketed, double boiler type melting unit. Temperature of the heat transfer medium shall not exceed 245°C (475°F). Application of the hot-melt sealant shall be made with a pressure feed applicator or pour pot. Sealant shall be applied when the pavement surface temperature is greater than 4°C (40°F). Containers of hot-melt sealant shall be delivered to the job-site in unopened containers that are clearly marked with data showing the manufacturer's name, the product designation and the manufacturer's batch number and lot numbers. The level of the sealant shall be flush with the surface of the existing pavement. All excess sealant shall be removed from the crack with a minimum overlap onto adjacent pavement. Add the following section. 302-11.4. Measurement and Payment. Quantities of full depth asphalt concrete patch and crack sealing set forth in the bid item are for estimating purposes only, final quantity will be as designated and measured in the field. The Engineer will designate and mark the limits of the Full depth asphalt concrete patch and crack sealant application areas. Payment for emulsion-aggregate slurry treatments shall include post emergent herbicide treatment of the areas to receive for emulsion-aggregate slurry treatment. Full compensation for conforming to the requirements of constructing full depth asphalt concrete patch shall include but not be limited to: furnishing all labor, tools, equipment, and materials necessary for doing the work including, saw cutting and removing and disposing 300 mm (!') thick section of existing asphalt concrete, aggregate base/subbase and basement soil as designated by the engineer, placement of asphalt concrete, compaction of subbase and asphalt concrete, placement of SS-lh asphalt emulsion and all other work incidental to full depth asphalt concrete patch shall be considered as included in the contract unit price bid for full depth asphalt concrete patch and no additional compensation will be allowed therefore. Full compensation for conforming to the requirements of crack sealing shall include but not be limited to, furnishing all labor, materials, tools, equipment, and incidentals necessary to do the work. Crack cleaning, roadway clean up, application of sealant, removal of excess sealant and all other work incidental to crack sealing shall be considered as included in the contract unit price bid and no additional compensation will be allowed therefore. July 2005 Page 94 of 115 SECTION 303 CONCRETE AND MASONRY CONSTRUCTION. 303-1 CONCRETE STRUCTURES 303-1.1 General, add the following: Precast and cast-in-place concrete for soldier pile walls shall conform to Section 303 of the standard specifications. Prestress wire in precast panels shall conform to Section 303-3 of the Standard Specifications. Add the following section: 303-1.9.5 Surface Finish for Concrete Spillway. The Contractor shall provide a surface finish for concrete spillway to prevent the use of rollerblades, skateboards, and other rolling devices. Surface finish shall be a rough rake finish approved by the Engineer. 303-2 AIR-PLACED CONCRETE. 303-2.1.1 General, add the following: Modify Regional Standard Drawing D-75 as follows: replace stucco netting with 150mm x 150mm (6" x 6") by No. 10 by No. 10 welded wire mesh. Add the following section: 303-5 CONCRETE CURBS, WALKS, GUTTERS, CROSS GUTTERS, ALLEY INTERSECTIONS, ACCESS RAMPS, AND DRIVEWAYS. 303-5.5.2 Curb, add the following: The Contractor shall stamp the curb face with 75 mm (3") high block letters directly above the point that it is crossed by underground facilities with the marking specified in Table 303-5.5.2(A) TABLE 303-5.5.2(A) Curb Face Markings Type of underground facilities Water Service Lateral Sewer Service Lateral Irrigation Water Lateral or Sleeve Marking Ws RW 303-5.9 Measurement and Payment, add the following: Curb and gutter, and curb, shall be considered as continuing across driveways and access ramps when constructed adjacent thereto. Neither curb and gutter nor curb will be paid for across the length of local depressions, except that which occurs in gutter transitions at each side of an inlet. 303-6 STAMPED CONCRETE. 303-6.1 General. Add the following: Concrete shall be 560-C-3250 with 6"x6" - 10 guage wire mesh throughout. Add the following: 303-6.5 Medians- Use color application method "B" (integral color). Color shall be per Section 201-1.2.4(a). The pattern shall match the existing median condition adjacent to the proposed construction along San Marcos Boulevard. Add the following: 303-6.6 Measurement and Payment. Payment for colored, stamped concrete paving shall be paid under the contract unit price bid per square foot for median concrete paving. Said payment shall include compensation for all excavation, grading, backfill, permeable material, forming, mesh, reinforcing steel, concrete, integral July 2005 Page 95 of 115 color, texture sealers, and other material necessary to construct the specific paving. 303-7 CONCRETE RETAINING WALL 303-7.1 General. This work shall consist of constructing concrete retaining wall and 6' chain link fence (vinyl coated) as shown on the Plans and as specified herein. Proposed retaining wall shall be poured with integral-colored concrete (color to be approved by City Planning Division). Architectural treatment shall conform to the San Marcos Ledger Stone Texture used on the Las Posas/SR 78 Interchange retaining walls (sample panel to be approved by Construction Manager) 303-7.2 Concrete Retaining Wall. Concrete retaining wall shall be constructed in accordance with Section 303- 1, Concrete Structures, of the SSPWC. 303-7.3 Payment. The lump sum price paid for Concrete Retaining Wall shall include full compensation for furnishing all labor, materials, tools, and equipment and performing all work necessary to construct the concrete retaining wall, and 6' chain link fence (vinyl coated) as shown on the plans and as specified herein including excavation, backfill, stucco finish, painting parking lot reconstruction (except for reset of parking lot street lights), bar reinforcing steel, pervious backfill, weep holes, wall gutter outlet, 4' chain link fence (vinyl coated), and expansion joint filler. SECTION 304 - METAL FABRICATION AND CONSTRUCTION 304-1 STRUCTURAL STEEL. 304-1.4 Steel Structures, add the following: This work at the Soldier Pile Wall near Station 170+88 shall consist of furnishing and installing steel piling; cleaning and preparing portions of the pile for splicing; splicing steel piles; securing the piling prior to and during concrete encasement; shaping the tops of the piles; cleaning and preparing portions of the pile for welding concrete anchors; and furnishing, cleaning and welding concrete anchors to piling in accordance with the details shown on the plans, and these special provisions. Stud connectors shall be Type B as defined in AWS D1.5, Section 7. Steel soldier piles shall be placed in a drilled hole and shall be plumbed and aligned before placing concrete backfill and lean concrete backfill. Alignment shall be maintained while placing backfill material in the drilled holes. Cleaning and preparing the pile shall be performed hi heat affected areas before splicing steel piles or welding stud type shear. 304-3 CHAIN LINK FENCE. 304-3.2 Fence Construction, add the following: Chain Link Fence (Vinyl Coated) shall conform to section 206-6 of the Standard Specifications. Fence shall be 6' in height. The chain-link vinyl coated fence shall conform to SDRSD drawings M-6 and M-20. The wire used in the manufacture of new chain link fabric shall be 9 gage with green vinyl coating. Existing Fence Relocation shall be paid for by unit price of installation, not for just removal. SECTION 306 - UNDERGROUND CONDUIT CONSTRUCTION 306-1 OPEN TRENCH OPERATIONS Add the following section: 306-1.1.7 Steel Plate Bridging - With a Non-Skid Surface. This section covers the use of steel plate July 2005 Page 96 of 115 bridging. The Contractor shall not employ the use or use steel plate bridging or trench plate that does not meet the requirements of this section both in application and circumstance of use. Add the following section: 306-1.1.7.1 Requirements for Use. Alternate construction methods that avoid the use of steel plate bridging shall be used by the Contractor unless otherwise approved by the Engineer. It is recognized that to accommodate excavation work, steel plate bridging may be necessary. All conditions for use of steel plate bridging set forth in the following requirements must be fulfilled as conditions of approval of the use of steel plate bridging. Consideration of steel plate bridging in the review process will take into account the following factors: 1. Traffic volume and composition. 2. Duration of use of the steel plate bridging. 3. Size of the proposed excavation. 4. Weather conditions. The following formula shall be used to score the permitted use of steel plate bridging: PS = [ APT + EWL + DAYS + 10 X WEEKEND + 5 X NIGHTS + 20 X WEATHER + SPEED flanM + SLOPE X 1001X LANES 1000 8 PS = [ ADT + EWL + DAYS + 10 X WEEKEND + 5 X NIGHTS + 20 X WEATHER + SPEED fmptt + SLOPE X 100] X LANES 1000 5 where: PS = plate score. ADT = average daily traffic as defined in the Federal Highway Administration (FHWA) Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement. EWL = equivalent wheel loads as defined in the Federal Highway Administration (FHWA) Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement. DAYS = total number of 24 hour periods during which the plates will be utilized at the site being considered. WEEKEND = total number of Saturdays, Sundays and holidays that the plates will be utilized at the site being considered. NIGHTS = total number of overnight periods that the plates will be in place, exclusive of Saturday, Sunday and holiday nights. WEATHER = total number of 24-hour periods that the plates will be utilized at the site being considered when the possibility of rain exceeds 40 percent. SPEED = the design speed in kilometers per hour or miles per hour, as applicable in the formulae above, of the street where the plates are to be installed. This number shall not be reduced for construction zone speed reductions. SLOPE = the quotient of the vertical differential divided by the horizontal distance. The vertical and horizontal dimensions shall be measured at the locations spanning a dis- tance of 15 m (50') up and downstream of the position of the proposed steel plate bridging. LANES = the number of lanes where plates will be used. When the computed value of the plate score exceeds 50, steel plate bridging shall not be used unless, and at the sole discretion of the Engineer, the Engineer determines that no alternative method of construction is possible in lieu of using steel plate bridging or that other overriding considerations make the use of steel plate bridging acceptable. Alternatives considered to bridging shall include, but not be limited to, detouring traffic, construction detour routes, tunneling, boring and other methods of trenchless construction. Unless specifically noted in the provisions of the Engineer's approval, the use of steel plate bridging at each location so approved shall not exceed four (4) consecutive working days in any given week. July 2005 Page 97 of 115 Add the following section: 306-1.1.7.2 Additional Requirements. In all cases when the depth of the trench exceeds the width of the steel plate bridging resting on each side of the pavement adjacent to the trench, safety regulations require or. the Engineer determines that shoring is necessary to protect the health or safety of workers or the public the* Contractor shall install shoring conforming to Section 7-10.4.1 of the Standard Specifications. The trench shoring shall be designed and installed to support the steel plate bridging and traffic loads. All approvals for design, substitution of materials or methods shall be submitted by the Contractor in accordance with all provisions of section 2-5.3 Shop Drawings and Submittals. The Contractor shall backfill and resurface excavations in accordance with section 306-1.5. Add the following section: 306-1.1.7.3 Installation. When backfilling operations of an excavation in the traveled way, whether transverse or longitudinal cannot be properly completed within a work day, steel plate bridging with a non- skid surface and shoring may be required to preserve unobstructed traffic flow. In such cases, the following conditions shall apply: a) Steel plate bridging when the plate score exceeds 50 is not allowed except when, at the sole discretion of the Engineer, it is approved as specified hereinbefore. b) Steel plates used for bridging must extend a minimum of 610 mm (2') beyond the edges of the trench. c) Steel plate bridging shall be installed to operate with minimum noise. When the use of steel plate bridging and shoring is approved by the Engineer, the Contractor shall install using either Method (1) or (2) depending on the design speed of the portion of street where the steel plate bridging is proposed for use. Method 1 [For speeds more than 70 Km/hr (45 MPH)]: The pavement shall be cold planed to a depth equal to the thickness of the plate and to a width and length equal to the dimensions of the plate. The cold milling shall produce a flat surface that the plate shall rest on with no horizontal or vertical movement. Horizontal gaps between the unmilled pavement and the plate shall not exceed 25 mm (1") and shall be filled with elastomeric sealant material which may, at the contractor's option, be mixed with no more that 50%, by volume, of Type I aggregate conforming to the requirements of tables 203-5.2(B) and 203-5.3(A) . Method 2 [For speeds 70 Km/hr (45 MPH) or less]: Approach plate(s) and ending plate (if longitudinal placement) shall be attached to the roadway and shall be secured against displacement by using two adjustable cleats that are no less than 50 mm (2") shorter than the width of the trench bolted to the underside of each plate and located within 150 mm (6") of the beginning and end of the trench for plates at the beginning and end of the trench, a minimum of two 300 mm long by 19 mm diameter (12" x %") steel bolts placed through the plate and driven into holes drilled 300 mm (12") into the pavement section, or other devices approved by the Engineer. Subsequent plates shall be butted to each other. Fine graded asphalt concrete shall be compacted to form ramps, maximum slope 8.5% with a minimum 300 mm (12") taper to cover all edges of the steel plates. When steel plates are removed, the dowel holes in the pavement section shall be completely filled with elastomeric sealant material. At the Contractor's option, the methods required for Method 1 may be used. If the Contractor so elects, all requirements of Method 1 shall be used. The Contractor shall maintain the steel plates, shoring, and asphalt concrete ramps and maintain and restore the street surface during and after their use. Add the following section: 306-1.1.7.4 Materials. The minimal thickness of steel plate bridging shall be as shown in Table 306- TABLE 306-1.1.7.4(A) REQUIRED PLATE THICKNESS FOR A GIVEN TRENCH WIDTH Maximum Trench Width (1) 0.3 m (10") 0.6 m (23") Minimum Plate Thickness j 13 mm (V2") 19 mm (V) July 2005 Page 98 of 115 0.8m (31") 1.0m (41") 1.6m (63") 22 mm (V) 25mm (1") 32 mm (1 !4") (1) For spans greater than 1.6 m (5'), a structural design shall be prepared by a registered civil engineer and submitted to the Engineer for review and approval in accordance with section 2-5.3. Steel plate bridging shall be steel plate designed to support the HS20-44 truck loading per CALTRANS Bridge Design Specifications Manual. The Contractor shall maintain a non-skid surface on the steel plate with no less than a coefficient of friction of 0.35 as determined by California Test Method 342. If a different test method is used, the Contractor may utilize standard test plates with known coefficients of friction available from the CALTRANS District 11 Materials Engineer to correlate skid resistance results to California Test Method 342. In addition to all other required construction signing, the Contractor shall install Rough Road (W33) sign with black lettering on an orange background in advance of steel plate bridging. Add the following section: 306-1.1.7.5 Measurement and Payment. Steel plate bridge materials including, but not limited to: steel plates, anchoring devices, cold milling, elastomeric sealant material, asphalt ramping and padding, signage, placing, installation, removal, relocation, preparation and processing of shop drawings and submittals to support the use of steel plate bridging and all other materials, labor, supervision, overhead of any type or description will be paid for as an incidental to the work that the bridging is installed to facilitate. No separate payment for steel plate bridging will be made. No extension to contract tune will be allowed for, or because of, the use of steel plate bridging. 306-1.2.1 Bedding. All installation of, and bedding for recycled water, or potable water mains shall conform to Carlsbad Municipal Water District Rules and Regulations for the Construction of (Potable or Reclaimed) Water Mains, latest edition. 306.1.2.2 Pipe Laying, add the following: The Contractor shall place electrical conduit per SDG&E plans, Construction Order No. xxx, Project No. xxx. 306-1.2.4 Field Jointing of Reinforced Concrete Pipe, add the following: The Contractor shall provide Gasket-type joints for reinforced concrete pipe (watertight joints) where indicated on plans. 306-1.3.1 General, add the following: The Contractor shall install detectable underground utility marking tape 230 mm x75 mm (9" x 3") above each or, in the case of bundled underground conduit of the same type, the upper underground conduit being installed by the open trench method. The type and color of detectable underground utility marking tape shall conform to the requirements of section 207-25 et seq. 306-1.3.4 Compaction Requirements, delete Section 306-1.3.4 and replace with the following: The Contractor shall densify trench backfill to a minimum of 90 percent relative compaction except that in the top 300 mm (12") of the street right-of-way, compaction shall be 95 percent. 306-1.5 Trench Resurfacing. 306-1.5.1 Temporary Resurfacing. Delete the fourth and fifth paragraphs and substitute the following: Temporary bituminous resurfacing materials which are placed by the Contractor are for its convenience and shall be at no cost to the Agency. Temporary bituminous resurfacing materials shall be used in lieu of permanent resurfacing only when approved by the Engineer. When temporary bituminous resurfacing materials are used in lieu of permanent resurfacing it shall be removed and replaced with permanent resurfacing within 7 days of placement. No additional payment will be made for temporary bituminous resurfacing materials. The price bid for the associated conduit or structure shall include full compensation for furnishing, placing, maintaining, removing, and disposing of such temporary resurfacing materials. July 2005 Page 99 of 115 306-1.5.2 Permanent Resurfacing. Add the following: Except as provided in section 306-1.5.1, "Temporary Resurfacing," the Contractor shall perform permanent trench resurfacing within 24 hours after the completion of backfill and densification of backfill and aggregate base materials. 306-1.6 Basis of Payment for Open Trench Installation, add the following: Payment for utilities undergrounding which includes the utility trench for CATV and SDG&E and conduit for SDG&E's electric conversion shall be made on the basis of contract lump sum price for utilities undergrounding and no other payments will be made. Cox Cable will supply and deliver conduits and fittings to be installed by the Contractor. Cox Cable will install enclosures. The Contractor will furnish and install 6.4 mm (/4") nylon pull ropes in all conduit. 306-5 ABANDONMENT OF CONDUITS AND STRUCTURES. Add the following: Unless otherwise noted on plans, the Contractor shall remove all existing abandoned pipelines and conduits of any type, or use, and pipelines and conduits of any type, or use, that are abandoned during the course of the work and shall replace said pipelines and conduits with properly compacted soils. Payment for removal and disposal of abandoned utilities shall be included in the lump-sum bid for Clearing and Grubbing, and no additional payment will be made. SECTION 307 - STREET LIGHTING AND TRAFFIC SIGNALS 307-3 STREET LIGHTING CONSTRUCTION. Modify as follows: Section 209, "Signals, Lighting and Electrical Systems" herein, shall replace Section 307- 3, "Street Lighting Construction ", of the SSPWC in all matters pertaining to the specifications for measurement, payment, warranty, and methods of construction for all elements of street lighting. 307-4 TRAFFIC SIGNAL CONSTRUCTION. Modify as follows: Section 209, "Signals, Lighting and Electrical Systems" herein, shall replace Section 307- 4, "Traffic Signal Construction ", of the SSPWC in all matters pertaining to the specifications for measurement, payment, warranty, and methods of construction for all elements of traffic signals. SECTION 308 LANDSCAPE AND IRRIGATION INSTALLATION 308-2 EARTHWORK AND TOPSODL PLACEMENT 308-2.3.2 Fertilization and Conditioning Procedures, add the following: The Contractor shall cultivate the surface of all areas to be planted or hydroseeded by discing, ripping or scarifying the finish grade. After cultivation the Contractor shall clear the planting areas of stones to the depth of cultivation and shall be rake the planting areas to a smooth friable and plantable surface. The Contractor shall cultivate all planting areas, except slopes steeper than 3-1/2:1 (horizontal to vertical), to a depth of 300 mm (12"). The planting areas that are slopes steeper than 3-1/2:1, shall be cultivated to a depth of 150 mm (6"). After cultivation, the soil amendments shown in table 308-2.3.2(A) shall be thoroughly blended 150 mm (6") deep in all planting areas. Except for planting pits the cultivation depths are designated as the root area. Backfill for planting pits shall conform to the requirements of section 308-4.5. After surface preparation and application of the soil amendments shown in Table 308-2.3.2(A) the Contractor shall obtain a minimum of one test for each soil property listed in Tables 308-2.3.2(B) and 308-2.3.2(C) from each median planter, at least one test per 150 m (500') from each parkway and for each hectare (2.5 acres) of hydroseeded area and shall submit the results of said tests to the Engineer. The Contractor shall then adjust the soil properties to the acceptable ranges of soil properties shown in Tables 308-2.3.2(8) and 308-2.3.2(C) using such materials and methods as may be necessary. Organic soil amendment materials shall not be included in the samples used to determine compliance to the soil particle gradation requirements of Table 308-2.3.2(C). If adjustments are necessary the soil shall be tested by the Contractor after such adjustments for each soil property listed in Table 308-2.3.2(B) and 308-2.3.2(C) to determine that the adjustments to the soil made by the Contractor result in soil properties within the acceptable range. The Contractor shall adjust the soil properties and show acceptable ranges prior to any planting or application of hydroseed slurry. Prior to the start of any planting or application of hydroseed J uly 2005 Page 100 of 115 slurry the surface and root area shall be evenly and thoroughly moistened to no less than 75 percent of field capacity. The Contractor shall certify, in writing, that the ground surface has been prepared in accordance with this section and shall request inspection by the Engineer prior to any planting or seeding. The Contractor shall obtain the Engineer's approval before any planting or hydroseeding. TABLE 308-2.3.2(A) SOIL AMENDMENTS Soil Amendment Agricultural Gypsum Iron Sulfate Calcium Carbonate Lime Organic Soil Amendment Metric Application Rate 500 g per square meter 50 g per square meter 500 g per square meter 0.04115 cubic meters per square meter (average depth 41 mm) Approx. U.S. Application Rate 100 Ibs. per 1,000 square feet 10 Ibs. per 1,000 square feet 100 Ibs. per 1,000 square feet 5 cubic yards per 1,000 square feet (average depth 1 %") TABLE 308-2.3.2(8) SOIL PROPERTIES Soil Property PH Dissolved Salts (Ece) Liquid Limit Plasticity Index Acceptable Range 6.5 to 7.3 < 4.0 dS in1 N/A to 30 NPtolO Test Method Saturation Paste pH Saturation Paste Soluble Salts ASTM D 423 ASTM D424 Repeatability Range of Test ±0.1pH ± 7% ± 2 ± 2 TABLE 308-2.3.2(C) SOIL PARTICLE GRADATION Sieve Siize 19 mm(3/4") 9.5 mm (%") 4.75 mm (No. 4) 1.89 mm (No. 10) 475 u,m (No. 40) 75 urn (No. 200) Percent Passing 100 95 - 100 60-85 40-75 35-70 30-70 For areas to receive planting of all types, excluding only hydroseeding, the Contractor shall amend the prepared soil by blending 200 g of 7-7-7 fertilizer per square meter (40 Ibs. per 1,000 square feet) into the top 150 mm (6") of soil after the completion of adjustment of soil properties and acceptance of the planting area by the Engineer. The Contractor shall apply post-plant 12-4-6 fertilizer at the rate of 20 pounds per 1,000 square feet, 30 days after planting and every 30 days through the end of the maintenance period. 308-2.4 Finish Grading., add following: The Contractor shall prepare the finish grade in hydroseed slope areas with a moderately rough texture to provide a suitable surface for adherence of the hydroseed mix. 308-4 PLANTING. 308-4.1 General, add the following: The Contractor shall perform actual planting during those periods when weather and soil conditions are suitable and in accordance with locally accepted horticultural practice and as approved by the Engineer. No planting shall be done in any area until it has been satisfactorily prepared in accordance with these specifications. Soil moisture level prior to planting shall be no less than 75 percent of 0July 2005 Page 101 of 115 field capacity. The Contractor shall obtain the Engineer's approval of planting pits before planting operations begin. For pit planted vegetation when the soil moisture level is found to be insufficient for planting, the Contractor shall fill the planting pits with water and allow them to drain before starting planting operations. more plants shall be distributed in the planting area on any day than can be planted and watered on that day. I The Contractor shall plant and water all plants as herein specified immediately after removal from their containers. Containers shall not be cut prior to placing the plants in the planting area. It shall be the responsibility of the Contractor to provide continuous horticultural services and temporary and/or permanent irrigation to all planted and hydroseeded areas so that the planted and hydroseeded vegetation is 100 percent healthy and thriving prior to, and throughout the, landscape maintenance period. 308-4.2 Protection and Storage, add the following: The Contractor shall submit a sheltered and secure location for on-site plant storage area for the Engineer's approval prior to the delivery of any plant materials. Any plant determined by the Engineer to be wilted, broken, or otherwise damaged shall be rejected at any time during the project, whether in the ground or not. All plants shall be handled by then1 containers. Any plant that has been handled by its trunk or stem shall be rejected. All rejected plants shall be removed from the site immediately. 308-4.3 Layout and Plant Location, modify as follows: Planting areas shall be staked by the Contractor and the Contractor shall obtain the Engineer's approval of the planting layout before planting operations begin. 308-4.5 Tree and Shrub Planting, add the following: The Contractor shall amend the backfill for planting holes to a thoroughly blended mixture of clean loamy soil meeting the requirements of Tables 308-2.3.2(B) and 308-2.3.2(C) and then blend the amendments listed in Table 308-4.5(A) into the backfill for planting holes. TABLE 308-4.5(A) BACKFILL AND AMENDMENTS FOR TREE AND SHRUB PLANTING Soil Amendment Agricultural Gypsum Iron Sulfate Calcium Carbonate Lime Organic Soil Amendment Planting Tablets ' Planting Tablets ' Planting Tablets ' Metric Application Rate 1 8 kg per cubic meter 600 g per cubic meter 6 kg per cubic meter 0.67 cubic meters per cubic meter 1 per 100 mm dia. pot container 2 per 19 liter container 1 per each 50 mm width of each box-size container Approx. U.S. Application Rate 4 30 Ibs. per cubic yard "^ 1 Ib. per cubic yard 10 Ibs. per cubic yard 2/3 cubic yards per cubic yard 1 per 4" dia. pot container 2 per 5 gal. container 1 per each 2" width of each box- size container Planting tablet requirements are not cumulative and apply to the size container indicated Pruning shall be limited to the minimum necessary to remove injured twigs and branches, and to compensate for loss of roots during transplanting, but never to exceed one-tenth the branching structure. Pruning may be done only with the approval of, and in the presence of, the Engineer. Cuts over 19 mm (%") shall be painted with an approved tree wound paint. Add the following section: 308-4.5.1 Root Barriers. Root barriers shall conform to section 212-1.8, Root Barriers. The Contractor shall install root barriers continuously at the edges of all median planter areas. The top of the root barrier shall be 25 mm (1") below the finish grade of the planted area. The bottom of the root barrier shall be installed 520 mm (20V2") or 1.25 m (40") below the finish grade of the planted area. Install as indicated on the plans, eliminating any breaks in the barrier by providing at least 150 mm (6") of overlap at splices or damaged areas. Splices and repair patches shall be stitched to the root barrier material by a running stitch of no less than 6 ± 1 stitches per 25mm(l"). 308-4.6 Plant Staking and Guying, add the following: The Contractor shall install all boxed trees per July 2005 Page 102 of 115 drawings L-l and L-2 of the San Diego Regional Standard Drawings unless details shown on the project plans differ therefrom. 308-4.8.2(b) Method B. add the following: The Contractor shall prepare hydroseeding slurry on the job site. Slurry additives shall arrive at the site in bags sealed and properly identified by the manufacturer. All specified additives and water shall be added on the job site at the rates specified and shall be thoroughly mixed at the job site. The Contractor shall add seed to the slurry after the fiber mulch has been thoroughly incorporated. The Contractor shall spray all areas with a uniform, visible coat using the green color of the mulch as a guide. The Contractor shall apply the slurry in a sweeping motion, in an arched stream so as to fall like rain allowing the mulch fibers to built on each other until a good coat is achieved and the material is spread, evenly, at the required rate per area. The Contractor shall use care not to drag spray hoses over container planted material and shall attempt to spray from the edges of the planting areas wherever possible. Any slurry mixture which has not been applied to the planting areas within four (4) hours after mixing is be rejected and removed from the project at the Contractor's expense. Any slurry spilled into areas outside the limits of work shall be cleaned up at the Contractor's expense to the satisfaction of the Engineer. The Contractor shall assure that the site is properly prepared. The Contractor shall repair all tire ruts created by the equipment. Areas needing grading repair prior to hydroseeding shall be blended and floated to match surrounding grades. Areas having less than 80% plant coverage within thirty (30) days after the initial application shall be reseeded every twenty (20) days until 80% of the ground surface is evenly covered by hydroseeded or subsequently reseeded growth. Add the following section: 308-4.8.3.1 Weed Eradication. The Contractor shall water all irrigated areas to be hydroseeded for three (3) weeks prior to hydroseeding to allow for germination of the weed seeds. The Contractor shall spray all weeds with a post emergent herbicide immediately after the completion of the three week irrigation period. After two (2) weeks, the Contractor shall again eradicate the weeds and complete the preparation of the soil prior to the application of the hydroseed mixes. Add the following section, 308-4.10 Erosion Control Matting Installation Add the following section, 308-4.10.1 General. Before installation of erosion control matting the Contractor shall complete all soil preparation, fine grading, and hydroseeding of the areas to receive erosion control matting. Add the following section: 308-4.10.2 Coordination with Hydroseeding. Erosion control matting shall be installed by the Contractor immediately after the first application of hydroseed materials. In all cases the Contractor shall place the erosion control matting within three days after the first hydroseed material application. Should any seed in the hydroseed materials begin to germinate within the three-day period after application or before the installation of the erosion control matting, the installation of the erosion control matting shall be considered as late and the Contractor shall disc the hydroseed materials into the top 100m (4") of the underlying soil, condition the soil for hydroseeding, apply hydroseeding materials at the rates and of the type specified and then install the erosion control matting. No additional payment will be made for second or subsequent hydroseed applications resulting from late installation of erosion control matting. Add the following section: 308-4.10.3 Installation. The Contractor shall install erosion control matting using the following techniques: 1. Begin at the top of the slope by placing the erosion control matting into a 150 mm (6") wide by 150 mm (6") deep trench with the end of the matting laid flat in the bottom of the trench 2. Anchor the end of the erosion control matting with erosion control mat staples spaced no more than 300 mm (12") on centers placed at the intersection of the bottom and the downhill vertical face of the trench. 3. Roll the erosion control matting down the slope. 4. Staple the erosion control matting on an alternating grid consisting of three across and two across lines of staples in horizontal lines spaced 900mm (3') on centers. July 2005 Page 103 of 115 5. Erosion control mat so stapled shall be spaced such that no less than 1 % staples per square meter (1 VL staples per square yard) are provided to anchor the erosion control matting. 6. Start the adjacent erosion control mat as in Item 1. of this section, overlapping the previously placed mat no less than 50 mm (2"). 7. Staple placement may be such as to use the staples used to secure the adjacent mat to secure both mats along their edges. 308-5 IRRIGATION SYSTEM INSTALLATION. 308-5.1 General. add the following: The Contractor shall apply irrigation water as often and in sufficient amounts, as conditions may require, to germinate and establish the seed and keep the container plants healthy and growing. The Contractor shall lay out lines, valves, and other underground utilities and receive the approval of the Engineer before digging trenches. The Contractor shall be responsible for damages caused by its operations. Connections shall be made at approximately the locations shown on the drawings. The Contractor shall be responsible for unapproved changes. Permission to shut off any existing in-use water lines must be obtained 48 hours in advance, as to the date, time and exact length of time of each shut-off. The Contractor shall demonstrate that the entire irrigation system is under full automatic operation for a period of seven days prior to any planting. 308-5.2 Irrigation Pipeline Installation, add the following: The Contractor shall install all pressure main line piping from the irrigation system so as to maintain 3.1 m (10') minimum horizontal separation from all potable water piping. Where reclaimed and potable water pressure mainline piping cross, the reclaimed water piping shall be installed below the potable water piping, sleeved in a pressure rating of 200 PSI SDR 21 "Alertline" PVC sleeve which extends a minimum of 3.1 m(10') on either side of the potable water piping and be located to provide a minimum vertical clearance of 300 mm (12") between the reclaimed and potable water lines. Conventional (white) PVC pipe Schedule 40 may be used for sleeving material if it is taped along its entire length with 75 mm (3") wide purple warning tape which reads "Caution Reclaimed Water". For trenching through areas where topsoil has been spread, the Contractor shall deposit topsoil on one side of trench and subsoil on opposite side. Subsoil shall be free of all rocks 13 mm ('/£") in diameter or larger, debris, and litter, prior to use as backfill. The Contractor shall repair any leaks and replace all defective pipe or fittings until lines meet test requirements. The Contractor shall not cover any lines until they have been inspected and approved by the Engineer for tightness, quality of workmanship, and materials. The Contractor shall not be backfill trenches until all required tests and observations are performed. Observations include sprinkler heads, all fittings, lateral and mainline pipe, valves, and direct burial wire. 308-5.23 Plastic Pipeline, add the following: The Contractor shall store all pipe and fittings under cover until used, and all pipe and fittings shall transported in a vehicle with a bed long enough to allow the length of pipe to lay flat so as not to be subjected to undue bending or concentrated external load at any point. Pipe ends and fittings shall be wiped with MEK, or equal, before welding solvent is applied. Welded joints shall be given a minimum of 15 minutes to set before moving or handling. All field cuts shall be beveled to remove burrs and excess before fitting and gluing together. The Contractor shall center load pipe with small amount of backfill to prevent arching and slipping under pressure. Joints shall be exposed for inspection during testing. Plastic-to- plastic joints shall be solvent-welded, using only solvent recommended by pipe manufacturer. Add the following section: 308-5.2.6 Installation of Brass Pipe. The Contractor shall cut brass piping by power hacksaw, circular cutting machine using an abrasive wheel, or hand hacksaw. No piping shall be cut with metallic wheel cutter of any description. The Contractor shall ream and remove rough edges or burrs on all pipe so that smooth and unobstructed flow is obtained, place Teflon tape, Teflon dope, or approved equal on male threads only, and tighten to prevent any leakage. The Contractor shall tighten screwed joints with tongs or wrenches. Caulking is not permitted. Add the following section: 308-5.3.1 Valves, add the following: J uly 2005 Page 104 of 115 The Contractor shall install each control valve in a separate valve box with a minimum of 300 mm (12") separation between valves and 150 mm (6") from any fixed obj ect or structure. Add the following section 308-5.3.2 Valve Boxes. The Contractor shall install no more than one valve per box. All boxes are to be marked as to the type of valve. Remote control valve boxes shall also indicate control station number. Add the following section: 308-5.3.3 Backflow Preventer. The Contractor shall install backflow preventer assembly in accordance with manufacturer's specifications and as directed on drawings. Exact location and positioning shall be verified on the site by the Engineer. 308-5.4.4 Sprinkler Head Adjustment. add the following: The Contractor shall flush and adjust all irrigation heads and valves for optimum performance and to prevent overspray onto walks, roadways buildings, walls, and other structures. Add the following section: 308-5.4.5 Drip Assembly. The Contractor shall install drip emitter filter on the supply side of all electric pressure regulating control valve for all emitter systems. The Contractor shall install a flush valve on the discharge side of all drip laterals. 308-5.5 Automatic Control System Installation, add the following: The Contractor shall install all portions of the electrical installation with materials and methods conforming to the requirements of the 1996 National Electrical Code. The Contractor shall provide no less than one control wire and one common ground wire to service each valve in system. 308-5.63 Sprinkler Coverage Test, add the following: This test shall be accomplished before any ground cover is planted. 308-6 MAINTENANCE AND PLANT ESTABLISHMENT. Add the following: For all landscaping/planting areas: hydroseeded areas, median planting, retaining wall areas, and mitigation area, the Contractor shall maintain said areas for period of no less than 120 days or until final acceptance of the project, whichever is the greater. Mowing is not required for hydroseeded areas. The Contractor shall provide complete landscape maintenance of all planted areas. The work shall include, but not be limited to, watering, litter control, weed control, stake repair, cultivating, supplementary fertilization, repair of irrigation systems, and control of diseases and pests. The Contractor shall submit a written plan to control weeds, disease, and pest infestations in the planting areas. The submittal shall conform to the requirements for shop drawings as specified in section 2-5.3 et seq. of the specifications. The Engineer shall approve all methods and materials for such control. Upon approval, the Contractor shall implement the control measures, exercising extreme caution in using pesticides and taking all steps to ensure the safety of the public. Only licensed personnel will be permitted to perform toxic spraying work. During the plant establishment period, the Contractor shall furnish sufficient workers and equipment on a daily basis to perform the work required by this section. Any day when the Contractor fails to adequately carry out specified maintenance work, as determined necessary by the Engineer, will not be credited as one of the plant establishment days. All planting areas which are damaged by construction shall be repaired by the Contractor within twenty (20) days following completion of construction in such. The Contractor shall repair such damaged areas. The repair shall consist of bringing the damaged area back to final grade, preparing the soil, replanting the area with the same vegetation as originally specified, and maintaining the area to achieve acceptable plant establishment. The Contractor shall provide temporary irrigation for all landscaping/planting areas for a minimum of 120 days to ensure adequate plant establishment. Towards the end of the maintenance period, the Contractor shall gradually reduce the amount of irrigation to allow plant adaptation to non-irrigated conditions. Upon the approval of the engineer, the temporary irrigation system shall be shut off at the end of the maintenance period. The hydroseeded areas must have their growth of 80% established and the coverage must be evenly successful over the entire hydroseeded area and adequate to prevent erosion no less than 30 days before the end of the July 2005 Page 105 of 115 maintenance period. Should the coverage not be achieved the maintenance period shall be extended until the required coverage is achieved plus an additional 30 day period. The Contractor shall call for a final inspection 30 days before the end of the maintenance period and at the end of the maintenance period. Failure to pass inspection will result in an extension of the maintenance period. The Contractor shall continue to provide maintenance for such time necessary to obtain conformance to the specifications. 308-7 GUARANTEE. Add following: The Contractor shall guarantee all 600 mm (24") box trees installed under the contract to live and grow for one year from the day of final acceptance of the contract work. The Contractor shall guarantee all other plant material, including ground covers to live and grow for a period of 30 days from the last day of the maintenance period or final acceptance of the contract work, whichever is the later. The Contractor shall replace, at its expense, all plant material found to be dead, missing, or in poor condition during the maintenance period within 5 days of discovery of such plant material. The Engineer shall be the sole judge as to the condition of the plant material. Plant material found to be dead or in poor condition within the guarantee period shall be replaced by the Contractor, at its expense, within 15 days of written notification. Replacements shall be made to the same specifications required for the original plantings. The Contractor shall submit written vegetation, planting and irrigation guarantee in approved form that all work showing defects in materials or workmanship will be repaired or replaced at no cost to the Engineer for a period of one year from the date of acceptance by the Engineer. The Guarantee form shall be retyped on the Contractor's letterhead and contain the following verbiage: "Guarantee For Vegetation, Planting and Irrigation System For (Project Name) We hereby guarantee that the vegetation, planting and irrigation system we have furnished and installed for (project name) is free from defects in materials and workmanship, and the work has been completed in accordance with the drawings and specifications. We agree to repair or replace any defect in vegetation, material or workmanship, including that due to ordinary wear and tear, which may develop during the periods specified in section 308-7 of the Standard Specifications and the Special Provisions of said project from date of completion of the Work or termination of any maintenance period, whichever is the later, and also to repair or replace any damage resulting from the repairing or replacing of such defects at no additional cost to the Agency. This guarantee does not extend to unusual abuse or neglect that may occur subsequent to the date of completion of the Work or termination of any maintenance period, whichever is the later. We shall make such repairs or replacements within a reasonable time, as determined by the City, after receipt of written notice. In the event of failure to make such repairs or replacements within a reasonable time after receipt of written notice from the City, we authorize the City to proceed to have said repairs or replacements made at our expense, and we will pay the costs and charges therefore upon demand. Add the following section: 308-7.1 Landscape Record Drawings. In addition to the requirements of section 2-5.4, herein, the Contractor shall prepare record drawings that show all changes in the work constituting departures from the original contract drawings, including those involving both constant-pressure and intermittent-pressure lines and appurtenances. The Contractor shall accurately record, on a daily basis, on one set of blue line prints of the irrigation drawings, all changes in work constituting departures from the original contract drawings, including changes in both pressure and nonpressure line. The Contractor shall post information on record drawings no later than the next working day after the work is installed. The Contractor shall record changes and dimensions in a legible and professional manner. When the drawings are approved by the Engineer the Contractor shall transfer all information to a set of reproducible photo mylar drawings. Items required to be shown shall be dimensioned by the Contractor from two permanent points of reference (buildings, monuments, sidewalks, curbs, pavement). The accuracy of location of all items to be shown on the drawings shall be 150 mm (6") in both the vertical and horizontal planes. All text and numerals placed on drawings shall be 0.30 mm (Vg") in size. Facilities and items to be located in their horizontal and vertical positions and shown on the record drawings include all: a) Point(s) of connection, for water and electrical services b) Routing of irrigation pressure mainlines July 2005 Page 106 of 115 c) Backflow preventers d) Ball, gate and check valves e) Irrigation control valves. f) Quick coupler valves g) Routing of service wires h) Routing of control wires i) Electrical service equipment j) Electrical junction boxes k) Irrigation controllers 1) Sleeves for future connections m) Other equipment of a similar nature (as directed by the Engineer). The Contractor shall keep the blue print drawings available for the Engineer's inspection at any time. The Contractor shall make all changes to reproducible drawings in waterproof black ink (no ball point pen). Changes in dimensions shall be recorded in a legible and professional manner. Record construction drawings shall be maintained at the job site during construction. The Contractor shall provide one set of mylar "record" drawings to the Engineer after submitting blueline prints of the proposed "record" drawings for, and obtaining their approval by, the Engineer. Add the following section: 308-7.2 Controller Chart. The Contractor shall prepare record drawings which shall be submitted to the Engineer for approval by the Engineer before charts are prepared. The Contractor shall provide one controller chart of the maximum size the controller doorwill allow, for each controller supplied, showing the area covered by that automatic controller. The chart shall be a reduction of the actual record system drawing with a legend to explain all symbols. If the controller sequence is not legible when the drawing is reduced, The Contractor shall enlarge it to a size that will be readable when reduced. The Contractor shall photocopy the chart, with a pastel transparent color used to show area of coverage for each station. When completed and approved, the Contractor shall hermetically seal the chart between two pieces of plastic, each piece being a minimum 20 mils thick. The Contractor shall complete the charts and obtain the Engineers approval prior to final inspection of the irrigation system. Add the following section: 308-7.3 Operation and Maintenance Manuals. The Contractor shall prepare and deliver to the Engineer, within 10 calendar days prior to completion of construction, all required and necessary descriptive material in complete detail and sufficient quantity, properly prepared in four individual bound copies. The descriptive material shall describe the material installed in sufficient detail to permit qualified operating personnel to understand, operate, and maintain all equipment. The Contractor shall include spare parts list and related manufacturer information for each equipment item installed. Each manual shall include the following: a) Index sheet stating Contractor's address and telephone number. b) Duration of Guarantee period. c) List of equipment, with names and addresses of manufacturer's local representative. d) Complete operating and maintenance instructions on all major equipment. e) In addition to the maintenance manuals, the Contractor shall provide the agency maintenance personnel with instructions for major equipment, and show written evidence to the Engineer at the conclusion of the work that this service has been rendered. Add the following section: 308-7.4 Check List. The Contractor shall complete and forward signed and dated checklist to the Engineer before final acceptance of project, the following checklist at the end of the project, using the format shown: a) Plumbing permits (if none required, so note) b) Materials approval c) Pressure mainline test (by whom, and date) d) Record drawings completed (received by, and date) e) Controller chart completed (received by, and date) July 2005 Page 107 of 115 f) Materials furnished (received by, and date) g) Operation and maintenance manuals furnished (received by, and date) h) System and equipment operation instructions (received by, and date) i) Manufacturer warranties (received by, and date) j) Written guarantee by Contractor (received by, and date) 308-8 MEASUREMENT AND PAYMENT. add the following: The lump-sum or unit prices set forth in the contract documents shall include, but not be limited to, full compensation for furnishing all labor, materials, tools, and equipment and performing all work necessary to complete, maintain, and guarantee the planting and irrigation work described or specified in the contract documents, including soils testing and recommended soil amendments, seed and hydroseed slurry, tree stakes, bark mulch, erosion control matting, plant materials, temporary irrigation and permanent irrigation, including reduced-pressure back-flow preventer, ball valves, drip valve assembly, electric control valves, quick couplers, control wires, pull boxes, valve boxes, all piping and sleeves, electrical conduits, irrigation heads, drip emitters, bubblers, drip irrigation equipment, connection from electrical service to irrigation electrical meter, connection from meter to irrigation controllers), installation of controller enclosure, concrete pads, preparation, correction, reproduction and lamination of "as-built" drawings, controller charts, assembly and submittal of the check list and operation and maintenance manuals and all appurtenances to the aforementioned items, as well as 120 days' maintenance and project guarantees. After completion of the project, the Engineer will retain $12,000 of the total contract amount, and will subsequently disburse the $12,000 to the Contractor on a monthly basis of $3,000 per month. The Engineer reserves the right to stop payment until all punch list submitted to the Contractor every month are completed. SECTION 310 - PAINTING 310-5 PAINTING VARIOUS SURFACES. 