HomeMy WebLinkAboutCass Construction Inc; 2004-11-03; 34461 Part 2 of 2SHOP DRAWING TRANSMITTAL FORM
FROM: DATE:
Phone: FAX:
PROJECT NAME: Recvcled Water Transmission Main El Camino Real 20-Inch
TO: Citv of Carlsbad PROJECT NO.: 3887-H
5950 El Camino Real
Carlsbad, CA 92008 OWNER: Citv of Carlsbad
ATTN: Construction Manaaement and 5950 El Camino Real
InsDection Division Carlsbad. CA 92008
THIS IS AN ORIGINAL THIS IS A REVISION
SUBMITTAL NO.: SUBMITTAL OF SUBMITTAL NO.:
SUBJECT OF SUBMITTAL:
S P EC I F I CAT1 ON S ECTl ON (S) :
PLAN SHEET NUMBER(S):
CONTRACTOR'S CERTIFICATION: Check & Complete either (A) or (B) below:
(A) We have reviewed in detail and certify that the material, equipment or
construction procedure(s) contained in this submittal meet all the requirements specified in or shown on the Contract Documents,
Construction Specifications and Construction Plans with no exceptions.
We have reviewed in detail and certify that the material, equipment or construction procedure(s) contained in this submittal meet all the
requirements specified in or shown on the Contract Documents, Construction Specifications and Construction Plans except for the followinq deviations:
CONTRACTOR'S AUTHORIZED SIGNATURE:
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01300 - Shop Drawing Submittals - 8 of 8
SECTION 01 31 0
PROGRESS SCHEDULE, SUBMllTAL SCHEDULE,
AND SCHEDULE OF VALUES
PART 1 - GENERAL
1.1 Scope
This section addresses preparation and submission of the construction progress schedule,
submittal schedule, schedule of values, and other reports specified herein, including the up-
to-date maintenance thereof as required.
1.2 Related Work Described Elsewhere
A. Section 01 31 0 Shop Drawing Submittals
1.3 Construction Schedule
A. General
Immediately upon being awarded the Contract and prior to issuance of the Notice
to Proceed, the Contractor shall prepare and submit to the Engineer a
construction progress schedule for review and approval. The schedule shall be
prepared and shall conform to the working time and time of completion
established under the terms of the Contract and shall be subject to modification
by and approval of the Owner. When in the opinion of the Owner, it becomes
necessary to accelerate the Work, the Contractor, when so ordered, shall modify
the schedule to conform to such requirements at no additional cost to the Owner.
B. Schedule Preparation and Updates
The Construction Schedule shall be in conformance to the requirements of
Section 6-1.1.1 and Sections 6-1.2 through 6-1.8.3 of the Supplemental provisions.
1.4 Submittal Schedule
A. General
The Contractor shall also furnish a separate schedule along with the Construction
Schedule specified herein, showing the proposed dates for submittal of shop
drawings, product data and samples.
B. Quantity
Submit two copies of the submittal schedule to the Engineer.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 31 0 - Progress Schedule, Submittal Schedule, and Schedule of Values - 1 of 2
1.5 Schedule of Values
A. General
Immediately upon being awarded the Contract, and before Pre-Construction
Conference, the Contractor shall prepare and submit to the Engineer, a Schedule
of Values allocated to the various portions of the Work. This Schedule of Values,
unless objected to by the Engineer, shall be used as the basis for the Contractor's
Applications for Payment and for contract change order negotiation if necessary.
B. Methodology
The schedule shall list the installed value of the component parts of the Work in
sufficient detail to serve as a basis for computing values for progress payments
during construction. Follow the table of contents of this Project Manual as the
format for listing component items. For each major line item list sub-values of
major products or operations under the item, where applicable.
Each item shall include a directly proportional amount of the Contractor's
overhead and profit.
For items on which progress payments will be requested for stored materials,
break down the value into (1) the cost of materials, delivered and unloaded, with
taxes paid, and (2) the total installed value. -
The sum of all values listed in the schedule shall equal the total Contract sum as
well as the total values of all lump sum bid items of work.
C. Submittal
The schedule of values must be submitted as a Shop Drawing Submittal
approved by the Owner prior to commencing with the work.
PART 2 - PRODUCTS (Not Applicable)
PART 3 - EXECUTION (Not Applicable)
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 31 0 - Progress Schedule, Submittal Schedule, and Schedule of Values - 2 of 2
SECTION 01 340
SHOP DRAWINGS, PRODUCT DATA AND SAMPLES
PART 1 - GENERAL
1.1 Scope
This section addresses preparation and submission of shop drawings, product data, and
samples as specified herein and in the various sections of these specifications. The
requirements specified herein are in addition to requirements for shop drawings, product
data, samples, materials lists, substitutions of materials, or other submittals specified
elsewhere in these specifications.
1.2 Definitions
As used herein, the term "manufactured" applies to standard units usually mass-produced;
and "fabricated" means items specifically assembled or made out of selected materials to
meet individual design requirements.
1.3 General Submittal Procedures
A. Scheduling
Submit shop drawings, product data, and samples in accordance with the
schedule specified in Section 01310. Extension of Contract time will not be
granted because of the Contractor's failure to make timely submittals. Do not
purchase materials or equipment or begin construction activities covered by the
required submittals until submittals have been reviewed and returned.
B. Transmittal
Accompany each submittal with a dated, signed and sequence numbered
transmittal on forms prescribed by the Engineer. Include information required
by this form including project identification, name and address of Contractor
and of subcontractor or supplier, a list of items included in the submittal, and
identification of drawing numbers, specification section and paragraph numbers
to which submittal pertains, and space for Contractor's review and approval
stamp.
C. Check of Returned Submittals
City of Carlsbad
03/04 (DBE)
Check the submittals returned for correction and ascertain if the corrections
result in extra cost above that included under the Contract Documents, and
give written notice within five days if, in Contractor's opinion, such extra cost
results from corrections. By failing to so notify or by starting any Work covered
by a submittal, Contractor waives all claims for extra costs resulting from
required corrections.
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 340 - Shop Drawings, Product Data and Samples - 1 of 7
1.4 Shop Drawings and Product Data
A. Shop Drawings
City of Carlsbad
03/04 (DBE)
The term "Shop Drawings" as used herein includes fabrication and installation,
layout, and setting drawings; wiring and control diagrams; and other drawings
as defined in the General Conditions.
Check and verify all field measurements and submit for review, with such
promptness as to cause no delay in the Work or in that of any other contractor
or subcontractor, all shop or setting drawings and schedules required for the
construction activities of the various trades. Shop Drawings shall be prepared
at the Contractor's expense and shall be sent to the office of the Engineer,
carriage prepaid.
Drawings shall show all information required by the applicable technical section
and shall be in sufficient detail as may be required to show that fabricated
materials, equipment or systems, and the positions thereof conform to the
Contract Documents.
Shop Drawings shall establish the actual detail of fabricated items, indicate
proper relation of adjoining construction, amplify design details of mechanical
and electrical equipment in proper relation to physical spaces in the structure,
and incorporate minor changes of design or construction to suit actual
conditions. Shop Drawings shall be drawn to scale and shall be completely
dimensioned.
-
1. Composite Shop Drawings and Field Layouts
Prepare and submit composite Shop Drawings and field layouts as
required to solve tight field conditions and when required to coordinate
the construction activities of several trades. Include dimensioned plans,
elevations, sections, and details and give complete information
particularly as to kinds and types of materials and equipment, size and
location of sleeves, inserts, attachments, chases, openings, conduits,
ducts, boxes, and structural interferences. Coordinate these composite
Shop Drawings and field layouts in the field for proper relationship to
construction activities of applicable trades based on field conditions.
Contractor shall have competent personnel readily available for
coordinating, checking, and supervising of field layouts. The
procedures for submittals and resubmittals, and final distribution shall
be as specified for Shop Drawings.
2. Shop Drawing Format
Prepare Shop Drawings on sheet of same size as Contract Drawings or
on 8E-inch by 1 1-inch three-hole punched vellum type sheets suitable
for both Xerox and blue line reproduction.
-
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 340 - Shop Drawings, Product Data and Samples - 2 of 7
Each Shop Drawing shall have a title block containing the following
information.
a. Name and location of the Project.
b. Name and address of the Contractor.
c. Name and address of the subcontractor, manufacturer, supplier
or distributor as applicable.
d. Name and address of Owner.
e. Date, scale of drawings, and identification number.
f. Space for the Contractor's review and approval stamp.
3. Quantity of Each Shop Drawing
Submit five blue or black line prints and one reproducible transparency
of each shop drawing.
B. Product Data
The term "product data" as used herein includes manufacturer's standard
drawings, certificates of conformance, substantiating calculations and other
data as defined in the General Conditions.
The data shall include all information required by the applicable technical
section and shall be in sufficient detail to show that manufactured materials
and equipment conform to the Contract Documents.
1. Catalog Cuts
Clearly mark each copy to indicate the product or model as well as
optional sizes, finishes or other features proposed for use. Delete
inapplicable data.
2. Submittal Preparation
Bind product data with sturdy, labeled covers with an index listing the
contents. Loose unbound submittals will be returned without review.
Submit six copies of all product data.
,-
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 340 - Shop Drawings, Product Data and Samples - 3 of 7
1.5 Samples
A.
B.
C.
D.
E.
F
City of Carlsbad
03/04 (DBE)
1
General
Furnish for review samples of the various materials, together with the finish
thereon, as specified for and intended to be used on or in the Work. Samples
shall be sent to the office of the Engineer, carriage prepaid.
Schedule
Submit samples to the Engineer for review before purchasing, fabricating,
applying, or installing such materials and finishes. The Engineer will review
and take action on samples within 15 working days of the Contractor's
submittal. All actions will be by the Engineer in writing.
Quantity
Submit samples, other than field samples, in duplicate. A cover letter shall
accompany the sample and shall list all items being transmitted, designating
their particular usage and location in the Work and shall be identified as to
manufacturer, trade name, style, model. One approved sample will be
returned to the Contractor.
Sample Approval -
Approval of a sample shall not be taken in itself to change or modify any
contract requirement. Materials, finishes. and workmanship in the completed
building shall be equal in every respect to that of the approved sample.
Sample Size
Unless otherwise specified, samples shall be 8-inch by 1 O-inch in size and shall
be limited in thickness to a minimum consistent with sample analysis. In lieu
thereof, the actual full size item may be submitted.
Samples of Value
Samples of value may be returned to the Contractor for use in the Work after
review, analysis, comparison or testing as may be required by the Engineer,
provided that the location is recorded and the samples bear temporary
identification as samples.
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 340 - Shop Drawings, Product Data and Samples - 4 of 7
G. Field Samples
c
,..-
Field samples shall be prepared at the site by the Contractor as specified in the
various sections of these Specifications. Affected finished construction shall
not be commenced until the Engineer has given written approval of the field
samples.