310-5.6 Painting Traffic Striping, Pavement Markings and Curb Markings. Modify the fifth paragraph as follows: The Contractor shall furnish all equipment, materials, labor, and supervision necessary for painting traffic lanes, directional arrows, guidelines, curbs, parking lines, crosswalks, and other designated markings in accordance with the Plans, or for approved temporary detours essential for safe control of traffic through and around the construction site. The Contractor shall remove by wet grinding all existing or temporary traffic markings and lines that may confuse the public. When temporary detour striping or markings are no longer required, they shall be removed prior to painting the new traffic stripes or markings. 310-5.6.3 Equipment. Delete the ninth paragraph and substitute the following: The Contractor shall provide a wet grinding machine with sufficient capacity to completely remove all existing or temporary traffic striping or markings that conflict with the striping plan, or are contrary to the Traffic Manual, or that may be confusing to the public. The surface produced by grinding the existing or temporary traffic striping or markings on pavement shall not exceed variations from a uniform plane more than 3 mm (V8") in 3 m (10') when measured parallel to the centerline of the street or more than 6 mm (V4") in 3 m (10') when measured perpendicular to the centerline of the street. The use of any equipment that leaves ridges, indentations or other objectionable marks in the pavement shall be discontinued, and equipment capable of providing acceptable surface shall be furnished by the Contractor. This equipment shall meet all requirements of the air pollution control district having jurisdiction. 310-5.6.6 Preparation of Existing Surfaces. Modify the first paragraph as follows: The Contractor shall remove all existing markings and striping, either permanent or temporary, which are to be abandoned, obliterated or that conflict with the plans by wet grinding methods. Removal of striping by high velocity water jet may be permitted when there is neither potential of the water and detritus from the high velocity water jetting to damage vehicles or private property nor to flow from the street into any storm drain or water course and when approved by the Engineer. The Contractor shall vacuum all water and detritus resulting from high velocity water jet striping removal from the pavement immediately after the water jetting and shall not allow such materials to flow in the gutter, enter the storm drain system or to leave the pavement surface. Surface July 2005 Page 108 of 115 variation limitations for high velocity water jet striping removal shall be the same as for grinding. The Contractor shall not use dry or wet sandblasting in any areas. Alternate methods of paint removal require prior approval of the Engineer. Obliteration of traffic striping with black paint, light emulsion oil or any other masking method other than a minimum 30mm (0.10') thick asphalt concrete overlay is not permitted. 310-5.6.7 Layout, Alignment, and Spotting. Modify the first paragraph as follows: The Contractor shall establish the necessary control points for all required pavement striping and markings by surveying methods. No layout of traffic striping shall be performed by the Contractor before establishment of the necessary control points. The Contractor shall establish all traffic striping between these points by string line or other method to provide striping that will vary less than 80mm per 100m (1/2 inch in 50 feet) from the specified alignment. The Contractor shall obliterate, straight stripes deviating more than 80mm per 100mm (I/ 2 inch in 50 feet) by wet grinding, and then correcting the markings. The Contractor shall lay out (cat track) immediately behind installation of surface course asphalt and as the work progresses. 310-5.6.8 Application of Paint. Modify the second paragraph as follows: The Contractor shall apply the first coat of paint immediately upon approval of striping layout by the Engineer. The Contractor shall paint the ends of each median nose yellow. Add the following to the eighth paragraph: The Contractor shall apply temporary traffic stripes in one coat. Temporary traffic stripes shall be maintained by the Contractor so that the stripes are clearly visible both day and night. 310-5.6.10 Measurement and Payment. Modify the first paragraph as follows: Final and temporary traffic striping, curb markings and pavement markings as shown on the plans and required by the specifications shall be included in the lump-sum price bid for final traffic striping, and no additional compensation will be allowed therefore. Reapplication of temporary stripes and markings shall be repainted at the Contractor's expense, and no additional compensation will be allowed therefore. The lump sum prices bid and shall include all labor, tools, equipment, materials, and incidentals for doing all work in installing the final and temporary traffic striping. SECTION 312 - PAVEMENT MARKER PLACEMENT AND REMOVAL 312-1 PLACEMENT. Add the following to the third paragraph: 4) When being installed on asphalt concrete pavement sooner than 14 days after placement of the asphalt concrete pavement course on which the pavement markers are to be placed. Add the following section: 312-1.1 Reflective Channelizer Placement and Removal. The Contractor shall place and remove reflective channelizers the same as for pavement marker placement and removal. The Contractor shall place the channelizers uniformly, straight on tangent alignment and on a true arc on curved alignment to the same tolerances of position as for application of paint in section 310-5.6.8. The Contractor shall perform all layout work necessary to place the channelizers to the proper alignment. If the channelizers are displaced or fail to remain in an upright position, from any cause, the channelizers shall immediately be replaced or restored to their original location, by the Contractor. When reflective channelizers are removed the pavement surface shall be restored to the same color and surface finish as the adjacent pavement. SECTION 313 - TEMPORARY TRAFFIC CONTROL DEVICES Add the following section: 313-1 TEMPORARY TRAFFIC PAVEMENT MARKERS. Add the following section: 313-1.1 General. The Contractor shall supply and install temporary traffic pavement markers, channelizers, July 2005 Page 109 of 115 signing, railing (type K), crash cushions and appurtenances at the locations shown on the plans and as required in the specifications, complete in place prior to opening the traveled way served by said final and temporary traffic pavement markers, signing, railing (type K) and appurtenances to public traffic. 313-1.2 Temporary Pavement Markers. Temporary reflective raised pavement markers shall be placed in accordance with the manufacturer's instructions. Temporary reflective raised pavement markers shall be cemented to the surfacing with the adhesive recommended by the manufacturer, except epoxy adhesive shall not be used to place temporary reflective raised pavement markers in areas where removal of the markers will be required. Pavement striping, legends and markers which conflict with any traffic pattern shall be removed by grinding as determined by the Engineer. The Contractor shall use temporary reflective raised pavement markers for temporary pavement marking, except when the temporary pavement markers are used to replace patterns of temporary traffic stripe that will be in place for less than 30 days. Reflective pavement markers used, in place of the removable-type pavement markers shall conform to the section 312 "Pavement Marker Placement and Removal", except the 14-day waiting period before placing the pavement markers on new asphalt concrete surfacing as specified in section 312-1 "Placement", shall not apply; and epoxy adhesive shall not be used to place pavement markers in areas where removal of the markers will be required. Add the following section: 313-1.3 Channelizers. Channelizers shall be new surface-mounted type and shall be furnished, placed, and maintained at the locations shown on the plans. Channelizer posts shall be orange in color. Channelizers shall have affixed white reflective sheeting as specified in the special provisions. The reflective sheeting shall be 75 mmx 300 mm (3" x 12") in size. The reflective sheeting shall be visible at 300 m (1000') at night under illumination of legal high beam headlights, by persons with vision of or corrected to 20/20. The channelizer bases shall be cemented to the pavement in the same manner as provided for cementing pavement markers to pavement in section 312-1, "Placement." Channelizers shall be applied only on a clean, dry surface. Channelizers shall be placed on the alignment and location shown on the plans and as directed by the Engineer. The channelizers shall be placed uniformly, straight on tangent alignment and on a true arc on curved alignment. All layout work necessary to place the channelizers to the proper alignment shall be performed by the Contractor. If the channelizers are displaced or fail to remain in an upright position, from any cause, the channelizers shall immediately be replaced or restored to their original location, by the Contractor. The Contractor shall provide the Engineer with a Certificate of Compliance in accordance with the provisions of section 4-1.5, "Certification". Said certificate shall certify that the channelizers comply with the plans and specifications and conform to the prequalified design and material requirements approved by the Engineer and were manufactured in accordance with a quality control program approved by the Engineer. Add the following section: 313-2 TEMPORARY TRAFFIC SIGNING. Add the following section: 313-2.1 General. The Contractor shall provide and install all temporary traffic control signs, markers, markings, and delineators at locations shown on plans and specified herein. Add the following section: 313-2.2 Maintenance of Temporary Traffic Signs. If temporary traffic signs are displaced or overturned, from any cause, during the progress of the work, the Contractor shall immediately replace the signs in their original approved locations. The Contractor shall maintain all temporary traffic signs used in the Work in a clean, reflective and readable condition. The Contractor shall replace or restore graffiti marked temporary traffic signs and posts used in the Work within 18 hours of such marking being discovered during non-working hours or, when the marking is discovered during working hours, within 2 hours of such discovery of marking. Add the following section: 313-3 TEMPORARY RAILING (TYPE K) AND CRASH CUSHIONS. Add the following section: 313-3.1 Temporary Railing and Crash Cushions. Temporary railing (TypeK) shall consist of July 2005 Page 110 of 115 interconnected new or undamaged used precast concrete barrier units as shown on the plans. Temporary sand- filled crash cushions shall consist of new or undamaged used temporary sand-filled crash cushions units as shown on the plans. 313-3.1.1 Appearance. Exposed surfaces of new and used units of Temporary railing (Type K) shall be freshly coated with a white color paint prior to their first use on the project. The paint shall conform to the provisions in sections 210-1.5 "Paint Systems" and 310 "Painting". Contractor shall be responsible for the removal and cleanup or painting over the graffiti from the K-Rails within 48 hours. The Contractor Shall replace or repaint units of Temporary railing (Type K) or shall remove graffiti, tire or vehicle marks, dirt or any and all materials such that said marks or discoloration mar the appearance of said units when ordered by the Engineer after the units are in place. Add the following section. 313-3.1.2 Manufacture of Temporary Railing. In addition to the requirements herein the temporary railing (TypeK) shall be manufactured per CALTRANS Standard DrawingT3. Concrete used to manufacture Temporary railing (TypeK) shall conform to the provisions in sections 201-1, "Portland Cement Concrete" and 303-1 "Concrete Structures"." Load tickets and a Certificate of Compliance will not be required. Reinforcing steel shall conform to the provisions sections 201-1, "Portland Cement Concrete" and 303-1 "Concrete Structures". Steel bars to receive bolts at ends of concrete panels shall conform to ASTM Designation: A36/A36M. The bolts shall conform to ASTM Designation: A 307. A round bar of the same diameter may be substituted for the end-connecting bolt shown on the plans. The bar shall conform to ASTM Designation: A 36/A 36M, shall have a minimum length of 660 mm and shall have a 75 mm (3") diameter by 9 mm (3/g") thick plate welded on the upper end with a 5-mm (3/ie") fillet weld. The final surface finish of temporary railings (Type K) shall conform to the provisions in section 303-1.9.2 "Ordinary Surface Finish." Exposed surfaces of concrete elements shall be cured by the water method, the forms-in-place method, or the pigmented curing compound method. The pigmented curing compound shall be type 2 curing compound. Temporary railing (Type K) may have the Contractor's name or logo on each panel. The name or logo shall not be more than 100 mm in height and shall be located not more than 300 mm above the bottom of the rail panel. Add the following section. 313-3.13 Installation of Temporary Railing. In addition to the requirements herein the temporary railing (Type K) shall be installed per CALTRANS Standard Drawing T3. Temporary railing (Type K) shall be set on firm, stable foundation. The foundation shall be graded to provide a uniform bearing throughout the entire length of the railing. Abutting ends of precast concrete units shall be placed and maintained in alignment without substantial offset to each other. The precast concrete units shall be positioned straight on tangent alignment and on a true arc on curved alignment each rail unit placed within 3 m (10') of a traffic lane shall have a reflector installed on top of the rail as directed by the Engineer. Reflectors and adhesive will be furnished by the Contractor. A Type P marker panel conforming to the requirements of the Federal Highway Administration (FHWA) Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement shall also be installed at each end of railing installed adjacent to a two-lane, two-way highway and at the end facing traffic of railing installed adjacent to a one-way roadbed. If the railing is placed on a skew, the marker shall be installed at the end of the skew nearest the traveled way. Type P marker panels shall conform to the provisions of section 206-7.2, "Temporary Traffic Signs". Where shown on the plans, threaded rods or dowels shall be bonded in holes drilled in existing concrete. When temporary railings (Type K) are removed, any area where temporary excavation or embankment was used to accommodate the temporary railing shall be restored to its previous condition, or constructed to its planned condition. Add the following section: 313-3.2 Temporary Sand-Filled Crash Cushions. Temporary sand-filled crash cushion units shall be "Energite III" manufactured by Energy Absorption Systems, "Fitch Inertial Barrier System Modules" manufactured by Roadway Safety Service, or equal. Features required to determine equivalence of any other temporary sand-filled crash cushion units shall be approval of the system by CALTRANS and that the July 2005 Page 111 of 115V temporary sand-filled crash cushion units meet NCHRP 350 standards. Other features will be suitability to application, operational characteristics, durability and other such characteristics that the Engineer shall determine. Temporary sand-filled crash cushions (TSFCC) shall be of the type and array configurations sho1 on plans, and installed at every end of, or gap in, the temporary railing (Type K) whenever the closest point o approach of traffic, regardless of direction, is 4.6 m (15') or less to the end of the temporary railing (Type K) being considered. The TSFCC shall be installed per CALTRANS Standard Drawings Tl and T2 for approach speeds no less than the posted speed of the street prior to construction or 55 kilometers per hour (35 mph), whichever is the greater. The TSFCC array shall be appropriate to the application as shown on said standard drawings. A TypeJ and/or P marker panel conforming to the requirements of the Federal Highway Administration (FHWA) Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement shall also be installed at each TSFCC array as shown in CALTRANS Standard Drawings Tl and T2. Particular care shall be taken to assure that crash cushions are installed with the soil supporting them and the adjacent soil leveled to match the elevation of the bottom of the temporary railing immediately adjacent to the crash cushion. All routes of approach to the TSCFF array shall be graded such that any vehicle diverging from the traveled way to strike the TSCFF will travel on a vertical alignment parallel to the segment of the travel lane that it departed from. Add the following section: 313-4 MEASUREMENT AND PAYMENT. Temporary traffic pavement markers, temporary channelizers, temporary signing, temporary railing (type K), temporary crash cushions and temporary appurtenances thereto shown on the plans or required in the specifications are a part of the lump-sum item for traffic control and payment therefore shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals and for doing all the work involved in applying, installing, maintaining, and removing temporary traffic pavement markers, channelizers, signing, railing (type K), crash cushions and appurtenances, complete in place, as shown on the plans, as specified in the Standard Specification and these special provisions, and as directed by the Engineer. Payment for temporary crash cushions, concrete barriers and the signs and reflectors marking them shall include the installation, grading for installation, grading for the approach path, maintenance, painting and re-painting, replacement of damaged units and removal and shall also be included in the lump-sum price bid for traffic control. Payment for installation and/or relocation of K-rails and crash cushions when not shown on the plans and requested by the Engineer shall be made per section 3-3, Extra Work, SSPWC. July2005 Page112of115 SUPPLEMENTAL PROVISIONS TO STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART 6, MODIFIED ASPHALTS, PAVEMENTS AND PROCESSES 600-3 RUBBERIZED EMULSION - AGGREGATE SLURRY 600-3.2 Materials add the following: Aggregate for Rubberized Emulsion - Aggregate Slurry shall be Type I Slurry Aggregate. 600-3.4 Application of REAS add to the first paragraphs: No slurry shall be applied until the provisions of subsection 212-1.2.6, Herbicide Application, Section 302-11 Asphalt Concrete Pavement Crack Filling and Sealing, Section 312-3 Pavement Marker Removal have all been satisfied. The Contractor shall remove all existing markings, legends and striping, either permanent or temporary in those areas to be slurried. Removal of striping by high velocity water jet may be permitted when there is neither potential of the water and detritus from the high velocity water jetting to damage vehicles or private property nor to flow from the street into any storm drain or water course and when approved by the Engineer. The Contractor shall vacuum all water and detritus resulting from high velocity water jet striping removal from the pavement immediately after the water jetting and shall not allow such materials to flow in the gutter, enter the storm drain system or to leave the pavement surface. Surface variation limitations for high velocity water jet striping removal shall be the same as for grinding. The Contractor shall not use dry or wet sandblasting in any areas. All cracks and areas between existing curb and gutter and edge of pavement that contain weeds or plant growth of any kind shall be treated with herbicides. Herbicides shall be applied at least 2(two) working days prior to sealing of street. Allowance for the two day period shall be shown in the schedule required per section 6-1. Contractor shall remove any visible plant growth prior to placement of Herbicide. Full compensation for removal of striping and herbicide application shall include but not be limited to: furnishing all labor, tools, equipment, and materials necessary for doing the work and shall be considered as included in the contract unit price bid for Rubberized Emulsion Aggregate Slurry and no additional compensation will be allowed therefore. 600-3.6 Public Convenience and Traffic Control modify the first line with the following: Public Convenience and traffic control shall conform to 302-4.4.4. There shall be no stockpiling of material allowed on City right-of-way. July 2005 Page 113 of 115 APPENDIX "A" CITY OF SAN MARCOS ROAD WORK ABC CONTRACTORS OFFICE # (760)XXX-XXXX FIELD # (760)XXX-XXXX Dear resident: As a part of the City of San Marcos's ongoing pro- gram to maintain its streets, your street will be resur- faced with asphalt concrete over the existing roadway surface. This construction will require the closing of your street to through traffic for one day. Your street, from XYZ St. to DEFAve. will be closed to through traffic and resurfaced on: MON. TUB. WED. THU. FRI. DATE: XX/XX/XX from 7:OOA.M. to 5:00 P.M. [f you don't plan to leave your home by 7:00 A.M. on the above date please park your car on an adjacent street in your neighborhood that will not be resur- faced. Streets scheduled for resurfacing can be de- termined by calling either the Contractor or the City of San Marcos's Project Inspector. When walking to and from your car, remember not to walk on the newly overlaid street or you will have black residue on the bottom of your shoes. Please do not drive, walk on, walk pets, play, or skate on the newly over- laid asphalt. Also, please refrain from watering your lawns, washing cars, etc., approximately 6-8 hours after the asphalt is laid as running water will cause damage to the new surface. ABC is the Contractor that will be performing the re- surfacing work for the city and you may call them at the above phone number if you have any questions regarding the project. Resurfacing of your street will not occur on the day your trash is collected. Mail de- livery may be delayed if the postman cannot reach the mailbox that day. If you have a moving company scheduled for that day please call and inform the !ontractor of the date. If you have any concerns which cannot be addressed by the Contractor, you may call the City's Project Inspector @ (xxx) xxx- xxxx. Thank you for your cooperation as we work to make a better City of San Marcos. July 2005 Page 114 of 115 APPENDIX "B" VARIOUS STANDARD PLAN DRAWINGS July 2005 Page 115 of 115 13mm (1/2") R Weakened Plane Joint 25.4mm (1") R TYPE W 610mm (24") •AREA .124sq. m (l.34sq ft.) 762mm (30") .150sq. m (1.6!sq ft.) * with 152mm (6") Cjrt> Face NOTES 1 Concrete shall be 3GSkg/M3-C- 17-Mpo (520-C-2500). 2. See Standard Drawir.g G-10 for joint details. 3. S'ope top of curb 6.35mm (1/4'') per foot toward street.LEGEND ON PLANS ORIGINAL Add Metric Bv Approved Date T. Stanton .12/75 03/03 SAN DIEGO REGIONAL STANDARD DRAWING CURB AMD GUTTER - COMBINED RECOMMENDED BY THE SAN DIE CO REGIONAL STANDARDS COMMITTED Chairperson R.C.E. 19246 Date DRAWING NUMBER _0Z 17 •V £eVilir.~-i | <vc £Z 7mm (5") ^ \ *• • V * 10'mrr / 1 \ \\ V--- -.. 229mm (9") | (4") ^^_51mm (2") Weokene ^^ Plane Joint t~ OO E r^> OCM \O E t5 , Top of - f Pavement _ »f** V. 50mm (2") ^ "T lunorO ( I I d f(_> 127mm (5"J r ~~iIJmm (1/2') (5 25mm (1 <nc i o ^\ \\ A ^Slmr 101mm (4") ^ . 381mm (15") UD e rvjin n (2") 610mm 13nm (!/?') R {_ ~^ r^Weakened Plane Joml •_ (24") IO B-1 Areo= .073 sq. m (0.79 Sq.R.) B-2 Areo= .120 Sq.m (1.29 Sq.Ft.) 127mm 51mm (1/2") 89mm (3-1/2")89mm (3 1/2 '/2') 13mm (1/2") dio. Continuous Steel Bar 19mm (3/4") f Top of Pavement 76mm (3 Area= adhesive to bose -51mm (2") Weakened Plane Joint ||p 13mm (1/2") dio Steel Dowels @ 1.22m (4-) c.c mm length 203mm (3") (see note 3) B-3 .027 sq. m (0.29 Sq.Ft.) 8-4 Areo= .033 sq. m (0.35 Sq.R.) NOTES 1 Concrete shall be 303kg/M3-C-!?-Mpo (52Q-C-25CO) 2 See Standard Drawing G-10 lor join! details 3 Extruded type B-J curb shall be anchored to existing pavement by placing stee! dowels and reinforcing steel 03 shown or by usmg an approves adnesive. LEGEND ON PLANS Gul'er Type e-l. 3-i 6-4 Ob ReMSion ORiGiNiL Add Metric | By! Approved iKe'chevcl i T. Stonton i Ii 1 Dale i2/?5 03/03 CURBS AND GUTTER - MEDIANS RCCOMUEN05.0 9" 1"- S»N O'CCO ^ 'Jj&k^^ 3IOH8003 Ch^rperson ROE. I92«6 Date DRAWNC r r | MUMEEP '-' U I P.C.R._Rogjius "/4 (TYP. v\\ \ Contoct Joints per Standard Drawing G-10 when separate pours are mode PLAN 3m (10') unless otherwise ^ shown on plan ,-I.T™, fi/7'1 R iwirnl 178TLl2l_i£*j — r?// /, x>J^' ' ^Z3&ZZZZZZZ\ 1 5% / Top o(_Poving • •ni , , , , .^ ^ — Base material as shown on plans SECTION A-A NOTES 1 Concrete shall be 3.32 kg/M3 C 22 Mpo (560 C 3250). 2 = Weakened plone joints 3. ~™ * = Typical flowlines. 4. ° = Elevations to be shown on plans. 5 Return segments to be 178mm (T) Thick. 6 Curb between P.C.R.s. shall be considered os port of cross gutter. 7. In all cases subgrode shall be compocteo to 95% mm relative compaction to depth of 305mm (12"). LEGEND ON PLANS Revision ORIGINAL Add Metric By Approved Kercheval T. Stonton Dole 12/75 03/03 QAM nirpn RFPIOMAI ^TAMDARH DRAWIMH CROSS GUTTER RECOMMENDED B* THE SAN OlECO REGIONAL STANDARDS COMMiTTtf Atfrfi~^£^<r 4k. W$fcl<^ 3\OWXB Chairperson R.C.E. 19246 Date I DRAWING p 1 7 NUMBER U Manhole frame ond cover see drawing M-1 This drawing is NOT in conformonce with latest UBC and should be used with care and judgment. A Transition lo normal curb Calv. steel angle hirtth CiHoC i inlae-c- around opening B /— bee note 7 / #13 continuous and protection bor. See drawing 0-12 102mm (4")_/ radius -Edge o/ Gutter cnr^j |!3@305mn7 (#4@12 305mm O'-O") i2mm (6") Length shown on plans PLAN #13 457mm SECTION B-B Slope gutter 76mm (3") or match existing roodwoy surface — -254mm (10")unless shown otherwise 76mm (3") clr. 191mm (7-1/2") ID Io "_ (|4) around pipe Slope floor 12: towards outlet Determined by pipe size- 1.22m (4') min., 2.44m (B')mox SECTION C-C Rounded pipe ends see drawing D-61 Elev. shown on plans 1T1 -#13@305mm 1.22m NOTES l.See Standard Drawings D-11 & D-12 lor additional notes and details. 2 Types are designated as follows: (no wing)A. (one wing)A-l. (two wings)A-2. 3 Exposed edges of concrete shall be rounded with a radius of 13mm (1/2"). 4 When V exceeds 4' steps shall be installed See Standard Drawing D-11 lor delails 5 Concrete gutter to match adjacent gutters. 6. An expansion |oin( shall be placed at the ends of the inlet where the curb is to adjoin. 7. Provide 6.35mm (1/4") tooled groove in top slob in line with bock of adjacent curb. 8. Surface of lop slab shall be sidewalk finished to dram toward street al o slope of 6 35mm (1/4") per loot 9 Maintain 38mm (1-1/2") clear spacing between reinforcing and surface unless otherwise noted SECTION A-A LEGEND ON PLANS Revision ORIGINAL dd Metric By Approved Kercheval T. Slanton Dote 2/75 03/OJ SAN DIEGO REGIONAL STANDARD DRAWING CURB INLET - TYPE A RECOMMENDED BY I»E S*N DiECO REGIONAL STANDARDS COMMITTEE DRAWING 0-1 NUMBER J This drowing is NOT. in conformance with latest UBC ond should be used with core ond judgment -Manhole frame ond cover see \dro*ing M-2.'3 (jf4) | | around opening Wmq. » one or r 'here occurs both sides Transition to normal curb height in 3m (10') on both sides unless otherwise noted • See note 7 Colv steel angle continuous and protection bor. See Std Dwg. 0-12 . i _____ _ ____ _ i i /i 102mm (4"radius) - ' \, Curb Line PLAN — 152mm (5") — Edge of Gutter #13 (jf4)@ 152mm (6"). #13 (jjf4)@304mm (12") ITo _ O'-O") 457mm SECTION B-B 76mm (3") dr. 191mm (7-1/2") around pipe JrU' Slope floor 12:i towards outlet Y+254mm (Y+10") t=J S-#I3 (|4) 51mm (2> -Curb Line 254mm (10") unless otherwiseShown-i p"T£T3g ^ :O) TEen- -CM-*" CM ^r* f \_ ! . (WJ i 1 _ . . — Rounded pipe endsJsee drowing 0-61 /—Elev. shown / on plans | I 305mm (r-0") 1.22m (4P-0") Determined by pipe size-1.22m (4') min., 2.44m (8 )max. SECTION C-C SECTION A-A NOTES 1. See Standard Drawings 0-11 <k 0-1? for oddit.onal notes ond details 2. Types ore designated as follows: (no wing)8. (one wing)B-1, (two wmgs)B-2. 3 Maintain 38mm (1-1/2") clear spacing between reinforcing ond surface unless otherwise noted 4 When V e«ceeds 4' steps shall be .nstolled See Standard Drawing D-ll lor details 5. Concrete gutter to match adjacent gutters. 6. An expansion jo>nt snail be placed o! the ends of the inlet where tr>e curb is to adjoin 7. Provide 6.35mm (1/4") tooled g'oove in top s'cb in line with beck oi cdjacenl cjrb. 8. Surface of top slab shall be sidewalk finished to drain toward street o! a slooe of 6 35mm (1/4") oer foot. 9 Mcir-ia.n 53rrr~, (1-1/2") dear spacing between r°in!crc;ng ond surfoc? unless ol^er^ise ncied LEGEND ON PLANS Re'/iSiOri ORIGINAL Add Mctnc By Approved K'ercnevai T Slanton Dote '2/~5j D3/OJ C;AM nirro RrntnNAi ^TAMnAPn DRAwiMr, CURB INLET TYPF B RECCMMCNOEO BT THE SAN D'ECO •?EC'ONAL S"4NO»ROS COMMi nEt A^^^II^^r- ^ jjmfarf^ 3I°'I*X3 Ch^rperson R.C.E. 192«6 °°(e DRAWING r) 7 NUMBER L L This drowing is NOT. in conformonce with lotest U8C ond should be used with core ond judgment #13 (#4) Bars placed diagonally #13 (#4) @ 203mm (8) both ways ' Bend Down 381mm (15") (Typ.)PUN TYPE A 4 A 5 A 6 A 7 A 8 PIPE DIA. up to 991mm (39") 1.1m (42") to 1.22m (48") 1.30m (51") to 1.50m (60") 1.60m (63") to 1.80m (72") 1.90m (75") to 2.13m (84") X 1 22m (41) 1.52m (5') 1.83m (6') 2.13m (71) 2 44m (8') Y 1.22m (4') 1.22m (41) 1.22m (4-) 1.22m (4') 1.22m (4-) Z 1.83m (6') 1.83m (6-) t.83m (6') 2 13m (?•>, 2 44m (8') 51mm (2") Bend Down IS' (Typ) Diagonal Bars 2-#13 (#4) bars Elev. shown on plans Rounded Pipe Ends See D'owing D —61 Manhole Frame ond Cover see Standard Drawing M-3 For step details, see Standard Drawing 0-11 *-#'3 (#4) Around pipe Slope floor 12.1 towards outlet -J, NOTES SECTION A-A 1 See Standard Drawing D-H lor additional notes and details 2 Concrete base shall be 332kg/M3-C-22Mpo (560-C-3250) 3 All precast components shall be reinforced with 6.35mm (1/4") diameter steel, wound spirally on 1C2mm (4") centers 4 All joi-its snail be set in Class C mortar 5 Mointon 38mm (1 1/2") dear spocina bel*een reinforcing and surface unless otherwise noted LEGEND ON PLANS "o] Revision ORIGINAL Add Metric a Bv LxposS'J ec Aporoved •<»rchsvol T. Stanton yes o Date 12/75 03/03 concrete snan ce rgur.aeu win: a 'uaius 01 umm \\/i j CAM nirpn DCTIHMAI crTAKinADn no AM/IMPoAIN L/ILuU Kt-ulUINAL OlMINUArvL' UrXAWIlNU STORM DRAIN CLEANCUT TYPE A — 1^1 — RECOMMENDED 3Y rut SAM 0!£SO REGIONAL SfNOAROS COMMlI'LL ^ 'J$jffiZt^ 3IOW003 CWjirpersor. R.C.E. '92*6 Dote DRAWING n q NiiWRFR u ^ Varies Width os shown on plan IJrrm (1/2") R I Weakened Plane Joint • 51mm (2") NON-CONTIGUOUS IJmm (1/2" R) L __ __ P ^Smm (1/4") per U. Weakened Plane Joinl 51mm (2") CONTIGUOUS NOTES I Concrete snail be 308 kq,/M3 C 17 Mpa (:20-C-2500).LEGEND ON PLANS 2. Revision ORIGINAL Add Metric See By Stanocrd D Approved Kerchevoi T. Stonton rowing Date 12/75 03/03 C-9 and G-IO for pml details. REGIONAL STANDARD DRAWING SIDEWALK TYPICAL SECTIONS ..„.;. RCCOMMENOEO BY THE SAN DiCGO orr.iDNAL STANDARDS rOM'.uTT^^ JfaLsf^~~^Z^- i| JjjzffifaMw sioiismf Chairperson R.C E. 192<6 Dote DRAWING p 7 NUMBER u Non-contiguous Sidewalk R/W CMvn Curb \ Depressed Curb— "" Contiguous Gutter 914mm (J'-O") 914mm (3'-0") PLAN Drivewoy Curb Opening Sidewalk '/V/MW/ Driveway Width Shown On Plans 1 . . 1 s ~*y/xr/>if/&/'»'/)-r/*> L^yj " \\ Bottom of Curb ELEVATION -305mm (12") R (typ.) Edge of Sidewalk 140mm (5 1/2") SECTION NOTES 1. No concrete shall be placed until (orms and subgrade are inspected by the Agency. 2. Concrete shall be 308 kg/M3 C 1? Mpa (520-C-2500). 3 See Standard Drawings G-15 and G-16 for width and location requirements 4. Driveway ramp to extend to 3m (10') from curb face or to property line whichever is less. (For commercial driveways only) 5. See Standard Drawings G-2 and G—10 for curb and joint details. Revision ORIGINAL Add Metric By Approved R Munoz T. Slanton Dole 4/97 03/03 SAN DIEGO REGIONAL STANDARD DRAWING RESIDENTIAL CONCRETE DRIVEWAY (PARKWAY LESS THAN 10' IN DEPTH) RECOMMENDED BY THC SAN DIEGO REGIONAL STANDARDS COMMITTFT J$0f%j^l<r*y 3loil zoos Otorperson R.C.E 19246 Dote DRAWING p 1/p NUMBER u ' ^ 305mm (12") wide border with 6.35mm (1/4") grooves CURB HEIGHT Tronsilion oreo PLAN •-•-A (TYPE 8-1) Z or Z^ c ~ ,.- .-;. ./.:./. .--.•-•'•.;.; - ;-..., < Z or Zl r-— r -•••" -•'• " -'' : ••... '-.- ••••;•"•"'.•' / — Top 1 / / C X / Face of curb Lip (toe) of Gutter Top of curb Gutter flow line ELEVATION i.22m (4 ; Lending See Note 1. 1 2% mox. .. . ; ;^ : — «» . , . » . , • Y "os — 305mm (12") 12 | J 1 II:zi::^2Z£ZZ2^-^~^^-^-J/V 5% max. gutter apron slope at ramp opening SECTION A-A TABLE A RAMP LENGTH (12:1) 152mm (Q'-6") 457mm 762mm (2'-6") 1.1m 1.54m (4'-6") 1.6Sm 1.98m (6'-5") 2.29m (7'-6") SIDE SLOPE (10:1) 457mm (l'-6'"> 457mm (l'-6") 635mm (2'-1") 389mm (2'-1 1") 1.14m (3'-9") 1.4m 1.65m (5'-5") 1.91m (6'-3") 21 SIDE SLOPE (12:1) 457mm (l'-6") 457mm 762mm (2'-6") 1.1m 7.37m (4'-6") 1.68m (5'-6") 1.98m t'6'-6") 2.29m (7'-6"1 See Detail B Std. Dwg. G-32 NOTES 1. If inadequate R/W exists to provide a 4' landing, a landing width less than 1.22m (4') but at least 3' is acceptable if the side slopes are revised to 12:1 per side slope Z1 in loble A. 2. See Standard Drawing G-32 for general notes. 3. Type A-l is o designation for ramp at curb return. 4. Type B-l is o designation for ramp at straight curb. (Shown above) 5. Delete 305mm (12") wide border when X=1" Revision ORIGINAL dd Metric By Approved G.Parkinson T. Stanton Dote 2/95 03/03 SAN DIEGO REGIONAL STANDARD DRAWING CURB RAMP - TYPES A-1 and.B-1 (For Existing Sidewalk) RECOMMENDED BY WE SAN DIEGO REGIONAL STANDARDS COMMiTTEf 310112003 R.C.E. DRAWING NUMBER G-28 r 3 1m (10') mo*3 1m (10") mo» Corner or End Posl Fastener ^ Crown lor drainage Ground Line (2") 229mm 0") I Depth = 762mm (2'-6") for 51mm (2 ) fence height of 1.5m (5') or — under. Depth = 914mm (3'-0") for fence height of over 1.5m (5' -Fooling -51mm (2") Diameter of looting = 4 limes- outside diameter of post. NOTES 1. All loolings shall be 309kg/M3-C-22-Mpa (520-C-2500) concrete. 2 The following items shall be furnished and installed only when shown on the plans and/or called for in the special provisions. o Barbed Wire b Extension Arm c Top Horizontal Rail 3 Chain link f;nce shell conform to Section 206-6 of the Standard Specifications for Public Works Construction unless spec'iicclly noted on this drawing. •i See Stondo'd Drawing M-2G for additional delo;ls EXTENSION ARM AND BARBED WIRE LEGEND ON PLANS —O—* * * O ORIGINAL Add Metric By Approved A.Kercheval \ T. Slanton I Ode 12/75 OJ/03 SAN DIEGO REGIONAL STANDARD DRAWING CHAIN LINK FENCE RECOMMENDED BY THE SAN DIEGO REGIONAL STANDARDS COMMITTEE DRAWING NUMBER M-6 2002 REVISED DUAL UNITS STD. PLAN RSP A88A 2O02 DUAL UNITS STD PLAN D74B 2002 DUAL UNITS STD PLAN D77B •„ 'ii'."."! _ t e.,^^- •: u_.. .!.._. 'i ^Sli.J-Ji1 -^^r-171'" f» ••• |_ J5 . II- j•„o iu - L j i'l J. ^cl -. § s5 r I • f ^^ IllllJil CARLSBAD MUNICIPAL WATER DISTRICT SAN MARCOS BOULEVARD 30-INCH DOMESTIC WATER TRANSMISSION MAIN TABLE OF CONTENTS Section No. Title DIVISION 1: GENERAL REQUIREMENTS 01010 Summary of Work 01011 General Construction Sequence 01025 Measurement and Payment 01040 Coordination 01047 Connections to Existing Facilities 01048 Special Construction Conditions and Procedures - General 01500 Construction Facilities and Temporary Controls 01530 Protection of Existing Utilities 01580 Project Identification and Signs 01600 Material and Equipment 01700 Contract Closeout 01710 Cleaning and Final Cleaning 01720 Record Drawings DIVISION 2: SITE WORK 02130 Removal and Resurfacing of Pavement Surfaces 02223 Trenching, Excavation, Backfilling, and Compacting DIVISIONS: CONCRETE 03000 Cast-In Place Concrete DIVISIONS: FINISHES 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines 09900 Painting and Coating 09902 Petrolatum Wax Tape Coating City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) Table of Contents -1 of 2 DIVISION 15: MECHANICAL 15000 General Piping System and Appurtenances 15041 Disinfection of Piping 15044 Hydrostatic Testing of Pressure Pipelines 15056 Ductile-Iron Pipe and Fittings 15057 Copper Tubing, Brass and Bronze Pipe Fittings 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 15064 Polyvinyl Chloride (PVC) AWWA C-900 Pressure Pipe 15074 Blowoff Assemblies 15100 Resilient Wedge Gate Valves (RWGV's) 15102 Butterfly Valves (BFV's) 15108 Air Release Valve, Air and Vacuum Valve and Combination Air Valve Assemblies DIVISION 16: CATHODIC PROTECTION 16640 Cathodic Protection by Sacrificial Anodes City of Carlsbad 4/05 (DBE) San Marcos Blvd. Domestic Water Transmission Main Table of Contents - 2 of 2 SECTION 01010 SUMMARY OF WORK PART 1 - GENERAL 1.1 Work Covered by Contract Documents A. The Work generally includes, but is not limited to, furnishing products, labor, tools, transportation, and services to construct the following: 1. Pavement removal and replacement, traffic control and coordination with utility companies for locating their facilities. 2. Construction of 30-inch I.D. domestic water transmission main with connections and appurtenances as described in the plans. 3. Testing, disinfection and placing into service of domestic water transmission mains. 4. Demolition of existing valve vault at Viewpoint Drive after acceptance of new pipeline. 1.2 Project Location A. The Project is located in San Marcos, California, generally along San Marcos Boulevard between Acacia Drive and Rancho Santa Fe Road. B. Conditions at the Project site are as follows: Ground Elevation: 442 - 585 feet MSL Typical Temperature Range: 31 ° -110° F 1.3 Related Work A. Section 01011: General Construction Sequence B. Section 01048: Special Construction Conditions and Procedures - General C. Section 01700: Contract Closeout D. Section 01710: Cleaning and Final Cleaning PART 2 - PRODUCTS (Not Applicable) City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01010 - Summary of Work -1 of 2 PART 3 - EXECUTION 3.1 Contractor Use of Premises A. The following facilities shall remain operational during construction of this project: 1. Existing water facilities. Shut downs only permitted under observation of Water Department personnel and according to schedule of required shutdowns. 2. Install approved signs, barricades and lights necessary to ensure public safety and safety of Owners operators and personnel. Provide plates across ditches to enable safe access of Owner's personnel to facilities or the public across excavations within public right-of-way that can not be backfilled at the end of the day. END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01010 - Summary of Work - 2 of 2 SECTION 01025 MEASUREMENT AND PAYMENT PART 1 - GENERAL 1.1 Description Measurement and payment for bid items listed in the proposal shall be based upon use of a lump sum or unit price method. Extra work or changes in the Work shall be accomplished as provided in the General Provisions. 1.2 Related Work (Not Applicable) 1.3 Submittals (Not Applicable) 1.4 Payment A. Payment for Unit Price Items Payment for a unit price bid item shall be based upon the amount shown in the bid schedule multiplied by the total quantity measurement of the item and shall be full compensation for furnishing all labor, transportation, materials, equipment, tools and appurtenances required for construction of the item complete in place in accordance with the Plans and Specifications. B. Payment for Lump Sum Items Payment for lump sum bid items shall be based upon the amount shown in the bid schedule and shall be full compensation for furnishing all labor, transportation, materials, equipment, tools and appurtenances required for construction of the unit complete in place in accordance with the Plans and Specifications. The Carlsbad Municipal Water District reserves the right to adjust any Lump Sum Item if the Total Bid Amount does not reflect the added value of the individual Bid Items. C. Work Not Listed in the Bid Schedule Costs for related work and appurtenances which are required and/or implied by the General Provisions, Technical Specifications, Special Provisions and Plans and are not listed as a separate bid item but are necessary to complete the project shall be included in the appropriate bid item or items within the proposal. PART 2 - MATERIALS 2.1 General (Measurement) Measurement for unit price quantities shall be based upon the appropriate bid item in the proposal. The actual quantity of measurement shall be as constructed by the Contractor in place in conformance with the Plans and Specifications. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01025 - Measurement and Payment -1 of 8 2.2 Linear Measurements Pipelines' and related facilities' measurement shall be made horizontally and/or vertically along the centerline of the pipeline and related facilities through tees, bends, valves, fittings and as shown on the Plans for its limits or as otherwise specified in the Special Provisions. Manholes and vaults shall be measured vertically from the lowest to the highest elevations and as shown on the Plans or as otherwise specified in the Special Provisions. 2.3 Area Measurements Measurement for bid items involving area units shall be based upon the surface area measured in acres, square yards, square feet or as indicated in the bid item. 2.4 Volume Measurements Measurement for bid items involving volume units shall be based upon the volume measured in cubic yards, tons or as indicated in the bid item. 2.5 Unit Measurements Measurement for bid items involving units of the item shall be based upon the number of units counted as indicated in the bid item. 2.6 Lump Sum Measurement Measurement for a lump sum bid item shall be considered as a complete project or a portion of a project constituting a unit. The items to be included in the lump sum bid shall be as specified in the proposal bid item and/or the Standard or Special Provisions. PART 3 - EXECUTION 3.1 GENERAL This section covers methods of measurement and payment for items of Work under this Contract. The total Bid Price shall cover all Work required by the Contract Documents. All costs in connection with the proper and successful completion of the work, including furnishing all materials, equipment, supplies, and appurtenances; providing all construction plant, equipment, and tools; and performing all necessary labor and supervision to fully complete the Work, shall be included in the unit and lump sum prices bid. All Work not specifically set forth as a pay item in the Bid Form shall be considered a subsidiary obligation of Contractor and all costs in connection therewith shall be included in the prices bid. The descriptions of bid items provided hereafter apply to Schedules 1 through 3. 3.2 ESTIMATED QUANTITIES All estimated quantities stipulated in the Bid Form or other Contract Documents are approximate and are to be used only (a) as a basis for estimating the probable cost of the Work and (b) for the purpose of comparing the bids submitted for the Work. The actual City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01025 - Measurement and Payment - 2 of 8 amounts of work done and materials furnished under unit price items may differ from the estimated quantities. The basis of payment for work and materials will be the actual amount of work done and materials furnished. Contractor agrees that he will make no claim for damages, anticipated profits, or otherwise on account of any difference between the amounts of work actually performed and materials actually furnished and the estimated amounts therefore. 3.3 BID SCHEDULE NO. "B" - DOMESTIC WATER TRANSMISSION MAIN - CONTRACT NO. 39561 The drawings associated with Bid Schedule No. "B" are titled "San Marcos Boulevard 30" Water Transmission Main," sheets 1 through 18, CIP No. 39561. A. MOBILIZATION. DEMOBILIZATION AND CLEANUP. Bid Item 1. 1. No measurement shall be made for this item. This item covers all the work necessary for mobilization, demobilization, providing project sign, on-going compliance with the General Conditions and final clean-up of construction site. Mobilization includes: (1) Obtaining all permits necessary for performing the work. (2) Assembly, equipment, material and supplies for the prosecution of the work but which are not to be incorporated in the work. (3) Construction of temporary yards, access road, development of disposal areas and other facilities. (4) Provide project sign and install as directed by the District. (5) Compliance with the General Conditions. Demobilization includes: (1) removal of all temporary facilities from the site. (2) Clean up of all debris and disposal offsite. (3) Contract closeout. 2. Payment for Bid Item 1, will be based upon the following: a. During the course of project construction the amount paid for Mobilization and Demobilization will be 100 percent of the contract price for Bid Item 1 or 6.5 percent of the original contract amount, whichever is the less. b. During the course of project construction, the amount paid for Mobilization will be 70 percent of the contract price for Bid Item 1 or 70 percent of 6.5 percent of the original contract amount, whichever is the less. The initial partial payment for Mobilization will not exceed one-third of the amount to be paid for this item. Payment requests for Mobilization shall be accompanied by information (invoices, timesheets, etc.) that support the amount being requested. c. During the course of project construction, the amount paid for Demobilization will be 30 percent of the contract price for Bid Item 1 or 30 percent of 6.5 percent of the original contract amount, whichever is the less. d. After completion of the work and acceptance of the contract, the amount, if any, of the contract item price for Mobilization and Demobilization in excess of 6.5 percent of the original contract amount will be included for payment in accordance with General Conditions Subsection 6-8 CompJetion and Acceptance. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01025 - Measurement and Payment - 3 of 8 B. PERFORM EXPLORATORY EXCAVATIONS FOR UNDERGROUND UTILITIES. Bid Item 2. 1. Measurement for payment for performing exploratory excavation at all under ground utility crossings and points of connection to verify location, size and type of existing facility will be based upon the complete work, all in accordance with the requirements of the Contract Documents. 2. Payment for performing exploratory excavation at all underground utility crossings and points of connection to verify location, size and type of existing facility will be made at the lump sum price named in the Bid Schedule under Item No. 2, which shall constitute full compensation for completely performing all exploratory excavations, including but not limited to, pavement removal and restoration, excavation and backfill, obtaining depths and sizes of utilities, traffic control and other ancillary work. C. CONSTRUCT 30-INCH I.D. DIAMETER TRANSMISSION MAIN. Bid Item 3. 1. Measurement for payment for construction of 30-inch diameter CML, tape-wrapped and mortar coated steel pipe transmission main will be based upon the number of linear feet of such pipe actually placed as determined by measurement along the centeriine of such pipe, all in accordance with the requirements of the Contract Documents. 2. Payment for construction of 30-inch diameter transmission main will be made at the unit price per linear foot named in the Bid Schedule under Item No. 3, which price shall constitute full compensation for furnishing and placing such pipe including excavation, backfill, bedding, compaction, fittings, thrust blocks, locator tape, disposal of excess excavated material, pavement removal and, testing, flushing and disinfection and any appurtenant work as shown on the Plans or called for in the Specifications, complete in place for the unit price. D. PROVIDE TRAFFIC CONTROL. Bid Item 4 1. No measurement shall be made for these items. 2. Payment for traffic control related to construction of the 30-inch diameter transmission main will be made at the lump sum price named in the Bid Schedule under Item Nos. 4. Partial payments will be made on the basis of the percentage of construction completion with respect to each wateriine up to a maximum of 50- percent of the lump sum price. The final amount which constitutes full compensation for the complete work can be applied for upon completion and acceptance by the jurisdictional agency of the paving repair, final paving, pavement overlay, and re-striping. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01025 - Measurement and Payment - 4 of 8 E. CONSTRUCT CONNECTION AT STATION No. 10+00.00. Bid Item 5. 1. Measurement for payment for construction of the connection to the existing 36-inch diameter steel water main at Station No. 10+00 will be based upon the complete work, all in accordance with the requirements of the Contract Documents. 2. Payment for construction of the connection to the existing 36-inch diameter steel water main will be made at the lump sum price named in the Bid Schedule under Item No. 5, which shall constitute full compensation for furnishing and placing such pipe including excavation, backfill, bedding, compaction, fittings, couplings, removal of steel dished head, installation of butt strap for closing section, installation of blow-off assembly, abandonment of existing piping, properly plugging abandoned piping, thrust blocks, locator tape, disposal of excess excavated material, pavement removal and replacement, pavement overlay, re-striping, traffic control, testing, flushing and disinfection and any appurtenant work as shown on the Plans or called for in the Specifications, complete in place for the unit price. F. CONSTRUCT CONNECTION AT STATION No. 49+25.67. Bid Item 6. 1. Measurement for payment for construction of the connection to the existing 21-inch diameter transmission main, at Station No. 49+25.67 will be based upon the complete work, all in accordance with the requirements of the Contract Documents. 2. Payment for construction of the connection to the existing 21-inch diameter at the intersection of San Marcos Boulevard and Rancho Santa Fe Road will be made at the lump sum price named in the Bid Schedule-under Item No. 6, which shall constitute full compensation for furnishing and placing such pipe including excavation, backfill, bedding, compaction, fittings, couplings, removal of existing piping and valving and appurtenances, thrust blocks, locator tape, disposal of excess excavated material, pavement removal and replacement, pavement overlay, re-striping, removal and storage of City's pavers, reinstall pavers, traffic control, testing, flushing and disinfection and any appurtenant work as shown on the Plans or called for in the Specifications, complete in place for the unit price. All removals of existing piping, valves and appurtenances shown on Detail 2 on Sheet C-6 shall be included in this bid item. G. CONSTRUCT 2-INCH AIR RELEASE AND VACUUM RELIEF ASSEMBLY. Bid Item 7. 1. Measurement for payment for construction of 2-inch air release and vacuum relief valve assembly, will be based upon the actual quantity, each, of such 2-inch air release and vacuum valve assembly furnished and installed per the Carlsbad Municipal Water District Standard Drawing No. W7-A, all in accordance with the requirements of the Contract Documents. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01025 - Measurement and Payment - 5 of 8 2. Payment for said 2-inch air release and vacuum relief valve assembly, will be made at the unit price, each, named in the Bid Schedule under Item No. 7, which price shall constitute full compensation for the complete 2-inch air release and vacuum valve assembly including, but not limited to, excavation, backfill, bedding, compaction, thrust blocks, piping, fittings, couplings, disposal of excess excavated material, pavement removal and replacement, re-striping, traffic control and any appurtenant work as shown on the Plans or called for in the Specifications, complete in place for the unit price. H. FURNISH AND CONSTRUCT 6-INCH BLOW OFF ASSEMBLY. Bid Item 8. 1. Measurement for payment for construction of 6-inch blow off assembly, will be based upon the actual quantity, each, of such 6-inch blow off assembly furnished and installed per the Carlsbad Municipal Water District Standard Drawing No. W11-A, all in accordance with the requirements of the Contract Documents. 2. Payment for said 6-inch blow off assembly, will be made at the unit price, each, named in the Bid Schedule under Item No. 8, which price shall constitute full compensation for the complete 6-inch blow off assembly including, but not limited to, excavation, backfill, bedding, compaction, thrust blocks, fittings, linings, couplings, disposal of excess excavated material, pavement removal and replacement, re-striping, traffic control and any appurtenant work as shown on the Plans or called for in the Specifications, complete in place for the unit price. I. FURNISH AND INSTALL 30-INCH BUTTERFLY VALVE. Bid Item 9 1. Measurement for payment for construction of 30-inch butterfly valve, will be based upon the actual quantity, each, of such 30-inch butterfly valve and valve assembly per the Carlsbad Municipal Water District Standard Drawing Nos. W17 and W13, all in accordance with the requirements of the Contract Documents. 