H. Furnish one sample of approved products, colors, or textures to the Engineer
for final record. Show identification previously described including, if finish
sample, manufacturer, mix proportion, name of color, building, Contractor,
subcontractor, and surfaces to which applied on back of sample.
1.6 Engineer's Action
A. General
The Engineer will review the submittals with reasonable promptness and will
affix the Engineer's initials or signature as follows:
City of Carlsbad
03/04 (DBE)
1. Submittals stamped "ACCEPTED" require no further action and
fabrication or construction may proceed. The Engineer will return to the
Contractor the stamped transparency of Shop Drawings and two
stamped copies of brochures, schedules, materials lists, and other
product data, except where required otherwise.
2. Submittal stamped "ACCEPTED AS NOTED" require no further action
and fabrication or construction may proceed contingent upon all
corrections being made as noted. Quantities returned will be as
specified for "Accepted."
3. Submittals stamped "REJECTED/RESUBMIT AS SPECIFIED" or
REVISE AS NOTED/RESUBMIT" require the Contractor to resubmit
them with reasonable promptness and no fabrication or construction
may begin. The Engineer will return to the Contractor; one stamped
transparency and one marked copy of shop drawings and one marked
copy and three unmarked copies, all stamped, of brochures, schedules,
materials lists, and other product data.
4. Submittals stamped "NO ACTION REQUIRED" indicate the submittal
was for informational purposes only and does not require review. The
Engineer will return to the Contractor the submitted materials as
outlined under "Accepted."
5. Submittals stamped "SUBMITTAL NOT REQUESTED/RETURNED
WITHOUT REVIEW" indicate the Contractor has submitted drawings,
etc. that were not required and therefore, were not reviewed or
accepted by the Engineer.
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01340 - Shop Drawings, Product Data and Samples - 5 of 7
B.
C.
D.
E.
F.
City of Carlsbad
03/04 (DBE)
Resubmittals
If first or subsequent submittal is stamped "REJECTED/RESUBMIT AS
SPECIFIED 'I or "REVISE AS NOTED/RESUBMIT," corrective action shall be
taken and resubmittal procedure shall be same as for first submittal. The
Contractor shall direct specific attention in writing on resubmitted Shop Drawing
to revisions other than the correction requested by the Engineer on previous
submittals.
1
Distribution Copies
The Contractor shall be responsible for obtaining required prints and for
distribution to subcontractors. Make distribution copies from the transparency
bearing the Engineer's stamp.
Intent of Review
The Engineer will check and take action on such drawings and schedules only
for conformance with the design concept of the Work and compliance with
information given in the contract documents. When so directed by the
Engineer, the Contractor shall make corrections required.
Cost of Review - The Engineer will review the Shop Drawings as originally submitted as well as
the first resubmittal thereof at his own cost. If additional resubmittals are made
or required, the costs incurred by the Engineer in reviewing them shall be paid
by the Contractor.
Contractor's Responsibility
The shop drawings, product data and supporting data shall be prepared by the
Contractor or his suppliers and subcontractors, but shall be submitted as the
instruments of the Contractor.
The Contractor shall check the drawings of his suppliers and subcontractors as
well as his own drawings before submitting them. In particular, the Contractor
shall ascertain that the drawings meet all requirements of the contract
Drawings and Specifications and conform to the structural and space
conditions. If such shop drawings show variations from Contract Documents,
whether because of standard shop practice or other reasons, the Contractor
shall clearly describe in his letter of transmittal, such variations including other
chanaes reauired to correlate the construction .
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 340 - Shop Drawings, Product Data and Samples - 6 of 7
G. Contractor's Review
Shop Drawings when submitted to the Engineer for review shall be
accompanied by a written statement signed by the Contractor, that the Shop
Drawings have been checked by him and found to be in accordance with the
contract Drawings and Specifications and that proper provisions has been
made to accommodate abutting construction. This statement may be in the
form of an approval stamp bearing the Contractor's signature.
H. Substantiating Calculations
Substantiating calculations, when specified, shall be prepared and signed by a
California registered Civil or Structural Engineer, employed by the Contractor.
I. Contractor's Responsibility for Errors
The Engineer's review of Shop Drawings will be general only and shall not
relieve the Contractor from responsibility for errors of any sort, for deviations
from Drawings or Specifications, or for conflict with the construction activities of
others that may result from such deviations. Engineer's review of a separate
item does not indicate a review of an assembly in which the item functions.
c PART 2 - PRODUCTS (Not Applicable)
PART 3 - EXECUTION (Not Applicable)
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 340 - Shop Drawings, Product Data and Samples - 7 of 7
SECTION 01 400
QUALITY CONTROL
PART 1 - GENERAL
1.1 Work Included
Inspection and testing laboratory qualifications, duties and responsibilities, Contractor's
quality control requirements, Owner's inspection and testing.
1.2 Related Work
A. Section 01300: Shop Drawing Submittals
1.3 Reference Standards
Work shall conform to Federal, State and local building codes, electrical codes, fire codes,
mechanical codes and plumbing codes, and to Occupational Safety and Health Act (OSHA)
Regulations. Nothing in Contract Documents shall be interpreted as permission or direction
to violate any governing code or ordinance.
- 1.4 Submittals
A. Certificates of compliance shall be submitted at Owner's request.
B. Transcripts of results of acceptance to verify quality of manufactured products
shall be submitted at Owner's request.
1.5 Testing Laboratorv Services
Where required by these specifications, the Contractor shall hire an Owner-approved
independent laboratory to perform testing and certify results. Provide labor, products, tools,
instruments, water, and power as directed for sampling for required tests.
Tests of products shall follow commonly recognized standards of national technical
organizations, and specified sampling and testing methods.
Contractor shall pay for quality assurance testing unless otherwise shown.
Owner may test representative samples of each type and size of product furnished. Failure
of samples to pass tests will be deemed sufficient cause to reject entire lot delivered.
/--
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01400 - Quality Control - 1 of 3
1.6 Contractor's Quality Control
Arrange work to be readily accessible and easy to operate and maintain where detail
drawings are not included in Contract Documents, supplementary drawings or shop drawings
and submittals.
Combinations of manufactured equipment shall be fully compatible and work safely and
successfully as a unit. Furnish necessary mountings, couplings and appurtenances with
each unit.
---c
Relocations or adjustment of existing facilities noted in Contract Documents shall be done as
needed. If existing items are lost or damaged during construction, replace with new items of
equal or better quality.
Make field measurements needed to fabricate and install Work before ordering or beginning
work. Make minor changes in alignments and dimensions as needed to remedy or avoid
utilities and structural conflicts.
1.7 Proiect Conditions
Ascertain suitability of native soil for backfill before submitting bid. If native soil is found to be
unsuitable, provide suitable material for meeting compaction requirements at no additional
cost to Owner.
Items furnished shall be capable of fulfilling their intended purpose in environment in which
they are installed. Allow for local temperature extremes, climactic conditions and corrosive
environments where necessary to ensure proper functioning of furnished products.
-
1.8 Unit Prices
Payment for Contractor-provided testing required in Contract Documents will be included in
the price bid for items of work for which Contractor-provided testing is specified.
PART 2 - PRODUCTS (Not Applicable)
PART 3 - EXECUTION
3.1 Inspection
Notify Engineer of time and place of shop tests five working days before they begin.
Complete manufacturing operations, checks, adjustments and tests before factory inspection.
The Engineer will inspect products after delivery and throughout construction process.
Products will be subject to rejection at any time on account of failure to meet Contract
Documents even though samples may have been accepted as satisfactory at place of
manufacture. -c
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01400 - Quality Control - 2 of 3
Before backfilling, request inspection by the Engineer to verify proper installation of buried
ZI work.
Before finishing, request inspection by the Engineer to verify that no surfaces to receive
product have defects or errors which could result in poor or potentially defective application or
cause latent defects in workmanship.
3.2 Installation/Application/Erection
Install products according to manufacturer's installation and warranty requirements. Install
products to tolerances recommended by manufacturer. Unless otherwise shown, install
equipment true and level using precision gauges and levels.
Refer variances between manufacturer's installation instructions and Contract Documents to
the Engineer.
Construct walls plumb, straight, level, square and true.
Welds, unless otherwise shown, shall be continuous, watertight, and conforming to Structural
Welding Code of American Welding Society. Welds shall be free of sharp points or edges.
Pipework, valves, fittings, tanks and appurtenances shall have no leaks at design pressures.
Exposed surfaces shall be finished in appearance. Grind smooth exposed welds. Round or
chamfer corners of exposed structural shapes for personal protection. -
Prime and paint exposed surfaces of ferrous products, piping, and conduit except for
stainless steel or galvanized or sherardized surfaces or unless otherwise shown. Clean
painted surfaces and touch up bare or marred spots with finish to match factory finish.
3.3 Field Qualitv Control
Maintain complete set of Contract Documents at jobsite field office or superintendent's truck
at all times.
Frequency of sampling and testing shall be as shown, and shall be performed at such other
times as necessary to document contract compliance.
Notify the Engineer and regulating authorities three days before field tests.
Perform field tests in presence of the Engineer who will record results.
Repair damage to work that is not cause for rejection.
Repair, correct or replace work failing tests or inspection. Repeat tests until results satisfy specifications. Repair damages resulting from tests
END OF SECTION
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01400 - Quality Control - 3 of 3
SECTION 01 41 0
TESTING AND INSPECTION OF EARTHWORK AND CONCRETE -
PART 1 - GENERAL
1.1 Scope
This section addresses testing laboratory services and inspections required during the course
of construction, as specified.
1.2 Testing Laboratorv
A. Selection of Laboratory
Testing and inspections will be performed by the Owner or by an independent
testing laboratory selected by the Owner.
B. Testing Requirements
Testing and inspection services which are performed will be in accordance with
requirements of the Uniform Building Code, and as specified herein.
1.3 Payments
A.
B.
C.
rc
Tests Showing Compliance
Costs of initial testing and inspection, except as specifically modified herein, or
specified otherwise in technical sections, will be paid by the Owner, providing
such testing and inspection indicates compliance with Contract Documents. Initial
tests and inspections are defined as the first test and inspections as specified
herein.
Tests Showing Failure
In the event a test or inspection indicates failure of a material or procedure to
meet requirements of Contract Documents, costs for retesting and re-inspection
will be borne by the Contractor.
Additional Tests at Owner's Request
Additional tests and inspections not specified herein but requested by the Owner,
will be paid for by the Owner, unless result of such tests and inspections are
found to be not in compliance with Contract Documents, in which case the Owner
will pay all costs for initial testing as well as retesting and re-inspection and
backcharge the Contractor.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01410 - Testing and Inspection of Earthwork and Concrete - 1 of 5
D. Additional Test Due to Changes
Costs for additional tests or inspections required because of change in materials
being provided or change of source or supply shall be paid by Contractor direct to
testing laboratory.