2. Payment for said 30-inch butterfly valve and valve box assembly, will be made at the unit price, each, named in the Bid Schedule under Item No. 9, which price shall constitute full compensation for the complete installed 30-inch butterfly valve and valve box assembly. J. FURNISH AND INSTALL CATHODIC PROTECTION. Bid Item 10. 1. No measurement will be made for this item. 2. Payment for cathodic protection of 30-inch CML, tape wrapped and mortar coated steel pipe transmission main will be made at the lump sum price named in the Bid Schedule under Item No.10, which shall constitute full compensation for completely furnishing all labor, materials and equipment to install cathodic protection for steel transmission mains including: excavation, backfill, bedding, compaction, wiring, welding, test stations, testing of system and documented recordation of initial readings, disposal of excess excavated materials, removal and replacement of pavement, traffic control, and any appurtenant work as shown on the Plans and Specifications. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01025 - Measurement and Payment - 6 of 8 K. INSTALL TRAFFIC VIDEO DETECTION SYSTEM. Bid Item 11. 1. Measurement for payment for installation of permanent traffic video detection equipment, will be based upon the actual quantity, each 4 leg system, of such detection systems furnished and installed per the City of San Marcos standards, all in accordance with the requirements of the traffic control Contract Documents. 2. Payment for said traffic video detection equipment assembly, will be made at the unit price, each, named in the Bid Schedule under Item No. 1 1 , which price shall constitute full compensation for the completed and functioning installation. L. PROVIDE PROJECT CONSTRUCTION INSPECTION FIELD TRAILER. Bid Item 1. No measurement shall be made for this item. This item covers all the work necessary for providing the project construction inspection field trailer in accordance with the requirements of the General Conditions and Contract Documents. 2. Payment for Bid Item 12, will be based upon the following: a. See General Condition Section 8-2. M. PROVIDE AND PREPARE DRAWINGS FOR SWPPP AND BMP PERMITS AND FURNISH AND INSTALL EROSION CONTROL AND WATER POLLUTION CONTROL DEVICES. Bid Item 13 1 . No measurement will be made for this item. 2. Payment for providing and preparing drawings for SWPPP and BMP permits and furnishing and installing erosion control and water pollution control devices, will be made at the lump sum price named in the Bid Schedule under Item No. 13, which shall constitute full compensation for this item. N. PROVIDE EXCAVATION SAFETY MEASURES. Bid Item 14. 1 . No measurement will be made for this item. 2. Payment for providing excavation safety measures including sheeting, shoring and bracing, or equivalent method for the protection of life and limb in trenches and open excavation in conformance with applicable safety orders, will be made at the lump sum price named in the Bid Schedule under Item No. 14, which shall constitute full compensation for this item. O. BACKFILL EXISTING 21-INCH PIPE WITH SAND SLURRY. Bid Item 15. 1 . Measurement for payment for backfilling the existing 21 -inch diameter CML, and mortar coated steel pipe transmission main will be based upon the number of linear feet of such pipe actually abandoned and backfilled with sand slurry as City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01025 - Measurement and Payment - 7 of 8 determined by measurement along the centerline of such pipe, all in accordance with the requirements of the Contract Documents. 2. Payment for backfilling the existing 21-inch diameter transmission main will be made at the unit price per linear foot named in the Bid Schedule under Item No. 15, which price shall constitute full compensation for furnishing and placing sand slurry, including excavation, backfill, pumping, end caps, compaction, thrust blocks, (disposal of excess excavated material, pavement removal and replacement, pavement overlay, re-striping, and any appurtenant work as shown on the Plans or called for in the Specifications, complete in place for the unit price. P. CONSTRUCT TRENCH RESTORATION . Bid Item 16. 1. Measurement for payment for construction of trench restoration will be based upon the number of linear feet of such actually placed as determined by measurement along the centerline of such pipe, all in accordance with the requirements of the Contract Documents. 2. Payment for trench restoration will be made at the unit price per linear foot named in the Bid Schedule under Item No. 16, which price shall constitute full compensation for furnishing and placing such trench restoration as shown on Sheet 10 of 20 including excavation, pavement grinding, backfill, compaction, disposal of excess excavated material, pavement removal and replacement, pavement overlay, re-striping, and any appurtenant work as shown on the Plans or called for in the Specifications, complete in place for the unit price. END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01025 - Measurement and Payment - 8 of 8 SECTION 01040 COORDINATION PART 1 - GENERAL 1.1 Work Included A. Licenses, permits, sales taxes, coordination with Owner, Federal, State and Local authorities, utilities, neighboring property owners, special events and other contractors. 1.2 Related Work A. Section 01500: Construction Facilities and Temporary Controls B. Section 01300: Submittals C. City of San Marcos - "San Marcos Boulevard Street Improvement Plans" CIP No. 274. 1.3. Permits A. Obtain, pay for, and comply with required permits, licenses, work permits and authorizations from appropriate agencies, including the following: 1. Licenses a. Before submitting bids, Contractors shall be licensed in accordance with provisions of Chapter 9, Division 3, of the Business and professions Code of the State of California. 2. State and federal permits a. Excavation and Dirt Moving Permit from Cal OSHA b. Safety Permit from California Division of Industrial Safety c. NPDES permit for dewatering 3. Other permits a. Air Pollution Control District b. County of San Diego Health Department c. Vallecitos Water District for Construction Water City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01040 Coordination -1 of 4 4. City Permits The Contractor will obtain for the Project, the following permits: a. Encroachment permits for access to City of San Marcos right-of-way. b. Haul routes from the City of San Marcos and the City of Carlsbad. c. Carlsbad Municipal Water District Connection/shut down permit, (no fee) 1.4 Coordination with Owner A. Notify Owner at least 72 hours before start of construction. B. Submit written details and reasons for proposed deviations from Contract Documents. Do not deviate from contract documents until written authorization is received. C. If Contractor fails to comply with a request of Owner, or is unable to comply with a request, and it is necessary for Owner's forces to do Work that is Contractor's responsibility, Owner will bill Contractor. Each incident requiring work by Owner's forces will be covered by a separate billing. 1.5 Coordination with Carlsbad Municipal Water District A. Contact City of Carlsbad Public Works Department, 72 hours before start of construction at the following location: C/O CITY OF CARLSBAD Construction Management and Inspection Division 5950 El Camino Real Carlsbad, CA 92008 (760) 602-2780 (760) 438-4178 (Fax) B. Do not begin Work until Contractor's schedule, traffic control plans, haul routes, and permits have been reviewed and approved by District. C. Submit a written Request for Shutdown to the Agency seven (7) Working Days in advance of the anticipated shutdown date for any water, sewer, or storm drain facility. In regard to any water or sewer utility, the Water Utility Department must confirm that all necessary materials (valves, piping, appurtenances, etc.) have an approved submittal, have been inventoried and verified by the District Inspector, and are on the jobsite prior to the written Request for Shutdown being submitted. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01040 Coordination - 2 of 4 Do not assume water or sewer lines can be shut down. Do not shut down utilities without prior written authorization. D. Coordinate draining and filling of water lines, and operation of existing valves with District Engineer or appropriate Utility Owner. E. Coordinate with Utility Operations of Public Works regarding time of day that system tie-ins are made. 1.6 Coordination with District. County or State Traffic Engineer A. Coordinate with City, District, County or State Traffic Engineer as required, to perform all portions of the Work. 1.7 Coordination with Property Owners A. Coordinate construction with property owners neighboring project limits, especially with regard to any limitations with access to their property. B. At a minimum, the contractor shall coordinate with concurrent projects in the area such as City of San Marcos projects. 1.8 Coordination with Utilities A. Protect existing underground utilities. The Contractor shall coordinate with all utilities affected by the project to mark-out their locations for potholing and notify utilities of progress during construction so utility field personnel are available when required. SDG&E and San Diego County Water Authority require a standby inspector(s) be present for work near their utilities. The contractor shall be responsible for coordination, payment (if any) and scheduling issues with utilities. B. Electrical utility companies may maintain energized aerial electrical power lines in immediate vicinity of Work. Do not consider these lines to be insulated. Construction personnel working near these lines are exposed to an extreme hazard from electrical shock. Contractors, their employees and construction personnel working on this project must be warned of the danger and instructed to take adequate protective measures, including maintaining a minimum of 10 feet clearance between lines and construction equipment and personnel. (See OSHA Std. 1926.550(A)15). As an additional safety precaution, call electrical utility company to arrange, if possible, to have these lines de-energized or relocated when Work reaches their immediate vicinity. Cost of such temporary arrangements shall be borne by Contractor. C. All demolition of existing facilities or portions there of shall be coordinated and performed by the Contractor. All costs associated with abandonments or demolition shall be borne by the Contractor. D. Contractor shall coordinate and otherwise contract with Vallecitos Water District for furnishing construction water. City of Carlsbad Sari Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01040 Coordination - 3 of 4 1.9 Submittals A. Supplementary progress schedules shall be submitted after Work is in progress, when requested by the Engineer. Schedule changes requiring an increase in Owner's, Servicing Utility's or District's Engineering personnel on project shall not be put into effect until Owner, Servicing Utility, or District has made arrangements for additional personnel. B. The Contractor shall submit a detailed plan and written description of any water facility tie-in. The plan will include, but is not limited to, all necessary pumps, standby pump(s), piping, appurtenances, and 24-hour staffing schedule. When the submittal has been approved, and all necessary testing has been successfully completed, the Contractor will submit a Request for Shutdown seven (7) working days in advance of the anticipated shutdown date. 1.10 Unit Prices A. Payment for obtaining and complying with permits during construction, including NPDES permits, building permits, encroachment permits, excavation permits, drilling permits, disposal permits, temporary easements, licenses, inspection fees, and Federal, State and local taxes will be included in prices bid for Work for which such costs are appurtenant. B. Payment for coordinating with agencies, events and persons described will be included in prices bid for Work to which coordination is appurtenant. PART 2 - PRODUCTS (Not Applicable) PART 3 - EXECUTION (Not Applicable) END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01040 Coordination - 4 of 4 SECTION 01047 CONNECTIONS TO EXISTING FACILITIES PART 1- GENERAL 1.1 SCOPE A. Perform all construction necessary to complete connections and tie-ins to existing facilities under District Supervision. B. Keep existing facilities in operation, unless otherwise specifically permitted in these Specifications or approved by OWNER. C. CONTRACTOR shall perform all construction activities so as to avoid interference with operations of the facility and the work of others. D. CONTRACTOR shall provide potholing for locating and field verifying all existing piping, structures and equipment affected by the Work. All potholing shall be performed by the CONTRACTOR at no additional cost to the OWNER. Delays in the Work, as a result of insufficient potholing, will be solely the CONTRACTORS responsibility. No time extensions will be allowed for Contract Work that is delayed as a result of insufficient potholing and field verification. 1.2 SEQUENCING AND OPERATIONS A. All operation of existing valves required for the Work shall be done by the District. B. Insofar as possible, all equipment shall be tested and in operating condition before the final tie-ins are made to connect equipment to the existing facility. C. CONTRACTOR shall carefully coordinate all Work and schedules and shall provide OWNER written notice before shut-downs or by-passes are required in accordance with Section 01040, 1 .5.C. •1.3 SUBMITTALS A. Submit detailed schedule of proposed connections, listing sequence and durations of all activities including shut-downs and tie-ins. PART 2 - PRODUCTS (Not Applicable) PART 3 - MATERIALS (Not Applicable) END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01047 Connections to Existing Facilities - 1 of 1 SECTION 01048 SPECIAL CONSTRUCTION CONDITIONS AND PROCEDURES - GENERAL PART 1 - GENERAL 1.1 SCOPE A. This section covers special construction conditions and procedures associated with this construction contract. 1.2 REQUIREMENTS COVERED IN OTHER SPECIFICATION SECTIONS A. Section 01011: General Construction Sequence B. Section 01040: Coordination C. Section 01047: Connection to Existing Facilities 1.3 SANITARY ARRANGEMENTS A. The Contractor shall be responsible for providing sanitation facilities for his employees and shall fully comply with the rules and regulations of the State Board of Health and/or other bodies having jurisdiction. B. The Contractor shall, at all times, provide for his employees abundant supply of safe drinking water and shall give orders against the use of, for drinking purposes, any water in the vicinity of the Work known to be unsafe. C. The Contractor shall provide suitable and conveniently located temporary toilets for use by his forces. They shall be left at the site until final inspection has been made. 1.4 NORMAL WORK SCHEDULE A. See Supplemental Provisions Section 6-7.2 "working Day". City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01048 - Special Construction Conditions and Procedures - General -1 of 3 1.6 MITIGATION MEASURES A. The Contractor shall not operate noisy or otherwise irritating construction equipment except during normal working hours as stated above in Section 1.4. B. The Contractor shall employ dust control measures to the satisfaction of the Owner throughout the duration of the project. C. The Contractor shall reopen lanes of traffic with all traffic control devices functioning properly per the traffic control plans. The Contractor shall open traffic lanes by the stated time per Sections 1.4 and shall have completed any required placing of trench plates, sweeping, washdown, as directed by the District and City of San Marcos representatives. D. Contractor shall obtain written permission from the City of San Marcos for the storage of equipment during non-working hours when said equipment is within public right-of-way. Any equipment stored on private property shall be at the property owner's written approval and shall be obtained by the Contractor at no additional cost to the District. 1.7 COOPERATION WITH OTHER CONTRACTORS A. The Owner may have additional work performed in this area by other Contractors. The Contract requires cooperation with those contractors in the area. Any difference or conflict which may arise between the Contractor and other contractors shall be adjusted and determined by the Owner. The Contractor shall conduct his operations as to interfere to the least possible extent with the work being done by other contractors. The Contractor shall make good, promptly, any injury or damage to other contractor's work caused at his hands and at his own expense, and no additional allowance will be made therefore. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01048 - Special Construction Conditions and Procedures - General - 2 of 3 1.8 SITE CLEARANCE A. Contractor to stake southerly ROW boundary as first order of work. All work shall be within public ROW. Protect Landscaping trees and landscaping adjacent to southerly ROW boundary. Trees are currently located on private property and are not anticipated to be moved. Trees will remain inder the ownership of the private property owner. If survey finds trees are encroaching into public ROW the City will notify the property owner to move the trees. B. The Contractor shall restrict his area of activity to avoid damage of trees and shrubs and shall not remove trees unless specifically directed by the contract Plans and Specifications or at the Owner's direction. The Contractor is responsible for the disposal of all material to be removed. If burning is anticipated, the Contractor shall obtain all necessary permits and shall give ample and proper notice to the local fire warden. C. All fences, walls, shrubs, sprinkler systems, substructures or any other improvement removed or disturbed by the Contractor during construction shall be replaced and/or repaired at the Contractor's expense to the satisfaction of the Owner immediately. 1.9 PUBLIC UTILITIES A. Location of utilities shown on the Plans were obtained from maps furnished by the various utility companies, but may not be entirely accurate. The Contractor shall cooperate with the utility companies' representation in the field in order to ascertain the location of the utility lines ahead of potholing and trenching operations. The Contractor shall excavate and expose all utilities crossing the alignment or parallel to it, and within 5 feet from the alignment, prior to the submittal of shop drawings for pipe and fittings, in order that any adjustments to the alignment and/or grade of the proposed work requires modifications or redesign. PART 2 - PRODUCTS (Not Applicable) PART 3 - EXECUTION (Not Applicable) END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01048 - Special Construction Conditions and Procedures - General - 3 of 3 SECTION 01500 CONSTRUCTION FACILITIES AND TEMPORARY CONTROLS PART 1 - GENERAL 1.1 Work Included Mobilization, storage yard, temporary utilities, security, access roads and parking areas, temporary controls and traffic regulation. 1.2 Related Work A. Section 01040: Coordination B. Section 01300: Shop Drawing Submittals C. Section 01700: Contract Closeout D. City of Carlsbad - Supplemental Provisions 1.3 Submittals A. Storage yard description shall describe Contractor's proposed methods for dust and noise control in storage areas to satisfaction of Owner. B. Property owner's written approval of storage yard shall be submitted along with District Planning Department permit for use of property used as storage yard for project. Conform to setbacks and other conditions required by District or County regulations or permits. C. Submit shop drawings and stamped calculations for the trench plates, including details of installation per City of San Marcos' requirements. 1.4 Mobilization A. Obtain temporary easements, which Contractor may require for construction activities outside of existing easements and/or rights of way secured by Owner, at Contractor's expense. B. When using vacant property to park and service and store products, obtain approval from Engineer and permit from District Planning Department. Notify adjacent property owners of this proposed use. Obtain written approval from property owner stating requirements which are a condition of this approval. C. Remove obstruction ".in right-of-way before starting construction. Where private property, such as parked cars, must be removed prior to construction, notify respective property owners 72 hours in advance of right of way clearing to allow them to remove their property. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01500 Construction Facilities and Temporary Controls -1 of 4 1.5 Temporary Utilities A. Construction power shall be purchased or generated on-site for constructing work where existing outlets are not available. B. Construction water shall be clean and free from objectionable deleterious amounts of acids, alkalies, salts, or organic materials. If water is taken through fire hydrants, coordinate and obtain appropriate equipment from the Owner. Contractor shall pay all fees and deposits required. Reserve remaining outlets for use by fire department. Unless otherwise stated, make arrangements to develop water sources, provide backflow protection and supply labor and equipment to collect, load, transport, and apply water as needed for compaction, testing, concrete work, dust control dust, and other construction use. The Contractor shall not draw water from any fire hydrant, except to extinguish a fire, without obtaining permission from the local water purveyor. C. Provide safe drinking water and sanitation facilities on jobsite at all times. D. Construction telephone shall be available at site at all times Work is in progress. Cellular phones are acceptable. 1.6 Construction Aids Trench plates, shoring, scaffolding, rigging, hoisting and services needed to safely deliver and install products shall be provided. Remove same from premises when installation is complete. 1.7 Access Roads and Parking Areas Construct and maintain access or haul roads required for project, and personnel movement into and within construction and excavation areas, subject to prior approval by Owner. Access facilities shall provide for surface drainage. Install and remove earth ramps as needed to protect concrete and asphalt curbs. Areas used for temporary access, haul roads and access from public roads shall be graded and restored to original grade conditions to Owner's satisfaction. Treat access roads and parking areas as needed to control dust and prevent tracking of mud onto paved streets. 1.8 Temporary Controls A. Contractor shall also adhere to the City of Carlsbad's Supplemental Provisions. B. Dust control operations shall prevent construction dust from harming or annoying persons living in or occupying buildings near Work. Use water or dust preventative to control dust. Cover or wet loads of excavated material or rubbish leaving site or of material being imported to prevent blowing dust. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01500 Construction Facilities and Temporary Controls - 2 of 4 C. Noise control shall be done to comply with local noise ordinances. Schedule Work to comply with noise ordinances. Install sound barriers if needed to comply with noise ordinances and Contract Documents. D. Fire danger shall be minimized at and near construction site. Protect surrounding private property from fire damage resulting from construction operations. E. Storm water management operations shall be conducted and maintained as needed to prevent runoff or seepage from entering excavations and to control erosion in conformance with Federal, State and local regulations. F. Any erosion control measures required to meet Federal, State and local regulations shall be designed and provided by the Contractor and included in the contract price for the work. 1.9 Traffic Regulation and Controls A. Contractor shall implement whatever traffic control measures may be required to facilitate the Work of this contract, in accordance with the encroachment permit, the traffic control plans and the direction of the field engineer/inspector, at no additional cost to the Owner than that included in original contract. B. The traffic control devices shall be per the contract documents and the City of Carlsbad's Supplemental Provisions. The bid amount shall include all required equipment and labor to install properly working devices. C. The permanent traffic control devices, such as video detection, advanced loops, etc., shall be per City of Carlsbad's Supplemental Provisions and the City of San Marcos' prior written approval. The pipeline contractor shall be responsible for repair of all advanced traffic loops damaged by the installation of a 30-inch steel transmission main. D. All traffic devices shall be coordinated between the City of San Marcos - "San Marcos Boulevard Widening Improvement Project" and the City of Carlsbad's "San Marco Boulevard 30-inch Water Transmission Main." 1.10 Unit Prices A. Payment for mobilization, demobilization, including payment for construction, modification, maintenance, removal and restoration associated with access, and storage facilities, will be included in the price bid for major items of Work for which mobilization is required. B. Payment for construction surveying and staking will be included in the price bid for items of Work for which alignment or limits must be staked. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01500 Construction Facilities and Temporary Controls - 3 of 4 C. Payment for verification of field dimensions and utility locations will b© included in the price bid for items of Work which may require relocation or refitting if field dimensions differ from those shown on plans. D. Payment for water to be furnished by Contractor for construction use will be included in the price bid for items to which it is appurtenant. Payment under these items will include full compensation for furnishing labor, products, tools and equipment and doing work necessary to develop sufficient water supply and furnishing necessary equipment for applying water as specified. E. Payment for power to be furnished by Contractor for construction use will be included in the price bid for items to which it is appurtenant. Payment under these items will include full compensation for furnishing labor, products, tools, and equipment and doing work necessary to obtain and distribute power for construction purposes. F. Payment for dust control, including dust palliatives and water supply and application will be included in the price bid for items of work for which dust control during construction is appurtenant. G. Payment for costs arising from fire or prevention of fire will be included in the price bid for items of work for which fire protection during construction is needed. H. Payment for noise control facilities will be included in the price bid for items of work where noise control facilities are required during construction. PART 2 - PRODUCTS (Not Applicable) PART 3 - EXECUTION (Not Applicable) END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01500 Construction Facilities and Temporary Controls - 4 of 4 SECTION 01530 PROTECTION OF EXISTING UTILITIES PART 1 - GENERAL 1.1 SCOPE This section addresses verification and protection of existing utilities encountered during the course of construction. 1.2 RELATED WORK A. Section 02225: Utility Crossings B. CMWD Standard Specifications 1.3 DRAWINGS The Consulting Engineer has endeavored to determine the existence of utilities at the site of the work from the records of the owners of known utilities in the vicinity of the work. The positions of these utilities as derived from such records are shown on the Plans. The service connections to these utilities may not be shown on the Plans. PART 2 - PRODUCTS (Not Applicable)- PART 3 - EXECUTION 3.1 CONTRACTOR'S DUTIES Prior to excavating the Contractor shall notify Underground Service Alert. The Contractor shall be responsible for verifying the actual location and elevation of all utilities in the field prior to start of construction by potholing all crossings, connections and parallel utilities which may impact the waterline installations by hand excavation methods. The Contractor shall protect all existing utilities from damage, whether they are shown on the plans or not. The existing utilities are to remain in place and be protected against damage during construction operations. The Contractor shall not interrupt existing utilities except when authorized in writing by the District. If the existing utilities interfere with construction, the Contractor shall submit drawings showing methods, material and sequences of operation for continuing construction and maintaining utility service. The Contractor shall not turn off or shut down any utilities. No additional cost will be accepted nor time extension granted, if a delay in work is caused by failure to comply with this requirement. END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01530 - Protection of Existing Utilities -1 of 1 SECTION 01580 PROJECT IDENTIFICATION AND SIGNS PART 1 - GENERAL 1.1 DESCRIPTION A. Furnish, install and maintain temporary project identification and informational signs. B. The CONTRACTOR will include in the bid the cost to provide, install and maintain, at the worksite, two Project Identification Signs. CONTRACTOR will be required to provide the sign, mount the sign in a manner and location approved by the DISTRICT and return the sign to the DISTRICT upon acceptance of the project by the City. A sign permit, if required, will be obtained by the CONTRACTOR at no cost to the DISTRICT. C. No signs except those specified shall be displayed unless approved by DISTRICT. 1.2 SUBMITTALS A. Submit in accordance with prescribed Shop Drawing procedure. B. Include the following information: 1. Type of grade of materials. 2. Layout, size, trim, framing, supports and coatings. 3. Size and style of lettering. 4. Samples of colors. 1.3 CONSTRUCTION SIGN AGE A. Use %-inch exterior grade plywood unless shown otherwise or approved. B. Use, trim, mitered on all edges. C. Design signs and supports to withstand 75 mile per hour wind. D. Paint with exterior gloss-finish enamel. Sign painter shall be a professional in the type work required. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01580 Project Identification and Signs -1 of 2 E. Provide two (2) 4' x 8' project signs mounted to 4' x 4' posts. Submit detailed shop drawings for approval of verbiage and appearance. As a minimum, the verbiage should contain the City of Carlsbad and City of San Marcos symbol, project name, CIP number and anticipated duration of construction. 1.5 INSTALLATION! AND MAINTENANCE A. Location of signs shall be as directed by the DISTRICT. B. Maintain signs so they are clean, legible and upright. Keep grass and weeds cut away from signs. C. Repair and repaint damaged signs. Relocate signs as required by progress of the Work. D. Remove signs when project is completed or when directed by DISTRICT. 1.6 PAYMENT A. Work is incidental and paid for within various bid items. PART 2 - PRODUCTS (Not Applicable) PART 3 - EXECUTION (Not Applicable) END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01580 Project Identification and Signs - 2 of 2 SECTION 01600 MATERIAL AND EQUIPMENT PART 1 - GENERAL 1.1 Work Included Transportation and handling, storage and protection, acceptable manufacturers, and' procedures for seeking substitutions. 1.2 Related Work A. Section 01300: Shop Drawing Submittals B. Section 01700: Contract Closeout 1.3 Submittals Supplemental information, including certification of compliance, transcripts of acceptance tests, samples, names and addresses of nearest local representatives and list of three installations, shall be submitted at Owner's request for product substitutions. 1.4 Quality Assurance If products are furnished which differ from those shown and which require changes to enclosures, mounting and support structures, power and control circuitry or other work to accommodate furnished product, provide changes required at no additional cost to Owner and of same quality as shown. 1.5 Delivery. Storage and Handling Deliver products to jobsite in manufacturer's original, unopened, labeled packaging. Construction working hours shall be followed for product deliveries. Not deliveries shall be made within the public right-of-way during non-approved time durations as indicated as indicated in Section 01048. Oil lubricated gearing, bearings and other lubricated components shall be shipped with oil soluble protective coating as described in warranty requirements or recommended by manufacturer. Coating shall provide protection for one year after final acceptance. Protect products against moisture, temperature extremes, dust, debris, tampering, vandalism, ultraviolet radiation, or damage from improper handling, storage, or exposure. Protect exposed metals from rust and corrosion even though they will be sandblasted or otherwise cleaned before painting. Clean and protect machined surfaces and shafting from corrosion using proper type and amount of coating as described in warranty requirements to assure protection to one year after final acceptance. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01600 - Material and Equipment -1 of 2 Store items not designed for outdoor exposure off ground and under cover. Handle products with care and using proper equipment according to manufacturer's recommendations. Lift large heavy items only at points designated by manufacturer. Do not drop, drag, bump or handle products in manner that causes bruises, cracks, scratches or other damage. Use padded slings and hooks for lifting as needed to prevent damage. Improper handling shall be cause to reject mishandled products. Inspect each product item for damage, defects, completeness and correct operation before installing. Notify Owner in writing if delivered or stored product is damaged. Do not repair damaged products without prior written approval. Maintain records for Owner's review of deliveries to show Contractor's order number, purchase order number and equipment number. Include labeling or shipping tag in records. / PART 2 - PRODUCTS 2.1 Acceptable Manufacturers Products of listed acceptable manufacturers shall meet specifications notwithstanding the fact that manufacturer is "listed". Owner reserves right to reject submittals and products from "acceptable manufacturers" if they fail to demonstrate compliance with specifications. 2.2 Materials and Equipment Materials and materials sources shall be approved by Owner at least three days before use of materials in Work. Similar items on project shall be products of same manufacturer. Corresponding parts of identical products shall be interchangeable. Mating ends of pipe shall match. Design and fabrication of products shall ensure products withstand stresses and loads which may occur during testing, installation, start-up and normal operation. Furnish mounts, guides, bearing plates, flanges, anchor and attachment bolts and screws, saddles, supports, pads and skids necessary to securely mount products and equipment. PART 3 - EXECUTION (Not Applicable) END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01600-Material and Equipment-2 of 2 SECTION 01700 CONTRACT CLOSEOUT PART 1 - GENERAL 1.1 Work Included Specific administrative procedures, closeout submittals, and forms to be used at substantial completion and final completion of Work, and project record documents. 1.2 Related Work A. Section 01300: Shop Drawing Submittals B. Section 01410: Testing and Inspection of Earthwork and Concrete C. Section 01710: Cleaning and Final Cleaning 1.3 Quality Assurance Upon completion of Contract, Work shall be finished, tested and ready for operation. Work shall fulfill its intended purpose as described in Contract Documents, in submittals, and in manufacturer's literature. Where connections or disruptions have been made to existing work, repair, reactivate, refill and recharge components, restoring them to preconstruction conditions. Follow procedures of authorities having Ownership or jurisdiction for work involving existing utilities and services. 1.4 Project Record Documents Final record drawings shall be prepared from survey notes, field notes and system demonstration logs and shall be submitted in ink on sepia mylar prints bearing seal of registered land surveyor who performed survey for record drawings. Note hydraulic and electric equipment control settings used for system demonstration on record drawings. Record changes neatly and accurately using 1/8-inch size lettering and dimensions. Monument survey showing record locations of monuments or benchmarks disturbed and reset by Contractor shall be sealed by surveyorand submitted to Owner. 1.5 Unit Prices Payment for record drawings required in Contract Documents is incidental and paid for within various bid items. City of Cartsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01700 - Contract Closeout - 1 of 2 1.6 Warranty Warranties shall cover improper assembly or erection, defective workmanship and products, and incorrect or inadequate operation. For equipment bearing manufacturer's warranty in excess of one year, furnish copy of warranty to Owner named as beneficiary. PART 2 - PRODUCTS (Not Applicable) PART 3 - EXECUTION 3.1 Adjusting and Cleaning Valve box cover elevations are not shown on drawings. Determine and set cover elevations in field so that finished rim elevations are flush with finished pavement where directed by Owner's Representative. 3.2 Extra Stock/Spare Parts Spare parts required shall be delivered in manufacturer's original containers labeled to completely describe contents and equipment for which it is furnished. END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01700 - Contract Closeout - 2 of 2 SECTION 01710 CLEANING AND FINAL CLEANING PART 1 -GENERAL 1.1 Work Included Cleaning during construction and final cleaning on completion of the Work. Provisons noted in Section 7-8 of the supplemental provisions. 1.2 Cleaning During Construction Maintain areas covered by Contract, adjacent properties, and public access roads. Keep these areas free from waste, debris and rubbish caused by construction. Conduct cleaning and disposal to comply with local ordinances and antipollution laws. Do not burn or bury rubbish and waste materials on project site. Do not dispose of volatile wastes, such as mineral spirits, oil or paint thinner, in storm or sanitary drains. Do not dispose of wastes into streams or waterways. Use only cleaning materials recommended by manufacturer of surface to be cleaned. Wet down dry materials and rubbish to prevent blowing dust. Provide containers for collection and disposal of waste materials, debris and rubbish. Clean public access roads to site. Remove material falling from haul trucks. 1.3 Final Cleaning Restore construction areas to preconstruction conditions after completing of Work and immediately before final inspection. Restore lines and grades of areas used for earthwork storage. Clean, sweep, and wash Work and equipment including finishes. Remove grease, dust, dirt, stains, labels, fingerprints and foreign materials from sight- exposed interior and exterior finished surfaces. Polish surfaces so designated. Repair, patch and touch up marred surfaces to specified finish to match adjacent surfaces. Broom-clean paved surfaces. Rake-clean other surfaces of grounds. Remove from Owner's property temporary structures and materials, equipment and appurtenances not required as part of, or appurtenant to, completed Work. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01710 - Cleaning and Final Cleaning -1 of 2 After Work is complete, remove from site loose concrete, lumber, wire, aggregate or rock piles, reinforcing, rubbish, debris and materials not incorporated in Work. Remove excess pointing mortar materials and other debris within pipes. 1.4 Unit Prices Payment for cleaning will be included in items of Work to which cleaning is appurtenant. PART 2 - PRODUCTS (Not Applicable) PART 3 - EXECUTION (Not Applicable) END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01710 - Cleaning and Final Cleaning - 2 of 2 SECTION 01720 RECORD DRAWINGS PART 1 - SCOPE 1.1 General Requirements Contractor shall keep accurate and legible records on a single set of full size project blueline prints of the Drawings. Make the record drawings available for review by Owner in Contractor's field office. Maintain record drawings on an up-to-date basis with all entries reviewed by Resident Engineer. Protect the record set from damage or loss. 1.2 Detailed Requirements The Contractor shall provide Record Drawings which shall clearly show all differences between the contract Work as drawn and as installed for all concealed construction, as well as construction added to the Contract which is not indicated on the Contract Drawings. Concealed shall mean construction installed underground or in an area which cannot be readily inspected by use of access panels, inspection plates or other removable features. Show all changes in the Work, or Work added on the Record Drawings in a contrasting color. In showing changes in the Work, or added Work, use the same legends that are used on the Contract Drawings. Indicate exact locations by dimensions and exact elevations. Give dimensions from a permanent point. Record by marking on the Drawings all changes in the Work which occur during construction, including adding approved change orders. Show locations by key dimensions, depths, elevations of all underground lines, conduit runs, sensor lines, valves, capped ends, branch fittings, pull boxes, etc. Record information on how to maintain and/or service concealed Work. Make a record of finalized hydraulic and electrical equipment control settings in the tables and spaces provided on the Drawings. PART 2 - PRODUCTS (Not Applicable) City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01720 - Record Drawings -1 of 2 PART 3-EXECUTION 3.1 General Deliver the marked record set of Drawings to the Owner prior to acceptance of the Work. END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 01720 - Record Drawings - 2 of 2 SECTION 02130 REMOVAL AND RESURFACING OF PAVEMENT SURFACES PART 1- GENERAL 1.1 Description Street pavement and surfaces shall be removed and replaced in all areas of construction excavation in conformance with details shown on the Plans and/or as specified herein. Resurfacing of existing pavement and surfaces damaged or removed in connection with the construction of project improvements including all appurtenances, shall conform to the provisions of permits issued by the local governing body, agency or association having jurisdiction of public and private streets for work performed within the rights-of-way of the respective governing body, agency or association. 1.2 Related Work Described Elsewhere The Contractor shall refer to the following Specification section(s) for additional requirements: A. Asphaltic Concrete Pavement: City of Carlsbad - Supplement Part 2 1.3 Submittals Submittals shall be provided as required in the related section(s) of the Specifications for the appropriate material. 1.4 Payment Payment for the Work in this section shall be included as part of the lump sum or unit-price bid amount for which such Work is appurtenant thereto. PART 2 - MATERIALS AND EXECUTION 2.1 Earthwork Earthwork shall conform to the provisions of the City of Carlsbad - Supplement Part 2 and Section 02223, Trenching, Excavation, Backfilling and Compacting. 2.2 Pavement Removal A. General: Street pavement or existing road surfacing shall be removed within the limits of all construction excavations prior to proceeding with excavation operations of any nature. Surplus material shall be removed as specified in the Specifications. Prior to removal of existing surfacing, pavement cuts for pipelines shall be made as shown on the Plans and/or specified herein. All pavement cuts for pipelines shall be neat and straight along both sides of the trench and parallel to the alignment of the pipe to provide an unfractured and level pavement joint for City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 02130 - Removal and Resurfacing of Pavement Surfaces -1 of 4 bonding existing surfacing with pavement replacement. Where large irregular surfaces are removed, such trimming or cutting as hereinafter provided shall be parallel with roadway centerline or at right angles to the same. All cut edges shall provide clean, solid vertical faces free from all loose material. B. Portland Cement Concrete Surfaces: Concrete pavement, including cross gutters, curbs and gutters, sidewalks, driveways, and concrete surfaces of whatever nature, shall be saw cut to a minimum depth of 21/a-inches prior to removal in accordance with details shown on the Plans or as specified herein. Said saw cut shall be made at the edge of the trench and/or excavation. With the written permission of the Owner's Representative pneumatic tools or other approved equipment may be used to cut concrete pavement prior to removal at the limits of the excavation. In such an event, the saw cut as provided herein, shall be made after backfilling, and the additional concrete pavement shall be removed and disposed of by the Contractor prior to resurfacing. C. Plant Mix Surfacing (Asphalt Concrete Pavement): Streets, alleys and areas surfaced with asphalt concrete pavement shall be initially cut by means of pneumatic pavement cutters or other approved equipment at the limits of the trench and/or excavation prior to removal of surfacing. Pavement saw-cutting will be required within the right-of-way of the county roads and highways, or as required by local governing bodies. D. Road-Mixed Surfacing: Streets, alleys and areas surfaced with road-mixed surfacing shall be cut at the limits of the trench and/or excavation prior to removal of existing surfacing. Cuts may be made with pneumatic tools or other approved equipment. The extra trimming width by saw cuts prior to resurfacing will not be required unless otherwise specified. 2.3 Asphalt Concrete Resurfacing In all areas in which the surface is removed, broken, or damaged by equipment, or in which the ground has caved in or settled due to the installation of the improvements, the surface shall be restored to the original grade and crown section by the Contractor at his own expense. In the absence of specific designation on the Plans, and where the street has been improved with roadway surface, base course, curb, sidewalk or gutter, trenches, or damaged sections shall be restored with the type of improvement conforming to that which existed at the time the Contractor entered upon the Work. Prior to resurfacing, the existing surfacing shall be removed as provided above. All Work shall match the appearance of the existing improvements and finished pavement shall not deviate from existing grade by more than 1/8- inch in 10-feet and shall be free from ruts, depressions, and irregularities. Where large irregular surfaces are to be resurfaced, existing surfacing shall be cut and removed as provided herein. Asphaltic emulsion shall be applied to the vertical faces of all asphaltic concrete pavement against which the pavement replacement materials are to be placed. The completed surface, when ready for acceptance, shall be thoroughly compacted, true to grade and cross section, and shall be free from ruts, depressions, and irregularities. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 02130 - Removal and Resurfacing of Pavement Surfaces - 2 of 4 Asphalt pavement shall be replaced 1-inch thicker than that removed. Aggregate base shall be a minimum of 4-inches thick. The trench section shall be lapped at least 12-inches on each side and shall be hand raked so that the lapped section will feather-in smoothly with the existing pavement. The resulting edge of contact between the new and existing pavement on each side shall parallel the existing trench and be a straight and neat join line. 2.4 Resurfacing of Concrete Surfaces Portland concrete cement pavement surfaces shall be replaced in kind, with an aggregate base layer 8-inches minimum thickness. Minimum thickness of concrete pavement shall be equal to that removed. Portland cement concrete sidewalks shall be replaced to the nearest scoreline or over a sufficient width to replace any portions of the sidewalk damaged, fragmented, cracked, or otherwise made unusable as a result of construction operations. Minimum thickness of concrete shall be 4-inches. 2.5 Portland Cement Concrete Portland cement concrete shall be Class B and shall conform to Section 40 of the State Standard Specifications and the Specifications. Concrete shall be placed over the width of the excavated trench where the edge of the trench is more than 2-feet from the edge of an existing concrete excavation and is within 2^feet of the existing gutter. 2.6 Temporary Paving All pavement removal for trenching operations shall be replaced with 2-inches of temporary paving mix after compaction is approved by the Owner's Representative or within three days after the installation of the pipe, whichever comes first. The temporary patch shall conform to the City of San Marcos' requirements. Cross streets and all accesses shall be paved with temporary pavement on the same day that excavation is made. Temporary pavement shall be maintained so that a smooth traversable surface is available at all times for vehicular traffic, free from ruts, depressions, holes, and loose gravel. Cost for temporary paving shall be included in the contract unit prices for the Work, and no extra compensation will be made to the Contractor. PART 3 - EXECUTION 3.1 Removal and Re-Paving A. All asphalt pavement removal and re-paving shall be in accordance with the City of Carlsbad's and the City of San Marcos' guidelines, and shall include sawcut, grinding, compaction and placement as indicated in the standard guidelines. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 02130 - Removal and Resurfacing of Pavement Surfaces - 3 of 4 B. Sawcut or edge of trench patches shall not be located where typical wheel tracking occur. Any excess excavation, grinding and patch required shall be included in the bid price. END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 02130-Removal and Resurfacing of Pavement Surfaces-4 of 4 SECTION 02223 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING PART1 GENERAL 1.01 DESCRIPTION This section includes materials, testing, and installation for trench excavation, backfill, and compaction of piping, conduit, manholes, and vaults. 1.02 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. ASTM C 131 - Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM C 150 - Portland Cement ASTM D 75 - Practice for Sampling Aggregates ASTM 1556 - Test Method for Density and Unit Weight of Soil in Place by the Sand-Cone method ASTM D 1557 - Test Method for Moisture-Density Relations of Soils Using a Modified Effort ASTM D 2419 - Test Method for Sand Equivalent Values of Soil and Fine Aggregate ASTM D 3017 - Test Method for Water Content of Soil and Rock in Place by Nuclear Methods ASTM D 3776 - Test Method for Mass Per Unit Area (Weight) of Woven Fabric ASTM D 4253 - Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Plate ASTM D 4254 - Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density ASTM D 4632 - Test Method for Grab Breaking Load and Elongation of Geotextiles ASTM D 4751 - Test Method for Determining the Apparent Opening Size of a Geotextile CAL-OSHA - Title 8 General Industry Safety Orders 1.03 RELATED WORK SPECIFIED ELSEWHERE Standard Specifications 15000, 15044,15056,15061 and 15064. 1.04 GEOTECHNICAL TESTING The Developer or Contractor shall engage the services of a geotechnical engineering firm or individual licensed in the State of California to monitor soil conditions during earthwork, trenching, bedding, backfill, and compaction operations. Sampling and testing procedures shall be performed in accordance with the Reference Standards and as follows: A. The soils technician shall be present at the site during all backfill and compaction operations. Failure to have the soils technician present will subject such operations to rejection. JUNE 2004 Page 1 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting B. Density and optimum moisture content of soil shall be determined by the use of the sand cone method, ASTM D 1556, or nuclear density gauge method, ASTM D 2922 & D 3O17. Since the composition of the pipe and the walls of the trench have an effect on the nuclear density gauge output, a minimum of 25% of the density and optimum moisture tests shall be made using the sand cone method. C. Determine laboratory moisture-density relations of existing soil by ASTM D 1557, Method C and/or D. D. Determine the relative density of cohesion less soils by ASTM D 1557, Method C and/or D. E. Sample backfill material by ASTM D 75. F. Express "relative compaction" as a percentage of the ratio of the in-place dry density to the laboratory maximum dry density. A report of all soils tests performed shall be stamped and signed by the soils firm or individual and shall be submitted by the Contractor prior to the filling of the Notice of Completion by the District. The report shall document the sampling and testing of materials, the location and results of all tests performed, and shall certify that materials and work are in compliance with this specification. 