-4
E. Correction of Deficiencies
Costs for construction activities which are required to correct deficiencies shall be
borne by the Contractor.
F. Additional Tests to Assist Contractor
Cost of testing which is required solely for the convenience of Contractor in his
scheduling and performance of Work shall be borne by the Contractor.
1.4 Availabilitv of Samples
A. Acquisition of Samples
Contractor shall make materials required for testing available and assist in
acquiring these materials as directed by Engineer. The samples shall be taken
under the immediate direction and supervision of the Engineer. - B. Uncovering Construction
If construction which is required to be tested or inspected is covered up without
prior notice or approval, such construction may be uncovered at the discretion of
the Engineer.
C. Advance Notice for Inspections
Unless otherwise specified, Contractor shall notify the Engineer a minimum of 10
working days in advance of required inspections. Extra construction activities
resulting from a failure to notify the Laboratory shall be paid for by the Contractor.
D. Cancellation of Tests or Inspection
Contractor shall give sufficient advance notice to the Engineer in the event of
cancellation or time extension of a scheduled test or inspection. Charges due to
insufficient advance notice of cancellations or time extension shall be paid for by
the Contractor.
1.5 Removal of Materials
Unless otherwise directed, materials not conforming to the requirements of Contract -
Documents shall be promptly removed from the Project site.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 41 0 - Testing and Inspection of Earthwork and Concrete - 2 of 5
PART 2 - PRODUCTS (Not Applicable) __-
PART 3 - EXECUTION
3.1 Earthwork
A. Engineer's Role
The Engineer will provide continuous inspection of fill and will field test fill and
earth backfill as placed and compacted, and inspect excavations and subgrade
before concrete is placed and provide periodic inspection of open excavations,
embankments, and other cuts or vertical surfaces of earth. The Engineer will
submit a report indicating that he has observed and tested fills and that in his
opinion the fills were placed in accordance with the Project Specifications.
B. Removal of Unsatisfactory Material
Contractor shall remove unsatisfactory material, reroll, adjust moisture, place new
material, or in the case of excavations, provide proper protective measures,
perform other operations necessary, as directed by the Engineer whose decisions
and directions will be considered final.
- C. Engineer may require deepening of footings and so order such deepening in
accordance with Section 02200.
D. Test and Inspection Procedure
1. General
Allow sufficient time for testing and evaluation of results before material is
needed. The Engineer will be sole and final judge of suitability of all
materials.
2. Tests
Laboratory compaction tests to be used will be in accordance with ASTM
D1557-78.
3. Field Density Tests
Field density tests will be made in accordance with ASTM D1556 or ASTM
D2922.
City of Carlsbad
03/04 (DEE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains 0141 0 - Testing and Inspection of Earthwork and Concrete - 3 of 5
4. Number of Tests -_
The number of tests along the pipeline will be determined by Engineer, but
generally every 300' to 400'.
5. Use of Tested Materials
Materials in question may not be used pending test results.
6. Excavation and Embankment Inspection Procedure
Excavation and embankment inspection procedure: Engineer will visually or
otherwise examine such areas for bearing values.
3.2 Testina of Concrete
A.
8.
C.
D.
E.
General
Notify Engineer of brand and type of cement and sources of aggregates in time
for review, sampling and testing, if required.
Number of Tests
At least four cylinders for each 100 cubic yards or each separate mix design of
concrete of required strength in excess of 2000 psi, or fraction thereof being
placed each day will be taken.
-
Sampling Procedures
Cylinders will be taken so as to represent as nearly as possible the batch of
concrete from which they are taken. Sampling procedures shall conform to ASTM
C 172-82.
Test Cylinders
Test cylinders shall be made and cured in compliance with ASTM C 31-88, except
as modified herein.
Test Procedures
Test cylinders from respective batches, one at age of 7 days, one at 14 days and
one at age of 28 days. The fourth shall be tested as directed if concrete strength
is under that specified. Cylinder testing procedures shall conform to ASTM C39-
86 for strength.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 41 0 - Testing and Inspection of Earthwork and Concrete - 4 of 5
F.
,P
G.
H.
Slump Tests
Slump tests shall be taken as required by Testing Laboratory to certify compliance
with Contract Documents. Slump shall be tested in accordance with ASTM C143-
89a.
Compressive Strength
Minimum compressive strength of test cylinders, in pounds per square inch, shall
not be less than the specified required design strength.
Test Cores
If minimum strengths of test cylinders fall below those specified, Engineer may
require test cores from hardened concrete to be taken and tested. Each core test,
if taken, shall consist of 3 cores. Costs of such cores and tests shall be borne by
the Contractor. Cores shall be taken in accordance with ASTM C42-84a, from
locations selected by Engineer. Contractor shall repair core holes with dry-pack
or a nonshrinking mortar.
1. Test Core Strength
Concrete tested by coring shall be considered acceptable if the average
strength of three cores is equal to at least 85 percent of the minimum
specified 28 day strength and if no single core strength is less the 75
percent of the minimum 28 day strength.
3.3 Concrete Inspections
An authorized inspector of the Owner will be present at all times during placing of structural,
reinforced cast-in-place concrete. Before placing concrete he will inspect and approve (if
satisfactory) accuracy of all formwork and quantity and placement of all reinforcing steel.
Concrete construction activities shall not proceed until inspections are complete and the
inspected construction is approved.
END OF SECTION
.-
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
0141 0 - Testing and Inspection of Earthwork and Concrete - 5 of 5
SECTION 01 500
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 01 040: Coordination
B. Section 01 300: Shop Drawing Submittals
C. Section 01590: Field Offices and Sheds
D. Section 01 700: Contract Closeout
1.3 Submittals
- Storage yard description shall describe Contractor's proposed methods for dust and noise
control in storage areas to satisfaction of Owner.
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.
1.4 Mobilization
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.
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.
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.
1.5 Temporary Utilities
Construction power shall be purchased or generated on-site for constructing Work where
existing outlets are not available.
e
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic 8, Recycled Water Transmission Mains
01 500 Construction Facilities and Temporary Controls - 1 of 4
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.
-
Provide safe drinking water and sanitation facilities on jobsite at all times.
Construction telephone shall be available at site at all times Work is in progress. Cellular
phones are acceptable.
1.6 Construction Aids
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 Construction Signaqe
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’s symbol, project name, CIP number and anticipated duration of construction.
-
1.8 Access Roads and Parkinq 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.
1.9 Temporary Controls
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
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 500 Construction Facilities and Temporary Controls - 2 of 4
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.
c.
Fire danger shall be minimized at and near construction site. Protect surrounding private
property from fire damage resulting from construction operations.
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.
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.
1.1 0 Traffic Requlation
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.
1.11 Unit Prices
-. 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.
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.
Payment for verification of field dimensions and utility locations will be included in the price
bid for items of Work which may require relocation or refitting if field dimensions differ from
those shown on plans.
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. *
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.
._ 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.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 500 Construction Facilities and Temporary Controls - 3 of 4
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.
-
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
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 500 Construction Facilities and Temporary Controls - 4 of 4
SECTION 01 520
MAINTENANCE OF TRAFFIC AND DETOURS -
PART 1 - GENERAL
1.1 Description
The work of this Section includes furnishing, constructing, maintaining, and finally removing
detours, road closures, lights, striping, dots, signs, barricades, fences, flares, miscellaneous
traffic devices, flagmen, drainage facilities, paving, and such other items and services as are
necessary to adequately safeguard the public from hazard and inconvenience. All such work
shall be as provided in the specifications herein and shall comply with the ordinances, directives,
and regulations of the City of Carlsbad.
It is the intent of these Specifications to provide for adequate traffic detour routing and signing to
maintain a smooth and safe flow of traffic through and around the construction areas. Traffic
shall be maintained at those locations indicated and in conformance with the Plans and
Specifications.
1.2
-
1.3
1.4
Related Work Described Elsewhere
A. Shop Drawing Submittals: 01300
B. Shop Drawings, Product Data and Samples: 01340
C. Section 7-1 0 of the Supplemental Provisions
Submittals
A. The Contractor shall submit any proposed revisions to the traffic control plans,
that were included within the construction plans, to the City of Carlsbad Traffic
Department, for the their review and approval, thirty (30) days prior to the
beginning of construction. No construction will be allowed until these traffic control
plans have been approved by the City.
B. The Contractor shall submit any proposed revisions to the traffic control plans,
that were included within the construction plans, in accordance with the shop
drawing submittal requirements in Sections 01300 and 01340 of these Technical
Specifications.
Notification
A. Prior to the start of construction operations, the Contractor shall provide the City of
Carlsbad police and fire departments, a construction schedule giving the expected
starting date, sequence of work, timing for each phase of construction, completion
date, and the name and telephone number of two responsible persons who may
be contacted at any hour in the event of a condition requiring immediate
correct ion.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 520 - Maintenance of Traffic and Detours - 1 of 3
B. Prior to restricting normal access from public streets to adjacent properties, the
the nature of the access restriction, the approximate duration of the restriction, and
the best alternate access route for that particular property.
Contractor shall notify each property owner or responsible person, informing him of _-
1.5 Payment
Payment for Maintenance of Traffic and Detours and for conforming to all provisions of these
Specifications and all Federal, State, and Local regulations and requirements, unless otherwise
specified and itemized on the bid form, shall be considered to be included in the contract unit or
lump sum prices paid for the various items of work wherein maintenance of traffic and detours is
required and no additional allowance will be made therefore.
PART 2 - MATERIALS
2.1 Construction Siqning
Construction signing used for handling traffic and public convenience shall conform to the most
current edition of the State of California, Department of Transportation "Manual of Warning
Signs, Lights, and Devices for Use in Performance of Work Upon Highways" and the most
current edition of the "Work Area Traffic Control Handbook."
All signs shall be illuminated or reflectorized when they are used during hours of darkness. All - cones, pylons, barricades or posts used in the diversion of traffic shall be provided with flashers
or other satisfactory illumination if in place during hours of darkness.
2.2
Striping shall conform to the State of California, Department of Transportation, "Traffic Manual",
latest edition.
PART 3 - EXECUTION
3.1 General
Contractor shall adhere to approved traffic control plan which is discussed in Section 1.3
Submittals. The signing, barricading, and diverting of traffic shall be subject to the approval of
the City of Carlsbad. The Contractor shall maintain a 24-hour emergency service to remove,
install, relocate, and maintain warning devices and shall furnish to the Owner's Representative
and Police Department, names and telephone numbers of three persons responsible for this
emergency service. In the event these persons do not promptly respond when notified by the
Owner's Representative, the Owner's Representative reserves the right to call out other forces to
accomplish such required emergency service. The Contractor will be held responsible for the
cost of such emergency service. -
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 520 - Maintenance of Traffic and Detours - 2 of 3
3.2 Vehicular Traffic Control
Public traffic shall be permitted to pass through the construction area with as little inconvenience
and delay as possible at all locations where approved detour alternate routes are not available.