1.05 PIPE ZONE The pipe zone includes the full-width of the trench from 6-inches below the bottom of the pipe to 12-inches above the top of the pipe and extends into manhole or vault excavations to the point of connection to or penetration of such structure. 1.06 TRENCH ZONE The trench zone includes the portion of the trench from the top of the pipe zone to the bottom of the pavement zone in paved areas, or to the existing surface in unpaved areas, and extends into manhole or vault excavations above the pipe zone. 1.07 PAVEMENT ZONE The pavement zone includes the concrete or asphalt concrete pavement and aggregate base section placed over the trench zone and extends into manhole or vault excavations above the trench zone. 1.08 PROTECTION OF EXISTING UTILITIES AND FACILITIES The Contractor shall be responsible for the care and protection of all existing utilities, facilities, and structures that may be encountered in or near the area of the work in accordance with Section 01000. JUNE 2004 Page 2 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting 1.09 PROTECTION OF EXISTING LANDSCAPING The Contractor shall be responsible for the protection of all the trees, shrubs, fences, and other landscape items adjacent to or within the work area in accordance with Section 01000. 1.10 ACCESS The Contractor shall provide continuous, unobstructed access to all driveways, water valves, hydrants, or other property or facilities within or adjacent to the work areas. 1.11 SAFETY A. Protection of workers within trenches shall be as required by the California Labor Code and in accordance with Section 01000. B. All excavations shall be performed in a safe manner and shall be protected and supported in accordance with CAL-OSHA regulations. C. Barriers and traffic delineators shall be placed in accordance with the requirements of the agency having jurisdiction. 1.12 BLASTING Blasting for excavation shall not be performed without the written permission of the District Procedures and methods of blasting shall conform to all Federal, State, and local laws and ordinances. 1.13 PIPE JACKING Pipe jacking may be permitted in accordance with Section 15125. District approval is required in advance of such operations. 1.14 EXCESS EXCAVATED MATERIAL A. The Contractor shall remove and legally dispose of all excess excavated material and demolition debris. B. It is the intent of these specifications that all surplus material shall be legally disposed of by the Contractor. Before acceptance of the work by District, the Contractor shall provide the District with written releases signed by all property owners with whom the Contractor has entered into agreements for disposing of excess excavated material, absolving the District from any liability connected therewith. 1.15 CHANGES IN LINE AND GRADE In the event obstructions not shown on the plans are encountered during the progress of the work, and which will require alterations to the plans, the Engineer shall have the authority to change the plans and order the necessary deviation from the line and grade, in accordance with Section 01000. The Contractor shall not deviate from the specified line and grade without prior written approval by the District. JUNE 2004 Page 3 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting 1.16 HYDROSTATIC TESTING Pre-testing of the piping system may be performed for the Contractor's convenience at any time. However, the final hydrostatic pressure test, as described in Section 15044, shall be performed following the completion of all backfilling and trench zone compaction with a minimum of 2.5-feet of material over the pipe. PART 2 MATERIALS 2.01 GENERAL The Contractor shall furnish backfill material as specified below. All materials used in and above the pipe zone shall be capable of attaining the required relative density. 2.02 IMPORTED GRANULAR MATERIAL - PIPE ZONE Imported Granular Material shall be used within the Pipe Zone for installations of PVC Pressure Pipe, Ductile-Iron Pipe, Cement-Mortar Coated Steel Pipe, Tape-Wrapped Steel Pipe, and Paint-Coated Pipe. The Imported Granular Material shall be quarry waste (decomposed granite) free from organic matter. Material shall have a sand equivalent value of not less than 30 per ASTM D 2419, a coefficient of uniformity of 3 or greater, and shall conform to the following gradation: U.S.Standard Sieve Size : 1-Inch 3/4-Inch No. 4 No. 30 No. 200 Percent! passing by Weight 100 90-100 50-95 25-45 3-9 Native materials may not be used in lieu of Imported Granular Material unless such materials meet all of the requirements specified above. 2.03 CRUSHED ROCK - PIPE ZONE Crushed Rock shall be used in the Pipe Zone on PVC Gravity Sewer Pipe. Crushed rock shall be clean, crushed stone free of organic matter. Crushed rock shall be certified to contain less than 1% asbestos by weight or volume and shall conform to the following gradation and requirements: ••"'' U.S. Standard Sieve Size " 1-Inch 3/4-Inch 1/2-Inch 3/8-Inch No. 4 No. 8 ASTM C 131 Testing Grade Percent Passing by Weight 100 90-100 30-60 0-20 0-5 — B JUNE 2004 Page 4 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting wfesf '.h'.ifV',"] ?Ff~ .'*• Percentage Wear 100 Revolutions 500 Revolutions Test §ethod Ht;* --5^ ASTMC 131 — ... Requirement'4 •"- *** -1* — 15 Maximum 52 Maximum 2.04 TRENCH PLUGS Trench plugs consisting of compacted Imported Granular Material or sand cement slurry shall be installed on piping systems that are backfilled with crushed rock. 2.05 IMPORTED GRANULAR MATERIAL - TRENCH ZONE Imported Granular Material shall be used within the Trench Zone for installations of PVC Pressure Pipe, Ductile-Iron Pipe, Cement-Mortar Coated Steel Pipe, Tape-Wrapped Steel Pipe, and Paint-Coated Pipe. Imported Granular Material for use within the trench zone shall conform in all ways to Imported Granular Material specified for use within the pipe zone. Native materials may not be used in lieu of Imported Granular Material within the trench zone unless such materials meet all of the requirements specified for Imported Granular Material within the pipe zone. 2.06 SAND-CEMENT SLURRY Sand-cement slurry shall consist of two sacks, 188 pounds, of Portland cement per cubic yard of sand and sufficient moisture for workability. District approval is required for use of slurry as a backfill material. 2.07 FILTER FABRIC Filter fabric shall be manufactured from polyester, nylon, or polypropylene. Material shall be of non-woven construction and shall meet the following requirements: Grab tensile strength (ASTM D 4632): 100 Ibs. minimum for a 1 -inch raveled strip Weight (ASTM D 3776): 4.5 oz./yd2) Apparent opening size (ASTM D 4751): 0.006-inch PART 3 EXECUTION 3.01 CLEARING AND GRUBBING A. Areas where work is to be performed shall be cleared of all trees, shrubs, rubbish, and other objectionable material of any kind, which, if left in place, would interfere with the proper performance or completion of the completed work, would impair its subsequent use, or would form obstructions therein. B. Organic material from clearing and grubbing operations will not be incorporated in the trench backfill and shall be removed from the project site or retained and incorporated into the topsoil. JUNE 2004 Page 5 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting 3.02 PAVEMENT, CURB, AND SIDEWALK REMOVAL Bituminous or concrete pavements, curbs, and sidewalks shall be removed and replaced in accordance with the requirements of the agency having jurisdiction. 3.03 DEWATERING A. The Contractor shall provide and maintain at all times during construction ample means and devices to promptly remove and dispose of all water from any source entering excavations or other parts of the work. Dewatering shall be performed by methods that will ensure a dry excavation and preservation of the final lines and grades of the bottoms of excavations. Dewatering methods may include well points, sump points, suitable rock or gravel placed as pipe bedding for drainage and pumping, temporary pipelines, or other means, all subject to the approval of the District. The cost of all dewatering activities shall be borne by the Developer or Contractor. B. Sewer systems shall not be used as drains for dewatering trenches or excavations, nor for disposal of collected or accumulated groundcover, without the approval of the agency of jurisdiction. C. Concrete shall not be poured in water, nor shall water be allowed to rise around concrete or mortar until it has set at least four hours. D. The Contractor is responsible for meeting all Federal, State, and local laws, rules, and regulations regarding the treatment and disposal of water from dewatering operations at the construction site. 3.04 SHORING AND SHIELDING A. The Contractor's design and installation of shoring shall be consistent with the rules, orders, and regulations of CAL-OSHA. B. Excavations shall be shored, sheeted, and supported such that the walls of the excavation will not slide or settle and all existing improvements of any kind, either on public or private property, will be fully protected from damage. C. The sheeting and shoring shall be arranged so as not to place any stress on portions of the completed work until the general construction has proceeded far enough to provide ample strength. D. Care shall be exercised in the moving or removal of trench shields, sheeting, and shoring to prevent the caving or collapse of the excavation faces being supported. 3.05 CORRECTION OF OVEREXCAVATION Over-excavations shall be corrected by backfilling with approved imported granular material or crushed rock, compacted to 90% relative compaction, as directed by the District. JUNE 2004 Page 6 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting 3.06 FOUNDATION STABILIZATION A. When unsuitable soil materials are encountered, the unsuitable material shall be removed to the depth determined necessary in the field by the Soils Technician, and as acceptable to the District. The sub-grade shall be restored with compacted Imported Granular Material or crushed rock as recommended by the Soils Technician. Place the appropriate bedding or base material on this restored foundation. B. When rock encroachment is encountered, the rock shall be removed to a point below the intended trench or excavation sub-grade as determined necessary in the field by the Soils Technician, and as acceptable to the District. The sub-grade shall be restored with compacted Imported Granular Material as recommended by the Soils Technician. Place the appropriate bedding or base material on this restored foundation. C. When excessively wet, soft, spongy, or similarly unstable material is encountered at the surface upon which the bedding or base material is to be placed, the unsuitable material shall be removed to the depth determined necessary in the field by the Soils Technician, and as acceptable to the District. Restore the trench with crushed rock enclosed in filter fabric as directed by the Engineer. Larger size rocks, up to 3-inches, with appropriate gradation, may be used if recommended by the Soils Technician. Place the appropriate bedding or base material on this restored foundation. 3.07 TRENCH EXCAVATION AND PLACEMENT OF BEDDING A. Excavate the trench to the lines and grades shown on the drawings with allowance for 6-inches of pipe bedding material. The trench section shall be as shown on the Standard Drawings. B. The maximum length of open trench shall be 500-feet except by permission of the District, City, or County. The distance is the collective length at any location, including open excavation and pipe laying, which has not been backfilled to the elevation of the surrounding gate. C. Trench walls shall be sloped or shored per the requirements of CAL-OSHA. D. The trench bottom shall be graded to provide a smooth, firm, and stable foundation that is free from rocks and other obstructions. E. Place the specified thickness of bedding material over the full width of the trench. Grade the top of the pipe base ahead of the pipe laying to provide a firm, uniform support along the full length of pipe. F. Excavate bell holes at each joint to permit proper assembly and inspection of the entire joint. G. Trenches for main pipelines and all appurtenances shall be backfilled with the materials and methods as specified for the Pipe Zone, Trench Zone, and Pavement Zone. H. Trench widths shall be in accordance with the Standard Drawings. JUNE 2004 Page 7 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting Trench depth shall be as required to install pipelines in accordance with the Approved Plans and these Standard Specifications. Unless shown otherwise in the Approved Plans, the minimum cover for pipelines shall be as follows: Pipeline Application Potable Water Recycled Water Sewer Minimum Cover Required ' 36-inches 48-inches 60-inches 3.08 MANHOLE AND VAULTS A. The Contractor shall prepare an excavation large enough to accommodate the structure and permit grouting of openings and backfilling operations. The walls of the excavation shall be sloped or shored per the requirements of CAL-OSHA. B. Manholes and vaults shall be placed at the location and elevation shown on the plans, on undisturbed soils and 6-inches of compacted crushed rock base. C. Manhole and vault excavations shall be backfilled with the materials and methods as specified for the Pipe Zone, Trench Zone, and Pavement Zone. 3.09 COMPACTION REQUIREMENTS A. Compaction shall be accomplished by mechanical means. Consolidation by water settling methods such as jetting or flooding is prohibited. B. If the backfill fails to meet the specified relative compaction requirements, the backfill shall be reworked until the requirements are met. All necessary excavations for density tests shall be made as directed by the Soils Technician, and as acceptable to the Engineer. The requirements of the Agency having jurisdiction shall prevail on all public roads. C. Compaction tests shall be performed at random depths, and at random intervals not to exceed 150-feet, as directed by the Soils Technician or District. D. Relative compaction shall be determined by the impact or field compaction test made in accordance with ASTM D 1557 Procedure C. E. Unless otherwise shown on the drawings or otherwise described in the specifications for the particular type of pipe installed, relative compaction, in pipe trenches shall be as follows: 1. Pipe zone - 90% relative compaction. 2. Trench zone - 90% relative compaction. 3. Structural section in paved areas - per agency requirements, 95% minimum. 4. Imported Granular Material for over excavation or foundation stabilization - 90% relative density. F. All excavations are subject to compaction tests. JUNE 2004 Page 8 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting 3.10 TRENCH PLUGS Trench plugs shall be installed at 200-foot intervals along the entire length of piping systems. Trench plugs shall be 10-feet in length and shall encompass the entire pipe zone. Additional trench plugs may be required as directed by the Engineer. 3.11 PIPE ZONE BACKFILL A. Care shall be taken in placing the imported granular backfill material simultaneously around the main pipeline and appurtenance pipes so that the pipe barrel is completely supported and that no voids or uncompacted areas are left beneath the pipe or on the sides of the pipe. Care shall be taken to place material simultaneously on both sides of the pipe to prevent lateral movement. This area shall be mechanically compacted to attain 90% relative density. Care shall be taken when compacting appurtenance laterals 2-inches and smaller to prevent the crushing or denting of the copper lateral. Additional lifts of 12-inches or less thickness may be required on 16-inch or larger diameter pipe to attain complete support of the haunch area. Soils tests may be taken on this layer or backfill. B. After the spring line backfill has been approved by the Soils Technician, backfill of the remainder of the Pipe Zone may proceed. Do not drop sharp, heavy pieces of material directly onto the pipe or the tamped material around the pipe. C. Place and compact the imported granular material at a maximum of 12-inch lifts. Compact all material placed in the Pipe Zone by mechanical methods. Sand cone tests shall be taken on this layer of backfill. D. The use of a backhoe mounted compaction wheel is prohibited within the pipe zone to 12-inches above the top of the pipe. E. ' Under no circumstances shall consolidation by water settling or water-setting methods (i.e., jetting, diking, etc.) be permitted. 3.12 TRENCH ZONE BACKFILL A. After the Pipe Zone material has been placed, compacted, approved by the Soil Technician, and accepted by the District, backfill in the Trench Zone may proceed. B. Compaction using vibratory equipment, tamping rollers, pneumatic tire rollers, or other mechanical tampers shall be performed with the type and size of equipment necessary to accomplish the work. The backfill shall be placed in horizontal layers of such depths as are considered proper for the type of compacting equipment being used in relation to the backfill material being placed. Each layer shall be evenly spread, properly moistened, and compacted to the specified relative density. The Contractor shall repair or replace any pipe, fitting, manhole, or structure damaged by the installation operations as directed by the District. 3.13 PAVEMENT ZONE BACKFILL AND RESTORATION A. After the Trench Zone material has been placed, compacted, approved by the Soil Technician, and accepted by the District, backfill in the Pavement Zone may proceed as necessary in accordance with the requirements of the agency having jurisdiction. B. Replace bituminous and concrete pavement, curbs, and sidewalks removed or damaged during construction in accordance with the requirements of the agency having jurisdiction. END OF SECTION JUNE 2004 Page 9 of 9 SECTION 02223 Trenching, Excavation, Backfilling, and Compacting SECTION 03000 CAST-IN-PLACE CONCRETE PART1 GENERAL 1.01 DESCRIPTION This section describes materials and methods for formwork, reinforcement, mixing, placement, curing and repairs of concrete, and the use of cementitious materials and other related products. This section includes concrete, mortar, grout, reinforcement, thrust and anchor blocks, valve support blocks, and manhole bases. 1.02 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. ASTMA185 - Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement ASTM A 615/A 615M - Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement ASTM C 150 - Specification for Portland Cement ASTM C 494 - Specification for Chemical Admixtures for Concrete ASTM C 881 - Specification for Epoxy-Resin-Base Bonding Systems for Concrete CRSI - Recommended Practice for Placing Reinforcing Bars SSPWC - Standard Specifications for Public Works Construction "Greenbook" 1.03 RELATED WORK SPECIFIED ELSEWHERE Standard Specifications 02223,15000, 15041, 15044, 15056, 15061, 15064, 15074, 15102, 15108 and 16640. 1.04 APPLICATIONS The following materials, referenced in other sections, shall be provided and installed in accordance with this specification for the applications noted below: A. Concrete for thrust and anchor blocks for horizontal and vertical bends, ductile-iron or steel fittings, fire hydrant bury ells, and support blocks for valves 4-inches and larger, all in accordance with the Standard Drawings. B. Concrete for collars, cradles, curbs, encasements, gutters, manhole bases, protection posts, sidewalks, splash pads, and other miscellaneous cast-in-place items. C. Mortar for filling and finishing the joints between manhole and vault sections and setting manhole grade rings and cover frames. Mortar may also be used for repairs of minor surface defects of no more than H-inch in depth of Va-inch in width on non-structural, cast-in-place items such as splash pads or concrete rings around manholes. (Note that large voids, structural concrete and pipe penetrations into vaults shall be repaired with non-shrink grout; repairs to precast manholes and vaults and cast-in-place manhole bases shall be repaired with an epoxy bonding agent and repair mortar, as outlined below). JUNE 2004 Page 1 of 9 SECTION 03000 Cast-ln-Place Concrete D. Epoxy bonding agent for bonding repair mortar to concrete on repairs to damaged surfaces to precast or cast-in-place concrete manoles and vaults. E. Repair mortar for repair to damaged surfaces of precast or cast-in-place concrete manholes and vaults. An epoxy bonding agent shall be used in conjunction with repair mortar. F. Non-shrink grout for general purposes repair of large construction voids, pipe penetrations into vaults and grouting of base plates for equipment or structural members. G. Epoxy adhesives for grouting of anchor bolts. H. Protective epoxy coating for application to reinforcing steel with existing concrete structures exposed during construction. I. Damp-proofing for application to the exterior surfaces of concrete manholes and vaults located at or below the water table or where showing evidence of moisture or seepage, and as directed by the Engineer. 1.05 DELIVERY, STORAGE, AND HANDLING Deliver reinforcing steel to the site bundled and tagged with identification. Store on skids to keep bars clean and free of mud and debris. If contaminated, all bars shall be cleaned by wire brushing, sand blasting, or other means prior to being set in forms. PART 2 MATERIALS 2.01 CONCRETE A. All Portland cement concrete shall conform to the provisions of Sections 201, 202, and 303 of the Standard Specifications for Public Works Construction (Greenbook). B. Class 560-C-3250 concrete, as described in the Greenbook, Section 201, shall be used for all applications unless otherwise directed by the District. The maximum water/cement ratio shall be 0.53 by weight, and the maximum slump shall be 4-inches. C. In certain circumstances, rapid-setting concrete may be required. Accelerating admixtures shall conform to ASTM C-494 and may be used in the concrete mix as permitted by the District. Calcium chloride shall not be used in concrete. 2.02 REINFORCING STEEL A. Reinforcing steel shall conform to ASTM A 615, Grade 60. B. Fabricate reinforcing steel in accordance with the current edition of the Manual of Standard Practice, published by the Concrete Reinforcing Steel Institute. JUNE 2004 Page 2 of 9 SECTION 03000 Cast-ln-Place Concrete 2.03 WELDED FIRE FABRIC Welded wire fabric shall conform to ASTM A 185. 2.04 TIE WIRE Tie wire shall be 16-gage minimum, black, soft annealed. 2.05 BAR SUPPORTS Bar supports in beams and slabs exposed to view after removal of forms shall be galvanized or plastic coated. Use concrete supports for reinforcing in concrete placed on grade. 2.06 FORMS A. Forms shall be accurately constructed of clean lumber. The surface of forms against which concrete is placed shall be smooth and free from irregularities, dents, sags or holes. B. Metal form systems may be used upon District approval. Include manufacturer's data for materials and installation with the request to use a metal form system. 2.07 MORTAR Cement mortar shall consist of a mixture of Portland cement, sand, and water. One part cement and two parts sand shall first be combined, and then thoroughly mixed with the required amount of water. 2.08 EPOXY BONDING AGENT The epoxy bonding agent shall be an epoxy-resin-based product intended for bonding new mortar to hardened concrete and shall conform to ASTM C 881. The bonding agent shall be selected from the Approved Materials List. 2.09 REPAIR MORTAR Repair mortar shall be a two-component, cement-based product specifically designed for structurally repairing damaged concrete surfaces. The repair mortar shall exhibit the properties of high compressive and bond strengths and low shrinkage. A medium-slump repair mortar shall be used on horizontal surfaces, and a non-sag, low-slump repair mortar shall be used on vertical or overhead surfaces. Repair mortar shall be selected from the Approved Materials List. 2.10 NON-SHRINK GROUT Non-shrink grout shall be a non-metallic cement-based product intended for filling general construction voids or grouting base plates for equipment or structural members. The non-shrink grout shall exhibit the properties of high compressive and bond strengths and zero shrinkage, and shall be capable of mixing to a variable viscosity ranging from a dry pack to a fluid consistency as required for the application. The non-shrink grout shall be selected from the Approved Materials List. JUNE 2004 Page 3 of 9 SECTION 03000 Cast-ln-Place Concrete 2.11 EPOXY ADHESIVE Epoxy adhesive shall be a high-modulus epoxy-resin-based product intended for structural grouting of anchor bolts and dowels to concrete. The epoxy adhesives shall conform to ASTM C 881. A pourable, medium-viscosity epoxy shall be used on horizontal surfaces, and a heavy-bodied, non-sag epoxy gel shall be used on vertical surfaces. The epoxy adhesives shall be selected from the Approved Materials List. 2.12 PROTECTIVE EPOXY COATING The protective epoxy coating shall be an epoxy-resin-based product exhibiting high bond strength to steel and concrete surfaces, and shall conform to ASTM C 881. The protective epoxy coating shall be selected from the Approved Materials List. 2.13 DAMP-PROOFING FOR CONCRETE STRUCTURES Damp-proofing material shall consist of two coats of a single-component self-priming, heavy-duty cold-applied coal tar selected from the Approved Materials List. PART 3 EXECUTION 3.01 FORMWORK A. The Contractor shall notify the District a minimum of one working day in advance of intended placement of concrete to enable the District to check the form lines, grades, and other required items before placement of concrete. B. The form surfaces shall be cleaned and coated with form oil prior to installation. The form surfaces shall leave uniform form marks conforming to the general lines of the structure. C. The forms shall be braced to provide sufficient strength and rigidity to hold the concrete and to withstand the necessary fluid pressure and consolidation pressures without deflection from the prescribed lines. D. Unless otherwise indicated on the plans, all exposed sharp concrete edges shall be 3/4-inch chamfered. 3.02 REINFORCEMENT A. Place reinforcing steel in accordance with the current edition of Recommended Practice for Placing Reinforcing Bars, published by the Concrete Reinforcing Steel Institute. B. All reinforcing steel shall be of the required sizes and shapes and placed where shown on the drawings or as directed by the District. C. Do not. straighten or re-bend reinforcing steel in a manner that will damage the material. Do not use bars with bends not shown on the drawings. All steel shall be cold bent - do not use heat. JUNE 2004 Page 4 of 9 SECTION 03000 Cast-ln-Place Concrete D. All bars shall be free from rust, scale, oil, or any other coating that would reduce or destroy the bond between concrete and steel. E. Position reinforcing steel in accordance with the Approved Plans and secure by using annealed wire ties or clips at intersections and support by qoncrete or metal supports, spacers, or metal hangers. Do not place metal clips or supports in contact with the forms. Bend tie wires away from the forms in order to provide the concrete coverage equal to that required of the bars. If required by the Engineer, the Contractor shall install bars additional to those shown on the drawings for the purpose of securing reinforcement in position. F. Place reinforcement a minimum of 2-inches clear of any metal pipe, fittings, or exposed surfaces. G. The reinforcement shall be so secured in position that it will not be displaced during the placement of concrete. H. All reinforcing steel, wire mesh, and tie wire shall be completely encased in concrete. I. Reinforcing steel shall not be welded unless specifically required by the Approved Plans or otherwise directed by the Engineer. I. Secure reinforcing dowels in place prior to placing concrete. Do not press dowels into the concrete after the concrete has been placed. J. Minimum lap for all reinforcement shall be 40 bar diameters unless otherwise specified on the Approved Plans. K. Place additional reinforcement around pipe penetrations or openings 6-inches diameter or larger. Replace cut bars with a minimum of 1/2 of the number of cut bars at each side of the opening, each face, each way, same size. Lap with the uncut bars a minimum of 40 bar diameters past the opening dimension. Place one same size diagonal bar at the four diagonals of the opening at 45° to the cut bars, each face. Extend each diagonal bar a minimum of 40 bar diameters past the opening dimension. L. Wire mesh reinforcement is to be rolled flat before being placed in the form. Support and tie wire mesh to prevent movement during concrete placement. M. Extend welded wire fabric to within 2-inches of the edges of slabs. Lap splices at least 1-1/2 courses of the fabric and a minimum of 6-inches. Tie laps and splices securely at ends and at lest every 24-inches with 16-gage black annealed steel wire. Pull the fabric into position as the concrete is placed by means of hooks, and work concrete under the steel to ensure that it is at the proper distance above the bottom of the slab. 3.03 EMBEDDED ITEMS All embedded items, including bolts, dowels and anchors, shall be held correctly in place in the forms before concrete is placed. JUNE 2004 Page 5 of 9 SECTION 03000 Cast-ln-Place Concrete 3.04 MORTAR MIXING The quantity of water to be used in the preparation of mortar shall be only that required to produce a mixture sufficiently workable for the purpose intended. Mortar shall be used as soon as possible after mixing and shall show no visible sign of setting prior to use. Re-mixing of mortar by the addition of water after signs of setting are evident shall not be permitted. 3.05 MIXING AND PLACING CONCRETE A. All concrete shall be placed in forms before taking its initial set. B. No concrete shall be placed in water except with permission of the District. C. As the concrete is placed in forms, or in rough excavations (i.e., thrust or anchor blocks), it shall be thoroughly settled and compacted throughout the entire layer by internal vibration and tamping bars. D. All existing concrete surfaces upon which or against which new concrete is to be placed shall be roughened, thoroughly cleaned, wetted, and grouted before the new concrete is deposited. 3.06 CONCRETE FINISHING A. Immediately upon the removal of forms, voids shall be neatly filled with cement mortar, non-shrink grout, or epoxy bonding agent and repair mortar as required for the application and as directed by the District. B. The surfaces of concrete exposed to view shall be smooth and free from projections or depressions. C. Exposed surfaces of concrete not poured against forms, such as horizontal or sloping surfaces, shall be screeded to a uniform surface, steel-trowelled to densify the surface, and finished to a light broom finish. 3.07 PROTECTION AND CURING OF CONCRETE The Contractor shall protect all concrete against damage. Exposed surfaces of new concrete shall be protected from the direct rays of the sun by covering them with plastic film wrap and by keeping them damp for at least 7 days after the concrete has been placed, or by using an approved curing process. Exposed surfaces shall be protected from frost by covering with tarps for at least 5 days after pouring. JUNE 2004 Page 6 of 9 SECTION 03000 Cast-ln-Place Concrete 3.08 REPAIRS TO DAMAGED CONCRETE SURFACES Minor surface damage to hardened cast-in-place or precast concrete may be repaired, at the discretion of the District, using the specified materials in accordance with the manufacturer's recommendations and the following procedures: A. Cast-in-place or precast concrete for manholes and vaults: Remove loose or deteriorated concrete to expose a fractured aggregate surface with an edge cut to a ninety degree angle to the existing surface. Clean all debris from the area, apply a 20 mil coat of epoxy bonding agent to the prepared surface, and place repair mortar while the epoxy is still wet and tacky. On horizontal surfaces, for repair depths greater than 2-inches, add aggregate to the repair mortar as recommended by the manufacturer. On vertical or overhead surfaces, for repair depths greater than 2-inches, apply the repair mortar in successive lifts, scarifying the lifts, allowing them to harden, and applying a scrub coat of the material prior to proceeding with the next lift. Cure the material as for concrete in accordance with this specification. B. General Purpose: Remove loose and deteriorated concrete by mechanical means, sandblasting, or high-pressure water blasting. Clean all debris from the area and apply non-shrink grout in a 1/4-inch minimum thickness, at the desired consistency, ranging from a dry pack, to a fluid-poured info a formed area, according to the application. Cure the material as for concrete in accordance with this specification. 3.09 EPOXY ADHESIVES FOR ANCHOR BOLT INSTALLATION Anchor bolts grouted in place with an epoxy adhesive shall be installed using the specified materials in accordance with the manufacturer's recommendations and the following general procedures: Drill the hole with a rotary percussion drill to produce a rough, unpolished hole surface, the hole shall be sized to the manufacturer's recommendations and should be approximately 1/4-inch wider than the diameter of the bolt, with a depth equal to 10 to 15 times the bolt diameter. Remove debris and dust with a stiff bristle brush and clean using compressed air. Utilizing a medium-viscosity epoxy for horizontal surfaces, and a gel-type non-sag epoxy for vertical surfaces, apply the material to fill the hole to approximately half its depth. Insert the bolt, forcing it down until the required embedment depth and projection length are attained and then twist the bolt to establish a bond. Secure the bolt firmly in place in the permanent position until the epoxy sets. 3.10 PROTECTIVE EPOXY COATING Following core drilling at existing concrete structures, clean the exposed concrete surface and ends of reinforcing steel and apply two coats of protective epoxy coating for a total dry film thickness of 10-15 mils. Allow the material to cure between coats and prior to continuing the installation through the penetration. 3.11 DAMP-PROOFING FOR THE EXTERIOR OF CONCRETE STRUCTURES Following completion of the exterior surfaces of manholes and vaults, including necessary repairs and piping penetrations into the structure, apply the specified material to prepared concrete surfaces in accordance with the manufacturer's recommendations. The surfaces to be coated shall be fully-cured and free of laitance and contamination. The material shall be applied to all exterior surfaces below a point 12-inches above the water table or indications of seepage or moisture as directed by the Engineer. Apply two 15 mil coats, curing between coats, prior to backfill and/or immersion in accordance with the manufacturer's recommendations. JUNE 2004 Page 7 of 9 SECTION 03000 Cast-ln-Place Concrete 3.12 THRUST AND ANCHOR BLOCKS Concrete thrust and anchor blocks shall be poured against wetted, undisturbed soil in accordance with the Standard Drawings and as directed by the District. The concrete shall be placed so that fittings and valves will be accessible for repairs or replacement. Prior to filling the pipeline with water, the concrete for thrust and anchor blocks shall cure for the following number of days: Thrust Blocks Anchor Blocks 3 days minimum 7 days minimum A. Safe Soil Bearing Load: Soil Muck, peat, etc.*** Soft Clay Fine Sand Decomposed Granite (D.G.) Sandy Gravel Cemented Sandy Gravel Hard Shale Granite 1 Safe gearing Load 0 PSF 500 PSF 1,000 PSF 1 ,500 PSF 2,000 PSF 2,000 PSF 2,500 PSF 10,000 PSF ***ln muck or peat soils, competent resistance shall be achieved by removal and replacement with ballast or sufficient stability to resist the intended thrusts. Consult the project geotechnical consultant. B. Thrust Block Placement and Sizing: Thrust blocks shall be located at all unrestrained pipe fittings and bear against firm, undisturbed soil. The thrust blocks shall be centered on the fitting so that the bearing area is exactly opposite the resultant direction of the thrust, refer to the Standard Drawings. Care shall be taken to prevent the placed thrust block concrete from eliminating maintenance access to the valve operators. All thrust block excavation location, shape, and the District prior to pouring the concrete shall verify size. The size, in sq. ft., of the thrust block can be calculated by dividing the thrust by the safe bearing load. For instance, use a 12-inch pipe, 45° end, at 200 psi test pressure with a D.G. trench the value of 11,720# of thrust can be obtained from the upper chart and 1,500#/sq. ft. safe bearing load from the lower chart as follows: 11,720# x 2 / 1,500#/Sq. ft. = 15.6 sq. ft. or 16 sq. Therefore, for this example, the trench wall adjacent to the fitting shall be excavated to the dimensions of 4 ft. x 4 ft. or 3.5 ft. x 5 ft. or some closely approximate multipliers to achieve the minimum required 16 sq. ft. bearing area. JUNE 2004 Page 8 of 9 SECTION 03000 Cast-ln-Place Concrete C. Anchor Block Placement and Sizing: For all vertical bends in pipelines (downward bends) that do not have restrained joints, the fittings shall be retained in place by means of an anchor block. The block shall be sized to withstand the thrust exerted for the particular deflection angle at the required test pressure plus 10%. (Do not rely on the restraining benefit from the soil). The District shall verify the size chosen and the reinforcing steel required. The size, in cu. ft. of the anchor block can be calculated by dividing the thrust by the unit weight of concrete (i.e., one cu. ft. or concrete weighs approximately 145#). For instance, use the same 12-inch pipe, 45° bend, at 200 psi test pressure - the value of 11,720# of thrust can be obtained from the upper chart: 11,720# x 2 / 145# = 162 cu. ft. (plus 10%) = 178 cu. ft. or 6.6 cu. yd. Therefore, for this example, the anchor block shall be 5.5' x 5.5' x 6" or 6' x 6' x 5', or some closely approximate multipliers to achieve a minimum of 178 cu. ft. of concrete. 3.13 VALVE SUPPORT BLOCKS Valve support blocks shall be installed as described below and in accordance with the Standard Drawings: A. Support blocks below valves shall be cut into the side of the trench a minimum of 12-inches. B. Support blocks shall extend up to a height of adjoining pipe and shall have a minimum depth below the valve of 12-inches. C. Support blocks shall be installed so that the valves will be accessible for repairs. END OF SECTION JUNE 2004 Page 9 of 9 SECTION 03000 Cast-ln-Place Concrete SECTION 09870 TAPE COATING SYSTEM WITH MORTAR SHIELD FOR THE EXTERIOR OF STEEL WATER PIPELINES PART 1 - GENERAL 1.1 DESCRIPTION A. The steel pipe shall be coated with polyethylene tapes in accordance with AWWA C214. Fittings and specials shall be coated with cold-applied polyethylene tapes in accordance with AWWA C209. A reinforced cement mortar shield shall be applied in accordance with AWWA C205. Any modifications to the aforementioned standards are as stated herein. 1.2 RELATED WORK ELSEWHERE The Contractor shall refer to the following specification section(s) for additional requirements: A. Painting and Coating: 09900 B. Petrolatum Wax Tape Coating: 09902 C. Cement Mortar Lined Steel Pipe: 15061 1.3 QUALIFICATIONS OF MANUFACTURERS A. Manufacturer to demonstrate a minimum of five years' successful application of tape coating system on similar diameter steel water pipelines as specified herein. 1.4 SUBMITTALS ii * ~ ' A. List of tape coating materials indicating manufacturer, product numbers, and thickness of materials related to tape system for joints and repairs. B. Certification of test results for each batch of liquid adhesive and each tape material specified shall be in accordance with AWWA C214. C. Tape application procedure approved by tape manufacturer. 1.5 COORDINATION WITH TAPE MANUFACTURER A. The pipe manufacturer shall require the tape material manufacturer to furnish qualified factory technical representative to visit the site for technical support at the beginning of the pipe installation as may be necessary to instruct Contractor on appropriate tape application methods in the field or to resolve problems. This visit shall be coordinated to allow City Inspection and Maintenance Staff to participate in the instruction. The Contractor shall allow time for representative to give field taping instructions to his workforce. JUNE 2004 1of9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines PART 2 - MATERIALS 2.1 POLYETHYLENE TAPE COATING A. Provide polyethylene tape coating in accordance with AWWA C214 with a reinforced cement mortar shield in accordance with AWWA C205 and as specified herein. Plant and field applied liquid adhesive, polyethylene tape, and plant and field applied repair tape shall be furnished by a single manufacturer. The physical properties of tape materials shall meet or exceed the requirements of AWWA C214 when tested in accordance with the methods described in Section 5.3, "Coating System Tests". B. The tape coating systems consist of an exterior polyethylene tape over the bare metal surface of steel pipe with a reinforced cement mortar coating applied over the tape system. Tape coating systems are specified for: 1. Normal plant cold-applied tape 2. Plant cold-applied tape for special sections, connections and fittings, and plant repairs of cold-applied tape 3. Field joint, field coated fittings and repair of field cold-applied tape. 2.2 LIQUID ADHESIVE A. Liquid adhesive shall consist of a mixture of suitable rubber and synthetic compounds and a solvent in accordance with AWWA C214. The liquid adhesive shall be Polyken #1039 primer or equivalent. 2.3 STORAGE PRIMER A. Storage primer on the exposed steel at the tape cutbacks shall be Polyken #924 or equivalent. 2.4 PLANT APPLIED POLYETHYLENE TAPE SYSTEM, POLYKEN, or equivalent (80 mil) A. Liquid adhesive shall be Polyken #1039 primer. B. Anti-corrosion inner layer tape shall be Polyken #989 (20 mil), black. C. First mechanical outer layer tape shall be Polyken #955 (30 mil), gray. D. Second mechanical outer layer tape shall be Polyken #956 (30 mil), white. E. Reinforced cement mortar shield 3/4" thick. F. Weld Stripping Tape shall be Polyken #933 (25 mil), if required. JUNE 2004 2 of 9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines 2.5 PLANT COLD-APPLIED TAPE COATINGS FOR SPECIAL SECTIONS, CONNECTIONS AND FITTINGS, AND PLANT REPAIR COLD-APPLIED POLYETHYLENE TAPE MATERIAL A. Liquid adhesive shall be Polyken #1039 primer. B. Anti-corrosion inner layer shall be Polyken #932-50 (50 mil), black. C. Mechanical layer outer tape for plant fittings and plant repair cold-applied polyethylene tape shall be Polyken #955 (30 mil), white. D. Reinforced cement mortar shield 3/4" thick. , E. Weld stripping tape shall be Polyken #933 (25 mil), if required. 2.6 FIELD JOINT, FIELD COATED FITTINGS, AND FIELD REPAIR COLD-APPLIED POLYETHYLENE TAPE A. Primer shall be Polyken #1029. B. Joint filler tape to be Polyken #939 (125 mil), black. C. Field joint, field fitting, and field repair outer layer tape shall be Polyken #932, (50 mil). D. Mechanical layer outer tape for field joint, field fittings and field repair shall be Polyken #932-50, continue inner layer with 50% overlap. PART 3 - EXECUTION 3.1 POLYETHYLENE TAPE COATING A. Apply polyethylene tape coating to pipe in accordance with AWWA C214. Apply polyethylene tape coating to fittings and specials in accordance with AWWA C209. Apply the reinforced cement mortar shield in accordance with AWWA C205. Any modifications to the aforementioned standards are as stated herein. B. Certificate of Compliance: Prior to shipment of pipe, furnish a certificate of compliance stating that tape materials and work furnished hereunder will comply or have complied with the requirements of these specifications and AWWA C214 and C209. 3.2 STRAIGHT RUN PIPE APPLICATION A. For straight run pipe, plant applied conditions, the polyethylene tapes shall be a four layer system consisting of: (1) liquid adhesive; (2) corrosion prevention tape (inner layer); (3) mechanical protective tape (first outer layer); (4) mechanical protective tape (second outer layer) JUNE 2004 3 of 9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines B. Perform the entire coating operation by experienced workers skilled in the application of polyethylene tapes and cement mortar coating under qualified supervisors. After completion of the tape system, all handling shall be by padded equipment to prevent any damage of the tape system. Testing of tape system shall be performed per 3.5 of this section. C. All equipment for blasting and application of the tape coating system shall be of such design and condition to comply with all the requirements of AWWA C214 and these specifications. Immediately repair or replace equipment that, in the opinion of the Engineer, does not produce the required results. Include equipment and a repair procedure for correcting defective tape application for use under this specification in the steel pipe fabrication plan. Make available for review a copy of this portion of the fabrication plan, and any updates, at the location of the coating operation, and a repair procedure for correcting defective tape application. D. Remove the exterior weld bead along the entire exterior surface of the pipe. The exterior weld bead shall be flush with the exterior surface of the pipe with a tolerance of plus 1/32-inch. E. Surface preparation shall conform to AWWA C214 and the following. 1. Bare pipe shall be clean of all foreign matter such as mud, mill lacquer, wax, coal tar, asphalt, oil, grease, or any contaminants. Remove welding slag or scale from all welds by wire-brushing, hammering, or other satisfactory means. Remove welding splash globules prior to priming. 2. Prior to blast cleaning, inspect surfaces and, if required, preclean in accordance with the requirements of SSPC SP-1, Solvent Cleaning, to remove oil, grease, and all foreign deposits. Remove visible oil and grease spots by solvent wiping. Use only approved solvents that do not leave any residue. Include in the manufacturer's fabrication plan the cleaning solvent applications procedure and safety precautions. F. Blast cleaning shall conform to AWWA C214 and the following. 1. Blast the pipe surface using a commercially available shot grit mixture to achieve a prepared surface equal to that which is specified in SSPC SP- 6, Commercial Blast Cleaning. 2. For plant mortar lined pipe, perform blast cleaning of said exterior surfaces after the initial curing of the spun mortar lining. Perform the exterior blast cleaning in such a manner as not to endanger the mortar lining in the pipe. Completely remove corrosion and foreign substances from the exterior of the pipe in the cleaning operation, and apply liquid adhesive after completion of blast cleaning. 3. Achieve from abrasive blasting an anchor pattern profile a minimum of 1.0 mil, but not exceeding 3.0 mils. Measure the anchor pattern or profile of the blasted surface using comparator tape as specified herein. JUNE 2004 4 of 9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines 4. Inspect the blast cleaned exterior pipe surface for adequate surface preparation prior to application of the liquid adhesive. Surface comparator tapes are to be used by the manufacturer in at least eight random areas, along any given 40-foot length of pipe. The results of the surface comparator tapes are to be documented on the quality control sheet for each pipe section. 5. Coat each pipe section with liquid adhesive and tape within the same day of being blast cleaned. Do not allow blasted and/or blasted and primed pipe to sit overnight. All Wasted and primed pipe must be coated by the end of the day. No coating will be permitted on pipe sections showing evidence of rust. G. Liquid adhesive application shall conform to AWWA C214 and the following. 1. Prior to liquid adhesive application, clean the pipe surface free of foreign matter such as sand, grease, oil, grit, rust particles, and dirt. 2. Apply the liquid adhesive in a uniform thin film at the coverage rate recommended by the manufacturer. Meet the recommendations of the manufacturer for the state of dryness of the liquid adhesive prior to the application of the inner layer of tape. 3. Limit the application of liquid adhesive to that length of pipe which can be taped within the same workday. Pipe coated with liquid adhesive that was not taped within the same workday shall be rejected at the discretion of the Engineer. The liquid adhesive shall be removed and the surface shall be re-primed. 4. Protect liquid adhesive coated pipe sections from moisture, dirt, sand, and other potentially contaminating materials 5. Apply storage primer to the exposed steel pipe at tape cutbacks to prevent oxidation of the cleaned metal surface. Apply minimum of 1.5 mils and maximum of 2.5 mils of storage primer to exposed steel per the manufacturer's recommendations. H. Inner layer tape application: 1. Apply the inner layer tape directly onto the primed surface using approved mechanical dispensing equipment to assure adequate, consistent tension on the tape as recommended by the tape manufacturer. Use rollers to apply pressure on the tape as it comes in contact with the pipe. Make necessary adjustments to mechanical application equipment to assure a uniform, tight coating. Maintain a tight, smooth, mechanically induced, wrinkle-free coating throughout the application process. JUNE 2004 5 of 9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines 2. The application of tension shall be such that the width of tape will be reduced between 11/fe to 2 percent of tape width prior to the pull. Provide a pressure readout gauge and chart recorder, suitable to the Engineer, with the tape let-off machine to document the tape tension during application. 3. Apply inner layer tape at a minimum roll temperature of 70°F. Continuously monitor the temperature of the tape within 12 inches of the point of contact with the pipe surface. Use a chart recorder, suitable to the Engineer, to document the temperature of the tape during application. Sections where the tape application tension and temperature is not maintained within manufacturer's recommendations shall be rejected and the tape removed from the entire pipe section and reapplied. 4. Continuously electronically test the inner tape layer at 6.OOO volts immediately following application of the tape by a holiday tester permanently mounted to the tape application station and equipped with an indicator light and audio buzzer, suitable to the Engineer to alert the workmen of the presence of holidays in the coating system. 5. Spirally wrap the inner layer tape over longitudinally or spirally welded pipe. Provide a 1-inch minimum tape overlap. 6. Splice each new roll by overlapping the new tape over the end of the preceding roll by at least 6 inches. Perform this end lap splice by hand or by a mechanical applicator so that the splice is wrinkle free and maintains the continuity of the inner wrap coating. Maintain the wrapping angle of the new roll parallel to that of the previous roll. 7. Provide tape cutbacks based on the joint type required, cutting the tape edge parallel to the end of the pipe. Perform cutbacks using a cutting device that is guided from the end of the pipe to insure a uniform, straight cutback. Mechanical outer layer tape application. 1. Apply the first mechanical outer layer of tape over the inner layer tape using the same type of mechanical equipment used in the application of the inner layer tape. No overlap splice of the other layer coinciding with the overlap splice of the inner layer will be permitted. Provide a minimum 6-inch separation between overlap of splices. Apply two mechanical outer layers of tape as specified herein. The inner layer tape shall be electrically tested, inspected, and approved prior to the application of the first mechanical outer layer tape and the first mechanical outer layer tape shall also be visually inspected and approved prior to the application of the second mechanical outer layer tape. Ensure that both mechanical outer layer tapes are smooth, tight and wrinkle-free. JUNE 2004 6 Of 9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines 2. Apply mechanical outer layer tapes in accordance with the requirements for the inner layer tape, except that the minimum tape roll application temperature shall be 90°F. Monitoring for tension and temperature will be required for the mechanical outer layer tapes. The use of rollers to apply pressure on the tape is not required during application of the mechanical outer layer tapes. Holiday testing of the mechanical outer layer tapes is not required during tape application. Test the complete tape system prior to coating as specified herein. J. Apply a reinforced cement mortar shield over the outer layer of tape in accordance with AWWA C205. Cement mortar shall be per Section 15061. K. Storage primer application shall conform to AWWA C214 as modified herein: 1. Prior to storage primer application, clean the pipe surface free from foreign matter such as sand, grease, oil, grit, rust particles and dirt. 2. Apply primer only to a dry pipe surface. Whenever the ambient air temperatures are cold enough to cause gelling of the primer, the use of heaters will not be permitted to return the primer back to a fully liquid state. Use new primer at a minimum of 40°F. 3. Apply storage primer to the exposed steel pipe at tape cutbacks to prevent oxidation of the cleaned metal surface. Apply minimum of 1.5 mils and maximum of 2.5 mils of storage primer to exposed steel per the manufacturer's recommendations. Do not place storage primer on the edge of the steel plate. 