Special requirements for traffic handling and permitted detours are contained in the Special
Provisions. No cross streets or intersecting streets shall be closed without approval of the City of
Carlsbad. Pre-timed actuation (recall) shall not be used. If inductive loops cannot be used, then
video detection shall be used.
c_
Prior to the start of each work day, the Contractor shall perform all necessary work incidental to
and commensurate with the proper signing, detouring, barricading, etc. heretofore and
hereinafter specified, that is required for that particular day's schedule of operations. No
construction shall be permitted until such signing and detouring operations have been
completed. At the completion of the project, the original striping pattern shall be replaced by the
Contractor, unless directed otherwise by the City of Carlsbad.
3.3 Permanent Traffic Controls
All existing permanent traffic control signs, barricades, and devices shall remain in effective
operation unless a substitute operation is arranged for and approved by the City of Carlsbad,
except inductive traffic loops, and magnetometer traffic detectors. Pre-timed actuation (recall)
shall not be used. If inductive loops cannot be used, then video detection shall be used.
c 3.4 Pedestrian Traffic Control
A minimum of one 4-foot-wide pedestrian walkway shall be maintained and safely delineated
along each public street at all times during construction.
3.5 Access to Adiacent Properties
Reasonable access, as determined by the governing body, from public streets to all adjacent
properties shall be maintained at all times during the construction.
END OF SECTION
.-
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 520 - Maintenance of Traffic and Detours - 3 of 3
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.
/L-
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 530 - Protection of Existing Utilities - 1 of 1
SECTION 01 550
TRAFFIC CONTROL AND RE-STRIPING
PART 1 - GENERAL
1.1 Work Included
Mobilization, temporary signs, barriers, lights and flagging personnel, and striping.
1.2 Submittals
The Contractor shall perform his work in accordance with the traffic control plans.
1.3 Payment
All costs for the requirements in this section shall be included in the contract unit or lump sum
prices for each bid item as delineated in Section 01025, and no additional allowance will be
made therefore.
PART 2 - MATERIALS AND EXECUTION
- 2.1 General
The Contractor shall implement approved Traffic Control Plans in accordance with these
Specifications for all portions of this contract within or adjacent to public or private rights-of-way
and streets and drives and replace all striping, reflectors, dots, or other traffic control materials.
Traffic shall be maintained throughout the project in conformance with these Technical
Specifications, General Requirements and the General Conditions. The Contractor shall furnish,
construct, maintain and finally remove detours, road closures, lights, signs, barricades, fences,
miscellaneous traffic devices, flagmen, and reconstruct paving and other such items and
services as are necessary to adequately safeguard the public from hazard and inconvenience.
All such work shall be as provided in the Contract Documents herein or as directed by the
Owner's Representative, and shall comply with the ordinances, directives, and regulations of
authorities with jurisdiction over the public or private roads in which the construction takes place,
and over which detoured traffic is routed by the Contractor.
It is the intent of these Specifications to provide for adequate traffic detour routing and signing to maintain a smooth and safe flow of traffic through and around the construction areas.
Prior to the start of construction operations, the Contractor shall provide the fire and police
departments in whose jurisdiction the project lies with the construction schedule giving the
expected starting date, sequence of work, and timing for each phase of construction completion -- date, and the name and telephone number of two responsible persons who may be contacted at
any hour in the event of a condition requiring immediate correction.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 550 - Traffic Control and Re-Striping - 1 of 3
2.2 Construction Signs And Barricades
Construction signs and barricades used for handling traffic and for public convenience shall
conform to the Traffic Control Plans furnished with the Contract Documents or as required by
them and the State of California, Department of Public Works "Manual of Warning Signs, Lights,
and Devices for Use in Performance of Work Upon Highways", latest edition, and "Work Area
Traffic Control Handbook", latest edition. The Contractor shall refer to above mentioned
document and also shall reference general provision section 7-1 0.3.1. Work provided shall
conform to most stringent requirements if not stated in the project documents.
-
All signs and barricades shall be illuminated or reflectorized when they are used during hours of
darkness. All delineators, cones, barricades or posts used in the diversion of traffic shall be
provided with flashers or other satisfactory illumination if in place during darkness.
The signing, barricading, and diverting of traffic shall be subject to the District. The Contractor
shall maintain a 24-hour emergency service to remove, install, relocate, and maintain warning
devices and shall furnish to the Owner's Representative and Police Department names and
telephone numbers of three person responsible for this emergency service. In the event these
persons do not promptly respond when notified by the Owner's Representative, the Owner's
Representative reserves the right to call other forces to accomplish such required emergency
service, and the Contractor will be held responsible for any and all costs incurred by the Owner.
2.3 Vehicular Traffic Control
Prior to the start of each work day, the Contractor shall perform all necessary work incidental to
and commensurate with the proper signing, detouring, barricading, etc., heretofore and
hereinafter specified, that is required for that particular day's schedule of operations. No
construction shall be permitted until such signing and detouring operations have been
completed. At the completion of the project, the original striping pattern shall be replaced by the
Contractor, unless directed otherwise by the Owner's Representative. Striping shall conform to
the State of California, Department of Transportation, "Traffic Manual", latest edition.
-
2.4 Permanent Traffic Controls
All existing permanent traffic control signs, barricades and devices shall remain in effective
operation unless a substitute operation is arranged for and approved by the RESPECTIVE
AUTHORITY as a portion of vehicular traffic control above, except inductive traffic loops, and
magnetometer traffic detectors.
Only advance inductive traffic loops which are removed during construction, or are damaged,
shall be replaced in kind by the Contractor from the nearest pullbox, all in accordance with
appropriate provisions of Section 86 "Signals and Lighting" of the State Specifications (except
measurement and payment), and the existing "As-Built" Plans for each particular intersection
involved. Copies of these as-builts may be found in the offices of the respective authorities.
Contractor shall provide and install permanent video detection systems, where indicated on
Traffic Control Plans. Contractor shall provide a separate line item bid price for such devices. -
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 550 - Traffic Control and Re-Striping - 2 of 3
Any magnetometers in the streets damaged during the course of construction shall be replaced - in full up to the pullbox. Temporary splices during construction are permitted.
2.5 Blocking Of Drivewavs
The Contractor shall conform to the requirements in the general provision section 7-1 0.1. The
notice to the public shall conform to the example provided in Appendix “A.
PART 3 - EXECUTION (Not Applicable)
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 550 - Traffic Control and Re-Striping - 3 of 3
SECTION 01 570
MAINTENANCE AND PROTECTION OF TRAFFIC -
PART 1 - GENERAL
1.1 DESCRIPTION
A.
B.
C.
e.
D.
E.
F.
G.
All streets, trafficways, and sidewalks shall be kept open in a safe manner for the
passage of traffic and pedestrians during the construction period unless otherwise
approved by the City. CONTRACTOR, at his expense, shall obtain traffic permit
from the City.
When required to cross, obstruct or temporarily close a street, trafficway or
sidewalk, CONTRACTOR shall provide and maintain suitable bridges, detours or
other approved temporary expedient for the accommodation of vehicular and
pedestrian traffic. Closings shall be for the shortest time practical, and passage shall
be restored immediately after completion of bacMill and temporary paving or
bridging. No two adjacent streets can be closed at the same time.
CONTRACTOR shall give the ENGINEER 96 hours advance notice of his proposed
operations within the public right-of-ways.
CONTRACTOR shall give 72 hours advance notice to owners or tenants of private
property/business who may be affected by his operations.
1. CONTRACTOR will restore access to propertieshusiness as soon as
possible. If primary access cannot be restored, CONTRACTOR will
provide an alternate which will be predetermined with the
property/business owner prior to any restrictions being done.
CONTRACTOR shall provide signs, signals, barricades, flares, lights and all other
equipment, service and personnel required to regulate and protect all traffic, and
warn of hazards. All such work shall conform to requirements of the traffic control
plans and the City of Carlsbad. Remove temporary equipment and facilities when no
longer required, restore grounds to original, or to specified conditions.
All open trenches shall be covered with a traffic bearing cover during non-working
hours.
Any damage caused to any roads which are caused by the CONTRACTOR'S
activities will be promptly repaired at the CONTRACTOR'S expense. The
CONTRACTOR shall also maintain all access routes free of all debris or spillage's.
Concrete trucks must be washed out at a designated area on site. All access roads
leading to the site must be promptly cleaned of any debris or spillage resulting from
the CONTRACTOR'S operations.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 570 Maintenance and Protection of Traffic - 1 of 2
PART 2 - PRODUCTS (Not Applicable)
PART 3 - MATERIALS (Not Applicable)
City of Carlsbad
03/04 (DBE)
END OF SECTION
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 570 Maintenance and Protection of Traffic - 2 of 2
SECTION 01 580
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 DISTRICT at no cost to
the CONTRACTOR.
C. No signs except those specified shall be displayed unless approved by DISTRICT.
1.2 SUBMllTALS
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
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
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 580 Project Identification and Signs - 1 of 2
1.4 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.
PART 2 - PRODUCTS (Not Applicable)
PART 3 - EXECUTION (Not Applicable)
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic i3 Recycled Water Transmission Mains
01 580 Project Identification and Signs - 2 of 2
SECTION 01 590
FIELD OFFICES AND SHEDS
PART 1 - GENERAL
1.1 Work Included
Temporary field off ice and accessory equipment for Owner.
1.2 Building Construction
The Contractor shall provide a Class A Field Office. This office shall have a minimum floor
space of 480 square feet, two partitioned offices with doors, and a window area of not less
than 30 square feet. All rooms shall be equipped with telephone service that includes phone
jacks for two (2) separate phone lines, one (1) dedicated fax line, and one (1) dedicated
phone line for a PC modem. All doors and windows shall be provided with screens; window
coverings shall be provided on all windows. The field office shall be selected and approved
by the Owner before delivery and setup.
The Contractor will provide, including making application and paying all costs and fees for,
electrical, telephone, water, and sanitary services. All work will include, but not be limited to
the following: a temporary power pole for electrical meter and service and telephone service.
The field office trailer will also be equipped with water service and sanitary service. The
Contractor will provide and pay for sanitary service including a septic tank mounted
underneath the field office to be serviced at least once a week. An outdoor lighting fixture
with 300 watt bulbs will be installed to effectively light the area around the office facility.
Heating and air conditioning of sufficient capacity will be provided at no expense to the
Owner to adequately control temperature in the trailer at all times. The Contractor will also
construct a wooden handicap ramp with handrailing according to ADA standards for handicap
access.
-
All facilities described herein will be removed under the Owner’s direction when the project is
completed.
All office furniture, equipment and supplies listed below will be in new condition and delivered
and setup in the Owner’s field office trailer. The Contractor will coordinate all deliveries with
the Owner’s field representative.
Contractor shall also provide the office furnishings and features described in revised
Table 1 “Required Field Office Characteristics” which is attached to this addendum.
Contractor shall pay all monthly telephone charges and the Construction Manager will
pay for all long distance charges.
-c In conformance with Paragraph 8.05.5 Removal of Facilities of the Special
Provisions, all computer equipment and other off ice equipment and accessories
provided by the Contractor for equipping the field office shall become the property of the
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01590 - Field Offices and Sheds - 1 of 3
Contractor at the completion of the Work. Any furniture provided by the Owner or
Construction Manager for use in the field office shall remain their property.
1.3 Accessory Equipment
A. Electrical Outlets and Lighting
Provide warm white fluorescent light fixtures to evenly illuminate the rooms to a
minimum of 50 foot-candles and an average of 70 foot-candles measure at desk
height. Provide a minimum 60-watt light fixture in the lavatory facility. Provide
light switch in each room.
Provide two duplex 120-volt outlets in each room (one only in restroom).
1.4 Unit Prices
Payment for the field office,, including cost of building (or trailer), utilities, services and
removal, will be proportionately spread throughout the price bids for all of the other work
items shown on the bid form.
PART 2 - PRODUCTS (Not Applicable)
PART 3 - EXECUTION (Not Applicable)
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 590 - Field Offices and Sheds - 2 of 3
TABLE 1 : REQUIRED FIELD OFFICE CHARACTERISTICS
Standard Specification
Class "A" Field Off ice
Off ice square footage
Window area
Number of office rooms
Air conditioning
Telephone service
Desk 1 required
Table
Chairs
Type Drafting tables
Dimensions
Drawers and locks
Dimensions
Dimensions
Equipment
Drafting stools
Plan rack Type
Metal stick files
c. Filing cabinet
Dimensions
Drawers
Locks
Dimensions
Adjustable shelves
Bookcase
Wastebaskets
Office equipment
Computer Equipment
Sanitary Facilities
Toilet
Shower
Wash basin and mirror
Fixtures
rc Exhaust fan
City of Carlsbad
03/04 (DBE)
480 sf minimum
30 sf minimum
2
required
required with answering machine
3' x 6'
required
1 required
3' x 5' or 4' x 8'
4 required
cushioned off ice swivel chair
1 required
4' x 6'
drafting machine and parallel bar
1 required
cushioned
1 required
6 required
1 required
18" wide x 30" deep x 52" high
4
required
1 required
12" deep x 48" long x 60" high
5 required
1 required
copy machine
fax machine on dedicated phone line
wall-mounted markerboard (4' x 4') and
3 markers each in red, green, blue and black
bottled water service with hot and cold water
Provide equipment per specifications
required
not required
required
towel rack
medicine cabinet
toilet paper dispenser
soap dispenser
paper towel cabinet
required
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains 01 590 - Field Off ices and Sheds - 3 of 3
SECTION 01 600
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 01 400: Quality Control
C. Section 01 700: 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 Qualitv 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 Deliverv, Storaqe and Handling
Deliver products to jobsite in manufacturer's original, unopened, labeled packaging.
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.
c 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
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
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
03/04 (DBE)
ECR (PAR to Cassia) Domestic i3 Recycled Water Transmission Mains
01 600 - Material and Equipment - 2 of 2
,-
SECTION 01 61 0
SUPPLIERWMANUFACTURERS' SPECIAL SERVICES
PART 1 - GENERAL
1.1 Scope
This section covers the Work for providing special services by the suppliers and
manufacturers associated with this Work.
PART 2 - PRODUCTS
2.1 General
Contractor, suppliers and manufacturers shall provide materials, equipment, devices, labor,
travel costs and expenses as required to perform the specified services.
PART 3 - EXECUTION
3.1 Installation Assistance
Competent and experienced technical personnel shall represent the manufacturer of all
equipment and systems as may be necessary to resolve assembly or installation problems at
the worksite, or at the location where factory built equipment is being assembled by others
into a larger, integrated system, which are attributable to, or associated with, the equipment
furnished.
-
3.2 Functional Testing
Where functional testing services are called for in the Technical Specifications, or when
technical assistance is necessary to resolve performance problems that may become
apparent during the performance test, the manufacturer's representative shall provide such
assistance as necessary to demonstrate the specified performance.
3.3 Plant Startup
Where startup services are called for in the Technical Specifications, or when technical
assistance is necessary due to any malfunction of the equipment or system furnished, the
manufacturer's representative shall provide such services as necessary to provide the Owner
with an acceptable operating facility.
3.4 Training of Owner's Personnel
Where training is called for in the Technical Specifications, the manufacturer's or supplier's
representative shall provide classroom and on-the-job training for the Owner's personnel in
the operation and maintenance of the specified equipment.
/I
City of Cartsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 61 0 - SupplierWManufacturer's Special Services - 1 of 2
3.5 Scheduling and Coordination of Services
The Contractor shall designate and provide one person to be responsible for scheduling,
coordinating, and expediting the specified services. Scheduling the services shall be done in
cooperation with, and with the approval of the Engineer and Owner's operating personnel.
Such schedule shall be arranged with the appropriate subcontractors, manufacturers, and
suppliers in sufficient time to assure their compliance with the service requirements.
3.6 Costs for Services
Cost for providing services during installation, testing, and for the training of Owner's
personnel shall be included in the costs for providing the applicable specified equipment.
Where the number of days for services is stated in the Technical Specifications, this shall be
considered as the minimum number of days. Should additional time be required for services,
such time shall be at the expense of the manufacturer, supplier, or Contractor as applicable,
and at no additional cost to the Owner.
Where the number of days for services is not stated in the Technical Specifications, services
shall be furnished for installation, testing, and plant startup as required to provide the Owner
with a satisfactory operating facility.
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 61 0 - Supplier's/Manufacturer's Special Services - 2 of 2
SECTION 01 630
PRODUCT OPTIONS AND SUBSTITUTIONS
PART 1 - GENERAL
1.1 Scope
This section addresses procedures for submittal of requests for substitution for materials
specified in these specifications by proprietary names.
1.2 General Requirements
A.
B.
C.
D.
E.
Standard Products
Whenever in the specifications products are by reference standard, any product
meeting the standards referenced may be used. Information on such products
shall be submitted in accordance with Section 01300.
Proprietary Products
Whenever in the specifications any material, article or process is indicated or
specified by trade, patent or proprietary name or name of manufacturer such
specification for material, article or process, unless marked "no substitution", shall
be deemed to be followed by the words "or equal as accepted in writing by the
Engineer", and will be considered as a substitution.
Selection of Proprietary Product
Where more than one proprietary name is specified, the Contractor may provide
any one of the materials or equipment specified. Only one brand, kind or make of
material or equipment shall be used for each specific purpose throughout the
Work notwithstanding that similar materials or equipment of two or more
manufacturers or producers may be specified for the same purpose.
Substitution Request Procedure
Submit a written request on the enclosed form for proposed substitutions to the
Engineer not later than 35 days after date of "Notice of Award". Proposed
substitutions relating to a particular subcontract or trade shall be submitted at one
time. If the Engineer accepts any proposed substitutions, such acceptance will be
set forth in a Change Order. No substitution will be considered after this 35 day
period.
Contractor's Responsibility for Construction Modifications
Drawings have been detailed in compliance with ICBO Evaluation Report for
material specified. If a proposed substitute material is accepted by the Engineer,
the Contractor will assume the responsibility for construction modifications and
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 630 - Product Options and Substitutions - 1 of 7
additional costs required by reason of this acceptance. If the substitution results
in a decrease in cost, the amount is to be submitted for consideration. -
F. Systems of Like Manufacture
Where materials or items of manufacturer are specified in groups and are made
or furnished by one manufacturer, no substitution will be considered that is not
made or furnished similarly by one manufacturer. Where the Contractor proposes
to use a system of equipment other than that specified or detailed on the
Drawings the substitution shall be proposed as a complete system.
1.3 Requirements for Submittinq Substitutions
A.
B.
C.
D.
Substantiating Data
The Contractor shall submit with his written request for a proposed substitution all
data substantiating his request as well as a "Certificate of Suitability" certifying
that the proposed substitution is equal or better in all respects to that specified
and that it will, in all respects perform the function for which it is intended. The
Contractor shall include with his request all required samples. All written requests
and data for proposed substitutions shall be submitted in three copies.
Determination of Equality
It shall be the responsibility of the Contractor to submit complete information to
the Engineer so that proper evaluation can be made. The burden of proof of
equality of the substituted item shall be on the Contractor. Acceptance of such
substitutions is entirely at the discretion of the Engineer and Owner. All materials
or items of manufacture, which the Contractor proposes to substitute for those
specified, must be accepted by the Engineer before they may be ordered.
-I
List of Accepted Substitutions
The Engineer will issue to the Contractor a list setting forth those items for which
substitutions are accepted. No substitution will be accepted for any materials or
item of manufacture called for in the Contract Documents which is not of equal
quality and which does not possess equal design or color characteristics to those
of the specified material or item.
Denial of Substitution
If, in the opinion of the Engineer or Owner, the proposed substitution is not equal
or better in every respect to that so indicated or specified, or was not submitted
for acceptance in the manner outlined above, the Contractor shall furnish the
specified materials.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 630 - Product Options and Substitutions - 2 of 7
..--
E. Responsibility for Coordinating Substitutions with Construction Trades
It shall be the responsibility of the Contractor, in proposing a substitution for any
item herein specified, to inform all other trades, vendors, and subcontractors of
the effects said substitution will have upon their work or products. Failure to so
notify shall require that the Contractor make payments arising from alterations in
specified materials or methods necessary to complete the Work in an approved
and acceptable manner.
1.4 Contractor's Responsibility for Cost of Substitution Reviews
The Contractor shall bear all costs by Engineer and Owner to review Requests for
Substitutions. Review costs shall be deducted on a regular basis from monthly
progress payment. Any and all design change costs, if any, because of an approved
substitution will be borne by the Contractor.
PART 2 - PRODUCTS (Not Applicable)
PART 3 - EXECUTION (Not Applicable)
END OF SECTION
.-
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 630 - Product Options and Substitutions - 3 of 7
SUBSTITUTION REQUEST FORM
TO: City of Carlsbad
1635 Faraday Avenue
Carlsbad, CA 92008
PROJECT NAME: El Camino Real / Cassia Road 24” And 30” Domestic Water Transmission
Mains
FROM CONTRACTOR:
We hereby submit for consideration the following product substitution of specified item for above project:
DRAWING OR SHEET NUMBER
SECTION NO, - OR PARAGRAPH SPECIFIED ITEM
Proposed
substitution:
Attach complete dimensional information and technical data, including laboratory tests, if applicable.
Include complete information on changes to Drawings andhr Specifications which proposed substitution will require for its proper installation.
Submit with request all necessary samples and substantiating data to prove equal quality and performance to
that which is specified. Clearly mark manufacturer’s literature to indicate equality in performance. Differences in
quality of materials and construction shall be indicated..