3.3 FITTINGS COATED AT THE PLANT A. Coat fittings that cannot be machine coated in accordance with AWWA C209 using materials as specified herein. Weld bead preparation, surface preparation, blast cleaning and liquid adhesive shall be as specified for straight run pipe. Apply an inner layer tape of Polyken #932-50 with a 1 -inch minimum tape overlap on all plant coated fittings. Apply an outer layer of cold-applied polyethylene tape as specified herein with a 55 percent overlap on all plant-coated fittings. Provide a minimum thickness of 110 mils for the total tape coat system for plant-coated fittings. B. Test all completed tape coated fittings in the presence of the Engineer with an electrical flaw detector prior to the application of the cement mortar coating. Applied voltage shall be in the range of 11,000 to 15,000 volts. Repair any holidays found. C. Repair cement mortar coating defects in accordance with the approved repair procedures. D. Apply cement mortar coating in accordance with AWWA C205, over the tape- coated fittings after completion of tape coating, testing and inspections. JUNE 2004 7 of 9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines 3.4 TAPE APPLICATION TO FITTINGS, SPECIALS AND PIPE JOINTS (Reid) A. Field cold applied plastic tape coating shall be in accordance with AWWA C209, as modified herein. B. Prior to welding any fieldjoints, wrap an 18-inch strip of heat resistance material over the entire coated pipe section to avoid damage to the plant applied coating by the hot weld spatter. C. Clean the pipe surface free of mud, mill lacquer, wax, tar grease, or any foreign matter. The pipe surface shall be free of any moisture and all foreign matter prior to the application of prime. D. Pack irregularities in joint with elastameric joint filler. E. Apply primer by brush or roller (4 mil wet, 1 mil dry). F. After primer has dried, apply tape to the joint and extend a minimum of 3-inch onto adjacent tape wrap. Maintain 55 percent overlap on all field joint tape to produce a minimum thickness of 100 mils. G. Apply tape with sufficient tension to conform with the surface. The finish wrap shall produce a smooth, wrinkle-free surface. H. The tape system for pipe joints is shown in Section 2.6. 3.5 INSPECTION OF TAPE COATING Test the applied tape coating in the presence of the engineer with an electrical holiday detector, as a part of the tape installation process. Repair all holidays and physical damage. If mortar shield is applied at a different location than the tape coating system, a second electrical holiday spark test shall be required after all transportation and handling to the mortar coating location confirming the integrity of the tape undercoating. Upon completion of the mortar coating process a continuity or spark test will again be preformed for the tape system. Repair any holidays and physical damage and spark test, verifying repair. 3.6 MORTAR SHIELD A. Apply mortar coating in accordance with Section 15061 cement. Mortar lined and coated steel pipe and specials, over the tape coated pipe immediately upon completion of tape wrapping, testing, and inspections. 3.7 PROTECTING COATED PIPE A. The CONTRACTOR shall protect all coated surfaces from damage prior to and during the pipe installation in accordance with these specifications. JUNE 2004 8 of 9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines B. In transporting the coated pipe, it shall rest in saddles shaped to the outside diameter of the coated pipe. The saddles shall be in contact with the bottom of the pipe along an arc of at least 60 degrees. Saddles shall be completely lined with adequate padding. No nails or any other fasteners that may damage the coating will be allowed in the installation of the padding of the saddles. C. While laying tape coated steel pipe, the pipe shall not be rolled or skidded when it is in contact with the ground at any point. Immediately before the coated pipe is lowered into the trench the CONTRACTOR shall provide a visual and holiday inspection of the coating on the entire pipe coating system. Coated pipe shall be lowered into the trench using saddled, not choked, belt slings. The use of chains, hooks, or other equipment which might damage the pipe coating will not be permitted. All other pipe handling equipment and methods shall be approved by the ENGINEER. Pipe stored alongside of the trench shall be supported on padded skids, sand bags, or rock-free sand berms. END OF SECTION JUNE 2004 9 of 9 SECTION 09870 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines SECTION 09900 PAINTING AND COATING PART 1 - GENERAL 1.1 DESCRIPTION This section described the requirements for the preparation of surfaces and subsequent application of protective coatings. The Contractor shall furnish all labor, materials and equipment required for satisfactory completion of all items contained herein. The Contractor shall furnish all necessary safety equipment and protective clothing, as well as be responsible for proper instruction and supervision of their use. Requirements for steel storage reservoirs are specified elsewhere in the Specifications. 1.2 RELATED WORK DESCRIBED ELSEWHERE The Contractor shall refer to the following Specification sectiori(s) for additional requirements: A. General Piping System & Appurtenances: 015000 1.3 SUBMITTALS . Contractor shall furnish submittals in accordance with the requirements of Section 01300, Shop Drawing Submittals. The following submittals are required: A. Submit a chart of the manufacturer's available colors for color selection well in advance of painting operation. B. Submit manufacturer's data sheets showing the following information: 1. Recommended surface preparation. 2. Minimum and maximum recommended dry-film thicknesses per coat for prime, intermediate, and finish coats. 3. Percent solids by volume. 4. Recommended thinners. 5. Statement verifying that the selected prime coat is recommended by the manufacturer for use with the selected intermediate and finish coats. 6. Application instructions including recommended application, equipment, humidity, and temperature limitations. 7. Curing requirements and instructions. C. Submit certification that all coatings conform to applicable local Air Quality Management District rules and regulations for products and application. JUNE 2004 1 of 9 SECTION 09900 Painting and Coating 1.4 PAYMENT Payment for the Work in this section shall be included as part of the lump-sum or unit-price bid amount for which such Work is appurtenant thereto. PART 2 - MATERIALS 2.1 GENERAL All materials shall be those of current manufacture and shall meet all applicable regulations for the application and intended service. All coats of any particular coating system shall be of the same manufacturer and shall be approved by the manufacturer for the intended service. In the event that a product specified herein is no longer manufactured or does not meet current regulations, the Contractor shall provide a substitute, currently manufactured product of at least equal performance which meets all applicable regulations subject to Engineer's approval, at no additional cost. All materials shall be delivered to the Project Site in their original, unopened containers bearing the manufacturer's name, brand, and batch number. Standard products of manufacturers other than those specified will be accepted when it is proved to the satisfaction of the Engineer they are equal in composition, durability, usefulness and convenience for the purpose intended. Paint listed in the system refers to products of the following manufacturers and distributors: Ameron Corrosion Control Division, Brea, CA I.C. Devoe, Louisville, KY Engard Coating Corporation, Long Beach, CA I. DuPont de Nemours & Company, Los Angeles, CA Tnemec Company, Inc., Kansas City, MO 64141 All surfaces to be coated or painted shall be in the proper condition to receive the material specified before any coating or painting is done. No more sandblasting or surface preparation than can be coated or painted in a normal working day will be permitted. All sharp edges, burrs, and weld spatter shall be removed. All concrete and masonry surfaces shall cure 30 days prior to coating or painting. Surface preparation, prime coatings, and finish coats for the various systems are specified herein. Unless otherwise noted, all intermediate and finish coats shall be of contrasting colors. It is the intent that the coating alternates specified herein serve as a general guide for the type of coating desired. 2.2 VALVES A. Exterior Coating: Coat metal valves located above ground, in vaults or in structures the same as the adjacent piping. If the adjacent piping is not coated, then coat valves per this Specification section unless otherwise noted. Apply the specified prime coat at the place of manufacture. Apply intermediate and finish coats in the field. Finish coat shall match the color of the adjacent piping. Coat handwheels and floor stands the same as the valves. Coat the exterior of buried metal valves at the place of manufacture per this specification. JUNE 2004 2 of 9 SECTION 09900 Painting and Coating B. Coating (Devoe Alternate): Prime coat shall be BarRust 231 or Devran 200 applied at 2 to 3 mils dry-film thickness. Intermediate coat shall be Devran 224H Epoxy applied at 2 to 4 mils dry-film thickness. Finish coat shall be 379 Urethane applied at 2 to 3 mils dry- film thickness. C. Interior Lining: Valves 4-inches and larger shall be coated on their interior metal surfaces excluding seating areas and bronze and stainless-steel pieces. Sandblast surfaces in accordance with SSPC-SP-10 (near white blast cleaning). Remove all protuberances which may produce pinholes in the lining. Round all sharp edges to be coated. Remove any contaminants which may prevent bonding of the lining. Coat the interior ferrous surfaces using one of the following methods: 1. Apply powdered thermosetting epoxy per the manufacturer's application recommendations to a thickness of 10 to 12 mils. 2. Apply two coats of polyamide epoxy to a dry-film thickness of 10 to 12 mils total. Follow the manufacturer's application recommendations including minimum and maximum drying time between the required coats. 3. Apply two coats of Tnemec Series 140 (for potable water) or Series 69 (for non- potable water), or equal, to a dry film thickness of 10 to 12 mils total. Follow manufacturer's application recommendations including minimum and maximum drying time between required coats. 4. Apply two coats of Devoe Bar-Rust 233H Epoxy applied to a dry-film thickness of 6 to 8 mils, each. Total dry-film thickness shall be 10 to 12 mils minimum. All epoxy lining shall be applied at the factory by the manufacturer of the valve, and shall meet current Volatile Organic Compound (VOC) content regulations. Epoxy lining for potable water valves shall also be listed by National Sanitation Foundation (NSF) for contact with potable water. Test the valve interior linings at the factory with a low-voltage holiday detector. The lining shall be holiday free. 2.3 METAL, INTERIOR AND EXTERIOR, NORMAL EXPOSURE A. General: The Contractor shall paint all exposed steelwork, non-galvanized handrails, exposed pipework, fittings, all mechanical equipment, pumps, motors, doors, door frames and window sash with this coating system. All metalwork previously given a shop prime coat approved by the Owner's Representative shall be touched up as required in the field with Tnemec Series 4 Versare Primer or equal. B. Surface Preparation: All exterior metal surfaces which are to be painted shall be commercial blast cleaned per Specification SP-6 (commercial blast cleaning) except as otherwise specified, in locations where sandblasting would damage previously coated surfaces and installed equipment, and in locations where dry sandblasting is prohibited. The above locations in which SP-6 commercial sandblasting is not possible shall be given a SP-3 power tool cleaning. This sandblasting shall be done not more than 8 hours ahead of the painting, subject to humidity and weather conditions between the time of sandblasting and painting operations. If any rusting or discoloration of sandblasted surfaces occurs before painting, such rusting or discoloration shall be removed by additional sandblasting. Sandblasted surfaces shall not be left overnight before painting. JUNE 2004 3 of 9 SECTION 09900 Painting and Coating C. Coating (Tnemec Alternate): Prime coat or spot prime coat as required shall be Tnemec Series 4 Versare primer applied to a dry-film thickness of 2 to 3.5 mils. Two or more finish coats of Tnemec Series 2H Tneme-Gloss enamel shall be applied to a thickness of 1.5 to 3.5 mils. Total dry-film thickness of the complete system shall be 7 mils, minimum. D. Coating (Devoe Alternate): Prime coat or spot prime as required shall be 4140 Q.D. Alkyd Primer. Two or more finish coats of Devshield 4328 Alkyd applied to a dry-film thickness of 1.5 to 2 mils, each. Total dry-film thickness of the complete system shall be 5 mils, minimum. 2.4 METAL, SUBMERGED OR INTERMITTENTLY SUBMERGED A. General: All submerged metalwork, gates, equipment, valves, exposed pipework and all other metalwork within areas which will be submerged, except as noted hereinafter, shall be painted with this coating system. B. Surface Preparation: All metal surfaces shall be field sandblasted according to SSPC- SP-10 (near white blast cleaning). C. Coating (Tnemec Alternate): Prime coat shall be Tnemec Series 69 Epoxoline II applied to a dry-film thickness of 4 to 6 mils. Two finish coats of Tnemec Series 69 Epoxoline II shall be applied to a dry-film thickness of 4 to 6 mils each coat. Total try- film thickness of the complete system shall be a minimum of 12 mils. D. Coating (Devoe Alternate): Apply two coats of Bar-Rust 233H Epoxy applied to a dry- film thickness of 6 to 8 mils each coat. Total dry-film thickness of the complete system shall be a minimum of 12 mils. 2.5 METAL, SEVERE EXPOSURE TO MOISTURE OR CHEMICAL FUMES A. Surface Preparation: All metal surfaces shall be field sandblasted according to SSPC- SP-10 (near white blast cleaning). B. Coating (Tnemec Alternate): Prime coat shall be Tnemec Series 104 H.S. Epoxy to a dry-film thickness of 6 to 10 mils. One or more finish coats of Tnemec Series 104 M.S. Epoxy topcoat shall be applied. Total dry-film thickness shall be a minimum of 12 mils. C. Coating (Devoe Alternate): Prime coat shall be Catha-Coat 304V Zinc, 2 to 3 mils dry- film thickness. Intermediate coat shall be Devran 224H Epoxy applied at 4 to 6 mils dry- film thickness. Finish coat shall be Devthane 379 Urethane applied at 2 to 3 mils dry- film thickness. Total dry-film thickness shall be 8 mils minimum. 2.6 METAL, HIGH-TEMPERATURE EXPOSURE A. General: Engine mufflers, exhaust systems and other metal surfaces subjected to high temperatures shall be coated with this system. B. Surface Preparation: Surface shall be field sandblasted in accordance with SSPC-SP- 10 (near white blast cleaning). JUNE 2004 4 of 9 SECTION 09900 Painting and Coating C. Coating (Tnemec Alternate): One coat of Tnemec Series 90-96 Tneme-Zinc to a minimum total dry-film thickness of 2 to 3.5 mils. D. Coating (Devoe Alternate): One coat of Catha-Coat 304V Zinc to a dry-film thickness of 2 to 4 mils. 2.7 METAL, GALVANIZED, ALUMINUM, COPPER, OR BRASS A. Surface Preparation: Surfaces shall be solvent cleaned in accordance with SSPC-SP-1 (solvent cleaning) and SSPC-SP-2 (hand tool cleaning). B. Coating: Pre-treatment prime coat shall be Tnemec Series 32-1215 Tneme-Grip or Sinclair 7113 Wash Primer applied at D mil dry-film thickness. Next, apply recommended coating or paint for the particular surface to be coated. C. Coating (Devoe Alternate): Pre-treatment prime coat shall be Devoe BarRust 231 primer applied at 3 mil dry-film thickness. Next, apply recommended coating or paint for the particular surface to be coated. 2.8 METAL, BURIED A. General: The Contractor shall coat all buried metal which includes valves, bolts, nuts, structural steel and fittings. It does not include steel storage reservoirs. B. Surface Preparation: Sandblast to SSPC-SP-6 (commercial blast cleaning) C. Coating (Tnemec Alternate): Prime none. Finish with two coats of Tnemec Series 46- 465 H.B. Tnemecol or equal at 10 to 12 mils dry-film thickness, each. Total dry-film thickness shall be 20 mils minimum. D. Coating (Devoe Alternate): Prime with Devtar221 (5A) Epoxy applied at 8 mil dry-film thickness. Two coats of Devtar (5A) Epoxy applied at 8 mils dry-film thickness, each. Total dry-film thickness shall be 24 mils, minimum. PART 3 - EXECUTION 3.1 GENERAL The Contractor shall arrange with the Owner's Representative so that all surface preparation may be inspected and approved prior to the application of any coatings. The Contractor is hereby notified that the Engineer will inspect the Work prior to the expiration of the warranty period and all defects in workmanship and material shall be repaired by the Contractor, at his own expense. JUNE 2004 5 of 9 SECTION 09900 Painting and Coating 3.2 WORKMANSHIP It is the intent of the Specif ications that finishes shall be provided which meet standards for best grades of painting. Drop cloths shall be placed where required to protect floors, surfaces and equipment from spatter and dropping, not to receive paint or coatings. The Contractor shall take all necessary precautions to protect all adjacent Work and all surrounding property and improvements from any damage whatsoever as a result of the painting and coating operation. Only good, clean brushes and equipment shall be used and all brushes, buckets, and spraying equipment shall be cleaned immediately at the end of each painting period. Each coat of paint shall be of the consistency as supplied by the manufacturer, or thinned, if necessary, and applied in accordance with manufacturer's instructions. Each coat shall be well brushed, rolled or sprayed to obtain a uniform and evenly applied finish. Work shall be free from "runs", "bridges", "shiners", or other imperfections due to faulty intervals. Particular care shall be taken to obtain a uniform unbroken coating overall bolts, threads, nuts, welds, edges and corners. Paint shall not be applied in extreme heat, in dust or smoke laden air, or in damp or humid weather, unless written permission of the Engineer is obtained. If paint is applied by spray, the air pressure used shall be within the ranges recommended by both the paint and spray equipment manufacturers. Spray painting shall be conducted under controlled conditions and the Contractor shall be fully responsible for any damage occurring from spray painting. Care shall be exercised not to damage adjacent Work during sandblasting operations. Stainless steel need not be sandblasted. Blasted surfaces shall not be left overnight before coating. All dust shall be removed from the surface following sandblasting. 3.3 APPLICATION PROCEDURES A. Surfaces to be Coated: All surfaces of materials furnished and constructed are to be painted or coated per the Specifications except as indicated below. B. Surfaces Not To Be Coated: The following surfaces shall not be coated unless otherwise noted on the Plans and shall be fully protected when adjacent areas are painted. Aluminum grating Grease fittings Nameplates on Aluminum surfaces Hardware machinery Bearings Lighting fixtures Machined Pipe interior* Brass and copper tubing, surfaces Shafts submerged* Metal letters Stainless steel Buried pipe Mortar-coated pipe and fittings Switch plates Couplings * unless specifically required on the Plans or elsewhere in the Specifications C. Protection of Surfaces Not To Be Coated: Surfaces not intended to be painted shall be removed, masked, or otherwise protected. Drop cloths shall be provided to prevent paint materials from falling on or marring adjacent surfaces. Working parts of mechanical and electrical equipment shall be protected from damage during surface preparation and painting process. Openings in motors shall be safely masked to prevent paint and other materials from entering the motors. All masking materials shall be completely removed and surfaces cleaned at completion of painting operations. JUNE 2004 6 of 9 SECTION 09900 Painting and Coating D. Weather Conditions: Paint shall not be applied in the rain, wind, snow, mist, and fog or when steel or metal surface temperatures are less than 5°F above the dew point. Paint shall not be applied when the relative humidity is above 80%, the air temperature is above 90°F, or the temperature of metal to be painted is above 125°F. Alkyd, chlorinated rubber, inorganic zinc, silicone aluminum, or silicone acrylic paints shall not be applied if air or surface temperature is below 50°F or expected to be below 50°F within 24 hours. Epoxy, coal tar epoxy, acrylic latex, and polyurethane paints shall not be applied on an exterior or interior surface if air or surface temperature is below SO°F or expected to drop below 50°F within 24 hours. 3.4 SURFACE PREPARATION A. General: Sandblast or prepare only as much surface area as can be coated in one day. All sharp edges, burrs, and weld spatter shall be removed. Epoxy-coated pipe that has been factory coated shall not be sandblasted. B. SSPC Specifications: Wherever the words "solvent cleaning", "hand tool cleaning", "wire brushing", or ".blast cleaning" or similar words are used in the Specifications or in paint manufacturer's specifications, they shall be understood to refer to the applicable SSPC (Steel Structures Paint Council, Surfaces Preparation Specifications, ANSI A159.1) Specifications listed below: SP-1 Solvent Cleaning SP-6 Commercial Blast Cleaning SP-2 Hand Tool Cleaning SP-7 Brush-Off Blast Cleaning SP-3 Power Tool Cleaning SP-8 Pickling SP-5 White Metal Blast Cleaning SP-10 Near White Blast Cleaning Oil and grease shall be removed from aluminum and copper surfaces in accordance with SSPC SP-1 using clean cloths and cleaning solvents. Weld spatter and weld slag shall be removed from metal surfaces. Rough welds, beads, peaked corners, and sharp edges including erection lugs shall be ground smoothly in accordance with SSPC SP-2 and SSPC SP-3. Welds shall be neutralized with a chemical solvent that is compatible with the specified coating materials using clean cloths and chemical solvent. C. Abrasive Blast Cleaning: Dry abrasive blast cleaning shall be used for metal surfaces. Do not recycle or reuse contaminated blast particles. Dry clean surfaces to be coated by dusting, sweeping, and vacuuming to remove residue from blasting. Apply the specified primer or touch-up coating within the period of an 8-hour working day. Do not apply coating over damp or moist surfaces. Reclean prior to application of primer or touch-up coating any blast cleaned surface not coated within said 8-hour period. Prevent damage to adjacent coatings during blast cleaning. Schedule blast cleaning and coating such that dust, dirt, blast particles, old coatings, rust, mill scale, etc., will not damage or fall upon wet or newly coated surfaces. JUNE 2004 7 of 9 SECTION 09900 Painting and Coating 3.5 PROCEDURES FOR THE APPLICATION OF COATINGS The recommendations of the coating manufacturer shall be followed, including the selection of spray equipment, brushes, rollers, cleaners, thinners, mixing, drying time, temperature and humidity of application, and safety precautions. Coating materials shall be kept at a uniform consistency during application. Each coating shall be applied evenly, free of brush marks, sags, runs, and other evidence of poor workmanship. A different shade or tint shall be used on succeeding coating applications to indicate coverage where possible. Finished surfaces shall be free from defects or blemishes. Only thinners recommended by the coating manufacturer shall be used. If thinning is allowed, do not exceed the maximum allowable amount of thinner per gallon of coating material. Apply a brush coat of primer on welds, sharp edges, nuts, bolts, and irregular surfaces prior to the application of the primer and finish coat. The brush coat shall be done prio r to and in conjunction with the spray coat application. Apply the spray coat over the brush coat. Apply primer immediately after blast cleaning and before any surface rusting occurs, or any dust, dirt, or any foreign matter has accumulated. Reclean surfaces by blast cleaning that have surface colored or become moist prior to coating application. A. Paint Mixing: Multiple-component coatings shall be prepared using all the contents of each component container as packaged by the paint manufacturer. Partial batches shall not be used. Multiple-component coatings that have been mixed beyond their pot life shall not be used. Small quantity kits for touch-up painting and for painting other small areas shall be provided. Only the components specified and furnished by the paint manufacturer shall be mixed. For reasons of color or otherwise, additional components shall not be intermixed, even within the same generic type of coating. B. Field Touch Up of Shop-Applied Prime Coats: Organic Zinc Primer: Surfaces that are shop primed with inorganic zinc primers shall receive a field touch up of organic zinc primer to cover all scratches or abraded areas. Organic zinc coating system shall have a minimum volume solids of 54% and a minimum zinc content of 14 pounds per gallon. Coating shall be of the converted epoxy, epoxy phenolic, or urethane type and shall be manufactured by the prime coat arid finish coat manufacturer. Other Primers: Surfaces that are shop primed with other than organic zinc primer shall receive a field touch up of the same primer used in the original prime coat. 3.6 DRY-FILM THICKNESS TESTING AND REPAIR A. Special Instructions to the Contractor: The Contractor shall furnish to the Owner at no charge for use during execution of the Work, necessary dry-film thickness gauge and electrical flaw detection equipment. The Contractor shall perform the holiday (pinholes) inspection in the presence of the Owner's Representative, and the Contractor shall monitor wet film measurements throughout the application of each coat of coating. JUNE 2004 8 of 9 SECTION 09900 Painting and Coating B. Coating Thickness Testing: Coating thickness specified for steel surfaces shall be measured with a magnetic-type dry-film thickness gauge. Dry-film thickness gauge shall be provided as manufactured by Mikrotest or Elcometer. Each coat shall be checked for the correct dry-film thickness. Measurement shall not be made until a minimum of eight hours after application of the coating. Non-magnetic surfaces shall be checked for coating thickness by micrometer measurement of cut and removed coupons. Contractor shall repair coating at all locations where coupons are removed. C. Holiday Testing: The finish coat (except zinc primer and galvanizing) shall be tested by the Contractor in the presence of the Engineer for holidays and discontinuities with an electrical holiday detector of the low-voltage, wet-sponge type. Detector shall be provided as manufactured by Tinker, Rasor, K-D Bird Dog, or approved equal. D. Repair: If the item has an improper finish, color, insufficient film thickness, or holidays, the surface shall be cleaned and top-coated with the specified paint material to obtain the specified color and coverage. Visible areas of chipped, peeled, or abraded paint shall be hand or power-sanded, feathering the edges. The areas shall then be primed and finish coated in accordance with the Specifications. Work shall be free of runs, bridges, shiners, laps, or other imperfections. 3.7 CLEANUP Upon completion of all painting and coating Work, the Contractor shall remove all surplus materials and rubbish. The Contractor shall repair all damage and shall leave the premises in a clean and orderly condition. END OF SECTION JUNE 2004 9 of 9 SECTION 09900 Painting and Coating SECTION 09902 PETROLATUM WAX TAPE COATING PART 1 - GENERAL 1.1 SCOPE This section covers the work necessary to furnish and install petrolatum wax tape coating on pipe, pipe flanges, fittings or other buried pipeline appurtenances, complete, as indicated on the drawings and specified herein. 1.2 SUBMITTALS DURING CONSTRUCTION Submit manufacturer's technical product data, details, installation instructions and general product recommendations. 1.3 PRODUCT IDENTIFICATION The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired only. Products of other manufacturers will be considered in accordance with the Contract Documents. PART 2-MATERIALS 2.1 GENERAL Wrap all exposed surfaces of buried ferrous pipe, flanges, couplings and other pipeline appurtenances (including bolts, nuts, etc.) with petrolatum wax tape, unless another corrosion protection system (other than a factory-installed paint coating) is otherwise specified or indicated by the Contract Drawings. Exposed piping shall be wrapped only where specifically called out on the Drawings. Ductile iron pipe encased with polyethylene sheathing shall not be wrapped with this product. 2.3 PRIMER Exposed surfaces shall be prime coated with a blend of petrolatum, plasticizer, and corrosion inhibitor having a paste-like consistency. The material shall have the following properties: Pour Point 400-100° F FlashPoint 350° F minimum Approximate Coverage 1 gal/100 square feet Color Brown The primer shall be Trenton Wax-Tape Primer or equivalent. JUNE 2004 1 of 2 SECTION 09902 Petrolatum Wax Tape Coating 2.3 WAX TAPE Two types of petrolatum wax tape shall be available from the manufacturer: one type for buried installations and another type for above-ground installations: 2.3.1 BURIED INSTALLATIONS The covering material shall be a plastic-fiber felt tape, saturated with a blend of petrolatum, plasticizers, and corrosion inhibitors that is easily formable over irregular surfaces. The tape shall have the following properties: Color: Brown Saturant Pour Point 115° -125°F Thickness 70-90 mils Dielectric Strength 170 volts/mil Tape Width 6 inches Wax tape shall be Wax-Tape #1 as manufactured by The Trenton Corporation (Ann Arbor, Michigan), or approved equal. 2.4 OUTER COVERING The primed and wax-tape wrapped surface shall be wrapped with a plastic tape covering consisting of three (3) layers of 50 gauge, clear, polyvinylidene chloride, high cling membranes wound together as a single sheet. The material shall have the following properties: Width 6 inches Thickness 1.5 mils Dielectric Strength 2000 volts/mil Water Absorption Negligible Color Clear The outer covering shall be Trenton Poly-Ply or approved equal. 2.5 OTHER PETROLATUM WAX TAPE SYSTEM COMPONENTS Any components not listed above, but required for a complete petrolatum wax tape coating system as recommended for this application by the manufacturer shall be provided at no additional cost to Owner. PART 3 - EXECUTION 3.1 GENERAL The petrolatum wax tape system shall be installed in conformance with the manufacturer's recommendations. END OF SECTION JUNE 2004 2 of 2 SECTION 09902 Petrolatum Wax Tape Coating SECTION 15000 GENERAL PIPING SYSTEM AND APPURTENANCES PART1 GENERAL 1.1 DESCRIPTION This Section describes the requirements and procedures for piping systems and appurtenances that apply to a number of other complimentary Specification Sections. The items are listed in this Section to avoid repetition in Sections elsewhere. This Section includes, but is not limited to: Temporary above ground piping (high line), wet taps, flexible pipe couplings, grooved and shouldered end couplings, joint restraint system, field touch up, bolts, nuts, polyethylene wrap, warning/identification tape, tracer wire, gate well and extension stems, meter boxes, abandonment and removal of existing facilities, and salvage. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. A. American National Standards Institute (ANSI) B. American Society for Testing and Materials (ASTM) 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings 1.4 SUBMITTALS Submit manufacturers' catalog data showing dimensions, materials of construction by ASTM reference and grade and coatings.. 1.5 LINING CONTAMINATION PREVENTION Volatile organic compounds present in the linings of items in contact with potable water or recycled water shall not exceed concentrations allowed by the latest requirements of the State Office of Drinking Water and Department of Health Services. Some products and materials may also require proof of NSF certification on the lining materials to be used. 1.6 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) High line piping, where shown on the Approved Plans or required by the District Engineer, shall be furnished, installed, disinfected, connected, maintained, and removed by the Contractor. Bacteriological sampling and testing shall be performed by a State of California Certified testing laboratory. The Contractor shall provide a submittal to the District showing pipe layout, materials, sizing, flow calculations, schedule and duration of use, and disinfection for all high line piping. The submittal shall be reviewed and approved by the Engineer prior to ordering or delivery of any materials. JUNE 2004 1of15 SECTION 15000 General Piping System and Appurtenances 1.7 PIPE TAPPING (WET TAP) All pipe tap (wet tap) connections to existing pipelines, whether for mainline extensions or service laterals, shall be performed by the Contractor under the inspection of the District. The Contractor shall provide materials and labor to excavate, pour thrust block, backfill, compact, and repair pavement as indicated in this Section. 1.8 JOINT RESTRAINT SYSTEM Joint Restraint Systems may be used for PVC or ductile-iron pipe only with prior approval of the District Engineer. Joint restraint systems shall be used in the place of, or in conjunction with, concrete thrust blocks as directed. Contractor shall submit shop drawings, calculations, and catalog data for joint restraint systems. Splined gaskets, also known as joint restraint gaskets, may be used for PVC or ductile- iron pipe located within casings, or for PVC pipe casings, only. 1.9 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be used for all ferrous metal materials not otherwise protectively coated. A. Polyethylene wrap shall be used for the protection of buried ductile-iron fittings and valves. B. Polyethylene sleeves shall be used for the protection of buried ductile iron pipe. C. Polyethylene wrap or sleeves may also be installed around buried PVC pipe for recycled water identification. 1.10 WARNING/IDENTIFICATION TAPE Warning/identification tape shall be used to identify location of underground utilities and to act as a warning against accidental dig-ins of buried utilities. Warning/identification tape shall be used on all underground water and recycled water mains, potable and recycled water irrigation systems, sewer mains, and all related appurtenances. Warning/identification tape shall also be used on cathodic protection wiring systems and tracer wire brought into and out of access ports. 1.11 GATE WELLS Gate Wells shall be used for buried valves 50mm (4") and larger, unless otherwise indicated on the Standard Drawings. Gate well box and lid shall be used on all gate wells. 1.12 VALVE STEM EXTENSION Valve Stem Extensions shall be installed when the valve operating nut is more than 1.5m (5') below grade. Stem extensions shall be of sufficient length to bring the operating nut to a point between 300mm (12") and 450mm (18") below the gate well lid. JUNE 2004 2 of 15 SECTION 15000 General Piping System and Appurtenances 1.13 METER BOXES A. Meter boxes shall be used for 25mm (1") and 50mm (2") water meters. B. Meter boxes shall be sized for the specific meter size or size as indicated on the Standard Drawings. 1.14 RECYCLED WATER IDENTIFICATION Facilities installed for the use of recycled water shall be identified with purple color coating, identification labels, or signs. 1.15 CURB IDENTIFICATION MARK FOR SERVICES The Contractor shall mark the location of all potable water, recycled water and sewer laterals at the curb crossing by stamping the face of the curb in 50mm (2") high letters as described below: A. Potable water laterals shall be stamped with a letter "W". B. Recycled water laterals shall be stamped with a letter "RW". C. Sewer laterals be stamped with a letter "S". PART 2 MATERIALS 2.1 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) High line piping layout, materials and appurtenances shall be as indicated on the approved submittal. 2.2 FLEXIBLE PIPE COUPLINGS Flexible pipe couplings shall be in accordance with the Approved Materials List and as described below: A. Steel Couplings shall have middle rings made of steel conforming to ASTM A 36/A 36M, A 53 (Type E or S), or A 512 having a minimum yield strength of 207 MPa (30,000 psi). Follower rings shall be ductile-iron per ASTM A 536, or steel per ASTM A 108, Grade 1018 or ASTM A 510, Grade 1018. Minimum middle ring length shall be 175 mm (7") for pipe sized 150 mm (6") through 600 mm (24"). B. Sleeve bolts shall be made of stainless steel per ASTM A193 and shall have a minimum yield strength of 276 MPa (40,000 psi), an ultimate yield strength of 414 MPa (60,000 psi), and shall conform to AWWA C111. JUNE 2004 3 of 15 SECTION 15000 General Piping System and Appurtenances 2.3 GROOVED END OR SHOULDERED COUPLINGS FOR DUCTILE IRON OR STEEL PIPE Groove end or shouldered couplings shall be in accordance with the Approved Materials List and as described betow: A. Use square-cut shouldered or grooved ends per AWWA C606. Grooved-end couplings shall be malleable iron per ASTM A 47, or ductile iron per ASTM A 536. Gaskets shall be per ASTM D 2000. B. Bolts in exposed service shall conform to ASTM A 183, 69 MPa (10,000 psi) tensile strength. 2.4 JOINT RESTRAINT SYSTEM Joint Restraint Systems shall be ductile-iron and shall consist of a split-ring restraint with machined (not cast) serrations - on the inside diameter, a back-up ring, and connecting bolts, and shall be selected from the Approved Materials List. Splined gaskets, also known as joint restraint gaskets, shall be a rubber-ring type with stainless steel locking segments vulcanized into the gasket. 2.5 FIELD TOUCH-UP APPLICATIONS All surfaces of metallic appurtenances in contact with potable water and not protected from corrosion by another system shall be shop-coated by the manufacturer. Appurtenances with damaged coatings shall be repaired or replaced as directed by the Engineer. Touch-up of damaged surfaces, when allowed by the Engineer, shall be performed in accordance with the manufacturer's recommendations. 2.6 BOLTS AND NUTS Bolts and nuts shall be as indicated below. A. Cadmium-plated or zinc-plated bolts and nuts shall be used for the installation of pipelines up to 500mm (20") diameter and shall be carbon steel conforming to ASTM A307, Grade A, unless otherwise indicated on the approved drawings. Bolts shall be standard ANSI B1.1, Class A coarse threads. Nuts shall be standard ANSI B1.1, Class 2H coarse threads. B. Stainless steel bolts and nuts shall be used for the installation of pipelines 600mm (24") diameter and larger and for submerged flanges. Bolts and nuts shall be Type 316 stainless steel conforming to ASTM A193, Grade B8M for bolts, and Grade 8M for nuts. Use lubricant for stainless steel belts and nuts. Lubricant shall be Husky Lube "O" Seal by Husk-ITT Corporation or equal C. All bolt heads and nuts shall be hexagonal, except where special shapes are required. Bolts shall be of such length that not less than 6.4mm (1/4") or more than 12.7mm (1/2") shall project past the nut in tightened position. D. Provide a washer under each nut and under each bolthead. Use washers of the same materials as the nuts. JUNE 2004 4 of 15 SECTION 15000 General Piping System and Appurtenances 2.7 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be as indicated below and shall be selected from the Approved Materials List. Polyethylene materials shall be kept out of direct sunlight exposure. A. Polyethylene sleeves shall be a minimum 0.305mm (0.012" or 12 mil) thick polyethylene plastic in accordance with AWWA C105. B. Polyethylene wrap shall be a minimum 0.203mm (0.008" or 8 mil) thick polyethylene plastic in accordance with AWWA C105. C. Polyethylene wrap and sleeves shall be clear for use with potable water and purple for use with recycled water. D. Polyethylene or vinyl adhesive tape a minimum of 50mm (2") wide or plastic tie straps shall be used to secure polyethylene encasement. 2.8 WARNING/IDENTIFICATION TAPE Warning/identification tape shall be as indicated below and in accordance with the Approved Materials List. A. Tape shall be an inert plastic film or metallic formulated for prolonged underground use that will not degrade when exposed to alkalies, acids and other destructive substances commonly found in soil. B. Tape shall be puncture-resistant and shall have an elongation of two times its original length before parting. C. Tape shall be colored to identify the type of utility intended for identification. Printed message and tape color shall be as follows: Printed Message Tape Color Caution: Waterline Buried Below Blue Caution: Recycled Waterline Buried Below Purple Caution: Cathodic Protection Cable Buried Below Red Caution: Electric Line Buried Below Red Ink used to print messages shall be permanently fixed to tape and shall be black in color with message printed continuously throughout. D. Tape shall be minimum 0.102mm (0.004" or 4 mil) thick x 150mm (6") wide with a printed message on one side. Tape used with the installation of onsite potable and recycled water irrigation systems shall be a minimum of 75mm (3") wide. JUNE 2004 5 of 15 SECTION 15000 General Piping System and Appurtenances 2.9 INSULATING UNIONS & COUPLINGS A. For insulating unions, use a molded nylong sealing sleeve mounted in a three- piece malcable-iron body (ASTM A47 or A197). Use thread ends when connecting to steel piping, and copper solder joint when connecting to copper piping. Minimum working pressure shall be 150 psi. B. Threaded insulating couplings shall provide dielectric protection from electrolytic corrosion at points where piping of dissimilar metals is joined. 2.10 GATE WELLS Valve gate wells shall be as indicated below in accordance with the Approved Materials List. A. Valve gate well size and material shall be as follows: B. - „ Valve Size, Larger than 100mm (4") +*'. . GaJiWeli Sfzeahd SlateriaL:. 200mm (8") diameter Class 1 50, C-900 PVC 1. 2. PVC gate wells for use in recycled water system applications shall be white. PVC gate wells for use in potable water system applications shall be white or blue. Gate well lids shall be as indicated below in accordance with the Approved Materials List. 1. Gate well box lids shall be circular ductile-iron, and shall include a skirt for a close fit inside the upper portion of the gate well. Lids shall be cast with the AGENCY NAME (CMWD) and the word WATER for use on potable water systems, and Recycled Water for recycled water systems. 2. Lids shall be Brooks 4TT with long skirt or approved equal. 3. Normally closed potable water valves and recycled water valves shall use box lids by Brooks 3RT or approved equal. 4. Lid sizes shall be as follows: '••'•'!• 'l • - Valves "•**' '«•• ; • ;. Larger than 1 00mm (4") where the speed limit is 56 km/h (35 mph) or greater Gate Well Lid S Machined ductile-iron frame and 200mm (8") lid with 150mm (6") long skirt JUNE 2004 6 of 15 SECTION 15000 General Piping System and Appurtenances 2.11 VALVE STEM EXTENSIONS Stem extensions shall be complete with operating nut, location ring, and lower socket to fit valve-operating nut. The configuration of the extension stem nut shall match that of the valve it operates. A. Stem extensions shall be square fiberglass tubing glued together to make a continuous one-piece unit used to a maximum length of 2.4m, eight feet (8'). B. Steel stem extensions shall be used where the maximum length of the extension exceeds 2.4m (8') or at the request of the District Engineer. Steel stem extensions may be round or square hot-dipped galvanized steel tubing of solid design (no pinned couplings permitted) with guides. 2.12 METER BOXES Meter boxes shall be polymer-type boxes with lids selected from the Approved Materials List. A. Meter box sizes shall be as follows: Meter Box Size 250mm x 500mm (12" x 20") 425mm x 750mm (17" x 30") Meter 0ox Uses, 25mm (1 ") water services 50mm (2") water services B. Meter box lids for use in potable water system applications shall be gray. C. Meter box lids for use in recycled water system applications shall be purple. 2.13 RECYCLED WATER IDENTIFICATION Materials used to identify pipe and appurtenances used for recycled water, not manufactured in purple color, shall be as described in Carlsbad Reclamation Rules & Regulation for Construction of Reclaimed Water Mains. PART 3 EXECUTION 3.1 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) A. All high line piping, fittings, and service connections shall be furnished, installed, and maintained by the Contractor, and the Contractor shall make connections to a water source designated by the District Engineer. B. All pipe, valves, fittings, hose and connections furnished by the Contractor shall be of good quality, clean, and suitable for conveying potable water in the opinion of the District Engineer. C. The high line pipe shall be installed in such a manner that it will not present a hazard to traffic and will not interfere with access to homes and driveways along its route. JUNE 2004 7 of 15 SECTION 15000 General Piping System and Appurtenances D. Valves shall be installed at 60m (200') intervals or as directed by the District Engineer. The use of pressure reducing valves (PRV) may be required as directed by the District Engineer. E. The Contractor shall be responsible for disinfecting all high lines, connections, and flushing. F. Following disinfection and acceptance of the high line as a potable water system, the Contractor shall maintain continuous service through the high line piping to all consumers normally served both directly and indirectly by the pipeline. G. Upon completion of the work, the Contractor shall remove the high line piping and appurtenances. H. If progress in making repairs to the high line is inadequate, the District Engineer, may order necessary corrective measures. Corrective measures may consist of directing District personnel or another contractor to complete the work. All costs for corrective measures shall be borne by the Contractor. 3.2 CONNECTION TO EXISTING FACILITIES (WET TAPS AND CUT-IN INSTALLATIONS) The Contractor shall furnish the tapping sleeve or tee, valves and all other materials as called for in the Standard Specifications in accordance with the Approved Materials List. The Contractor shall provide all equipment and labor required for the excavation and installation of the connection including, but not limited to, backfill and pavement replacement. In certain circumstances the Contractor may be required to provide a water truck, high line, and fittings as part of the equipment for making the connections. In addition, the Contractor shall assist the District in alleviating any hardship incurred during a shutdown for connections. Emergency standby equipment or materials may be required of the Contractor by the District Engineer. Wet taps or cut-in tee and valve installations shall be performed as follows: A. Prior to construction, Contractor shall pothole the existing pipe at the location of the proposed connection. The District shall inspect the pothole prior to Contractor's repair of trench. Refer to Section 01000 for protection of existing facilities. Contractor shall record the following information on as-built drawings: 1. Pipe size, outside diameter. 2. Pipe type such as ACP, PVC, Ductile-Iron or Steel. 3. Pipe class and/or pressure rating. 4. Elevation, grade, and alignment. 5. Location of collars, pipe bells, fittings or couplings, if found. Note: Collars, bells, fittings, or couplings shall not be within 18-inches of the outer dimension of the tapping saddle. 6. Potential conflicts with existing utilities. JUNE 2004 8 of 15 SECTION 15000 General Piping System and Appurtenances B. To facilitate the proposed connection and allow for slight adjustments in alignment, the Contractor shall leave a minimum 3.0m (10*) gap between the new pipe installation and the proposed connection point at the existing water main. The Contractor shall leave a gap longer than 3.0m (101) if conditions warrant, or if directed by the Engineer. C. The new pipeline shall have successfully passed pressure testing in accordance with Section 15044 and disinfection and bacteriological testing in accordance with Section 15041 prior to proceeding with the connection to the existing pipeline. D. After the City Engineer has given approval to proceed with the connection, the Contractor shall schedule with the District for the wet tap or cut-in installation. 1. Shutdowns will be scheduled at the convenience of the District. Shutdowns may be scheduled for nights or weekends if required. 2. The Contractor shall give the District a minimum of 5 working days notice prior to any proposed excavation or shutdown of existing mains or services. Scheduling shall be subject to approval by the District Engineer. 3. The District may postpone or reschedule any shutdown operation if, for any reason, the District Engineer believes that the Contractor is improperly prepared with competent personnel, equipment, or materials to proceed with the connection. 4. If progress in completing the connection within the time specified is inadequate, the Engineer may order necessary corrective measures. Corrective measures may consist of directing District personnel or another contractor to complete the work. All costs for corrective measures shall be borne by the Contractor. E. Contractor may proceed with excavation only after potholing has been completed, materials have been approved and delivered, and wet tap or cut-in installation has been scheduled with approved Connection Permit. 1. The Contractor shall saw-cut pavement, excavate and provide and install shoring and steel plating, when necessary, one day prior to the wet tap or cut-in installation. 2. The Contractor shall provide lights, barricades and traffic control in accordance with the agency of jurisdiction and as deemed necessary for the excavation by the Engineer. 3. The Contractor shall de-water existing mains in full compliance with NPDES standards where cut-in installations are required and shall be done in the presence of the Engineer and in accordance with Section 15041. Only District personnel are authorized to operate existing valves. The Contractor shall be responsible for any and all damage resulting from unauthorized operation of existing District facilities. JUNE 2004 9 of 15 SECTION 15000 General Piping System and Appurtenances 4. The Contractor under the inspection of the City shall perform the following work for wet taps and cut-in installations: a. Wet taps: Disinfect and install and tapping saddle and tapping valve and perform tapping operatbns. b. Cut-ins: Cut and remove portions of existing mains, and disinfect and install tees, valves, couplings, and appurtenances required to complete the closure. The Contractor shall discard pipe and appurtenances removed from service in accordance with this Section. 5. After the Contractor has performed tapping or cut-in operations, and the Engineer has given approval to proceed, the Contractor shall complete the installation as shown on the Approved Plans in accordance with the Standard Specifications including, but not limited to: a. Disinfecting and installing the pipe section(s) necessary to make the closure to the new system. b. Installing and setting the valve gate well(s) in accordance with the Standard Drawings. c. Installing thrust and anchor blocks in accordance with Section 03000. d. Completing all backfill and compaction of the trench in accordance with Section 02223. e. Repairing or replacing pavement as necessary. 3.3 FLEXIBLE PIPE COUPLINGS Flexible pipe couplings shall be installed in accordance with the manufacturers recommendations and as described below: A. Use plain-end pipe with flexible couplings per AWWA C200. Provide joint harnesses per AWWA M11 for aboveground applications or where indicated on the Approved Plans. B. Flexible couplings may be used only where indicated on the drawings. C. Clean oil, scale, rust, and dirt from the pipe ends and touch-up the epoxy coating and allow time for curing before installing the coupling. Clean the gaskets before installing. D. Follow the manufacturer's recommendation for Installation and bolt torque using a properly calibrated torque wrench. E. Lubricate the bolt threads with graphite prior to installation. JUNE 2004 10 of 15 SECTION 15000 General Piping System and Appurtenances 3.4 GROOVED-END OR SHOULDERED COUPLINGS FOR DUCTILE IRON OR STEEL PIPE Grooved-end or shouldered couplings shall be installed in accordance with the manufacturer's recommendations and as described below: A. Grooved-end or shouldered joint couplings shall be installed per AWWA C606 and the manufacturer's recommendations. B. Clean loose scale, rust, oil, grease, and dirt from the pipe or fitting groove and touch-up the epoxy coating as necessary, allowing time for curing before installing the coupling. C. Clean the gasket before installation. Apply a lubricant selected from the Approved Materials List to the gasket exterior including lips, pipe ends, and housing interiors. D. Fasten the coupling alternately and evenly until the coupling halves are seated. Follow the manufacturer's recommendation for bolt torque using a properly calibrated torque wrench. 