Fill in Blanks Below:
A. Does the substitution affect dimensions shown on Drawings?
Yes - No - If yes, clearly indicate changes.
B. Will the undersigned pay for the changes to the project design, including engineering and detailing costs caused by the requested substitution?
C. What effect does the substitution have on other trades?
D. What effect does substitution have on applicable code requirements?
E. What is the ICBO Approval Number?
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03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 630 - Product Options and Substitutions - 4 of 7
F. Differences between proposed substitution and specified item:
G. Manufacturer's guarantees of the proposed and specified items are:
Same -Different-( Explain)
CONTRACTOR'S CERTl FlCATiON OF
PERFORMANCE AND ASSUMPTION OF
LIABILITY FOR EQUAL PERFORMANCE
Submitted By:
Signature Title
-- Firm
For use by Design Engineer: - Accepted - Accepted as Noted - Not Accepted - Received Too Late - Approved as Alternate-See Bid Form
BY
Date
Remarks
Address
Telephone Date
Signature must be by person having authority to
legally bind his firm to the above terms. Failure to
provide legally binding signature will result in
retraction of approval.
Concurrence By:
Owner
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 630 - Product Options and Substitutions - 5 of 7
SUBSTITUTION REQUEST FORM
.-
TO: City of Carlsbad 1635 Faraday Avenue
Carlsbad, CA 92008
PROJECT NAME: El Camino Real 20-Inch Recvcled Water Transmission Main
FROM CONTRACTOR:
We hereby submit for consideration the following product substitution of specified item for above project:
DRAWING OR SHEET NUMBER OR PARAGRAPH SPECIFIED ITEM SECTION NO. -
Proposed substitution:
Attach complete dimensional information and technical data, including laboratory tests, if applicable.
Include complete information on changes to Drawings and/or Specifications which proposed substitution will
require for its proper installation.
Submit with request all necessary samples and substantiating data to prove equal quality and performance to
that which is specified. Clearly mark manufacturer's literature to indicate equality in performance. Differences in
quality of materials and construction shall be indicated..
Fill in Blanks Below:
A. Does the substitution affect dimensions shown on Drawings?
Yes - No - If yes, clearly indicate changes.
B. Will the undersigned pay for the changes to the project design, including engineering and detailing costs
caused by the requested substitution?
C. What effect does the substitution have on other trades?
D. What effect does substitution have on applicable code requirements? -_
~~~~~ ~~ ~ ~~~~~
E. What is the ICBO Approval Number?
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 630 - Product Options and Substitutions - 6 of 7
Differences between proposed substitution and specified item:
G. Manufacturer's guarantees of the proposed and specified items are:
Same - Different-( Explain)
CONTRACTOR'S CERTIFICATION OF
PERFORMANCE AND ASSUMPTION OF
LIABILITY FOR EQUAL PERFORMANCE
Submitted By:
For use by Design Engineer:
Accepted - Accepted as Noted - Not Accepted - Received Too Late - Approved as Alternate-See Bid Form
-
Signature Title
-
Firm Remarks
Address
Telephone Date
Signature must be by person having authority to
legally bind his firm to the above terms. Failure to provide legally binding signature will result in
retraction of approval.
Concurrence By:
Owner
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 630 - Product Options and Substitutions - 7 of 7
~~
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 01 300: Shop Drawing Submittals
B. Section 01400: Quality Control
C. Section 01 41 0: Start-up and Testing Procedure
D. Section 01 71 0: Cleaning and Final Cleaning
E. Section 01 730: Operating and Maintenance Data and Training
- 1.3 Qualitv 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 surveyor and submitted to Owner.
1.5 Unit Prices
.- Payment for record drawings required in Contract Documents will be included in the price bid
for items of work for which record drawings are required.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01700 - Contract Closeout - 1 of 2
50% of the lump sum bid price after Contractor submits record drawings for initial review by
the Owner.
50% of the lump sum bid price after Contractor submits final record drawings incorporating or
responding to the comments of Owner.
1.6 Warrantv
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 StocMSpare 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
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 700 - Contract Closeout - 2 of 2
SECTION 01 71 0
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 Cleanina Durinq 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 Cleaninq
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.
Y 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
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
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)
City of Carlsbad
03/04 (DBE)
END OF SECTION
-,
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01 71 0 - Cleaning and Final Cleaning - 2 of 2
c
PART 1 - SCOPE
SECTION 01720
RECORD DRAWINGS
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.
-c
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.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01720 - Record Drawings - 1 of 2
PART 2 - PRODUCTS (Not Applicable)
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
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01720 - Record Drawings - 2 of 2
SECTION 01730
OPERATING AND MAINTENANCE DATA AND TRAINING
PART 1 - GENERAL
1.1 Work Included
Operation and maintenance manual. Training of Owner's personnel
1.2 Related Work
A. Section 01300: Shop Drawing Submittals
1.3 Submittals
Operation and Maintenance manual shall be submitted.
Training outline shall be submitted for instruction program for Owner's personnel.
Equipment data sheets shall be submitted for equipment furnished under each specification
section. Include data sheets in Operation and Maintenance Manual.
.I 1.4 Operation and Maintenance Manual
Prepare and submit 3 copies of Operation and Maintenance Manual containing Shop
Drawings, Catalog Data, Installation or Application Instructions, and operation and
Maintenance Instructions requested in Contract Documents. Deliver copies in D-ring binders
tabbed and indexed by specification sections. Include table of contents. Label binders with
project name.
Each section of Operation and Maintenance Manual shall include:
A.
B.
C.
D.
E.
F.
G.
Equipment data sheet describing function of equipment.
Catalog data
Shop drawings
Installation or application instructions
Operation and maintenance instructions
Parts lists
Serial numbers.
List name, address and telephone number of vendor.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01730 - Operating and Maintenance Data and Training - 1 of 2
Before requesting payment for 80 percent completion point for the total contract, submit two
of six required copies of the Operation and Maintenance Manual containing copies of material
available at that time. -_
Within 30 days after approval by Owner of the two-copy submittal, submit remaining four
copies of Operation and Maintenance Manual.
1.5 Unit Prices
Payment for operation and maintenance manuals required in Contract Documents will be
included in the price bid for items of work for which sections of Operation and Maintenance
Manuals are required.
Payment for operation and maintenance training required in Contract Documents shall be
included in the price bid for items of work for which operation and maintenance training is
required.
PART 2 - PRODUCTS (Not Applicable)
PART 3 - EXECUTION (Not Applicable)
END OF SECTION
-.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
01730 - Operating and Maintenance Data and Training - 2 of 2
SECTION 021 30
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. Earthwork: Section 02200
B.
C. Cast-in-Place Concrete: Section 03300
Asphaltic Concrete Pavement: Section 0251 0
c
1.3 Submittals
Submittals shall be provided as required in the related section(s) of the Specifications for the
appropriate material.
1.4 Pavment
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 Section 02200, Earthwork.
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
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
021 30 - Removal and Resurfacing of Pavement Surfaces - 1 of 3
B.
C.
D.
to the alignment of the pipe to provide an unfractured and level pavement joint for
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.
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 2Z-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.
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.
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. I
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
021 30 - Removal and Resurfacing of Pavement Surfaces - 2 of 3
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 Resurfacinq 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. r.-
2.6 Temporary Pavinq
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.
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.
END OF SECTION
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
021 30 - Removal and Resurfacing of Pavement Surfaces - 3 of 3
SECTION 02223
TRENCHING, BACKFILLING, AND COMPACTING
PART 1 - GENERAL
1.1 Description
A. This section includes materials, installation, and testing of trench excavation,
backfilling, and compacting.
1.2 Reference Standards
A. 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 D1556 -
ASTM D2922 -
ASTM D3017 -
ASTM D1557 - -
ASTM D4253 -
ASTM D4254 -
ASTMD75 -
ASTMC90 -
ASTMA82 -
Standard Test Method for Density and Unit Weight of Soil in Place by
the Sand-Cone Method
Standard Test Methods for Density of Soil and Soil-Aggregate in Place
by Nuclear Methods (Shallow Depth)
Standard Test Method for Water Content of Soil and Rock in Place by
Nuclear Methods (Shallow Depth)
Test Method for Laboratory Compaction Characteristics of Soil Using
Modified Effort (56,000 ft-lbf/ft3(2,700 kN-m/m3))
Standard Test Methods for Maximum Index Density and Unit Weight
of Soils Using a Vibratory Table
Standard Test Methods for Minimum Index Density and Unit Weight
of Soils and Calculation of Relative Density
Standard Practice for Sampling Aggregates
Standard Specification for Load bearing Concrete Masonry Units
Standard Specification for Steel Wire, Plain, for Concrete
Reinforcement
1.3 Related Work Specified Elsewhere
A. Construction Plans.
B.
C.
D. Utility Crossings: Section 02225
E. General Concrete Construction: Section 03300.
F. General Piping Systems and Appurtenances: Section 15000.
Earthwork and Repairs in Citv, Countv, and State Riqhts of Wav
A.
Shop Drawing Submittals: Section 01300.
Removal and resurfacing of Pavement Surfaces: Section 021 30.
1.4 rc
Conform to the requirements and provisions of the permits issued by those
agencies in addition to the requirements of these Standard Specifications. If a
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02223 - Trenching, Backfilling and Compacting - 1 of 12
City of Carlsbad
03/04 (DBE)
1.5
1.6
1.7
1.8
permit is not required, earthwork and repairs shall conform to the standards of the
agency in whose right of way the work is done in addition to the requirements of
these Standard Specifications.
-
Safetv Precautions
A. Observe safety precautions in all phases of the work. Included shall be trench
shoring, bracing, lighting, and barricades as dictated by reason and by the Safety
Orders of the Division of Industrial Safety, State of California (CAL OSHA).
Acquire an exemption letter or trenching permit from the California Division of
Industrial Safety (CAL OSHA) and comply with Labor Code Section 6705,
Excavation Plans For Worker Protection. Submit a copy of the exemption letter or
trenching permit with excavation plans to the District prior to excavation work.
Obstructions
A. The Contractor's attention is directed to the possible existence of pipe and other
underground improvements which may or may not be shown on the Plans. The
Contractor shall preserve and protect any such improvements whether shown on
the Plans or not and expose such improvements in advance of the pipeline
construction to allow for changes in the alignment as necessary. Where it is
necessary to remove and replace or to relocate such improvements in order to
prosecute the work, they shall be removed, maintained, and, permanently replaced
by the Contractor at his expense. Existing underground utilities shall be protected in place. -
Submittals
A.
B.
C.
Submit shop drawings in accordance with Specification Section 01 300.
Submit a report from a testing laboratory verifying that imported material is
asbestos-free and conforms to the specified gradations or characteristics.