3.5 JOINT RESTRAINT SYSTEM Joint Restraint Systems shall be installed in accordance with the manufacturers recommendations and as described below: A. Length of pipe to be restrained on each side of bends, tees, reducers and other fittings shall be determined by the Private Engineer or manufacturer of the restraint device. B. Split ring restraint shall be installed on the spigot end of pipe, connected to a back-up ring which seats behind the bell of the adjoining pipe or fitting. C. Restraint devices can be installed prior to lowering pipe into the trench. D. Splined gaskets, also known as joint restraint gaskets, shall be installed in accordance with the manufacturer's recommendations. 3.6 BOLTS AND NUTS A. All bolts and nuts shall be new and unused. B. Bolts and nuts shall be cleaned, if needed, by wire brushing and lubricated prior to assembly. C. Tighten nuts uniformly and progressively. D. Buried bolts and nuts shall receive a heavy coat of protective non-oxide grease coating selected from the Approved Materials List prior to being wrapped with polyethylene. JUNE 2004 11 of 15 SECTION 15000 General Piping System and Appurtenances E. All stainless steel bolts shall be coated with an anti-seize compound selected from the Approved Materials List. F. Bolts and nuts shall not be reused once tightened. Used bolts and nuts shall be discarded and removed from the job. 3.7 POLYETHYLENE ENCASEMENT A. Polyethylene encasement shall completely encase and cover all metal surfaces. Pipe: All ductile-iron pipe shall be encased with polyethylene sleeves in accordance with Method A described in AWWA C105, or with polyethylene wrap in accordance with Method C described in AWWA C105. Fittings: Fittings such as tees, bends and reducers shall be encased with polyethylene wrap in accordance with AWWA C105. Valves: Valves shall have only the stem and operating nut exposed and the wrap shall be attached so that valve operation will not disturb the wrapping or break the seal. B. Polyethylene sleeves shall be secured with polyethylene or vinyl adhesive tape or plastic tie straps at the ends and quarter points along the sleeve in a manner that will hold the sleeve securely in place during backfill. Polyethylene wrap shall be secured with polyethylene or vinyl adhesive tape in a manner that will hold the wrap securely in place during backfill. 3.8 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be installed as described below in accordance with the Standard Drawings. A. Tape shall be placed at the top of the pipe zone 300mm (12") above and centered over the utility intended for identification. Tape used with onsite potable and recycled water irrigation systems shall be installed at 150mm (6") above the pipe. B. Tape shall be installed with the printed side up and run continuously along the entire length of the utility intended for identification. Tape shall be installed on the main piping and all appurtenant laterals, including blowoffs, air valve assemblies, fire hydrants, and services. Tape splices shall overlap a minimum of 600mm (24") for continuous coverage. C. Tape shall be installed prior to placement of the Trench Zone Backfill. JUNE 2004 12 of 15 SECTION 15000 General Piping System and Appurtenances 3.9 GATE WELLS AND VALVE STEM EXTENSIONS Gate wells shall be installed as shown on the Standard Drawings and as described below: A. Gate wells shall be installed as shown on the Standard Drawings and as described below: B. Gate wells shall be color coated to identify the type and use of the valve installed. 1. The inside portion of the gate well lid and interior portion of PVC gate well shall be identified with a minimum 50mm (2") diameter painted identification marking. Paint color shall be as follows: Color Gate Well Lid and PVC Gate Well for: Red Normally Closed System Valves (NCV) White Resilient Wedge Gate Valves (RWGV) Green Butterfly Valves (BFV) 2. The top exterior portion of the gate well lid and ring shall be coated in accordance with Section 09910. C. Valve Stem Extensions shall be installed when the valve operating nut is more than 1.5m (51) below grade. Stem extensions shall be of sufficient length to bring the operating nut to a point between 300mm (12") and 450mm (18") below the gate well lid. Valve stem extensions shall be installed in accordance with the Standard Drawings. 3.10 METER BOX INSTALLATION Meter boxes shall be installed at the elevations and locations shown on the Approved Plans and in accordance with the Standard Drawings. Near the completion of the project, a final meter box adjustment to finish grade may be required. Water meters shall not be installed until final adjustments are made to the meter box and approved by the District. 3.11 ABANDONMENT OR REMOVAL FROM SERVICE OF EXISTING FACILITIES Before excavating for new mains that are to replace existing pipes or services, the Contractor shall make provisions for the continuation and maintenance of service to customers as directed by the District Engineer. Abandonment or removal from service of existing mains, appurtenances or water services shown on the Approved Plans or as called for by the District Engineer shall be as directed by the District Engineer. JUNE 2004 13 of 15 SECTION 15000 General Piping System and Appurtenances Abandonment or removal from service of existing mains, appurtenances or water services shown on the Approved Plans or as called for by the District Engineer shall be as indicated below and in accordance with the Standard Drawings: A. Abandonment in place: 1. Existing pipe 100mm (4") and smaller shall have a short section of pipe removed and pipe ends encased in concrete. 2. Existing pipe 150mm (6") through 350mm (14") shall be cut and plugged with concrete or shall be pressure-grouted at intervals of 60m (2001) as recommended by the Engineer. 3. Existing pipe 400mm (16") and larger shall be entirely filled by pressure- grouting or by blown sand as determined by the Engineer. 4. Existing pipe ends shall be filled with concrete. 5. All valves shall be removed with remaining pipe or fittings permanently sealed with blind flange or concrete plug. 6. Gate wells shall be cut 600mm (24") below grade and filled with 1 -2 slurry sack concrete or removed and replaced with compacted backfill. 7. Water service corporation stops shall be closed. Meter boxes and curb stops shall be removed. Service laterals shall be cut back a minimum of 24-inches below the finish grade. 8. Water services to be abandoned that are connected to pipelines that will remain in service shall be abandoned in-place. 9. Sewer laterals shall be cut and plugged with concrete or capped at the main as directed by the Engineer for the specific circumstance and material type identified. 10. Sewer access holes shall have the cover and frame, concrete ring, grade rings and cone section removed. Inlet and outlet piping shall be plugged with concrete, manhole void shall be filled with sand, and a 300mm (12") thick, reinforced concrete slab shall be poured over the top of remaining manhole. The Contractor shall backfill hole to ground surface with compacted select fill. B. Removal by excavation: 1. Existing pipe and appurtenances shall be removed from the ground as indicated on the Approved Plans or as directed by the District Engineer. JUNE 2004 14 of 15 SECTION 15000 General Piping System and Appurtenances 2. Contractor shall provide measures that allow for the removal of existing sewer mains and appurtenances with no leakage of raw sewage. Transportation of sewer mains and appurtenances removed from service shall be in waterproof trucks to prevent raw sewage from leaking on public streets. 3. Removal of asbestos-cement pipe (ACP) and sewer mains and appurtenances shall be in accordance with all applicable State and Federal requirements. Legal disposal is the responsibility of the Contractor. Obtain approval from the agency having disposal jurisdiction with respect to disposal sites. 4. Backfill, compaction, and surface repair of all excavations for removal of pipe and appurtenances shall be made in accordance with the Approved Plans, Section 02223 of the Standard Specifications, and the Standard Drawings. 3.12 SALVAGE When the Contractor is required to remove existing pipe and appurtenances, or portions thereof, from the ground, such material may, at the discretion of the Engineer, be considered salvage. All materials identified as salvage are considered property of the District. A. The Contractor shall remove and temporarily stockpile all materials identified as salvage in a safe location that will not disrupt traffic or shall deliver salvage to the District's Field Operations Yard as directed by the District Engineer. B. The Contractor shall legally dispose of all other materials in an appropriate manner. Disposal is the responsibility of the Contractor. Obtain concurrence from the agency having disposal jurisdiction with respect to disposal sites and transportation methods. 3.13 RECONNECTIONS A. The Contractor may encounter unused service laterals or appurtenant piping connected to an existing pipeline being replaced. Laterals and appurtenance piping that will not be connected to the new pipeline shall be abandoned as described in section 3.11. B. Existing service laterals or appurtenances to be connected to new pipelines shall be installed as shown on the Approved Plans or as directed by the District Engineer in accordance with the Standard Drawings. END OF SECTION JUNE 2004 15 of 15 SECTION 15000 General Piping System and Appurtenances SECTION 15041 DISINFECTION OF PIPING PART 1 GENERAL 1.1 DESCRIPTION This section describes requirements for disinfection by chlorination of potable and recycled water mains, services, pipe appurtenances and connections. 1.2 REFERENCED STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. A. American Water Works Association (AWWA). B300 Standard for Hypochlorites B301 Standard for Liquid Chlorine C651 Disinfecting Water Mains 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Specifications 15000,15044,15056,15057, 15061, and 15064 1.4 SERVICE APPLICATION A. All water mains and appurtenances taken out of service for inspection, repairs, or other activity that might lead to contamination shall be disinfected before they are returned to service. B. All new water mains and temporary high lines shall be disinfected prior to connection to the District's existing system. C. All components incorporated into a connection to the District's existing system shall be disinfected prior to installation. 1.5 SUBMITTALS A. A written disinfection and dechlorination plan signed by a certified chlorinator shall be submitted to the Engineer for review and approval prior to starting disinfection or dechlorination operations. Plan for disinfection method and procedure shall include equipment used to inject the chlorine solution, gauges or scales to measure the rate at which chlorine is injected, qualifications of personnel, testing location and schedule, source of water and water disposal locations. Personnel performing the disinfection shall demonstrate a minimum of five years experience in the chlorination and dechlorination of pipelines. B. Qualification of certified testing laboratory. C. Four copies of bacteriological test results to the Engineer upon completion of each test. D. Emergency Response Plan. JUNE 2004 1 of 6 SECTION 15041 Disinfection of Piping 1.6 DELIVERY, STORAGE AND HANDLING Chlorination and dechlorination shall be performed by competent individuals knowledgeable and experienced in the operation of the necessary application and safety equipment in accordance with applicable Federal, State and Local laws and regulations. The transport, storage and handling of these materials shall be performed in accordance with Code of Federal Regulations (CFR) 1910.120 Hazardous Waste Operations and Emergency Response, CFR 49.172 Hazardous Materials Regulations, and the General Industry Safety Orders of the California Code of Regulations, Title 8, Section 51 94. 1.7 CONCURRENT DISINFECTION AND HYDROSTATIC TESTING The specified disinfection of the pipelines may be performed concurrently with the hydrostatic testing in accordance with Section 15044. In the event repairs are necessary, as indicated by the hydrostatic test, additional disinfection may be required by the Engineer in accordance with this specification. 1.8 CONNECTION TO EXISTING MAINS Prior to connection to existing mains, disinfection and bacteriological testing shall be performed in accordance with this specification, and hydrostatic testing shall be performed per Section 15044. A District Connection Permit is required authorizing connection to an existing system shall and be given only on the basis of acceptable hydrostatic, disinfection and bacteriological test results. Connection to existing mains shall be performed in accordance with Section 15000. PART 2 MATERIALS 2.1 CHLORINE (GAS) A. Liquid chlorine contains 100-percent available chlorine and is packaged in steel containers in net weights of 68.1kg (150 Ib.) or 907.2kg (1 ton). B. Liquid chlorine shall be used with appropriate gas flow chlorinators, heaters, and injectors to provide a controlled, high-concentration solution feed to the water. The chlorinators and injectors shall be the vacuum-operated type. 2.2 SODIUM HYPOCHLORITE (LIQUID) Sodium hypochlorite is available in liquid form in glass or plastic containers, ranging in size from 0.95 L (1 Qt.) to 18.93 L (5 Gal.). The solution contains approximately 10% to 15% available chlorine. 2.3 TABLET OR GRANULAR HYPOCHLORITE Tablet or granular hypochlorite may be used if a solution container is utilized to provide a continuous feed method. JUNE 2004 2 of 6 SECTION 15041 Disinfection of Piping PART 3 EXECUTION 3.1 GENERAL A. Disinfection of pipelines shall not proceed until all appurtenances and any necessary sample ports have been installed and the Engineer provides authorization. B. Every effort shall be made to keep the water main and its appurtenances clean and dry during the installation process. C. All piping, valves, fittings, and appurtenances which become contaminated during installation shall be cleaned, rinsed with potable water, and then sprayed or swabbed with a 5 percent sodium hypochlorite disinfecting solution prior to installation. D. Water mains under construction that become flooded by storm water, runoff, or groundwater shall be cleaned by draining and flushing with metered potable water until clear water is evident. Upon completion, the entire main shall be disinfected using a method approved by the Engineer. 3.2 METHODS A. Chlorine (Gas) 1. Only vacuum-operated equipment shall be used. Direct-feed chlorinators, which operate solely from gas pressure in the chlorine cylinder, shall not be permitted. The equipment shall incorporate a backflow prevention device at the point of connection to the potable water source used to fill the line being tested. 2. The chlorinating agent shall be applied at the beginning of the system to be chlorinated and shall be injected through a corporation stop, a hydrant, or other approved connection to ensure treatment of the entire system being disinfected. 3. Only a certified, licensed chlorination and testing contractor shall perform gas chlorination work. The chlorination contractor must also possess a Grade II Treatment Plant Operator Certification from the State of California if required by the Engineer. B. Sodium Hypochlorite Solution (Liquid) 1. Sodium hypochlorite solution shall be used for cleaning and swabbing piping and appurtenances immediately prior to installation and for disinfecting all components of connections to the District's existing system. JUNE 2004 3 of 6 SECTION 15041 Disinfection of Piping 2. Sodium hypochlorite solution may be used for the initial disinfection of newly installed water mains. The solution shall be applied at a terminus of the system to be chlorinated using an injector which can adjust the amount of solution being injected into the piping system. The solution shall be injected in the appropriate concentration to achieve the specified concentration range of chlorine throughout the entire piping system. Where pumping equipment is used in conjunction with an injector, an integral backflow prevention device shall be used and connected to the potable water supply. 3. Water trucks, pumping equipment, piping, appurtenances and all other equipment in contact with potable water shall be disinfected prior to use. 4. Sodium hypochlorite solution may also be used to increase the total chlorine residual if the concentration from the initial chlorination of the system is found to be low. The solution shall be added to the system in sufficient amounts at appropriate locations to ensure that the disinfecting solution is present at a concentration within the specified range throughout the piping system. 3.3 PROCEDURE FOR DISINFECTING WATER MAINS AND APPURTENANCES A. The pipeline shall be filled at a rate not to exceed 1,135 liters per minute (300 GPM) or a velocity of 0.3m per second (1 foot per second), whichever is less. B. Disinfection shall result in a total chlorine concentration of not less than 25-mg/l. This concentration shall be evenly distributed throughout the system to be disinfected, using a continuous feed method of chlorination. C. All valves shall be operated with the disinfection solution present in the pipeline. All appurtenances such as air-vacuum relief valves, blowoffs, hydrants, backflow prevention devices, and water service laterals shall be flushed with the treated water a sufficient length of time to ensure a chlorine concentration within the specified range in all components of each appurtenance. (Note the limitations for discharge of chlorinated water outlined below.) D. The Engineer will verify the presence of the disinfection solution throughout the system by sampling and testing for acceptable chlorine concentrations at the various appurtenances and/or at the test ports provided by the Contractor. Areas of the system found to be below the specified chlorine concentration level shall receive additional flushing as noted above and/or additional disinfection solution as necessary. (Note the limitations for discharge of chlorinated water outlined below.) Addition of disinfection solution after the initial charging of the line shall be made by either the liquid chlorine (gas) method, or the sodium hypochlorite method as directed by the Engineer. JUNE 2004 4 of 6 - SECTION 15041 Disinfection of Piping E. The chlorinated water shall be retained in the system for a minimum of 24 hours. The District Engineer will test the total chlorine residual. The system shall contain a total chlorine residual of not less than 80% of the initial total chlorine residual before the 24-hour soaking period began. If the total chlorine residual has decreased more than 20%, the system shall be soaked for an additional 24-hour period. If the total chlorine residual has not deceased after this additional 24-hour period, the system shall be flushed in accordance with the procedure detailed herein. If the total chlorine residual has decreased, the system shall be flushed in accordance with the procedure detailed herein, and shall be re-disinfected. F. Following a successful retention period as determined by the District Engineer, the chlorinated water shall be flushed from the system at its extremities and at each appurtenance, using potable water from a source designated by the District Engineer. The minimum water velocity during flushing shall be 0.9 meters per second (3 feet per second) or as directed by the Engineer. Flushing shall continue until the replacement water in the new system is equal in chlorine residual to the potable source of supply as verified by the District. (Note the limitations for discharge of chlorinated water outlined below.) G. The Contractor shall contract with a State certified sampling laboratory to perform sampling, transport samples and perform bacteriological sampling,and testing as specified herein. 3.4 DISCHARGE OF CHLORINATED WATER A. Indiscriminate onsite disposal or discharge to sewer systems, storrn drains, drainage courses or surface waters of chlorinated water is prohibited. B. In locations where chlorine neutralization is required, the reducing agent shall be applied to the water as it exits the piping system. The Developer shall monitor the chlorine residual during the discharge operations. Total residual chlorine limits in these locations, and for the discharge of chlorinated water from the testing of pipelines to surface waters of the San Diego Region are as follows: Total Residual Chlorine Effluent Limitations 30-Day Average - 0.002 mg/l Average Daily Maximum - 0.008 mg/l Instantaneous Maximum - 0.02 mg/l The various methods of dechlorination available can remove residual chlorine to concentrations below standard analytical methods of detection, 0.02 mg/l, which will assure compliance with the effluent limit. The Developer will perform all necessary tests, keeping and providing records to the Engineer to ensure that the total residual chlorine effluent limitations listed above are met. C. In locations where no hazard to the environment is evident based on the joint examination described above, the chlorinated water may be broadcast for dust control on the surface of the immediate site. Care shall be exercised in broadcasting the water to prevent runoff. JUNE 2004 5 of 6 SECTION 15041 Disinfection of Piping 3.5 BACTERIOLOGICAL TESTING The Contractor shall employ a State certified laboratory to perform bacteriological sampling and testing of all new system installations. The testing methodology employed by the District shall be as set forth in "Standard Methods for the Examination of Water and Waste Water" (current edition). Testing requirements are as set forth in the California Domestic Water Quality and Monitoring Regulations and commensurate with current requirements for surface water testing. The testing laboratory will analyze the samples for the presence of coliform bacteria and heterotrophic-type bacteria (heterotrophic plate count). The evaluation criteria employed by the District for a passing test sample is as follows: A. Coliform bacteria: no positive sample, and B. Heterotrophic plate count (HPC): 500 colony forming units/ml or less. 3.06 REDISINFECTION If the initial disinfection fails to produce satisfactory bacteriological test results, the pipeline system shall be re-flushed and re-sampled. If the second set of samples does not produce satisfactory results, the pipeline system shall be re-chlorinated, flushed, and re-stamped. The chlorination, flushing, and sampling procedure shall continue until satisfactory results are obtained. Re-disinfection and retesting shall be at the Contractor's expense. 3.07 DISINFECTING TIE-INS AND CONNECTIONS Pipes, fittings, valves and all other components incorporated into connections with the District's existing system shall be spray disinfected or swabbed with a liquid chlorine solution in accordance with AWWA C651 and as specified herein. Upon connection to the main, the line shall be flushed as directed by the District Engineer. Disinfection by this method is generally limited to assemblies of 6m (20') or less in length. Alternate methods such as "predisinfection" prior to installation in accordance with AWWA C651 may be required at the discretion of the District Engineer. END OF SECTION JUNE 2004 6 of 6 SECTION 15041 Disinfection of Piping SECTION 15044 - HYDROSTATIC TESTING OF PRESSURE PIPELINES PART1 GENERAL 1.1 DESCRIPTION This section describes the requirements and procedures for pressure and leakage testing of all pressure mains. 1.2 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 15000,15041, 15056,15061, and 15064 1.3 REQUIREMENTS PRIOR TO TESTING A. Provide testing procedure submittal including testing pressure, testing schedule, test bulkhead locations, and water supply details. B. All piping, valves, fire hydrants, services, and related appurtenances shall be installed prior to testing. C. The pipe trench shall have trench zone backfill placed and compacted with a minimum of 0.76m (2.51) of material over the pipe. D. All concrete anchor blocks shall be allowed to cure a sufficient time to develop a minimum strength of 13.79 MPa (2,000 psi) before testing. E. Pressure tests on exposed and aboveground piping shall be conducted only after the entire piping system has been installed and attached to pipe supports, hangers or anchors as shown on the Approved Plans. F. Steel pipelines shall not be tested before the mortar lining and coating on all pipe lengths within the line have been in place for a minimum of fourteen (14) days. Cement-mortar lined pipe shall not be filled with water until a minimum of eight hours has elapsed after the last joint has been mortared. 1.4 CONCURRENT HYDROSTATIC TESTING AND DISINFECTION OF PIPELINES Hydrostatic testing of pipelines shall be performed prior to or concurrently with the disinfection operations in accordance with Section 15041. In the event repairs are necessary, as indicated by the hydrostatic test, the District may require additional disinfection in accordance with Section 15041. 1.5 CONNECTION TO EXISTING MAINS Hydrostatic testing shall be performed prior to connections to existing mains. A District Connection Permit authorizing connection to the existing system shall be given only on the basis of acceptable hydrostatic, disinfection and bacteriological test results. Connection to existing mains shall be performed in accordance with Section 15000. JUNE 2004 1of4 SECTION 15044 Hydrostatic Testing of Pressure Pipelines PART 2 MATERIALS 2.1 WATER A. Potable water shall be used for hydrostatic testing of potable and recycled water mains. B. Potable water shall be supplied by a District-approved source. Make-up water for testing shall also be potable water. C. A chlorinated water solution, in accordance with Section 15041, shall be used to charge the line and for make-up water when hydrostatic testing and disinfection operations are combined. D. Meet all applicable state and local requirements for disposal of testing water. 2.2 CONNECTIONS A. Testing water shall be supplied through a metered connection equipped with a backflow prevention device in accordance with Section 15112 at the point of connection to the potable water source used. B. The Contractor shall provide any temporary piping needed to deliver potable water to the piping that is to be tested. Temporary piping shall be in accordance with Section 15000. PARTS EXECUTION 3.1 GENERAL A. All water systems shall be pre-tested to insure passage of test prior to scheduling official test with inspector. B. The Contractor shall provide the District with a minimum of 48 hours' notice prior to the requested date and time for hydrostatic tests. C. The Contractor shall furnish all labor, materials, tools, and equipment for testing. D. Temporary blocking during the tests will be permitted only at temporary plugs, caps or where otherwise directed by the District. E. All valves and appurtenances shall be operated during the test period. The test shall be conducted with valves in the open position. The Contractor is not permitted to operate any valves on the District's system. F. At the onset of testing, all valves, air vacuum assemblies, blowoffs, and services shall be monitored for possible leakage and repairs made, if necessary, before the test proceeds. The appurtenances shall be monitored through the duration of the testing. JUNE 2004 2 of 4 SECTION 15044 Hydrostatic Testing of Pressure Pipelines G. For pipe with porous lining, such as cement mortar, the pipe shall be filled with water and placed under a slight pressure for a minimum of forty-eight (48) hours prior to the actual hydrostatic test. H. Testing shall be made before connecting the new line with the existing District pipes and mains. I. The pipeline should be filled at a rate such that the velocity of flow is less than 1 fps. J. Maximum length of pipe to be included in any one (1) test shall not exceed 2,500 linear feet or vertical elevation difference of 58 feet. 3.2 FIELD TEST PROCEDURE A. Before applying the specified test pressure, care shall be taken to release all air within the pipe and appurtenances to be tested. Air shall be released through services, fire hydrants, air release valves, or other approved locations. B. The leakage shall be considered as the total amount of water pumped into the pipeline during the test period. C. Apply and maintain the test pressure by means of a hydraulic force pump. D. Maintain the test pressure for the following duration by restoring it whenever it falls an amount of 5 psi: Pipe Diameter (inches) 18 and less 20 to 36 Greater than 36 E. After the test pressure is reached, use a meter to measure the additional water added to maintain the pressure. This amount of water is the loss due to leakage in the piping system. The allowable leakage for various sizes of PUC & DIP with rubber gaskets are shown in the following table: TYPE OF PIPE: P.V.C. & D.I.P. CLASSES: 150&200 Pipe Sizes Allowable Leakage (inches) Gals/4 hrs/1000'of pipe 4" .33 Gals 6" .50 Gals 8" .66 Gals 10" .83 Gals. 12" .99 Gals. 14" 1.16 Gals. 16" 1.32 Gals. 18" 1.49 Gals. 20" 1.66 Gals. 24" 1.98 Gals. JUNE 2004 3 of 4 SECTION 15044 Hydrostatic Testing of Pressure Pipelines F. The allowable leakage for welded steel pipe shall be zero gallons. G. The allowable leakage for piping having threaded, brazed, or welded (including solvent welded) joints shall be zero gallons. H. Repair and retest any pipes showing leakage rates greater than that allowed in the above criteria. 3.3 TEST PRESSURE Pipe sizes in excess of 16" diameter shall be tested at a pressure based on hydraulic gradient elevation (H.G.L) as shown on the drawings. If no test H.G.L is shown, the pipeline at the low point in test section shall be pumped to a hydrostatic test pressure of 75 p.s.i. in excess of the pressure class of pipe. Pressure shall be maintained for a duration shown in section 3.2 and shall be repumped when it falls an amount of 5 p.s.i. Pipe sizes 16" diameter and less shall be tested at 75 p.s.i. in excess to the pressure class of the pipeline. Pressure shall be maintained for a duration shown in section 3.2 and shall be repumped when it falls an amount of 5 p.s.i. The test pump gauge and meter shall be connected to the water main at a location other than the highest point in the line, in order to allow release of air from the high point. Means shall be provided for accurately measuring the quantity of water pumped through a meter and pumped into the pipe immediately, during and after the test period in order to maintain or restore the initial test pressure. All pipe, fittings, valves, services and appurtenances shall be subjected to the hydrostatic test and irrespective of the measured quantity of leakage, all detectable leaks shall be repaired by the Contractor at the contractor's expense and no cost to Carlsbad Municipal Water district. If a tested system is damaged or a leak occurs after official test the entire system or portion of system will be retested as directed by Inspector. END OF SECTION JUNE 2004 4 of 4 SECTION 15044 Hydrostatic Testing of Pressure Pipelines SECTION 15056 DUCTILE-IRON PIPE AND FITTINGS PART 1 GENERAL 1.1 DESCRIPTION This section includes materials and installation of ductile-iron pipe and fittings for potable water systems. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. ANSI B16.42 Ductil iron pipe flanges and flanged fittings, classes 150 and 300. ASTM A536 Specification for ductile iron castings. AWWA C104 Cement mortar lining for ductile iron pipe and fittings for water AWWA C105 Polyethylene encasement for ductile iron pipe systems AWWA C111 Rubber-gasket joints for ductile iron pipe AWWA C600 Installation of ductile iron water mains and their appurtencences 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 09910,15000,15044, 15061,15064 and 15108. 1.4 SERVICE APPLICATION Ductile-iron pipe shall be used only in specific areas, locations, and uses allowed by the District. 1.5 DESIGN REQUIREMENTS A. General: 1. Ductile-iron pipe and fittings shall be manufactured per AWWA C110, C111, C115, C150, C151, and C153. Gray-iron and cast-iron fittings or flanges shall not be used. 2. Ductile-iron fittings manufactured per AWWA C153 shall be installed on mains 300mm (12") and smaller only. 3. Joints for ductile-iron pipe and fittings shall be mechanical, flanged, or push-on in accordance with AWWA C110, C111, and C153. 4. Except as amended herein, or otherwise shown on the Approved Plans, joints for ductile-iron pipe and ductile-iron fittings shall have a pressure rating equal to or greater than the adjacent piping. JUNE 2004 1 of 8 SECTION 15056 Ducile-lron Pipe and Fittings 5. Joints in buried piping may be of the push-on, flanged or mechanical-joint type per AWWA C111 except where particularly specified on the Approved Drawings. 6. Joints that are aboveground, within structures, or submerged shall be flanged unless otherwise shown on the Approved Plans. B. Unless otherwise specified, ductile-iron flanges shall be in accordance with AWWA C115, rated at a working pressure of 1,724 KPa (250 psi). Where required in order to connect to the flanges of 1,724 KPa (250 psi) butterfly valves, or as otherwise shown on the approved plans, ductile-iron flanges shall be compatible with AWWA C207, Class "F". Maximum working pressure of flanges shall be as specified in AWWA or ASME/ANSI. Flanges shall be integrally cast per AWWA C110 or shop-threaded per AWWA C115. Flanges shall be solid. Hollow-back flanges are not permitted. Gray-iron or cast-iron flanges are not permitted. Threading of flanges in the field is not permitted. Where threaded flanges are used, the pipe or spool piece to which they are connected will be hydrostatically tested in the presence of the Engineer prior to installation. The pipe section or spool piece shall be hydrostatically tested for 15 minutes at the pressure rating of the flanges. No leaks shall be permitted. C. Plain ends shall conform to the requirement of AWWA C151 and to the dimensions included within AWWA C110 to accept a mechanical joint, push-on joint, flanged coupling adaptor, flexible coupling, or grooved coupling. Refer to Section 15000 for coupling descriptions. D. The exterior surfaces of all pipe and fittings shall be factory coated with a minimum one-(1) mil thick petroleum asphaltic material per AWWA C110 and C151. E. All pipe and fittings shall be cement-mortar lined in accordance with AWWA C104, using the double thickness requirements indicated in said standard. Type II or Type V Portland cement per ASTM C 150 shall be used. 1.6 QUALITY ASSURANCE A. The manufacturer of each shipment of pipe shall be required to supply a statement certifying that each lot or load of pipe and fittings has been subjected to and met the tests specified for ductile-iron pipe and fittings per AWWA C110, C111, C115, C150, C151, and C153, as applicable. B. All pipe shall have a home mark on the spigot end to indicate proper penetration when the joint is made. C. Ductile-iron pipe shall bear indelible identification markings as required by AWWAC151. JUNE 2004 2 of 8 SECTION 15056 Ducile-lron Pipe and Fittings 1.7 SUBMITTALS The following items shall be submitted and reviewed by the District prior to shipping of ductile-iron pipe and fittings: A. An affidavit of compliance with AWWA C104, C110, C111, C115, C150, C151, C153, and the requirements of this specification. B. Typical joint details. C. Typical details and description of lining and coating. D. Calculations supporting selected wall thickness. E. Calculations demonstrating that each proposed restrained joint arrangement can resist the applied forces. F. Cathodic protection materials. 1.8 DELIVERY, STORAGE, AND HANDLING Delivery, storage, and handling of ductile-iron pipe and fittings shall follow the recommendations of AWWA C600 and as specified herein: A. Handling of pipe shall be performed with lifts, cranes, or other suitable equipment and devices. Slings, hooks, or pipe tongs shall be padded and used in such a manner as to prevent damage to the pipe, linings, and coatings. The pipes shall not be dropped or dragged. B. During transport, the pipe shall be supported and secured against movement using padded devices in such a manner to prevent damage. C. Stored pipe shall be protected from damage and kept free from dirt and foreign materials by closing the ends of the pipe. Other pipeline materials shall be protected by appropriate packaging or wrapping. Gaskets shall be stored in a cool location out of direct sunlight. Bolts, nuts, and washers shall be handled and stored in a dry location in a manner that will ensure proper use with respect to types and sizes. D. Pipe laid out for installation shall be placed on earth berms or timber cradles adjacent to the trench in the numerical order of installation. E. Maintain plastic end caps on all pipe and fittings in good condition until the pipe is ready to be installed in the trench. Periodically open the plastic end caps and spray clean potable water inside the pipe for moisture control. F. Under no circumstances shall ropes or other devices be attached through the fitting's interior for handling. JUNE 2004 3 of 8 SECTION 15056 Ducile-lron Pipe and Fittings 1.9 RECYCLED WATER IDENTIFICATION Ductile-iron pipe and fittings for recycjed water shall be identified with purple-colored coating, purple polyethylene sleeves, identification labels or signs in accordance with Section 15151. 1.10 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be installed for buried ductile-iron pipe and fittings in accordance with Section 15000. 1.11 TRACER WIRE Tracer wire shall be installed for ductile-iron pipe and fittings in accordance with Section 15000. 1.12 WARNING/IDENTIFICATION TAPE Warning/Identification tape shall be installed for ductile-iron pipe and fittings in accordance with Section 15000. PART 2 MATERIALS 2.1 DUCTILE-IRON Ductile-iron pipe and appurtenant components and materials shall be selected from the Approved Materials List in accord with the Standard Drawings. 2.2 GASKETS A. Mechanical joint rubber gasket configuration and materials shall comply with AWWA C111, and according to the applicable joint type and pressure rating of the piping system. B. Flange gaskets shall be 3.2mm (1/8") thick acrylic or aramid fibers bound with nitrite for all sizes of pipe. Gaskets shall be full-face type with pre-punched holes. Ring gaskets extending to the inner edge of the bolt circumference may be used only upon approval of the District Engineer. C. Push-on joint rubber gaskets shall be per AWWA C111. D. If organic, solvents or petroleum products are encountered during the course of the work, alternate gasket materials or joint treatment may be required by the Engineer. 2.9 BOLTS AND NUTS FOR FLANGES Bolts and nuts shall be in accordance with Section 15000 and shall be selected from the Approved Materials List. 2.10 WARNING/IDENTIFICATION TAPE Warning/Identification tape materials shall be in accordance with Section 15000 and selected from the Approved Material List. JUNE 2004 4 of 8 SECTION 15056 Ducile-lron Pipe and Fittings PART 3 EXECUTION 3.1 GENERAL At all times when the work of installing pipe is not in progress, including worker break times, ends of the pipe shall be closed with a vermin-proof and child-proof cap or plug. Do not permit trench water to enter the pipe. Do not place tools, clothing, or other materials in the pipe. The Contractor shall maintain the interior of the pipe in a sanitary condition free from foreign materials. 3.2 TRENCHING, BACKFILLING AND COMPACTING Trenching, backfilling and compacting shall be performed in accordance with SSPWC. 3.3 DEWATERING The Contractor shall provide and maintain at all times during construction ample means and devices to promptly remove and dispose of all water from any source entering trench excavations or other parts of the work. Any damage caused by flooding of the trench shall be the Contractor's responsibility. Dewatering shall be performed by methods that will maintain a dry excavation, preservation of the final lines and grades and protection of all utilities. If flooding of the trench does occur, the Contractor shall immediately dewater and restore the trench. Damaged or altered pipeline appurtenances or trench materials shall be repaired or replaced as directed by the Engineer. 3.4 PIPE INSTALLATION When the work requires and the size of the pipe allows entry of personnel into the pipe, the Contractor shall comply with all Federal and State regulations for confined space entry. Work inside pipelines shall not be undertaken until all the tests and safety provisions of the Code of Federal Regulations 1910.146, and the General Industry Safety Orders of the California Code of Regulations, Title 8, Section 5159 for confined space entry have been performed and the area is verified as safe to enter. The Contractor shall furnish and install all pipe, specials, fittings, closure pieces, valves, supports, bolts, nuts, gaskets, jointing materials, and all other appurtenances as shown on the Approved Plans and as required to provide a complete and workable installation. Install pipe in the trench as follows: A. Inspect each pipe and fitting before lowering the pipe or fitting into the trench. Inspect the interior and exterior protective coatings. Patch damaged areas in the field with material recommended by the protective coating manufacturer. Thoroughly clean the ends of the pipe. Remove foreign matter and dirt from inside of the pipe and keep pipe clean during and after installation. B. Install pipe according to the manufacturer's approved order of installation. Install pipes uphill if the grade exceeds 10%. Lower the pipe onto the bedding at the proper lines and grades. JUNE 2004 5 of 8 SECTION 15056 Ducile-lron Pipe and Fittings C. The manufacturer's printed installation guide outlining the radius of curvature that can be negotiated with pipe sections of various lengths shall be followed, except they shall not exceed the deflections allowed in AWWA C600 according to joint type. Combined deflections at rubber gasket or flexible coupling joints shall not exceed that recommended by the manufacturer. D. The pipe shall have firm bearing along its full length, and bell holes shall be provided at each joint to permit visual inspection of the joint and prevent the pipe from being supported by the bell end or coupling. E. Pipe Assembly: 1. Push-On Type: Assemble the pipe joint using a lubricant selected from the Approved Materials List. Insert the spigot end into the bell or coupling to the proper insertion mark. Check that the elastomeric ring has not left the groove during assembly by passing a feeler gauge around the completed joint. Drive spigot ends of the pipe into bell ends in accordance with the manufacturer's recommendations. Stabbing shall not be permitted. 2. Mechanical Joint Type: Assembly of mechanical joint fittings shall be in accordance with the manufacturer's recommendations regarding installation. F. During installation operations, do not place tools, clothing, or other materials in the pipe. G. When pipe installation is not in progress, including worker break times, ends of the pipe shall be closed with a vermin-proof and child-proof cap or plug. Do not permit trench water, animals, or foreign material to enter the pipe. 3.5 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be used for the buried installation of ductile iron pipe and fittings and shall be installed in accordance with Section 15000. 3.6 FLANGED PIPE AND FITTINGS Flanged connections shall be installed where indicated on the Approved Drawings. A. Bolt holes shall straddle the horizontal and vertical centerlines. B. The bolts, nuts and flange faces shall be thoroughly cleaned by wire brush prior to assembly. C. Bolts and nuts shall be lubricated with a District-approved anti-seize compound. D. Nuts shall be tightened in an alternating "star" pattern to the manufacturer's recommended torque. E. Coat the exterior of exposed flanges, bolts and nuts located aboveground or within vaults in accordance with Section 09910. JUNE 2004 6 Of 8 SECTION 1S056 Ducile-lron Pipe and Fittings 3.7 MECHANICAL JOINT CONNECTIONS A. Install mechanical joint connections per AWWA C600 and the manufacturer's recommendations. B. Prior to installation of the mechanical joint, clean the socket and plain end of the pipe. Lubricate both the gasket and plain end of the pipe with an approved lubricant per AWWA C111 immediately prior to slipping the gasket onto the plain end of the pipe. C. tighten the bolts to the normal range of bolt torque per the manufacturer's recommendations and AWWA C600k, Table 3, as follows: Pipe Diameter Bolt Size Range of Torque 75 mm (3") 16 mm (5/8") 61-81 N-M (45-60 ft.-lb.) 100-600 mm (4-24") 19 mm (3/4") 102-122 N-M (75-9O ft.-lb.) 750-900 mm (30-36") 25 mm (1') 136-163 N-M (100-120 ft.-lb.) 3.8 CROSSES A. Each flanged ductile-iron cross shall be installed with flanged ductile-iron pipe spools between the cross and the valves. The spools are included to position the valves a sufficient distance from the cross to allow installation of the thrust blocks without conflicting with the valve actuators. B. The spools shall be 450mm (18") long for pipe sizes 200mm (8") through 300mm (12"), and 600mm (24") long for pipe sizes 400mm (16") and larger. C. The spools shall be equal in class to the adjacent pipe. 3.9 JOINT BONDING AND CATHODIC PROTECTION Bonding of joints to provide continuity, flange insulation kits, internal epoxy linings, and other cathodic protection items and materials shall be installed where shown on the Approved Plans in accordance with the Standard Drawings and Section 13110. 3.10 COUPLINGS FOR DUCTILE-IRON PIPE Mechanical type flexible joints shall be installed where shown on the Approved Drawings. Grooved couplings shall be used in vaults and above ground. Flexible couplings may be used, where indicated on the drawings, below ground, but may also be used above ground with restrained joints. Flanged coupling adapters shall be used for buried pipelines, where allowed by the District. A. Grooved joint couplings shall be installed per AWWA C606 and as indicated in Section 15000. B. Flanged coupling adapters, where allowed by the District, shall be installed per the manufacturer's recommendations. JUNE 2004 7 of 8 SECTION 15056 Ducile-lron Pipe and Fittings C. Flexible couplings shall be installed per Section 15000 and the manufacturer's recommendations. D. All couplings for ductile-iron pipe shall be shop-coated in accordance with Section 15000. 3.11 CONCRETE Concrete thrust and anchor blocks shall be installed in accordance with SSPWC and the Standards Drawings. 3.12 WARNING/IDENTIFICATION TAPE Warning/Identification tape shall be installed in accordance with Section 1500O and the Standard Drawings. 3.13 DISINFECTION AND BACTERIOLOGICAL TESTING Disinfection, bacteriological testing, and flushing shall be performed in accordance with Section 15041. 3.14 HYDROSTATIC TESTING Field hydrostatic testing shall be performed in accordance with Section 15044. END OF SECTION JUNE 2004 8 of 8 SECTION 15056 Ducile-lron Pipe and Fittings SECTION 15057 COPPER TUBING, BRASS AND BRONZE PIPE FITTINGS PART1 GENERAL 1.1 DESCRIPTION This section includes materials and installation of copper tubing, brass and bronze pipe fittings and appurtenances. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. ANSI B1.20.1 Pipe treads, general purpose ANSI B16.18 Case copper alloy solder joint pressure fittings 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 15000,15041,15044,15056,15061 and 15064 1.4 SERVICE LATERAL WET TAP CONNECTIONS Contractor shall perform all wet tap connections to existing pipelines in accordance with Section 1500. 1.5 RECYCLED WATER IDENTIFICATION Copper Tubing, Brass, and Bronze Pipe Fittings for recycled water shall be identified with purple color coating, purple polyethylene sleeve, identification labels or signs in accordance with Section 15151. 1.6 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be used for all copper tubing, except that which is bored or jacked, in accordance with Section 15000. PART 2 MATERIALS 2.1 COPPER TUBING Copper tubing shall conform to the requirements of ASTM B 88 Type K or ASTM B 88 M (Metric) Type A seamless copper water tube. Copper tubing up to 25mm (1") diameter shall be soft; 50mm (2") may be soft or rigid. Components shall be selected from the Approved Materials List in accordance with the Standard Drawings. JUNE 2004 1of3 SECTION 15057 Copper Tubing, Brass and Bronze Pipe Fittings 2.2 BRASS PIPE, NIPPLES, AND FITTINGS Threaded nipples, brass pipe and fittings shall conform to ASTM B 43, regular wall thickness. Threads shall conform to ANSI B1.20.1. Fittings shall be flared or silver soldered pr CMWD Standard Drawings W3 and W4. 2.3 BRONZE APPURTENANCES A. Corporation stops, curb stops, meter and angle meter stops, meter flange adapters, and bronze-bodied service saddles shall be selected from the Approved Materials List in accordance with the Standard Drawings. B. Fittings shall be flared type or silver soldered. C. All items specified herein shall be manufactured of bronze conforming to ASTM B 62. D. Service saddles shall be the double strap type. Service saddles shall be used on all service and appurtenance connections on PVC piping. For piping materials other than PVC, service and appurtenance connections shall be performed in accordance with the Approved Drawings. 2.4 BOLTS AND NUTS FOR FLANGES Bolts and nuts shall be in accordance with Section 15000 and the Approved Materials List. 2.5 WARNING/IDENTIFICATION TAPE Warning/Identification Tape materials shall be in accordance with Section 15000 and shall be selected from the Approved Materials List. PART 3 EXECUTION 3.1 COPPER TUBING AND FITTINGS A. Trenching, bedding, backfilling and compacting shall be performed in accordance with CMWD Standard Drawings. Provide a minimum cover of 760mm (30") below finished street grade. B. Cut tubing true and square and remove burrs. C. Bends in soft copper tubing shall be long sweep. Shape bends with shaping tools. Form bends without flattening, buckling, or thinning the tubing wall at any point. D. Assemble copper tubing and fittings per the manufacturer's recommendation in accordance with the Standard Drawings. JUNE 2004 2 of 3 SECTION 15057 Copper Tubing, Brass and Bronze Pipe Fittings E. Install warning/identification tape in accordance with Section 15000 and the Standard Drawings. F. All fittings shall be soldered or flared as shown on the Approved Plans and Standard Drawings. 3.2 SERVICE SADDLES A. Service saddles shall be located a minimum of 600mm (24") from any pipe joint or fittings. B. Service saddles for connections shall be located a minimum of 600mm (24") from other saddles. Additionally, multiple service saddles for connections that are installed on the same side of a single pipe length shall be alternately staggered between 10o and 30o to prevent a weak plane in the pipe. C. The surface of the pipe shall be clean and all loose material shall be removed to provide a hard, clean surface. D. The service saddle shall be tightened in accordance with the manufacturer's recommendations to ensure a tight seal, using care to prevent damage or distortion of the service saddle or corporation stop due to over-tightening. E. The tap into the pipe shall be made in accordance with the pipe manufacturer's recommendation. Tapping tools and shell cutters with internal teeth or double slots that will retain the coupon shall be used. 3.3 DISINFECTION AND BACTERIOLOGICAL TESTING Disinfection, bacteriological testing, and flushing shall be performed in accordance with Section 15041. 3.4 HYDROSTATIC TESTING Reid hydrostatic testing shall be performed in accordance with Section 15044. END OF SECTION JUNE 2004 3 of 3 SECTION 15057 Copper Tubing, Brass and Bronze Pipe Fittings SECTION 15061 CEMENT-MORTAR LINED AND COATED STEEL PIPE AND SPECIALS PART1 GENERAL 1.1 DESCRIPTION This section includes materials, design, fabrication, and installation of cement-mortar lined and coated steel pipe and specials. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. AWWA C200 Steel Water Pipe 6-inches and Larger AWWA C205 Cement-Mortar Protective Lining and Coating AWWA C206 Field Welding of Steel Water Pipe AWWAC207 Steel Pipe Flanges AWWA C208 Dimensions for Fabricated Fittings AWWAC209 Cold Applied Tape Coating for the Exterior of Special Sections, Connection and Fittings for Steel Water Pipelines AWWA C210 Coal-tar Epoxy Coating System for Interior and Exterior of Steel Water Pipelines AWWA C213 Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines AWS Standard Qualification Procedure for Manual Welding Operators ASME Boiler and Pressure Vessel Code AWWAC214 Tape Coatings Systems for the Exterior of Steel Water Pipeline 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 15000, 15041,15044, 15074,15100, 15102 and 15108. 1.4 SERVICE APPLICATION Cement-mortar lined and coated steel pipe and specials shall be used only for specific purposes as shown on the Approved Plans. Generally, cement-mortar lined and coated steel pipe shall be used for transmission mains of 24" or larger. 1.5 SPECIALS A special is defined as any piece of pipe other than a normal full length of straight pipe. This includes, but is not limited to, elbows, short pieces, reducers, tees, crosses, spools, sections with outlets, beveled sections and access holes. 1.6 SUBMITTALS JUNE 2004 1of18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials The Contractor shall furnish submittals in accordance with Section 2-5.3, Submittals Shop Drawing. Submittals are required for the following: A. Submit Shop Drawings, material lists, manufacturer's literature and catalog cuts of, but not limited to, the following: Shop Drawings Fabrication Details Layout Schedule Dimensional Checks Manufacturer's tests Protective Coatings Mill Reports or Plant Test Reports Welding Rods for Field Welding Shop Drawings shall be submitted and approved prior to manufacture of pipe. The layout schedule shall indicate the order of installation, the length and location of each pipe section and special, the station and elevation of the pipe invert at all changes in grade, and all data on curves and bends for both horizontal and vertical alignment. B. Submit data used by the Contractor in manufacture and quality control. C. Test reports showing the physical properties of the rubber used in the gaskets shall be submitted. 1.7 PAYMENT A. Payment for the Work in this section shall be included as part of the lump-sum or unit-price bid amount for which such Work is appurtenant thereto. B. Payment by the linear foot shall be for each diameter and for each pipe strength designation measured horizontally over the pipe centerline. 1.8 QUALITY ASSURANCE A. Cement-mortar lined and coated steep pipe shall be inspected at the supplier's manufacturing plant by the District Engineer. Developer shall be responsible for District Engineer's expenses, including travel, time, meals and overnight accommodations. Overnight accommodations and air travel may be required, at the discretion of the Engineer, if the manufacturing plant is more than 100 miles from the District Engineer's office. B. In addition to the shop hydrostatic testing performed on pipe cylinders required per AWWA C200, all welds of specials and attachments (i.e., joint rings and nozzles) shall be tested by a dye-penetrant process. Certification of such testing shall be submitted to the District. C. Field welders shall be certified under Section IX, Part A of the ASME Boiler and Pressure Vessel Code or in accordance with AWWA C206, Section 3. Welders shall present a copy of their certification to the District prior to performing any field welding. Certifications shall be dated within three (3) years of the job to be performed. JUNE 2004 2 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials D. Plainly mark each length of straight pipe and each special at the bell end to identify the proper location of the pipe item by reference to the layout schedule. E. The top of all pipe and specials shall be clearly identified by marking the top with "T.O.P." for easy identification in the field. 1.9 DELIVERY, STORAGE, AND HANDLING Delivery, storage, and handling of the pipe and specials shall be as follows: A. Pipe and fittings shall be carefully handled and shall be protected against damage to linings and coatings due to impact shocks. Pipe shall not be placed directly on rough ground but shall be supported in a manner which will protect the pipe against injury whenever stored at the site or elsewhere. Pipe shall be handled and stored per these requirements and in accordance with the Manufacturer's recommendations. B. Temporary internal bracing shall be installed in all pipe 600mm (24") and larger prior to shipment to the job site. Temporary internal bracing shall be 100mm x 100mm (4" x 4") wooden struts installed in both the horizontal and vertical directions. Each set of struts shall be nailed together as a unit. Wooden wedges may be used to maintain the proper tight fit of the internal bracing. The bracing shall be located 300mm (12") in from each end of the pipe section for all pipe, and additionally at the mid-point for piping 800mm (30") and larger. Maintain internal bracing as specified under Pipe Installation. C. Transport pipe to the job site on padded bunks with nylon tie-down straps or padded bonding to protect the pipe. D. Pipes and specials shall only be handled with appropriate spreader bars and wide nylon slings. Chains or wire rope slings shall not be used. Under no circumstances shall pipe or specials be pushed or dragged along the ground. All pipe sections over 6m (20') in length shall be lifted at the quarter points from each end. E. Store pipe on earth berms or timber cradles adjacent to the trench in the numerical order of installation. Place the supports at about one-quarter point from the pipe ends. F. Maintain plastic end caps on all pipe and specials in good condition until the pipe is ready to be installed in the trench. Periodically open the plastic end caps and spray potable water inside the pipe for moisture control. JUNE 2004 3 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials PART 2 MATERIALS 2.1 PIPE DESIGN REQUIREMENTS Pipe manufacturing shall be the product of one company in the business of designing and manufacturing cement-mortar lined, tape wrapped and mortar coated steel pipe. The pipe shall consist of the following components: A welded steel cylinder with joints formed integrally with the steel cylinder or with steel joint rings welded to the ends; A centrifugally-cast cement-mortar lining; A self-centering bell and spigot joint with a circular preformed elastomeric gasket, so designed that the joint will be watertight under all conditions of service; Tape wrapping of the cylinder over a dielectric coating; A dense, concentric, steel reinforced exterior cement-mortar coating. The Plans indicate the elevations and alignment of the pipeline, the nominal inside diameter of the lined pipe, and the minimum steel cylinder thickness or design pressure (adjusted to satisfy transient conditions). Design soil cover shall be as stated on the Plans or Specifications or, if none is stated, the amount of cover shall be scaled from the Plans. Minimum thickness of the steel cylinder shall be as shown on the Plans or, if not shown on the Plans, as determined by the following formula, except that steel thickness shall not be less than 10 gauge (0.1345-inch). t = Pd Where P = Design pressure, in psi plus 50 psi minimum 2S S = Steel stress at design pressure, i.e., 16,500 psi t = Steel cylinder thickness, in inches d = OD of steel cylinder, in inches 2.2 STEEL CYLINDERS Materials used in fabricating steel cylinders shall be hot rolled carbon steel sheets conforming to the requirements of ASTM A53, Grade B, ASTM A570 Grade 36 or Grade 33, or steel plates conforming to the requirements of ASTM A36. The method of testing shall conform to the requirements of ASTM A570. Full penetration welds will be required. Welds may be straight or spiral seam. The circumferential stress in the steel shall not exceed 16,500 psi at the design pressure. Remove the exterior weld bead along the entire exterior surface of the pipe. The exterior weld bead shall be flush with the exterior surface of the pipe with a tolerance of plus 1/32-inch. JUNE 2004 4 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 2.3 CEMENT Cement for mortar lining and coating shall be Portland Cement Type II and conform to ASTM C150, unless otherwise specified. Admixtures containing chlorides shall not be used. 2.4 STEEL BAR OR WIRE REINFORCEMENT Circumferential steel bar or wire reinforcement shall conform to ASTM A615, Grade 40, "Specifications for Billet-Steel Bars for Concrete Reinforcement". Wire fabric reinforcing for cement-mortar coatings and linings of fittings shall conform to ASTM A185, "Specifications for Welded Steel Wire Fabric," or ASTM A497, "Specifications for Welded Deformed Steel Wire Fabric." Spiral-wire reinforcement for cement-mortar coatings shall conform to ASTM A82. 2.5 STEEL FOR JOINT RINGS Steel for bell rings shall conform to ASTM A575, "Specification for Merchant Quality Hot Rolled Carbon Steel Bars." Steel for spigot rings shall conform to ASTM A576, "Specification for Special Quality Hot-Rolled Carbon Steel Bars." 2.6 DIMENSIONS The steel pipe sizes shown on the Plans or otherwise referred to shall be the nominal inside diameter. Unless otherwise specified, the nominal diameter shown on the Plans shall be considered to be the inside diameter after lining. 2.7 MANUFACTURER'S TESTS Each steel cylinder with joint rings attached and cylinders for specials shall be hydrostatically tested to a circumferential stress of at least 22,000 psi, but not more than 25,000 psi. If leaks develop during testing, the cylinder shall be repaired by welding and retested until all leaks are eliminated. The seams in short radius bends and special fittings shall be tested by the air-soap method using air at a pressure of 5 psi or by the dye-check method. However, if the fitting is fabricated from cylinders which have been previously hydrostatically tested, no further test will be required on seams so tested. Hydrostatic testing of fittings to 150% of the design pressure may replace the tests described above. Any defects revealed by any of the alternate test methods shall be repaired by welding and the fitting retested until all defects have been eliminated. 2.8 FABRICATION DETAILS Each special and each length of straight pipe shall be plainly marked at the bell end to identify the design pressure and the proper location of the pipe or special by reference to layout schedule. Exposed portion of joint rings shall be protected from corrosion by the manufacturer's standard coating. The pipe shall be fitted with devices shown on the Plans to permit continuous electrical bonding of the various joints following field installation. JUNE 2004 5 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 2.9 PROTECTIVE COATINGS AND LININGS All exposed metal surfaces shall be painted or coated as specified in Section O9870 and 09900, Painting and Coating, except where other coatings are specified elsewhere and in this section. All steel pipe and fittings shall be cement-mortar lined in accordance with AWWA C205 and C602. Linings shall be in accordance with table below. All steel pipe and fittings for underground service shall be cement-mortar lined, taped wrapped and cement-mortar coated in accordance with AWWA C205, C214 and C602 and Section 09870 unless otherwise specified on the Plans. For the following nominal inside diameters, the lining thickness and minimum cement-mortar coating thickness shall be as follows: LINING COATING Nominal Pipe Size Thickness Tolerance Thickness Tolerance finches) (inches) (inches) (inches) (inches) 4-10 1/4 -1/32+1/32 1/2 +1/8 12-18 3/8 -1/16+1/8 5/8 +1/8 20-44 1/2 -1/16+1/8 3/4 +1/8 45-58 3/4 -1/16+1/8 1 +1/8 60 and over 3/4 -1/16+1/8 11/4 +1/8 2.10 STEEL PIPE AND SPECIALS Steel pipe and specials shall conform to the requirements of the AWWA C200 and C205, and AWWA M11, except as modified herein. A. Steel for fabricated cylinders shall conform to ASTM A 36/A 36M, ASTM A 283/ A 283M, Grade D, or ASTM A 570/A 570M, Grade 36. Other steel grades may be used only upon approval of the District Engineer. B. Cement-mortar coating shall be reinforced in accordance with AWWA C205. C. Cement mortar grout for field joints shall consist of a mixture of 1-1/2 to 2 parts sand to 1 part Type II or Type V Portland Cement with enough clean, potable water to permit packing and troweling without crumbling. The sand shall be washed, well-graded sand such that all will pass a No. 8 sieve. The quantity of water to be used in the preparation of grout shall be the minimum required to produce a mixture sufficiently workable for the purpose intended. Grout shall attain a minimum compressive strength of 12.4 MPa (1,800 psi) in 28 days. D. In certain circumstances, rapid-setting mortar may be required. Acceleration admixtures may be used in the mix as permitted by the District Engineer. Calcium chloride shall not be used in the mix. JUNE 2004 6 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 2.11 PAINTING AND COATING A. Paint and coating products for exterior surfaces of all pipe and appurtenances not otherwise mortar-coated shall be in accordance the Approved Materials List. B. Paint and coating products for areas in contact with potable water such plain ends of pipe, grooved and shouldered ends of pipe and exposed inside surfaces or threaded outlets and blind flanges shall be in accordance with Section 15000 and selected from the Approved Materials List. 2.12 BOLTS AND NUTS FOR FLANGES Bolts and nuts shall be in accordance with Section 15000 and the Approved Materials List. 2.13 GASKETS A. Rubber-ring gaskets shall comply with AWWA C200 according to the applicable joint type and pressure rating of the piping system. B. Range gaskets shall comply with AWWA C207. Flange gaskets shall be 3.18mm (1/8") thick acrylic or aramid fibers bound with nitrile for all sizes of pipe. Gaskets shall be full-face type with pre-punched holes or ring-type extending to the inner edge of the bolt circumference of the flange. C. In the event of encountering organic solvents or petroleum products during the course of the work, alternate gasket materials or joint treatment will be required as directed by the District Engineer. 2.14 CEMENT-MORTAR CURING The pipe shall be cured by water curing, steam curing or a combination of both. Water curing and steam curing may be used interchangeably on a time ratio basis of four hours water curing to one hour of steam curing. Where steam curing is used, the pipe shall be kept in steam maintained at a temperature of 100 F to 150 F for the specified period and, where water curing is used, the pipe shall be kept continually moist by spraying or other means for the specified periods. The pipe shall not be allowed to dry either on the inside or outside surfaces during the curing period. Where water curing is used, the pipe shall be kept continuously moist for seven days at a temperature of not less than 40 F before being moved to the trench site. Cement-mortar lining and coating of special pipe and fittings may be cured in accordance with the above provisions or by prompt application of a white-pigmented sealing compound conforming to ASTM C309. Sealing compound shall not be applied at joint ends where compound will interfere with the bond of joint mortar. JUNE 2004 7 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 2.15 SPECIAL PIPE AND FITTINGS The manufacturer shall furnish all fittings and special pieces required for closures, curves, bends, branches, manholes, outlets, connections for mainline valves, and other appurtenances required by the Plans. Special fittings shall be fabricated of welded steel sheet or plate, lined and coated with cement-mortar of the same type as the adjoining pipe and applied as specified for lining and coating of specials in AWWA C205 and as modified herein. Butt welding shall be used, unless otherwise indicated on the Plans. Minimum centerline radius of an elbow or bend shall be as follows. The maximum deflection at a mitered girth seam shall be 22-1/2 degrees. Pipe Size finches) Minimum Centerline Radius 30-48 2-1/2 times ID 51-60 10-feet Over 60 2 times ID The circumferential stress in the sheet or plate shall not exceed 13,500 psi at the design pressure. The minimum thickness of sheet or plate shall be as follows: Fitting Diameter Range Minimum Thickness of Sheet or Plate (Inches) 18 and under 10 gauge 20-24 3/16" or 7 gauge 26 - 36 1/4" 38-45 5/16" 48-54 3/8" 57-60 7/16" 63-72 1/2" 75-84 5/8" Outlets at special fittings shall be reinforced with collars or crotch plates. If collar reinforcement is used, the outlet diameter shall not exceed 69% of the ID of the fitting. The diameter of outlets reinforced with crotch plates may equal the fitting diameter. The effective shoulder width "W" of collars from the inside surface of the steel outlet to the outside edge of the collar measured on the surface of the cylinder shall be not less than one-third or more than one-half the ID of steel outlet. The thickness of the collar shall be not less than "T" as determined by: Pwx I Devi, x ID outlet T= 36,000 xW where Pw is the design pressure in pounds per square inch, and all other dimensions are in inches. Collars may be oval in shape or rectangular with well-rounded corners. Outlets 3-inches in diameter and smaller may be installed without collars. The design of crotch plates shall be based upon the paper by Swanson, Chapton, Wilkinson, King, and Nelson, originally published in June 1955 issue of the Journal of the American Water Works Association and in conformance with AWWA M-11. JUNE 2004 8 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 2.16 TAPE WRAP AND MORTAR SHIELD Tape wrap and mortar shield for concrete mortar lined steel pipe shall be in accordance with Section 09870. 2.17 HANDLING AND SHIPMENT Pipe and special fittings shall be handled carefully, and blocking and holddowns used during shipment shall prevent movement or shifting. Both ends of pipe and fittings on trucks or rail cars shall be bulkheaded or covered in order to prevent excessive drying of the interior lining. PART 3 EXECUTION 3.1 GENERAL At all times when the work of installing pipe is not in progress, including worker break times, the ends of the pipe shall be closed with a vermin-proof and child-proof cap or plug. Do not permit trench water to enter the pipe. Do not place tools, clothing, or other materials in the pipe. The Contractor shall maintain the interior of the pipe in a sanitary condition free from foreign materials. 3.2 DEWATERING The Contractor shall provide, and maintain at all times during construction, ample means and devices to promptly remove and dispose of all water from any source entering trench excavations or other parts of the work in accordance with Section 02223. Any damage caused by flooding of the trench shall be the Contractor's responsibility. Contractor shall obtain a Discharge Permit as required by the Regional Water Quality Control Board. Dewatering shall be performed by methods that will maintain a dry excavation, preservation of the final lines and grades and protection of all utilities. If flooding of the trench does occur, the Contractor shall immediately dewater and restore the trench. Damaged or altered pipeline appurtenances shall be repaired or replaced as directed by the Engineer. 3.3 PIPE INSTALLATION When the work requires and the size of the pipe allows entry of personnel into the pipe, the Contractor shall comply with all Federal and State regulations for confined space entry. Work inside pipelines shall not be undertaken until all the tests and safety provisions of the Code of Federal Regulations 1910.146, and the General Industry Safety Orders of the California Code of Regulations, Title 8, Section 5159 for confined space entry have been performed and the area is verified as safe to enter. Generally, the aforementioned safety provisions apply to pipe 600mm (24") and larger. Note that for pipe less than 600mm (24") diameter, more stringent safety procedures apply. JUNE 2004 9 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials The Contractor shall furnish and install all pipe, specials, fittings, closure pieces, valves, supports, bolts, nuts, gaskets, jointing materials, and all other appurtenances as shown on the Approved Plans and as required to provide a complete and workable installation. Pipe installations shall be as shown on the Approved Plans and Shop Drawings in accordance with the following: A. No pipe shall be installed where the linings or coatings show cracks that may be harmful as determined by the District Engineer. Such damaged linings and coatings shall be repaired or new, undamaged pipe sections shall be provided. B. Pipe damaged prior to Substantial Completion shall be repaired or replaced by the Contractor. C. The Contractor shall inspect each pipe and fitting to ensure that there are no damaged portions of the pipe. The Contractor shall remove or smooth out any burrs, gouges, weld splatter, or other small defects prior to laying the pipe. D. Before placement of pipe in the trench, each pipe or fitting shall be thoroughly cleaned of any foreign substance which may have collected thereon and shall be kept clean at all times thereafter. For this purpose, the openings of all pipes and fittings in the trench shall be closed during any interruption to the work as noted above. E. Pipe shall be laid directly on the bedding material. No blocking will be permitted, and the bedding shall be such that it forms a continuous, solid bearing for the full length of the pipe. Excavations shall be made as needed to facilitate removal of handling devices after the pipe is laid. Bell holes shall be formed at the ends of the pipe to prevent point loading at the bells or couplings and to permit visual inspection of the joint. Excavation shall be made as needed outside the normal trench section at field joints to permit adequate access to the joints for field connection operations and for application of coatings on field joints. F. Installation Tolerances: Each section of pipe shall be laid in the order and position shown on the approved layout schedule to the proper lines and grades in accordance with the following: 1. Each section of pipe having a nominal diameter less than 1200mm (48") shall be laid not to vary more than 0.2-ft horizontally or 0.1-ft vertically from the alignment and elevations shown on the Approved Plans. 2. Each section of pipe having nominal diameter 1200mm (48") and larger shall be laid not to vary more than five percent (5%) of the pipe diameter horizontally or two and one half percent (2.5%) of the pipe diameter vertically. 3. In addition to the horizontal and vertical tolerances above, lay the pipe so that no high or low points occur along the pipeline other than those shown on the approved layout schedule. JUNE 2004 10 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials G. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the District Engineer may change the alignment and/or the grades. Such change shall be made by the deflection of joints, by the use of bevel adapters, or by the use of additional fittings. However, in no case shall the deflection in the joint exceed seventy five percent (75%) of the maximum deflection recommended by the pipe manufacturer. No joint shall be deflected any amount that will be detrimental to the strength and water tightness of the finished joint. In all cases the joint opening, before finishing with the protective mortar inside the pipe, shall be the controlling factor. H. Pipes shall be laid uphill on grades exceeding 10 percent. Pipe that is laid on a downhill grade shall be blocked and held in place until the following pipe section has been installed to provide sufficient support to prevent movement. I. Temporary internal pipe bracing shall be left in place in pipe sizes larger than 600mm (24") until pipe zone compaction has been completed. Bracing in pipe smaller than 600mm (24") may be removed immediately after the pipe has been laid into the trench. The Contractor shall employ a laboratory to monitor pipe deflection by measuring pipe inside diameter before bracing is removed and 24 hours after struts are removed. Pipe deflection shall not exceed 3 percent in 24 hours after the bracing has been removed. After the backfill has been placed, the struts shall be removed. J. Cold Weather Protection: No pipe shall be installed upon a foundation onto which frost has penetrated or at any time that there is a danger of the formation of ice or penetration of frost at the bottom of the excavation. No pipe shall be laid unless it can be established that the trench will be backfilled prior to formation of ice and frost. K. Pipe and Special Protection: The openings of all pipe and specials where the pipe and specials have been mortar-lined in the shop shall be protected with suitable bulkheads to maintain a moist atmosphere and to prevent unauthorized access by persons, animals, water, or any undesirable substance. The bulkheads shall be designed to prevent drying out of the interior of the pipe. The Contractor shall introduce water into the pipe to keep the mortar moist where moisture has been lost due to damaged bulkheads. 3.4 RUBBER-RING JOINTS: SHALL ONLY BE USED AS SHOWN ON PLANS For pipe sizes smaller than 24-inches, the bell end shall be buttered with cement mortar in a manner and quantity that will completely fill the recess between the respective linings of the two joined sections of pipe. The spigot end shall then be entered into the bell end of the adjacent pipe section the distance shown on the Shop Drawings. Immediately after joining, the pipe interior shall be swabbed to remove all excess mortar by drawing a swab or squeegee through the pipe. The pipe interior shall be inspected by a closed circuit television camera, to assure quality of internal mortar. 1UNE2004 11 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials For pipe sizes 24-inches and larger, the joint recess shall be pointed from the inside with cement mortar after the backfill has been placed and compacted and the pipe permitted to take any normal settlement. The mortar shall be mixed of one part cement to one and one-half parts of sand and pointing accomplished in two or more lifts and finished off flush by troweling. Pipe shall be inspected visually by work persons within the pipe, to assure internal mortar quality. Each pipe joint shall be bonded to provide electrical continuity along the entire pipeline. The bond shall be made by the proper welding of pipe joints together as indicated on the Plans. The outside joint recess shall be grouted with cement mortar after a diaper has first been placed around the joint and tightened securely to prevent leakage while the mortar is being poured. The diaper shall be made of moisture resisting paper or heavy duty sail cloth of sufficiently close weave to prevent cement loss from the mortar. The diapers shall be hemmed on each edge and shall contain a metal strap within each hem sufficiently longer than the circumference of the pipe to allow a secure attachment of the diaper to the pipe. The diaper width will depend upon pipe size and design and shall be the width recommended by the manufacturer. Following installation of the diapers, the joints shall be poured and rodded from one side only until the mortar comes up to the top of the diaper on the opposite side. Approximately one hour subsequent to the pouring of the joint, the joint shall be rechecked and, if any settlement, leakage or shrinkage has taken place, the joint shall be refilled with mortar. Outside joints may be grouted before or after the placement of bedding and backfill materials if those materials are to be mechanically compacted. If bedding and backfill materials are to be hydraulically densified, grout shall be poured and allowed to set before applying water. In any case, joints shall be grouted before backfill is placed over the top of the pipe. 3.5 BUTT-STRAP CLOSURE JOINTS Butt-Strap Closure Joints: Butt-strap closure joints shall be completed in the trench after the pipe has been laid to the alignment and grade shown on the Plans. They should be field welded by full-circumferential fillet welds or one of the edges may be shop welded and the other field welded. Welding shall be done in the same manner as specified for welded joints. The interior of the joints shall be filled with stiff plastic mortar and finished off smoothly with the inside of the pipe. Clean the inside steel surfaces by wire brushing or power brushing. Wire mesh, 2" x 4" x No. 13 gauge, clean, and free from rust, shall be applied to the interior of the joints so that the wires on the 2-inch spacing run circumferentially around the pipe. The wires on the 4-inch spacing shall be crimped in such a manner that the mesh will be held 3/8-inch from the metal joint surface. The mesh shall be lapped a minimum of 8-inches and shall be securely wired in position. Pack the cement mortar into the recess of the joint and steel trowel finish to match the adjoining pipes. The joint exterior shall be coated with mortar to a minimum thickness of 1Vfe-inches. Immediately prior to applying mortar to the interior or exterior of the joints, a cement wash shall be applied to the metal to be coated. JUNE 2004 12 of 18 . SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 3.6 FIELD WELDED JOINTS A. Welded joints shall be completed after the pipe is in final position. Welded joints shall be a lap-welded slip joint as shown on the Plans. The minimum overlap of the assembled bell and 9 pigot section of lap joint shall be shown on the plans. Any recess between the bell and spigot shall be caulked with a rod to facilitate the welding. Pipe of 30-inches in diameter or more may be welded from the inside. Joints shall be welded on the inside and outside where indicated on the Plans as "Double Welded Joints." Field Welding shall be in accordance with AWWA C206 and AWS D1.1, except as modified herein. Welders assigned to the Work shall be qualified under the AWS standard qualification procedure, within the past three (3) years. B. Joints to be welded shall be cleaned, preferably prior to placing the pipe in the trench, of all loose scale, heavy rust, paint, cement, and grease. At least a 1/2-inch recess shall be provided between adjacent mortar-covered surfaces to place the weld. In all hand welding, the metal shall be deposited in successive layers and the minimum number of passes shall be 2. Preheat the joints to be welded where required in accordance with Table 1 of AWWA C206. C. All joints shall be visually inspected and shall undergo dye testing and hydrostatic testing, in accordance with AWWA C-206. D. After the joints have been welded, the interior joint shall be grouted with cement mortar. E. Welded joints shall be completed in the trench per AWWA C206. F. Both the bell and spigot ends shall be cleaned of foreign matter prior to welding. G. Welding electrodes shall be as recommended by the pipe manufacturer. Typically, electrodes shall be E6010 for root passes and for additional passes. Do not deposit more than 3.2mm (1/8") of throat thickness per pass. H. Weld material shall be deposited in successive layers. Complete and clean each pass around the entire circumference of the pipe before commencing the next pass. I. The minimum number of passes in the completed weld shall be as follows: Steel Cylinder Thickness Field Weld Minimum mm finches) Number of Passes 6.35 or less (0.2500 or 1/4") 2 Greater than 6.35 (0.2500 or VV) 3 J. To minimize longitudinal stresses due to temperature variations, it is necessary to leave unwelded one joint per each 120m (4001) of pipeline. This joint shall be left unwelded until all the joints on both sides of it are welded, and it shall be welded at the coolest time of the working day. The District Engineer shall decide if and when this procedure is warranted. JUNE 2004 13 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials K. Tack-welding the joint may be permitted to hold the pipe in place. If the joint is to be circumferentially welded, sufficient time shall elapse to allow for an initial set of interior joint lining prior to proceeding with joint welding. Rapid-setting mortar may be used in accordance with this Section. In some cases, the District Engineer may require hand holes. L. Field welders shall be certified in accordance with ASME Section 9 (pipe welders) or AWS D1.1 (plate welders). Welders shall present a copy of their certification to the District Engineer prior to performing any field welding. M. Prior to butt-strap welding, the pipe and pipe joint shall be properly positioned in the trench using line-up clamps so that, in the finished joint, the abutting pipe sections shall not be misaligned by more than 1,59mm (1/16"). N. The pipe ends shall be cut straight on joints where butt straps are used for realignment, adjustment, or deflection, and fillet welds shall be made as indicated. 0. Inspection of Field Welded Joints: 1. The District shall arrange for the welds to be inspected. Inspection of welds shall take place as soon as possible following the completion of the welds. 2. The Contractor shall coordinate and supply ventilation, lighting, and other equipment deemed necessary for inspection. The Contractor shall be responsible for providing safe entry into and out of the trench, safety of inspection personnel, traffic control and other safety precautions deemed necessary for the inspections. 3.7 PREVENTING FOREIGN MATTER FROM ENTERING THE PIPE At all times when pipe laying is not in progress, the open end of the pipe shall be closed with a tight-fitting cap or plug to prevent the entrance of foreign matter into the pipe. These provisions shall apply during the noon hour as well as overnight. In no event shall the pipeline be used as a drain for removing water which has infiltrated into the trench. The Contractor shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the Owner's Representative. 3.8 HANDLING OF PIPE Refer to Section 09870 regarding handling of the concrete mortar lined and tape wrapped and mortar coated steel pipe. JUNE 2004 14 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 3.9 INTERIOR JOINT FINISH - PIPE LESS THAN 600mm (24") Complete interior mortar joints for pipe sizes less than 600mm (24") by drawing through a tight-fitting swab or squeegee. Coat the face of the cement mortar lining at the bell with a sufficient amount of stiff cement mortar to fill the gap. Immediately after joining the pipes, draw the swab through the pipe to remove all excess mortar and expel it from the open pipe end. Do not move the pipe after the swab has been pulled past the joint. See requirements under "Field Welded Joints" for these joints requiring welding. 3.10 INTERIOR JOINT FINISH - PIPE 600mm (24") AND LARGER A. Complete interior mortar joints for pipe sizes 600mm (24") and larger by the trowel method. Prior to applying interior mortar at the joints all backfill in the area shall be completed. After cleaning the interior joint, pack cement mortar into each joint. Finish the surface with a steel trowel to a smooth finish and equal thickness to match the adjoining pipe mortar. B. Where more than a 100mm (4") joint strip of mortar is required, place galvanized welded wire mesh reinforcement in 50mm x 100mm (2" x 4") pattern of No. 13 gauge over the exposed steel. Install the mesh so that the wires on the 50mm (2") spacing direction run circumferentially around the pipe. Crimp the wires on the 100mm (4") spacing to support the mesh 9.5mm (3/8") from the metal surface. Steel-trowel finish the interior mortar to match adjoining mortar-lined pipe sections. 3.11 EXTERIOR JOINT FINISH A. The outside annular space between pipe sections shall be completely filled with grout formed by the use of polyethylene foam-lined fabric bands. The grout space shall be flushed with water prior to filling so that the surfaces of the joint to be in contact with the grout will be thoroughly moistened when the grout is poured. The joint shall be filled with grout by pouring from one side only. Grout shall be rodded with a wire or other flexible rod or vibrated so that the grout completely fills the joint recess by moving down one side of the pipe, around the bottom of the pipe and up the opposite side. Pouring and rodding the grout shall be continued to allow completion of the filling of the entire joint recess in one operation. Care shall be taken to leave no unfilled space. Grouting of the outside joint spaces shall be kept as close behind the laying of the pipe as possible except that in no case shall grouting be closer than three joints of the pipe being laid. B. The grout bands or heavy-duty diapers shall be polyethylene foam-lined fabric with steel strapping of sufficient strength to hold the fresh mortar, resist nodding of the mortar, and allow excess water to escape. The foam plastic shall be 100 percent closed cell, chemically inert, insoluble in water and resistant to acids, alkalis and solvents. Foam Plastic shall be Dow Chemical Company, Ethafoam 222, or equal. JUNE 2004 15 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials The fabric backing shall be cut and sewn into 224mm (9") wide strips with slots for the steel strapping on the outer edges. The polyethylene foam shall be cut into strips 150mm (6") wide and slit to a thickness of 6.35mm (1/4") that will expose a hollow or open-cell surface on one side. The foam liner shall be attached to the fabric backing with the open or hollow cells facing towards the pipe. The foam strip shall cover the full interior circumference of the grout band with sufficient length to permit a 200mm (8") overlap of the foam at or near the top of the pipe joint. Splices to provide continuity of the material will be permitted. The polyethylene foam material shall be protected from direct sunlight. The polyethylene foam-lined grout band shall be centered over the joint space with approximately equal widths extending over each pipe end and securely attached to the pipe with the steel straps. After filling the exterior joint space with grout, the flaps shall be closed and overlapped in a manner that fully encloses the grout with polyethylene foam. C. Following grouting, the joint shall then be wrapped with two layers of polyethylene encasement in accordance with Section 15000. 3.12 BUTT STRAP JOINTS Butt strap closure joints shall be installed where shown on the Approved Plans in accordance with AWWA C206. A. Butt straps shall be field welded to the outside plain end of the pipe along both edges with a full circumferential weld. A minimum of two weld passes shall be used. B. The interior of the joints shall be filled with a rapid-set mortar and finished off smoothly to match the pipe interior diameter. C. Clean the butt strap with a wire brush and apply a cement and water wash coat prior to applying cement mortar. D. Galvanized wire mesh, 50mm x 100mm (2" x 4") x No. 13 gauge shall be installed to the exterior of the joint prior to applying the mortar coating. E. Coat the exterior of the closure assemblies with mortar to cover all steel with a minimum of 32mm (1-1/4"). F. Seal weld the steep plug to the hand hole after the interior of the joint has been inspected and approved by the District Engineer. G. Following grouting, the joint shall then be wrapped with two layers of polyethylene encasement in accordance with Section 15000. JUNE 2004 16 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 3.13 FLANGED CONNECTIONS Flanged connections shall be installed where indicated on the Approved Plans. A. Bolt holes shall straddle the horizontal and vertical centerlinas. B. The bolts, nuts and flange faces shall be thoroughly cleaned by wire brush prior to assembly. C. Bolts and nuts shall be lubricated with a District-approved anti-seize compound. D. Nuts shall be tightened in an alternating "star" pattern to the manufacturer's recommended torque. E. Slip-on type flanges intended for field fit-up and welding shall be welded inside and outside in accordance with AWWA C207. F. Coat the exterior of exposed flanges, bolts and nuts in accordance with Section 09910. 3.14 FLANGED COUPKLING ADAPTERS Hanged coupling adapters shall be installed in accordance with the manufacturer's recommendations. Bolts shall be tightened with a torque wrench in the presence of the District Engineer to the torque recommended by the manufacturer. 3.15 JOINT BONDING/CATHODIC PROTECTION INSULATION Bonding of joints to provide continuity, flange insulation kits, internal epoxy linings, and other cathodic protection items and materials shall be installed where shown on the Approved Plans in accordance with the Standard Drawings and Section 13110. 3.16 WAX TAPE Wax tape shall be installed as shown on the Approved Plans or as directed by the District Engineer in accordance with Section 09902 and the Standard Drawings. 3.17 CONCRETE Where required, concrete thrust and anchor blocks shall be installed in accordance with Section 03000 and as shown on the Approved Plans. Prior to filling the pipeline with water, refer to Section 03000 for the minimum concrete curing time required. 3.18 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be installed in accordance with Section 15000 and the Standard Drawings. JUNE 2004 17 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials 3.19 DISINFECTION AND BACTERIOLOGICAL TESTING Disinfection, bacteriological testing, and flushing shall be performed in-accordance with Section 15041. 3.20 HYDROSTATIC TESTING Field hydrostatic testing shall be performed in accordance with Section 15044. 3.21 FIELD PAINTING AND COATING A. Exterior surfaces of all pipe and appurtenances not otherwise mortar-coated shall be field painted in accordance with Section 9900. B. Areas in contact with potable water such plain ends of pipe, grooved and shouldered ends of pipe and exposed inside surfaces of threaded outlets and blind flanges shall be coated in accordance with Section 15000. END OF SECTION JUNE 2004 18 of 18 SECTION 15061 Cement-Mortar Lined and Coated Steel Pipe and Specials SECTION 15064 POLYVINYL CHLORIDE (PVC) PRESSURE PIPE AND FITTINGS (AWWAC900) PART 1 GENERAL 1.1 DESCRIPTION This section designates the requirements for the manufacture and installation of polyvinyl chloride, abbreviated PVC, pressure pipe, to be furnished and installed by the Contractor, at the location and to the lines and grades shown on the Plans as herein specified. Specifications for related Work are as follows:, AWWA C900 PVC Pressure Pipe ANSIA21.10 Ductile Iron and Gray-Iron Fittings AWWA C110 Ductile Iron and Gray-Iron Fittings AWWA C153 Ductile Iron Compact Fittings AWWA Manual M23 Pipe Design and Installation 1.2 RELATED WORK DESCRIBED ELSEWHERE The Contractor shall refer to the following Specification section(s) for additional requirements: A. Disinfection of Piping: 15041 B. Hydrostatic Testing of Pressure Pipeline: 15044 1.3 SUBMITTALS The Contractor shall furnish submittals in accordance with Section 2-5.3, Submittals Shop Drawing. Submittals are required for the following: A. Submit Shop Drawings, material lists, manufacturer's literature and catalog cuts and other information. B. Submit an affidavit from the pipe manufacturer that all delivered materials comply with the requirements of AWWA C900, the Plans and Specifications. 1.4 PAYMENT A. Payment for the Work in this section shall be included as part of the lump-sum or unit-price bid amount for which such Work is appurtenant thereto. B. Payment by the linear foot shall be for each diameter and for each pipe strength designation measured horizontally over the pipe centerline. JUNE 2004 1 Of 5 SECTION 15064 Polyvinyl Chloride (PVC) Pressure Pipe and Fittings (AWWA C900) PART 2- MATERIALS 2.1 GENERAL Material used to produce the pipe shall be made from Class 12454-A or B rigid polyvinyl chloride compounds in accordance with AWWA C900 Section 2.1 (Basic Materials), with an established hydrostatic design basis (HDB) equal to or greater than 40OO psi for water at 73.4 degrees F (23 C). Elastomeric gaskets shall comply with the requirements of AWWA C900 Sections 2.1.5 and 2.1.5.1 (Gaskets and Lubricants). 2.2 PIPE PVC pressure pipe, 4-inch through 12-inch, shall be manufactured in accordance with AWWA C900, and shall be of the sizes and pressure classes shown on the Plans. The pipe shall have integral bell and spigot joints with elastomeric gaskets in accordance with AWWA C900 Section 2.2 (Pipe Requirements). The pipe shall conform with the outside diameter of cast-iron pipe unless otherwise specified and shall conform with the wall thickness of DR series 14,18, or 25. The pipe shall be manufactured by J.M. Manufacturing Company, Certainteed Corporation, Pacific Western Extruded Plastics Company or approved equal. 2.3 FITTINGS All fittings for PVC pressure pipe shall be manufactured in accordance with ANSI A21.10, AWWA C110 or C153. All fittings shall be made of ductile iron and the letters "Dl" or "DUCTILE" shall be cast on them, unless otherwise specified. Bell size shall be for Class 150 and Class 200 cast-iron equivalent PVC pressure pipe, including the rubber-ring retaining groove. 2.4 SERVICES SADDLES Service saddles for PVC pressure pipe shall be made of silicone bronze or brass and shall be double banded or wide single band style. The band(s) and nuts shall be type 304 stainless steel and designed specifically for use with AWWA C900 PVC pipe. Each saddle shall accurately fit the contour of the pipe O.D. without causing distortion of the pipe. The saddle shall be securely held in place with stainless steel bolts and nuts. The service saddle shall have a published working pressure at least equal to the pressure class of the pipe on which it is installed. All saddles shall be provided with torque information and installation instructions. Saddles shall be in accordance with Carlsbad Rules and Regulations for the Construction of Potable Water Mains. JUNE 2004 2 of 5 SECTION 15064 Polyvinyl Chloride (PVC) Pressure Pipe and Fittings (AWWA C900) PARTS- EXECUTION 3.1 PIPE LENGTHS Laying lengths shall be 20-feet with the manufacturer's option to supply up to 15% random (minimum length 10-feet) sections. No deflections at bells, fittings or of the pipe will be allowed. The use of deflection collars shall be required. 3.2 MARKING Each pipe length shall be marked showing the nominal pipe size, O.D. base, the AWWA pressure class, and AWWA specification designation in accordance with AWWA C900 Section 2.6 (Marking Requirements). For potable water application, the pipe shall be white or blue in color and the seal of the testing agency that verified the suitability of the material for such service shall be included. 3.3 EARTHWORK Excavation and backfill, including the pipe bedding, shall conform to the provisions of SSPWC. 3.4 GENERAL INSTALLATIONS PROCEDURES AND WORKMANSHIP PVC pressure pipe and fittings shall be installed per AWWA Manual M23 "PVC Pipe-Design and Installation", and as herein specified. Proper care shall be used to prevent damage in handling, moving, and placing the pipe. Hoist pipe with fork lift or other handling equipment to prevent major damage or shorten its service life. A cloth belt sling or a continuous fiber rope shall be used to prevent scratching the pipe. The pipe shall be lowered and not dropped from the truck. Dropped pipe will be rejected. Prior to laying the pipe, the bottom of the trench shall be graded and prepared to provide uniform bearing throughout the entire length of each joint of pipe. Bell holes of ample dimension shall be dug in the bottom of the trench at the locations of each joint to facilitate the joining. The trench shall have a flat or semi-circular bottom conforming to the grade to which the pipe is to be laid. The pipe shall be accurately placed in the trench to the lines and grades on the Plans. Fittings shall be supported independently of the pipe. JUNE 2004 3 of 5 SECTION 15064 Polyvinyi Chloride (PVC) Pressure Pipe and Fittings (AWWA C900) 3.5 LONGITUDINAL BENDING No longitudinal bending shall be allowed in the installation of PVC pressure pipe. All deflections shall be accomplished by the use of deflection collars or couplings specifically designed for use with PVC C900 pipe and the deflections as installed shall not exceed the manufacturers written recommendations. 3.6 PIPE JOINT ASSEMBLY The spigot and bell shall slide together without displacement of the rubber gasket. The joint shall be dirt free. The best laying practice is with the bell facing in the direction of laying. Insert the rubber ring into the groove making sure the ring is completely seated. Lubrication of the spigot and instruction of use shall be supplied by the pipe manufacturer. The spigot shall be inserted into the bell and forced slowly into position by use of a large bar lever and a wood block across the pipe end. For large pipe, a come-along (with padding that will not scratch the pipe) may be used. 3.7 CONCRETE THRUST BLOCKS Concrete thrust blocks shall be placed as shown on the Plans and shall consist of Class B portland cement concrete containing not less than five sacks of portland cement per cubic yard and shall conform to SSPWC. Concrete blocks shall be placed between the undisturbed ground and the fittings to be anchored. Quantity of concrete and the bearing area of the pipe and undisturbed soil shall be as shown on the Plans, unless otherwise determined by the Owner's Representative. The concrete shall be placed, unless specifically shown otherwise on the Plans, so that the pipe joints and fittings will be accessible to repairs. 3.8 MECHANICAL THRUST RESTRAINT No mechanical thrust restraint devices which transfer forces from fittings to the PVC pipe wall shall be permitted. 3.9 PREVENTING FOREIGN MATTER FROM ENTERING THE PIPE At all times when pipe laying is not in progress, the open end of the pipe shall be closed with a tight-fitting cap or plug to prevent the entrance of foreign matter into the pipe. These provisions shall apply during the noon hour as well as overnight. In no event shall the pipeline be used as a drain for removing water which has infiltrated into the trench. The Contractor shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the Owner's Representative. JUNE 2004 4 of 5 SECTION 15064 Polyvinyl Chloride (PVC) Pressure Pipe and Fittings (AWWA C900) 3.10 LEAKAGE TEST General: All pipelines shall be tested in accordance with Section 15044, Hydrostatic Testing of Pressure Pipe. 3.11 DISINFECTION Disinfection shall be in accordance with Section 15041, Testing, Flushing and Disinfection of Piping. END OF SECTION JUNE 2004 5 of 5 SECTION 15064 Polyvinyl Chloride (PVC) Pressure Pipe and Fittings (AWWA C900) SECTION 15074 BLOW-OFF ASSEMBLIES PART1 GENERAL 1.1 DESCRIPTION This section includes materials, testing, and installation of blowoff assemblies. 1.2 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 09900, 15000, 15041, 15044, 15056, 15057, 15061, 15064, and 15100 1.3 SERVICE APPLICATION A. Blowoff assemblies shall be installed on potable and recycled water mains. B. Blowoff assemblies shall be sized and located as shown on the Approved Plans. In general, blowoff assemblies will be installed at low points of pipelines as shown below: 1. 50mm (2") blowoff assemblies or multiple 50 mm (2") blowoff assemblies will be required on pipelines 100mm (4"), thru 300mm (12"). 2. 100mm (4") blowoff assemblies will be required on pipeline sizes 300mm (12") thru 400mm (16"). 3. 150mm (6") blowoff assembly will be required on pipeline sizes 450mm (18") and larger. 1.4 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be installed for blowoff assemblies in accordance with Section 15000. PART 2 MATERIALS 2.1 GENERAL Blowoff assemblies and appurtenant components and materials shall be selected from the Approved Materials List. 2.2 CONCRETE Concrete used for thrust or anchor blocks shall be in accordance with SSPWC. JUNE 2004 1of2 SECTION 15074 Blow-off Assemblies 2.3 WARNING/IDENTIFICATION TAPE Warning/Identification tape materials shall be in accordance with Section 15000 and the Approved Materials List. 2.4 FIELD PAINTING AND COATING Field painting and coating materials shall be in accordance with Section 0990O and the Approved Materials List. PART 3 EXECUTION 3.1 INSTALLATION A. Blowoff assemblies shall be installed at locations shown on the Approved Plans or as directed by the District Engineer in accordance with the Standard Drawings. B. Blowoff assemblies shall be connected to water mains no closer than 600mm (24") to a bell, coupling, joint or fitting. C. Locations of blowoff assembly shall be in accordance with the Standard Drawings. 3.2 CONCRETE Concrete thrust and anchor blocks shall be installed in accordance with the Standard Drawings. 3.3 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be installed in accordance with Section 15000 and the Standard Drawings. 3.4 DISINFECTION OF BLOWOFF ASSEMBLIES Blowoff assemblies shall.be disinfected in accordance with Section 15041 in conjunction with disinfecting the main to which it is connected. Blowoff assembly valves shall be operated and the assembly shall be flushed to completely disinfect all internal parts. 3.5 HYDROSTATIC TESTING Blowoff assemblies shall be hydrostatically tested in accordance with Section 15044 in conjunction with hydrostatically testing the pipeline to which it is connected. END OF SECTION JUNE 2004 2 of 2 SECTION 15074 Blow-off Assemblies SECTION 15100 RESILIENT WEDGE GATE VALVES (RWGV's) PART 1 GENERAL 1.1 DESCRIPTION This section includes materials, testing, and installation of manually operated resilient wedge gate valves (RWGV's). 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 15000, 15041, 15044, 15056, 15057, 15061, 15064, 15074 and 15108. 1.4 SERVICE APPLICATION A. Resilient wedge gate valves (RWGV's) shall be installed on potable and recycled water mains and appurtenances in accordance with the Approved Plans and the Standard Drawings. B. Resilient wedge gate valves shall be used for open/closed operations, throttling service and frequent operation after long periods of no actuation. C. In general, resilient wedge gate valves shall be used when valves are required on pipelines and appurtenances 100m (4") through 400mm (16"). D. Valves for pipelines sized 450mm (18") and larger generally require the use of butterfly valves (BFV) in accordance with Section 15102. 