Pipe Zone and Bedding Material: Submit current certification and test results for all
utility pipe zone and bedding material. Pipe zone and bedding material will
conform in all respects to the latest edition of the Carlsbad Municipal Water District
Engineers Design and Processing Manual.
Shoring: Prior to excavating submit shop plans and pertinent structural
calculations for the shoring design. The shoring must be designed by a structural
engineer and must comply in all respects to the Contract Documents, to all safety
regulations and requirements, and to the plans and contract documents.
D.
Testing for Compaction
The District or the agency having jurisdiction over the area of the work will require the Contractor
to test for compaction as described below:
Determine the density of soil in place by the sand cone method, ASTM D 1556 or
by nuclear methods, ASTM D 2922 and D 3017.
Determine laboratory moisture-density relations of soils by ASTM D 1557.
A. -.
B.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02223 -Trenching, Backfilling and Compacting - 2 of 12
1 C. Determine the relative density of cohesion less soils by ASTM D 4253 and D 4254.
D. Sample backfill materials by ASTM D 75.
E. "Relative compaction" is the ratio, expressed as a percentage, of the in place dry
density to the laboratory maximum dry density.
F. Make excavation for compaction tests at the locations and to the depths
designated by the District's Representative. Backfill and re-compact the
excavations at completion of testing. When tests indicate that the compaction is
less than the specified relative compaction, rework and retest those areas until the
specified relative compaction has been obtained.
1.9 Pipe Beddinq
A. The pipe bedding shall be defined as a layer of material immediately below the
bottom of the pipe and extending over the full trench width in which the pipe is
bedded. Thickness of pipe base shall be a minimum of 6 inches.
1.10 Pipe Zone
A. The pipe zone shall include the full width of trench from the bottom of the pipe to a
horizontal level 12 inches above the top of the pipe. Where multiple pipes are
placed in the same trench, the pipe zone shall extend from the bottom of the
lowest pipe to a horizontal level above the top of the highest or topmost pipe.
Thickness of pipe zone above the highest top of pipe shall be a minimum of 12
inches.
_I
1.1 1 Trench Zone
A. The trench zone includes the portion of the trench from the top of the pipe zone to
the bottom of the pavement zone or to the existing surface in unpaved areas.
1.1 2 Upper Zone
A. The upper zone includes the asphalt concrete and aggregate base pavement
section placed over the trench backfill.
1.1 3 Water for Construction
A. Water supplied by the District, for whatever needs and uses, shall be paid for in
accordance with the rates and rules of the District. The only exception is by
written agreement with the District.
- B. If District water is not available, the Contractor shall be responsible for supplying
the construction water.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02223 - Trenching, Backfilling and Compacting - 3 of 12
PART 2 -MATERIALS
2.1
2.2
2.3
I Native - -., Earth Backfill - Trench Zone
A. Native earth backfill used above the pipe zone shall be excavated fine grained
materials or loose soil free of asbestos, organic matter, roots, debris, rocks larger
than 3 inches in diameter, clods, clay balls, broken pavement, and other
deleterious materials. Sand Equivalent for said material shall be 30 or better.
Backfill material shall be so graded that at least 40% of the material passes a No.
4 sieve. The coarser materials shall be well distributed throughout the finer
material. 5ackfill materials that are obtained from trench excavated materials to
the extent such material is available, shall be either screened directly into the
trench or screened during the trenching operation. If screened during trenching,
Lhe material shall be maintained free of unscreened material during the handling
and backfilling process. Hand selecting of rocks from earth as it is placed into the
trench will not be permitted in lieu of the specified screening. Under no
circumstances will native earth backfill be allowed or used in the pipe base or pipe
zone areas.
.-... :mxorted Material for Backfill - Trench Zone
h Imported material shall conform to that specified for native earth backfill or
imported sand. -
b?gor%ed Sand - Pipe Beddinq and Pipe Zone
A, !illported sand used in the pipe base and pipe zone shall consist of natural or
manufactured granular material, or a combination thereof, free of deleterious
;’mounts of organic material, mica, loam, clay, and other substances. Under no
circumstances will decomposed granite or native earth backfill be allowed or used
in the pipe base or pipe zone areas. Impoi’ted sand shall have the following
gradation or similar:
City of Carlcbad
03/04 (DEE)
Sieve Size
3/8-i tich
NG.4
N0.30
No.100
No.200
Percent Passing
Bv Weiqht
100
75 -100
12- 50
5- 20
0- 15
Imported sand shall have a sand equivalent (S.E.) of 30 or greater as determined
by the latest version of Test Method No. Calif. 217.
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02223 - Trenching, Backfilling and Compacting - 4 of 12
2.4 Rock Refill for Foundation Stabilization
A.
-
Rock refill shall be crushed or natural rock having the following gradation:
_c
Sieve Size
3 inches
1-1/2 inches
3/4- i nc h
N0.4
No.30
No.200
Percent Passing
Bv Weiqht
100
70 -100
60 -100
25- 55
10- 30
0- 15
2.5 Granular Material For Backfill
A. Where crushed aggregate base is called for in these specifications or in the
Standard Drawings, the granular material for backfill shall be free of asbestos,
organic materials, clay balls, and shall have the following gradation:
Sieve Size
1 -inch
3/4-inch
1/2-inch
3/8-inch
No.8
N0.4
Percent Passing
Bv Weiaht
100
90 - 100
40- 70
20- 50
0- 10
0- 5
B. Whenever the phrase "crush aggregate base backfill material" is used in these
Standard Specifications, it shall mean granular material for backfill as described
above in 2.5.A.
C. Excavated material may be used for backfill provided it conforms to the Standard
Specifications for structural backfill material.
2.6 Concrete For Below Ground Installations
A. Concrete for anchors, collars, encasements, supports, and thrust blocks shall be
Class A for reinforced items and Class C for un-reinforced items per Standard
Specification Section 03300, except use rapid set concrete mix where indicated.
Concrete slurry backfill, when required, shall be in accordance with Table 201-
1.1.2 (A), 1 OO-E- 100.
B. Provide anchor blocks at valves in pipe having rubber gasket bell and spigot or
unrestrained mechanical joints.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains 02223 - Trenching, Backfilling and Compacting - 5 of 12
C.
D.
Provide support blocks at all valves.
Provide thrust blocks at fittings in pipe having rubber gasket bell and spigot or
unrest rained mechanical joints.
--
2.7 Water For Compaction
A. Water used in compaction shall have a maximum chloride concentration of 500
mg/l, a maximum sulfate concentration of 500 mgA, and shall have a pH of 7.0 to
9.0. Water shall be free of acid, alkali, or organic materials injurious to the pipe or
coatings. Salt water will not be allowed.
2.8 Soil Sterilant
A. The sterilant shall be Oust (EPA regulation #352-401) as manufactured by E. I
DuPont Nemours and Company or approved equal.
PART 3 - EXECUTION
3.1 General
The Contractor shall perform all site grading, soil sterilant application, structure excavation and
backfill, trench excavation and backfill for pipelines and conduits, and other earthwork required to
complete the work under this contract. Included are all necessary clearing, grubbing, grading,
and excavation of all classes and of whatever substance encountered, stockpiling, backfilling,
compaction, controlling water, bracing excavations, stabilizing subgrade, protecting existing
structures and facilities, complying with conditions of permits and safety regulations, cleaning up
debris, papers and loose rocks, restoring fences and other disturbed property, maintaining trees
which are not permitted to be removed, and disposing of excess material, and such
supplementary operations as are necessary to properly complete the entire work indicated or
specified.
-
3.2 Trenching Subject to Permit Conditions
Trenching within public rights-of-way controlled by a state, county or city, or trenching within
railroad rights-of-way shall be in accordance with requirements and provisions of the permits
issued by those agencies for the construction within their respective rights-of-way. Such permit
requirements and provisions which are more restrictive than those specified herein, shall take
precedence and supersede the provisions of these Specifications.
3.3 Protection of Workmen
Excavations shall be so braced or sheeted so as to provide conditions under which workmen
may work safely and efficiently at all times. The latest revision of the rules, orders and
regulations of the Division of Industrial Safety of the State of California shall be complied with. -
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains 02223 -Trenching, Backfilling and Compacting - 6 of 12
3.4 Public Safety
Barriers shall be placed at each end of all excavations and such places as may be necessary
along excavations to warn all pedestrian and vehicular traffic of such excavations. Lights shall
also be placed along excavations from sunset each day to sunrise of the next day until such
excavation is entirely refilled. Material for backfill or for protection of excavation in public roads
from surface drainage shall be neatly placed and kept shaped so as to cause the least possible
interference with public travel. Free access must be provided to all fire hydrants, water valves,
meters, and private drives, or other property or facilities that may have routine use.
3.5 Support of Adiacent Propertv
Excavations shall be so braced, sheeted, and supported that the ground alongside 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. Damage to adjacent property or to the
work occurring through settlements, water or earth pressures, slides, caves or other causes due
to failure of lack of sheeting or bracing or improper bracing, or through negligence or fault of the
Contractor in any other manner, shall be repaired by the Contractor at his own expense.
3.6 Existing Improvements
The Contractor's attention is directed to the possible existence of pipe and other underground
improvements which may or may not be shown on the plans. The Contractor shall preserve and
protect any such improvements whether shown on the plans or not. Where it is necessary to
remove and replace or to relocate such improvements in order to prosecute the work, they shall
be removed, maintained, and permanently replaced by the Contractor at his expense, except as
otherwise provided in the General Provisions.
-
3.7 Drainaqe Control
A. Control of Surface Drainage
The Contractor shall control grading in a manner to prevent water running into
excavations. Obstruction of surface drainage shall be avoided and means shall be
provided whereby storm and wastewater can flow uninterrupted in existing gutters,
other surface drains or temporary drains.
B. Preservation of Existing Drainage
Except as shown on the Plans, existing drainage patterns shall be preserved.
Where construction methods cause a temporary obstruction of drainage patterns
temporary facilities adequate for expected flows and a means of emergency removal
of the obstruction shall be provided.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02223 -Trenching, Backfilling and Compacting - 7 of 12
3.8 Compaction Requirements
Unless otherwise shown on the Plans or otherwise described in the Specifications and required
by the agency having jurisdiction over the area of the work, relative compaction in pipe trenches
shall be a minimum as follows:
-
A.
B.
C.
D.
E.
Pipe bedding - 90% relative compaction.
Pipe zone - 90% relative compaction.
Trench zone - 90% relative compaction.
Upper one foot of trench zone shall be 95% relative compaction
Upper zone - 95% relative compaction.
3.9 Sheeting, Shorinq, and Bracing of Trenches
Trenches shall have sheeting, shoring, and bracing conforming with 29CFR 1926, Subpart
P-Excavations, CAUOSHA requirements, and the District's requirements.