1.5 SUBMITTALS The following items shall be submitted for review and approval per Section 2-5.3, prior to ordering or delivery of resilient wedge gate valves. A. An affidavit from the valve manufacturer stating that valves have successfully passed hydrostatic tests in accordance with AWWA C509 and manufacturer's own coatings tests. B. The valve manufacturer's catalog data showing the size to be used, valve dimensions, pressure rating and materials of construction. C. Manufacturer's catalog data and proof of NSF certification for the lining materials to be used. JUNE 2004 1of5 SECTION 15100 Resilient Wedge Gate Valves (RWGV's) 1.6 SIZING OF VALVES Valves shall be the same size as the line in which they are installed unless otherwise noted on the Approved Plans. 1.7 VALVE ENDS Valve ends shall be compatible with the piping system in which they are being installed in accordance with the Approved Plans or directed by the District Engineer. Ductile-iron flanges shall be in accordance with Section 15056. 1.8 VALVE TESTING Resilient wedge gate valves shall be hydrostatically tested and valve coatings shall be holiday detected prior to shipment to the field in accordance with the testing procedures shown in Appendix A. Valves delivered to the site prior to successful hydrostatic testing and holiday detection shall be subject to rejection. 1.9 DELIVERY, STORAGE AND HANDLING Valves shall be delivered and stored in accordance with AWWA C550. The port openings shall be covered with plastic, cardboard or wood while in transit and during storage in the field. These covers shall remain in place until valves are ready to be installed. Valves shall not be stored in contact with bare ground. Valves shall not be stacked. 1.10 RECYCLED WATER IDENTIFICATION 1.11 POLYETHYLENE WRAP Polyethylene wrap shall be used for the buried installation of resilient wedge gate valves in accordance with Section 15000. PART 2 MATERIALS 2.1 RESILIENT WEDGE GATE VALVES (RWGV's) A. Resilient wedge gate valves and appurtenant components and materials shall be selected from the Approved Materials List. B. RWGV's shall be ductile-iron in accordance with AWWA C509 and C515 except as modified herein. C. Each valve shall have a smooth unobstructed waterway free from any sediment pockets. D. All RWGVs shall be leak-tight at their rated pressure. JUNE 2004 2 of 5 SECTION 15100 Resilient Wedge Gate Valves (RWGVs) E. RWGV's shall have a non-rising low-zinc bronze or stainless steel stern, opened by turning left (counterclockwise). F. Stem seals shall be the O-ring type incorporating a minimum of two rings as required by AWWA C509. G. Low-friction torque-reduction thrust washers or bearings shall be provided on the stem collar. H. Wedge (gate) shall be fully encapsulated with a bonded-in-place Nitrile elastomer covering. Minimum thickness of the rubber seating area shall be 6.35mm (1/4°). I. Valves for buried applications shall be provided with a 50mm (2") square operating nut, and valves located above ground or in structures shall be equipped with a hand wheel in accordance with AWWA C509 unless otherwise indicated on the Approved Plans. J. RWGV interior and exterior surfaces (except for the encapsulated disc) shall be coated as described below. K. All bolts and nuts used in the construction of RWGV's shall be Type 316 stainless steel. 2.2 EPOXY LINING AND COATING Epoxy linings and coatings for valves shallbe provided in accordance with AWWA C210, C213, and C550, with the following modifications: A. Epoxy lining and coating of valve surfaces shall be performed by the manufacturer in a facility with qualified personnel, where the environment can be controlled. Epoxy lining and coating of valves in the field is prohibited. B. Repairs made to manufactures applied coatings shall be performed in a facility with qualified personnel, where the environment can be controlled. The facility shall be approved by the valve manufacturer. C. Surface preparation shall be as detailed in SSPC-SP5, White-Metal Blast Cleaning. D. Liquid epoxy lining and coating materials shall be listed in the NSF Listing for Drinking Water Additives, Standard 61, certified for use in contact with potable water. E. The minimum dry film thickness for epoxy linings shall be 0.203mm (0.008" or 8 mils). Liquid epoxy lining shall be applied in two (2) coats in accordance AWWA C210. F. Powder epoxy coating materials shall contain one hundred percent (100%) solids, in accordance with AWWA C213. JUNE 2004 3 of 5 SECTION 15100 Resilient Wedge Gate Valves (RWGVs) 2.3 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be in accordance with Section 15000 and selected from the Approved Materials List. 2.4 CONCRETE Concrete used for anchor or thrust blocks shall be Class 560-C-3250. 2.5 POLYETHYLENE WRAP Polyethylene wrap shall be in accordance with Section 15000 and selected from the Approved Materials List. PARTS EXECUTION 3.1 INSTALLATION A. Install valves with the bolt holes straddling the vertical centerline of pipe and the operating nut in the vertical position unless otherwise noted on the Approved Plans. B. Valves shall be installed in accordance with the manufacturer's recommendations and the applicable section of these specifications for the piping material and joint type being used. C. Joints shall be cleaned and installed in accordance with Section 15056. 3.2 POLYETHYLENE WRAP Installation of polyethylene wrap for buried valves shall be in accordance with Section 15000. 3.3 CONCRETE Concrete thrust, anchor, and support blocks shall be installed in accordance the Standard Drawings. The concrete shall be placed so that valves and valve operators will be accessible for repairs or replacement. 3.4 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be installed in accordance with Section 15000 and the Standard Drawings. 3.5 DISINFECTION OF VALVES Disinfection and flushing of valves shall be in accordance with Section 15041, as part of the process of disinfecting the main pipeline. The valves shall be operated during the disinfection period to completely disinfect all internal parts. JUNE 2004 4 of 5 SECTION 15100 Resilient Wedge Gate Valves (RWGVs) 3.6 HYDROSTATIC TESTING Valves shall be hydrostatically tested in conjunction with the pipeline in which they are installed in accordance with Section 15044. 3.7 FIELD PAINTING AND COATING The exterior of valves installed above ground or exposed in vaults or enclosures shall be field painted in accordance with Section 09900. END OF SECTION JUNE 2004 5 of 5 SECTION 15100 Resilient Wedge Gate Valves (RWGVs) SECTION 15102 BUTTERFLY VALVES (BFV's) PARTI GENERAL 1.1 DESCRIPTION This section includes materials, testing, and installation of manually operated butterfly valves (BFV). 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. References shall be made to the latest edition of said standards unless otherwise called for. American Water Works Association (AWWA) C504 Standards for Rubber-Seated Butterfly Valves 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 09900,15000,15041, 15044,15056,15061 and 15064 1.4 SERVICE APPLICATION A. Butterfly valves (BFV) shall be installed on potable and recycled water mains and appurtenances where shown on the Approved Plans and in accordance with the Standard Drawings. B. Butterfly valves shall be used for open/closed operations and throttling service and frequent operation after long periods of inactivity. C. In general, butterfly valves shall be used when valves are required on pipelines 450mm (18") and larger and where the use of a motor-operated valve is required as shown on the Approved Plans, Butterfly valves smaller than 450mm (18") shall only be used as indicated on the Approved Plans or with the prior approval of the District Engineer. D. Valves for pipelines sized 400mm (16") and smaller generally require resilient wedge gate valves (RWGV's) in accordance with Section 15100. 1.5 SUBMITTALS A. Submittals are required per Section 2-5.3 including an affidavit from the valve manufacturer showing the following: 1. Actuators used were furnished and installed by the valve manufacturer. 2. Valves have successfully passed hydrostatic testing per AWWA C504 and coatings testing by the valve manufacturer. JUNE 2004 1of6 SECTION 15102 Butterfly Valves (BFVs) B. The valve manufacturer's catalog data showing the size to be used, valve dimensions, pressure rating and materials of construction. C. Actuator manufacturer's catalog data and detail construction sheets showing the dimensions, materials, number of turns, and required torque input of the actuator to be used. D. Manufacturer's catalog data and proof of NSF certification on the lining materials to be used. 1.6 SIZING OF VALVES Valves shall be the same size as the line in which they are installed unless otherwise shown on the Approved Plans. 1.7 VALVE ENDS Valve ends shall be flanged ductile-iron unless otherwise called for on the Approved Plans or as directed by the District Engineer. Ductile-iron flanges shall generally be in accordance with AWWA C115, rated at a working pressure of 1,724 KPa (250 psi). When Class 250 butterfly valves are shown on the Approved Plans or are otherwise required, ductile-iron flanges shall be compatible with AWWA C207, Class "F". Maximum working pressure of the flange shall be as specified in AWWA or ASME/ANSI. Flanges shall be integrally cast per AWWA C110. 1.8 VALVE TESTING Butterfly valves shall be hydrostatically tested and coatings holiday detected prior to shipment to the field. Valves delivered to the site prior to successful hydrostatic testing and holiday detection will be subject to rejection. 1.9 DELIVERY, STORAGE AND HANDLING Valves shall be delivered and stored in accord with AWWA C504 and AWWA C550. The port openings shall be covered with plastic, cardboard or wood while in transit and during storage in the field. These covers shall remain in place until the valve is ready to be installed. Valves shall not be stored in contact with bare ground. Valves shall not be stacked. 1.10 POLYETHYLENE WRAP Polyethylene wrap shall be used for buried installation of butterfly valves in accordance with Section 15000. JUNE 2004 2 of 6 SECTION 15102 Butterfly Valves (BFVs) PART 2 MATERIALS 2.1 BUTTERFLY VALVES (BFV) A. Butterfly valves and appurtenant components and materials shall be selected from the Approved Materials List. B. Butterfly valves shall be short body, leak-tight closing, and rubber-seated in accordance with AWWA C504 except as modified herein. C. Except as modified below, BFV's shall be Class 1506 in accordance with AWWA C504, rated for a flow velocity of 4.9m/s (16 ft/s). D. Where the static pressure of the pipeline in which the BFV is to be installed exceeds 1.03 Pa (150psi), a Class 250B butterfly valve in general conformance with AWWA C504 shall be required. Class 250B butterfly valves shall be submitted to the Engineer for approval prior to ordering or delivery. E. Butterfly valves shall open by turning left (counterclockwise). Valve disc shall rotate ninety degrees (90s) from the full open position to the tight shut position. F. Butterfly valve interior and exterior surfaces shall be coated as described below. 2.2 MANUAL VALVE ACTUATORS A. General: 1. All valve actuators shall be watertight, designed for buried or submerged uses. Actuators shall be fully gasketed, sealed, and factory packed with grease. 2. As directed by the District Engineer, actuators for valves located above ground or in vaults and structures may have hand wheels or chain wheels. Minimum hand wheel diameter shall be 300mm (12"). The actuator shall be equipped with a dial indicator, which shows the position of the valve disc. The District Engineer may require the use of 50mm (2") square operating nuts in some cases. 3. Actuators for valves shall be provided with a 50mm (2") square-operating nut when buried or when indicated on the Approved Plans. 4. Actuators shall have travel stops, which can be adjusted in the field without having to remove the actuator from the valve. 5. Actuators shall be sized for opening and closing the valve at the valve's full rated working pressure and at a flow velocity of 4.9m/s (16 ft/s). 6. Actuators shall accept a minimum of 407Nm (300 foot-pounds) of input torque at the full open and full closed positions without damage to the actuator or the valve. JUNE 2004 3 of 6 SECTION 15102 Butterfly Valves (BFVs) 7. Actuators equipped with 50mm (2") operator nuts shall require a maximum input torque of 203Nm (150 foot-pounds) to operate the valve. A maximum input torque of 108Nm (80 foot-pounds) shall be required to operate valves with hand wheels. 8. Actuators shall be of the same manufacturer as the valve where possible or as directed by the District Engineer. 9. Actuators shall be installed, adjusted, tested and certified by the valve manufacturer prior to shipping. 10. Actuators shall require a maximum of one hundred (100) input turns for the complete ninety-degree (90s) movement of the disc. 11. Actuators shall receive an epoxy coating on the exterior surface as described below. B. Traveling Nut Actuators: 1. Actuators for butterfly valve sizes 450mm (18") through 600rnm (24") may be the manual traveling nut type. Traveling nut actuators shall not be used on valves requiring motor driven actuators or where the District has specified a worm gear type actuator. 2. Actuators shall be capable of producing the below listed output torque at the closed position: Valve Size in mm (inches) Output Torque Nm (foot-pounds) 450(18") 3729(2750) 500 (20") 3729 (2750) 600 (24") 6372 (4700) C. Worm Gear Type Actuators: 1. Actuators for butterfly valve 750m (30") or larger shall be the worm gear type. In addition, worm gear type actuators shall be used on butterfly valves requiring motor driven actuators or where the District has specified a worm gear actuator. 2. Worm gear actuators shall be totally enclosed and self-locking. 2.3 EPOXY LINING AND COATING Epoxy linings and coatings for valves and actuators shall be provided in accordance with AWWA C210, C213 and C550, with the following modifications: A. Epoxy lining and coating of valve surfaces shall be performed by the manufacturer in a facility with qualified personnel, where the environment can be controlled. Epoxy lining and coating of valves in the field is prohibited. JUNE 2004 4 of 6 SECTION 15102 Butterfly Valves (BFVs) B. Repairs made to shop-applied coatings shall be performed in a facility with qualified personnel, where the environment can be controlled. The facility shall be one that is approved by the valve manufacturer. C. Surface preparation shall be as detailed in SSPC-SP5 White Metal Blast Cleaning. D. Liquid epoxy lining and coating materials shall be listed in the NSF Listing for Drinking Water Additives, Standard 61, certified for use in contact with potable water. E. The minimum dry film thickness for epoxy linings shall be 0.203mm (0.008" or 8 mils). Liquid epoxy lining shall be applied in two (2) coats in accordance with AWWAC210. F. Powder epoxy coating materials shall contain one hundred percent (100%) solids, in accordance with AWWA 213. 2.4 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be in accordance with Section 15000 and the Approved Materials List. 2.5 CONCRETE Concrete used for anchor or thrust blocks shall be in accordance with the Standard Drawings. 2.6 POLYETHYLENE WRAP Polyethylene wrap shall be in accordance with Section 15000 and the Approved Materials List. PART 3 EXECUTION 3.1 INSTALLATION A. Install valves with the bolt holes straddling the vertical and horizontal centerlines of pipe, with the operating nut in the vertical position, unless otherwise noted on the Approved Plans. B. Valves shall be installed per the manufacturer's recommendation in accordance with the applicable specification for the piping material and joint type being used for the valve and the water main. C. Joints shail be cleaned and installed in accordance with Section 15056. JUNE 2004 5 of 6 SECTION 15102 Butterfly Valves (BFVs) 3.2 FLANGE INSULATING KITS Flange insulating kits shall be installed where shown on the Approved Plans in accordance with Standard Drawing. 3.3 WAX TAPE COATINGS Wax tape coatings shall be installed only where shown on the Approved Plans or as directed by the District Engineer. 3.4 POLYETHYLENE WRAP Installation of polyethylene wrap for buried valves shall be performed in accordance with Section 15000. 3.5 CONCRETE Concrete thrust, anchor, and support blocks shall be installed as called for in the Standard Drawings. The concrete shall be placed so that valves and valve operators will be accessible for repairs or replacement. 3.6 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be installed in accordance with Section 15000 and the Standard Drawings. 3.7 DISINFECTION OF THE VALVES Disinfection and flushing shall be performed in accordance with Section 15041, as part of the process of disinfecting the main pipeline. The valves shall be operated during the disinfection period to completely disinfect all internal parts. 3.8 HYDROSTATIC TESTING Valves shall be hydrostatically tested in conjunction with the pipeline in which it is connected in accordance with Section 15044. 3.09 FIELD PAINTING AND COATING The exterior of valves installed above ground or exposed in vaults or enclosures shall be field painted in accordance with Section 09900. END OF SECTION JUNE 2004 6 of 6 SECTION 15102 Butterfly Valves (BFVs) SECTION 15108 AIR RELEASE VALVE, AIR AND VACUUM VALVE, AND COMBINATION AIR VALVE ASSEMBLIES PART 1 GENERAL 1.1 DESCRIPTION This section includes the materials and installation instructions for above ground air release valve, air and vacuum valve, and combination air valve assemblies. The term "air valve" is used generically in this specification to refer to requirements common to all of the specified air release valves, air and vacuum valves, and combination air valves. Otherwise, the various types of air valves are addressed by the individual designations commonly used in AWWA and industry standards. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. American Water Works Association (AWWA) C512 Standards for Combination Air Valve Assemblies 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 09900, 15000, 15041, 15044, 15056, 15057, 15061, 15064, 15100, 16640 1.4 SERVICE APPLICATION A. Combination air valves are generally installed on all potable and recycled water mains at high points and where shown on the Approved Plans and in accordance with the Standard Drawings. B. Unless otherwise directed by the District Engineer, combination air valves will be required as indicated below: 1. 25mm (1") combination air valve assemblies shall be Installed on pipeline sizes 150mm (6") and 200mm (8"). 2. 50mm (2") combination air valve assemblies shall be installed on pipeline sizes 250mm (10*) and 300m (12"). 3. Multiple (2") 50mm combination air valve assemblies shall be installed on pipeline sizes 400mm (16") and 500mm (20"), unless shown on the plans. C. Air release valves and air and vacuum valves shall be installed in accordance with the Approved Plans or as directed by the District Engineer. JUNE 2004 1of4 SECTION 15108 Air Release Valve, Air and Vacuum Valve, and Combination Air Valve Assemblies 1.5 DELIVERY, STORAGE, AND HANDLING Valves shall be delivered and stored in accordance with AWWA C550. The port openings shall be covered with plastic, cardboard, or wood while in transit and during storage in the field. These covers shall remain in place until the valve is ready to be installed. Valves shall not be stored in contact with bare ground. Valves shall not be stacked. 1.6 RECYCLED WATER IDENTIFICATION Air valve assemblies and enclosures used for recycled water shall be identified with purple-colored coating, identification labels or signs in accordance with Section 15151. 1.7 WARNING/IDENTIFICATION TAPE Warning/Identification tape shall be installed for air valve assemblies in accordance with Section 15000. PART 2 MATERIALS 2.1 COMBINATION AIR VALVES A. Combination air valves and appurtenant components and materials suitable for the system pressure shall be selected from the Approved Materials List. B. Combination air valves shall comply with AWWA C512 except as modified herein. C. 25m (1") and 50mm (2") combination air valves shall be the single-body type incorporating stainless steel internal components and National Pipe Threaded (NPT) inlet and outlet configurations. D. 100mm (4") and 150mm (6") Combination Air Valves shall be the single-body type. Valves shall incorporate stainless steel internal components, protective hood and flanged inlet. E. Internal protective epoxy coatings shall be provided in accordance with AWWA C550. 1. Liquid epoxy lining and coating materials shall be listed in the NSF Listing for Drinking Water Additives, Standard 61, certified for use in contact with potable water. 2. The minimum dry film thickness for epoxy linings shall be 0.203m (0.008" or 8 mils). Liquid epoxy lining shall be applied in two (2) coats in accordance with AWWA C210. JUNE 2004 2 of 4 SECTION 15108 Air Release Valve, Air and Vacuum Valve, and Combination Air Valve Assemblies 2.3 ENCLOSURES Air Valve Enclosures shall be selected from the Approved Materials List. 2.4 CONCRETE Concrete used for anchor or thrust blocks and equipment pads shall be in accordance with Section 03000. 2.5 BREAK-AWAY BOLTS Combination air valves, air release valves and air and vacuum valves located above ground sized 100mm (4") and larger shall be installed with break-away bolts in accordance with the Standard Drawings and selected from the Approved Materials List. 2.6 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be in accordance with Section 15000 and selected from the Approved Materials List. 2.7 FIELD PAINTING AND COATING Field painting and coating materials shall be in accordance with Section 09900 and selected from the Approved Materials List. PART 3 EXECUTION 3.1 INSTALLATION A. Air valve assemblies shall be provided as shown on the Approved Plans. Additional air valve assemblies may be required in areas of potential air entrapment, at the discretion of the District Engineer. B. Air valve assemblies shall be installed relative to street improvements in accordance with the Standard Drawings. C. Connections for the air valve assemblies shall be made within a section of the main line no closer than 600mm (24") to a bell, coupling, joint or fitting. 3.2 CONCRETE Concrete thrust or anchor blocks and equipment pads shall be installed in accordance with the Standard Drawings. 3.3 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be installed in accordance with Section 15000 and the Standard Drawings. JUNE 2004 3 of 4 SECTION 15108 Air Release Valve, Air and Vacuum Valve, and Combination Air Valve Assemblies 3.4 DISINFECTION Air valve assemblies shall be disinfected in accordance with Section 15041 in conjunction with disinfecting the main to which it is connected. The assembly valves shall be operated and the assembly flushed to completely disinfect all internal parts. 3.5 HYDROSTATIC TESTING Air valve assemblies shall be hydrostatically tested in accordance with Section 15044 in conjunction with the pipeline to which they are connected. 3.6 FIELD PAINTING AND COATINGS A. Field repairs to the enclosure shall not be permitted. Enclosures requiring repairs to the coating shall be returned to the supplier or coating vendor for repairs or recoating in accordance with Section 09900. END OF SECTION JUNE 2004 4 of 4 SECTION 15108 Air Release Valve. Air and Vacuum Valve, and Combination Air Valve Assemblies SECTION 16640 CATHODIC PROTECTION BY SACRIFICIAL ANODES PART 1 - GENERAL 1.1 Scope Of Work Furnish all labor, materials, tools equipment, and incidentals to install cathodic protection and corrosion monitoring facilities on the buried 30-inch steel water piping associated with City of Carlsbad, San Marcos Blvd. Project. Facilities shall include: insulating flange kits, sacrificial anodes, corrosion monitoring test stations, continuity bonding, attendant wiring, inspection, and testing for a complete and workable system. 1.2 Quality Assurance A. Qualifications: The Corrosion Engineer retained by the Contractor for testing shall be experienced with buried water line cathodic protection and either be a registered corrosion engineer in the State of California or a NACE International Certified Cathodic Protection Specialist. B. Reference Specifications, Codes and Standards: 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 designations only. ANSI B16.21 Nonmetallic Flat Gaskets for Pipe Flanges ASTM B3-01 Soft of Annealed Copper Wire ASTM B8-99 Concentric-Lay-Stranded Copper Conductors ASTM C94-00 Ready-Mix Concrete ASTM D1248 Polyethylene Plastics Molding and Extrusion Materials ASTM D2220 PVC Insulation for Wire and Cable, 75° C Operation AWWAC217-99 Cold-Applied Petrolatum Tape and Petroleum Wax Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Buried Steel Water Pipelines MIL-C-18480A Coating Compound, Bituminous, Solvent, Coal Tar Base NACE RP0169-96 Recommended Practice "Control of External Corrosion on Underground or Submerged Metallic Piping Systems". NACE RP0286-02 Electrical Isolation of Cathodically Protected Pipelines UL 83-98 Thermoplastic-Insulated Wires UL 486-00 Wire Connectors and Soldering Lugs for Use with Copper Conductors City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection-1 of 13 1.3 Definitions A. Contractor: The licensed, qualified construction firm selected by the Owner to have prime responsibility for the completion of the work. B. Owner The City of Carlsbad C. Engineer: The Owner's representative who is assigned to be the direct contact between the Owner and the Contractor. D. Inspector: The Owner's representative designated to have project inspection responsibilities. E. Corrosion Engineer The individual, designated and retained by the Contractor, who is trained and experienced in cathodic protection and who is a registered professional Corrosion Engineer in the State of California or who is a certified Cathodic Protection Specialist by NACE International. 1.4 Related Work Described Elsewhere A. Shop Drawing Submittals: 01300 B. Cold-Applied Plastic Tape Pipe Coating with Mortar Overcoated: 09870 1.5 Submittals The following information shall be submitted for approval of the Engineer in accordance with Section 01300 of these specifications. A. Catalog Cuts (5 copies): 1. Pre-packaged high potential magnesium anodes 2. At-grade test boxes 3. Shunts 4. Brass split-bolts 5. Brass wire tags 6. Wire and cable 7. Insulating flange kits 8. Wax tape wrap 9. Alumino Thermic Weld Kit 10. Weld caps and primer 11. Weld coating 12. Warning tape B. As-built Drawings: The Contractor shall maintain as-built drawings showing the exact locations of all insulators, anodes, wire runs and corrosion monitoring test stations. Location changes from the design drawings shall be indicated in red. These drawings shall be submitted to the Engineer before the work is considered complete. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection-2 of 13 PART 2 - MATERIALS Materials and equipment furnished under this section of the specifications shall be the standard product of manufacturers regularly engaged in the manufacturing of such products and shall be the manufacturer's latest standard design that complies with specification requirements. All materials and equipment shall bear evidence of U.L approval when U.L. standards exist. 2.1 Pre-Packaged Magnesium Anodes A. Capacity: All anodes shall be high potential magnesium ingots with a theoretical energy content of 1000 ampere-hours per pound and a minimum useful output of 500 ampere-hours per pound. B. Chemical Composition (High Potential Magnesium): Aluminum 0.01 percent (max) Manganese 0.5 to 1.3 percent Zinc 0.002 percent (max) Copper 0.02 percent (max) Nickel 0.001 percent (max) Iron 0.03 percent (max) Silicon 0.05 percent (max) Other 0.05 percent each (max) and 0.3 percent total (max) Magnesium Balance C. Open Circuit Potential: The open circuit potential of all anodes shall be between 1.55 and 1.65 volts DC versus a copper-copper sulfate reference electrode. D. Ingot Size and Weight: Anodes shall be 48-pound magnesium ingots with a trapezoidal cross section. Ingot size shall be 32 inches long. E. Anode Construction: Anodes shall be cast magnesium with a galvanized steel core rod. Recess one end of the anode to provide access to the rod for connection of the lead wire. Silver braze the lead wire to the rod and make the connection mechanically secure before brazing. Insulate the connection to a 600 volt rating by filling the recess with epoxy and covering any exposed bare steel core or wire with heat shrinkable tubing. The insulating tubing shall extend over the lead wire insulation by not less than one-half inch. F. Anode Lead Wire: Anode lead wire shall be AWG No. 12 stranded copper wire with THWN insulation conforming to UL Standard 83. Anode lead wire shall be of sufficient length to extend from the anode to the designated termination point without a splice. Wires with cut or damaged insulation will not be accepted and replacement of the entire lead will be required at the Contractor's expense. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection-3 of 13 G. Anode Pre-Packaged Backfill Material: The magnesium anodes shall be completely encased and centered within a permeable cloth bag in a. special low resistivity backfill mix with the following composition: Gypsum 75% Powdered Bentonite 20% Anhydrous Sodium Sulfate 5% Backfill grains shall be such that 100 percent is capable of passing through a screen of 100 mesh. Backfill shall be firmly packed around the anode such that the ingot is approximately in the center of the backfill and surrounded by at least two inches of backfill material. The resistivity of the backfill shall be no greater than 50 ohm-cm when tested wet in a soil box with no extraordinary means of compaction. The total prepackaged weight shall be approximately 10O pounds. 2.2 At-Grade Test Stations A. Test Box: At-grade test boxes shall be round, pre-cast concrete with dimensions of 14-1/4 inches O.D. by 9 inches I.D. by 12 inches high, similar to Christy G5 Utility Box with a cast iron supporting ring and lid, and shall have sufficient strength to support occasional vehicular traffic. The lid shall be cast with the legend "CP Test" using letters not less than 1-1/2 inches high. B. Brass Tags: All test leads shall be identified in each test box with 1-1/2-inch diameter brass tags with a 1/8-inch diameter hole. The tags shall be die stamped as indicated in the drawings with %-inch high characters. The tags shall be securely attached to the test leads with uninsulated No. 14 copper wire. C. Shunts: Anode test boxes shall have 0.01-ohm shunts rated at 6 amperes, Holloway Type RS or equal, and accurate to plus or minus one percent. D. Split Bolt Connector: Split bolt connectors shall be UL 486 copper or brass and sized to accommodate the lead wire and shunt being used. E. Concrete Pad: Test boxes mounted in un-paved areas shall have a 24-inch by 6-inch thick reinforced concrete pad constructed of ASTM C94 Ready-Mix concrete. 2.3 Wire And Cable A. Standard: All wire shall be single conductor, stranded copper of the gauge indicated. Wire sizes shall be based on American Wire Gauge (AWG). Copper wire shall be in conformance with ASTM Standards B3 or B8. Wire with high molecular weight polyethylene (HMWPE) insulation and shall conform with the requirements of ASTM D1248m Type 1, Class C, Grade 5. Wire with THWN insulation shall conform with the requirements of ASTM D2220. B. Wire Size: As shown in the drawings. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection-4 of 13 2.4 Insulating Flange Kit A. Gasket: ANSI B-16.21, Type "E" full-faced, laminated glass NEMA LI-1 G-10 material with rectangular nitrile or Viton O-ring seal for operation between 20°F and 150°F. Gaskets shallbe suitable for the temperature and pressure rating of the piping system in which they are installed. B. Insulating Sleeves: 1/32-inch thick tube, full length, laminated glass material as per NEMA Ll-1 G10 for operation between 20°F and 150°F. For installation at threaded valve flanges, the sleeves shall be half-length. C. Insulating Washers: 1/8-inch thick laminated glass sheet material as per NEMA Ll- 1 G10 for operation between 20°F and 150°F. D. Steel Washers: 1/8-inch thick cadmium plated steel to be placed between the nut and the insulating washer. 2.5 Wax Tape Wrap A. Intended Application and Standard: All petrolatum wax tape coatings shall be in accordance with AWWA C-217 and these specifications unless indicated otherwise in the drawings. B. Primer: All surfaces shall be prime coated with a blend of petrolatum, plasticizer, inert fillers, and corrosion inhibitor having a paste-like consistency. C. Wax Tape: Fitting covering material shall be a synthetic felt tape, saturated with a blend of petrolatum, plasticizers, and corrosion inhibitors that is easily formable over irregular surfaces. A compatible petrolatum filler should be used to smooth over irregular surfaces. D. Plastic Wrap: The primed and wax-tape wrapped fitting shall be wrapped with a plastic tape covering consisting of three (3) layers of 50 gauge (1.0 mil), polyvinylidene chloride or PVC, high cling membranes wound together. 2.6 Alum I no-Thermic Welds A. Alloy and Size: Cable-to-metal connections shall be made by the alumino-thermic welding process as illustrated in the drawings. Weld charge size, alloy and mold size are dependent upon the material to which the welds are attached and the size of the copper wire and shall be as specified by the manufacturer of the weld kit. The Contractor shall ensure that the correct charges are used. B. Primer: Weld cap primer shall be an elastomer-resin based corrosion resistant primer for underground services such as Royston Roybond Primer 747 or equivalent. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection - 5 of 13 C. Weld Cap: Alumino-thermic welds shall be sealed with a pre-fabricated plastic cap filled with formable mastic compound on a base of elastomeric tape. Weld caps shall be Royston Handy Cap 2 or equivalent. D. Coating: Bitumastic coatings shall be cold-applied, black, thixotropic material containing plasticized coal tar pitch, solvents, and special fillers per MIL-C- 18480A such as Carboline Bitumastic 50, Tnemec 40-H-413, Tape-coat TC Mastic or 3M Scotch Clad 244. Apply to at least 20 mils thickness. 2.7 Plastic Warning Tape A. Tape: Plastic warning tape for buried test leads in cable trenches shall be a minimum of four (4) mils thick and six-inches (6") wide, inert plastic film designed for prolonged use underground. The tape shall have the words, "CAUTION: Cathodic Protection Cable Below," or similar, clearly visible in repeating patterns along its entire length. PART 3 - EXECUTION Corrosion protection installations shall conform to NACE Publication RP0169-96 Recommended Practice, "Control of External Corrosion on Underground or Submerged Metallic Piping Systems". The installation of corrosion protection facilities shall be supervised by either a NACE Certified Cathodic Protection Specialist or a Registered Professional Corrosion Engineer in the State of California. 3.1 Magnesium Anodes A. Lead Wire Inspection: All lead wires shall be inspected to ensure that the wire is securely connected to the anode core and that the lead wire insulation has sustained no damage. Anode lead wire-to-anode connection failures shall require replacement of the complete anode and lead wire assembly. B. Anode Packaged Inspection: Each unit shall be inspected to ensure that the backfill material completely surrounds the anode and that the cloth bag containing the anode and backfill material is intact. If the prepackaged anodes are supplied in a waterproof container or covering, that container or covering shall be removed before installation. C. Location: All anodes are to be installed in augured holes as shown in drawings. Anode positions can be adjusted slightly to avoid interference with existing structures. Alternate anode positions must be approved by the Inspector. D. Handling: Care shall be taken to ensure that the anode is never lifted, supported, transported, or handled by the lead wire. All anodes shall be lowered into the hole using a sling or a rope. E. Anode Hole: Anode hole shall be 12-inches in diameter and 15-feet deep. If rock is encountered when auguring anode holes, the Inspector shall be consulted for direction. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection - 6 of 13 F. Soaking Requirements: All prepackaged anodes shall be completely submerged in water for 30 minutes before being placed in the trench. Once in the trench or hole, 15 gallons of water shall be poured on top of the anodes such that they are completely covered with water. Allow the anodes to soak for a minimum of 30 minutes before any soil backfill is added. Backfill with native, rock-free (1/2-inch maximum rock size) soil such that the soil backfill is level with the top of the anode. Add an additional 5 to 10 gallons of water to the trench or hole to completely saturate the soil around the anode. Allow the anode and soil to soak for 15 minutes (minimum) before completing the backfill operation. G. Anode Hole Backfill: After the anodes have soaked in the trench or hole, the . trench or hole is backfilled with native trench spoil (not sand) with all stones over 1-inch diameter removed. Backfill the trench or hole in 18-inch lifts and carefully tamp to compact the soil. No voids shall exist around the anode bags and the anode lead wire shall not be damaged. 3.2 At-Grade Test Stations A. Locations: At-grade corrosion monitoring test boxes shall be located behind the street curb as shown in the drawings. Test boxes can be moved slightly to accommodate surface features B. Soil Access: Native soil shall be accessible inside all test boxes. The test boxes shall not be filled with sand, gravel, rocks, concrete or any other foreign material. Plastic risers used to protect the test wires during construction shall be removed. C. Test Wire Connections: Test leads shall be attached to the pipe using the Alumino-Thermic weld process as shown in the drawings and per the W.A.S. Detail WC-01. A single 24-inch slack wire coil shall be placed at each weld. D. Brass Tags: All test leads shall be identified in each test box with 1-1/2 inch diameter brass tags with a 1/8-inch diameter hole. The tags shall be die stamped as indicated in the drawings with 1/4-inch high characters. The tags shall be securely attached to the test leads with uninsulated No. 14 copper wire. E. Splice, Depth and Slack: All buried lead wires shall be installed without splices. Where a trench is required, it shall be a minimum depth of 24 inches. All lead wires shall terminate in a test box and shall have 24 inches of slack coiled inside the test box. F. Wire Trench: The bottom of the finished trench shall be sand or stone-free earth. Lead wire shall be centered in the bottom of the trench, covered and tamped in 6 inch layers of stone free earth. Soil compaction shall be as specified elsewhere in these specifications. Do not stretch or kink the conductor. Care shall be taken when installing wire and backfilling trench so insulation is not broken, cut or bruised. If wire insulation is damaged during installation, it shall be rejected and replaced completely at the Contractor's expense. All rejected wire shall be removed from the job site at the close of each workday. Do not place roots, wood scraps, organic matter or refuse in the backfill. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection - 7 of 13 G. Concrete Pad: A 24-inch square by 6-inch thick concrete pad with No. 4 bar reinforcement as shown in the drawings is required around each at-grade test station that is not located in a paved area. 3.3 Insulating Flange Kit A. Standard: Insulators shall be installed and tested in accordance with this specification and NACE RP0286-02 Electrical Isolation of Cathodically Protected Pipelines. B. Flange Kit Preparation: Insulating kits shall be installed as shown on drawings and as recommended by the manufacturer. Moisture, soil, or other foreign matter must be carefully prevented from contacting any portion of the mating surfaces prior to installing insulator gaskets. If moisture, soil, or other foreign matter contacts any portion of these surfaces, the entire joint shall be disassembled, cleaned with a suitable solvent, and dried prior to reassembly. C. Pre-Assembly: All insulating flange kits 20-inches or greater shall be pre-installed and tested in the pipe spool before the spool is installed in the ditch D. Component Compatibility: The Contractor shall be responsible to provide insulating flange kits fit up properly. Specifically, the Contractor shall verify the following: the bolts or studs are the correct material and size; there are the correct number of bolts (studs), nuts, sleeves, insulating washers and steel washers; the gasket sealing surfaces match up properly on both flanges; there is enough clearance for the sleeves between the bolts or studs and the flange hole. E. Alignment: Alignment pins shall be used to properly align the flange and gasket and joining flange bolt holes. F. Bolt Tightening: The manufacturer's recommended bolt-tightening sequence shall be followed. Bolt insulating sleeves shall be centered within the insulation washers so that the insulating sleeve is not compressed and damaged. G. Paint Pigments: Neither aluminum, graphite, nor any other electronically conductive pigment shall be used in paints or coatings either externally or internally on the flanges, bolts, or washers of any insulating device. H. Testing: All insulating flanges must be tested as specified below. All buried insulating flanges must be tested before backfilling and before the wax tape primer and wrap are applied. 3.4 Wax Tape Wrap A. Installation Standard: All buried steel or iron appurtenances (i.e. in-line flanges, insulating flanges, valves, couplings) shall be wrapped with petrolatum wax tape per AWWA C217 and as described below. B. Primer: Surfaces must be cleaned of all dirt, dust and loose rust or mill scale by wire brush and by wiping with a clean cloth. The surface shall be dry. Apply primer by hand or brush. A thin coating of primer shall be applied to all surfaces and worked into all crevices, including the gap between meeting flanges. The City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection - 8 of 13 primer shall be applied generously around bolts, nuts, tie rods and in threads, and shall completely cover all exposed surfaces and fill all voids. The primer should overlap the pipe coating by a minimum of 3 inches. C. Filler: Additional primer or filler shall be applied to smooth out irregular surfaces so that the petrolatum saturated tape can be easily applied. D. Petrolatum Saturated Tape: The petrolatum can be applied immediately after primer and/or filler application. Short lengths of tape shall be cut and carefully molded around each individual bolt, nut, tie rod and stud-end. Coupling tire rods and odd surfaces must be individually wrapped to ensure complete coverage with tape directly against all surfaces. After all bolts and odd surfaces are covered, the tape shall be circumferentially wrapped over the item as appropriate with sufficient tension and pressure to provide continuous adhesion without stretching the tape. The tape shall be formed by hand into all voids and spaces. There shall be no gaps or air spaces under the tape. The tape shall be applied with at least a 55% overlap. The wax-tape system shall have a minimum thickness of 50 mils over smooth surfaces and 100 mils over sharp projections such as bolts, nuts and metal edges. E. Outer Covering: The clear plastic outer covering shall be applied by hand such that the material conforms and adheres to the petrolatum tape surface. Two layers of plastic outer wrapping shall be applied. F. Protection From Backfill Damage: Wax tape is susceptible to damage when backfilling, especially when backfilling with gravel that is dropped from a height of several feet. Contractor shall carefully backfill all wax taped components making sure that the surface is protected and that there is no erosion or damage to the tape. 3.5 Pipe and Mechanical Joint Bonding A. Continuity: All metallic pipe reaches shall be fully metallically and electrically continuous. B. Pipe Joints: Bond all pipe joints either by welding or by installing two (2) copper jumper wires across each joint as shown in the drawings. C. Mechanical Joints: Bond all mechanical joints, i.e. valves, flanges, couplings, adapters, etc., except joints specifically identified as insulating joints, with copper jumper wires as shown in the drawings. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection - 9 of 13 PART 4 - TESTING AND INSPECTION 4.1 Test Lead and Bond Wire Welds A. Responsibility: The Contractor shall be responsible for testing all test leads and bond wire welds. The Inspector shall observe testing at his or her discretion. B. Test Method: All completed wire connection welds shall be tested for strength by striking the weld with a sharp blow with a two-pound hammer while pulling firmly on the wire. Welds failing this test shall be re-welded and re-tested. Wire welds shall be spot tested by the Inspector or Engineer. After backfilling pipe, all test lead pairs shall be tested using a standard ohm meter for broken welds. C. Acceptance: Welds not loosened or broken by the hammer test can be backfilled. The resistance of test leads shall not exceed 150% of the total wire resistance plus the meter wire resistance as determined from the length and published wire data. Bond wire acceptance shall be determined by the continuity test results. 4.2 Test Lead Trenching And Backfill A. Responsibility: The depth, trench bottom padding, and backfill material shall be inspected by the Inspector at his or her discretion prior to backfilling. B. Method: The depth, trench bottom padding, and backfill material shall be visually inspected prior to backfilling. C. Jetted or Bored Wire Runs: The Inspector shall verify that the bore hole does not interfere with existing utilities. D. Acceptance: Conformance with these specifications. 4.3 Pipeline Continuity A. Responsibility: The Contractor is responsible for the metallic\electric continuity of the steel pipe. Continuity tests shall be conducted by qualified Corrosion Engineer who is retained by the Contractor. The contractor is also responsible for providing test access (temporary or permanent as needed) at either end of the pipe sections requiring testing. B. Pipe Requiring Continuity Testing: All reaches or sections of steel pipe that contain one or more bonded, mechanical or non-welded joints must be tested for continuity. C. Notification for Testing: The Contractor shall notify the Inspector at least five days before the completed pipe installation (including test access) is ready for testing. D. Test Method: Pipeline continuity shall be tested using the direct resistance method. Alternate methods must be approved by the Owner. The direct resistance method consists of measuring the linear resistance of individual pipe City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection-10 of 13 sections between two adjoining test stations (2-wire minimum) such that the entire line is tested. The resistance of the pipe section is measured by applying a known DC current through the section and measuring the IR drop. Current can be applied through the pipe using any dc source such as a battery. The IR drop shall be measured at a minimum of five different current values. Instruments used shall be sufficiently sensitive to measure a resistance equal to plus or minus 5% of the calculated resistance of the pipe section. E. Acceptance: The continuity of the pipeline shall be considered acceptable if the actual resistance measured as described above is equal to or less than 130% of the theoretical calculated pipe section resistance. The calculated resistance shall include the cylinder resistance and the bond wire resistance. If the actual resistance is greater than 130% of the calculated value the contractor shall, at his own expense, locate the open or high resistance joints, make all necessary corrections, and retest until this criterion is met. 4.4 Anodes And Cathodic Protection Performance A. Responsibility: The Contractor is responsible for providing the proper rated potential anode, sufficient anode lead wire length and the proper anode hole depth. The Contractor shall be responsible for insuring that the anode pre-packaged backfill sack is intact and that the wire leads are soundly attached. The Contractor's Corrosion Engineer shall test each installed anode for wire connection integrity and for open-circuit potential. B. Notification for Testing: The Contractor shall notify the Inspector at least five days in advance of plans to install the anodes and when all anodes are installed and ready for activation and testing. At their discretion, the anode installations shall be witnessed by the Inspector. C. Cathodic Protection Performance Test Method: The performance of the cathodic protection system will be tested by the Contractor's Corrosion Engineer. The testing shall include: measurement of all open-circuit anode potentials; pipe-to-soil potentials at each test station and other locations as necessary before the anodes are connected; initial anode currents after connecting anode leads to the pipe leads; and the pipe-to-soil potential at each previously tested site with all anodes connected. Pre- and post cathodic protection potentials are required to verify that the pipeline is fully protected. Adequate protection shall be as defined inNACERP0169. D. Test Report: The Corrosion Engineer shall immediately report all system deficiencies to the Inspector. Upon completion of the testing, the Corrosion Engineer shall submit a report to the Owner which includes all test results, conclusions regarding the performance of the system and recommendations for maintenance and monitoring. E. Repairs: The Contractor shall perform repairs due to system installation deficiencies reported by the Corrosion Engineer. These repairs and system re-testing shall be provided at no additional cost to the Owner. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection-11 of 13 F. Acceptance: The system will be accepted if all anodes, test stations, and supporting facilities are installed according to the drawings and these specifications and are in proper working order. 4.5 Insulating Flange Kits A. Responsibility: Insulators shall be tested by a qualified corrosion engineer or technician who has experience with insulating flange testers. This could be either the Inspector or the Corrosion Engineer. Insulator testing shall be done in the presence of the Contractor. B. Test Schedule: All buried insulating flange kits greater than 20 inches are to be installed on pipe spools before they are installed in the ground. Insulator tests shall be conducted after installation of the kit on the spool and then again after the spool is installed in the ditch. C. Test Method: The assembled flange shall be tested with an insulator testing device (i.e., Gas Electronics Model 601 Insulation Checker) specifically designed for this purpose. Additionally, insulators can be tested by the pipe-to-soil potential, leakage current or cathodic shift methods as described in NACE RP0286. The pipe-to-soil method shall be done using a high impedance voltmeter and suitable reference cell, shall be measured on each side of the insulator after installation in the trench but before backfilling. The testing shall be done by a qualified Corrosion Engineer. . D. Notification for Inspection: The Contractor shall notify the Inspector at least five days in advance of the testing of in-vault insulator installations. E. Acceptance: The installation shall be considered complete when the testing device indicates that no shorts or partial shorts are present and when the potential tests indicate greater than 20 millivolt pipe-to-soil potential difference across the flange. If shorts are detected the Contractor shall assist the qualified Corrosion Engineer in finding partial shorts or shorted bolts. All disassembly and re-assembly necessary to gain the acceptance of the qualified Corrosion Engineer shall be done at the Contractor's expense. 4.6 Wax Tape Coating A. Responsibility: All wax tape coating applications shall be inspected by the Engineer or Inspector. B. Notification for Inspection: The Contractor shall notify the Engineer at least five days in advance of completion of wax tape applications. C. Test Method: Each tape wrapped component shall be visually inspected. Backfilling shall not be done until this inspection is complete and the tape wrap application is approved by the Engineer. D. Backfill Protection: The Engineer or Inspector shall also observe the backfill operation to ensure protection of the wax tape. E. Acceptance: Conformance with this specification section. City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection -12 of 13 4.7 Compliance With Specifications A. Deficiencies: Any deficiencies or omissions in materials or workmanship found by these tests shall be rectified by the Contractor at his expense. Deficiencies shall include but are not limited to: unconnected or broken anode or test leads; incorrect anode type; improper or un-clean wire trench backfill; lack of 24 inches slack wire on each test lead in each test box; shorted or partially shorted insulators; inadequate insulator coating; broken wires or wire connections; failure to notify the Engineer in sufficient time to test buried insulators; high metallic pipeline resistance; and improperly mounted or located test boxes. END OF SECTION City of Carlsbad San Marcos Blvd. Domestic Water Transmission Main 4/05 (DBE) 16640—Cathodic Protection -13 of 13