3.10 Sidewalk, Pavement, and Curb Removal
Cut and remove bituminous and concrete pavements regardless of the thickness, and curbs and
sidewalks prior to excavation of the trenches with a pavement saw, hydrohammer, or pneumatic
pavement cutter. Width of the pavement cut shall be at least equal to the required width of the
trench at ground surface. Haul pavement and concrete materials from the site. Do not use for trench backfill. -
3.1 0 Dewatering
Provide and maintain means and devices to remove and dispose of all water entering the trench
excavation during the time the trench is being prepared for the pipelaying, during the laying of
the pipe, until cement mortar of exterior joints has set hard, when concrete is being deposited
and during the hydration process, and until the backfill at the pipe zone and trench zone has
been completed. These provisions shall apply during the noon hour as well as overnight.
Dispose of the water in a manner to prevent damage to adjacent property and in accordance
with regulatory agency requirements. If feasible, dewatering flows shall be discharged to storm
drain facilities in accordance with Riverside County Flood Control and Water Conservation
District requirements. Contractor shall be responsible for obtaining a permit and performing
monitoring and reporting to Regional Water Quality Control Board (RWQCB). Do not drain
trench water through the pipeline under construction.
3.1 2 Material Replacement
Remove and replace any trenching and backfilling material which does not meet the
Specifications, at the Contractor's expense.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02223 - Trenching, Backfilling and Compacting - 8 of 12
3.13 Trench Widths
Pipe trench widths in the pipe zone will be limited as follows:
-
Minimum Maximum
Pipe Diameter Trench Width Trench Width
4" through 12" O.D. + 12" O.D. + 16"
14" through 48" O.D. + 16" O.D. + 24"
Trench width at the top of the trench will not be limited except where width of excavation would
undercut the structural support of adjacent structures and footings. Where shoring or
encasement is required, trench widths shall be increased accordingly.
3.14 Trench Excavation
A. Perform all excavation regardless of the type, nature, or condition of the material
encountered to accomplish the construction. Do not operate excavation
equipment within 5 feet of existing structures or newly completed construction.
Excavate with hand tools in these areas.
B. Excavate the trench to the lines and grades shown on the Plans with allowance for
pipe thickness, sheeting and shoring if used, and for pipe base. If the trench is
excavated below the required subgrade, refill any part of the trench excavated
below the subgrade at no additional cost to the District with imported sand. Place
the refilling material over the full width of trench in compacted layers not exceeding
6 inches deep to the established grade with allowance for the pipe base. Compact
refill material to 95% of maximum density.
C. Trench depth shall accommodate the pipe and the pipe base at the elevations
shown in the profile on the Plans. No pipe shall be installed without a designed
profile unless approved by the District.
D. Construct trenches in rock by removing rock to a minimum of 6 inches below
bottom of pipe and backfilling with imported sand.
3.15 Location of Excavated Material
During trench excavation, place the excavated material only within the working area or within the
areas shown on the Plans. Do not obstruct any roadways or streets. Conform to federal, state,
and local codes governing the safe loading of trenches with excavated material.
3.16 Length of Open Trench
A. The total length of open trench shall not exceed 200 feet including excavation,
pipeline installation and backfill in any one location. c
B. Complete backfilling and temporary or first layer paving not more than 80 feet in
the rear of pipelaying.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02223 - Trenching, Backfilling and Compacting - 9 of 12
C. Where pipelines are located beneath or adjacent to existing paved roads, backfill
all trenches at the end of each workday and place temporary or first layer of
paving. Clean all new and adjacent existing paved surfaces of residual excavated
and backfill materials. Perform dust control operations in these areas with a brush
or vacuum type mobile street sweeper. No open trenches will be allowed in these
areas.
-
D. Provide ingress and egress to buildings and property at all times. Provide traffic
rated steel plates for covering for vehicular access and protect excavations which
must remain open beyond the initial day of the excavation.
3.17 Foundation Stabilization
After the required excavation has been completed, the District will inspect the exposed subgrade
to determine the need for any additional excavation. It is the intent that additional excavation be
conducted in all areas within the influence of the pipeline where unacceptable materials such as
soft, spongy or deleterious materials exist at the exposed grade. Over excavation shall include
the removal of all such unacceptable material that exists directly beneath the pipeline to a
minimum width equal to the maximum trench width and to a depth determined by the District.
Backfill the trench to the established subgrade of the pipe base with rock refill material for
foundation stabilization. Place the foundation stabilization material over the full width of the
trench and compact in layers not exceeding 6 inches deep to the required grade. Place imported
sand on the compacted foundation stabilization and apply water to wash the sand into the voids
of the rock refill material. Continue this procedure until the voids of the rock refill have been filled
with imported sand. Do not apply water in such quantities that it will damage the integrity of the
compacted foundation.
-
3.1 8 Concrete for Below Ground Installations
Place concrete between the undisturbed ground and the pipe or fittings to be restrained or
supported. Quantity or bearing area of the concrete against undisturbed ground shall be as
shown on the Standard Drawings, Plans, or as directed by the District. Provide temporary
support on the pipe, fittings, or valves until the concrete has obtained a 3-day cure. Place
concrete such that the pipe joints, fittings, or valves are accessible for repairs. Spade or rod the
concrete during placement to eliminate honeycombing. Backfilling of the trench adjacent to the
concrete will not be allowed until the concrete has cured for at least 3 days. Allow concrete to
cure for at least 7 days prior to subjecting the concrete to pipeline pressure. Where rapid set
concrete mix has been used, the 3-day and 7-day cure time is not required. Backfill the rapid set
concrete mix as soon as the concrete is hard (approximately one to two hours) and place
pipeline into service.
-.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains 02223 -Trenching, Backfilling and Compacting - 10 of 12
3.1 9 Trench Backfilling
.- A.
c
B.
C.
D.
E.
F.
Place the specified thickness of pipe bedding material over the full width of trench
and compact to the specified relative compaction. Grade the top of the pipe base
ahead of the pipelaying to provide firm, continuous, uniform support along the full
length of the trench for the pipe, fittings, and valves.
Excavate bell holes at each joint to permit proper assembly and inspection of the
entire joint. Fill and compact the area excavated for the joints with the pipe base
material.
After the pipeline has been bedded and the cement mortar used in the exterior
joints has set hard, place pipe zone material simultaneously on both sides of the
pipe, fittings, and valves, keeping the level of backfill the same on each side.
Carefully place the material around the pipe so that the pipe barrel is completely
supported and that no voids or un-compacted areas are left beneath the pipe. Use
particular care in placing material on the underside of the pipe to prevent lateral
movement during subsequent backfilling. Do not drop sharp, heavy pieces of
material directly onto the pipe or the tamped material around the pipe.
Compact material in the pipe zone by hand tamping only. Care shall be exercised
in backfilling to avoid damage to pipe coatings and polyethylene encasement.
Push the native earth backfill or imported material for backfill carefully onto the
imported sand previously placed in the pipe zone.' Do not permit free fall of the
material until at least 2 feet of cover is provided over the top of the pipe. Compact
backfill material in the trench zone to the specified relative compaction by
mechanical compaction or hand tamping.
Place and compact pipe zone material in layers not exceeding 12 inches of
compacted thickness. Place and compact native earth or imported material for
backfill in the middle zone in layers not exceeding 6 inches of compacted
thickness.
3.20 Mechanical Compaction or Hand Tamping
Place imported sand and backfill materials in uniform layers of the indicated thickness. Compact
each layer to the required minimum relative compaction at the optimum moisture content. Do
not use heavy duty compaction equipment with an overall weight in excess of 125 pounds until
backfill has been completed to a depth of 2 feet over the top of pipe. Do not use high impact
hammer type equipment except where the pipe manufacturer warrants in writing that such use
will not damage the pipe.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02223 -Trenching, Backfilling and Compacting - 11 of 12
3.21
Dispose of excess excavated material offsite. Contractor shall make his own arrangements for
the disposal of the excess material and bear all costs incidental to such disposal. Over
undeveloped property or street frontage] excess material may be disposed of within the right of
way by spreading, provided that rocks or lumps which cannot be readily covered by spreading
are removed.
Disposal of Excess Excavated Material
a
3.15 Soil Sterilant
A. General
The Contractor shall treat the finished subgrade of specified areas with an approved
soil sterilant.
B. Areas Requiring Soil Sterilant
All areas which are to receive bitumastic pavement] including embankments]
walkways, drainage structures, parking, and road areas, require soil sterilant.
Other areas requiring soil sterilant are storage reservoir or pond surfaces which are
to receive any lining material of less than 3-inches in thickness and lining perimeter
areas to a distance of 5-feet from the edge of lining material.
C. Material and Application
The sterilant shall be applied in a liquid or dry form and at a uniform rate of 10 to 12
ounces of dry sterilant per acre in accordance with the manufacturer's directions. At
the option of the Engineer, the area shall then be lightly sprinkled with water to
prevent loss of sterilant or scuffing.
END OF SECTION
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic 8, Recycled Water Transmission Mains
02223 - Trenching, Backfilling and Compacting - 12 of 12
.,--
SECTION 02225
UTILITY CROSSINGS
PART 1 - GENERAL
1.1 Description
Where utilities cross the pipeline trench but do not conflict with the permanent Work to be
constructed, the Contractor shall follow the procedures given below and as indicated on the
Plans and in the Specifications. For utility crossings not shown on the Plans, follow the
General Provisions and the instructions of the Engineer.
1.2 Related Work Described Elsewhere
A. Section 02200: Earthwork
1.3 Submittals (Not Applicable)
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 Replacement in Kind
Except as indicated below or as specifically authorized by the Engineer, the Contractor shall
reconstruct utilities with new material of the same size, type, and quality as that removed.
2.2 Vitrified Clav Sewer Pipe and Couplings
For sewer pipe eight inches in diameter or under, replacement shall consist of plain-end pipe
conforming to ASTM C700. Compression coupling shall conform to ASTM C594; Band seal
couplings or approved equal. At least two lengths of pipe shall be used in crossing the trench
section as shown on the details on the Plans or in the Special Provisions.
PART 3 - EXECUTION
3.1 Notification
The Contractor shall notify the utility owner 48 hours in advance of the potholing and at the
beginning of construction and will coordinate the construction schedule with the utility service
requirements. c
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02225 - Utility Crossings - 1 of 2
3.2 Exposing Utilities in Advance
It shall be the Contractor's responsibility to determine the true location and depth of all utilities
and service connections which may be affected by or affect the Work. He shall also
determine the type, material, and conditions of these utilities. In order to provide sufficient
lead time to resolve unforeseen conflicts, order materials, and take appropriate measures to
ensure that there is no delay in Work, the Contractor shall expose all utilities in advance of
submittal of shop drawings and lay diagrams for the pipeline construction. All costs incurred
in exposing utilities shall be borne by the Contractor.
---.
3.3 Protect in Place
The Contractor shall protect all utilities in place, unless abandoned, and shall maintain the
utility in service, unless otherwise specified on the Plans or in the Specifications.
3.4 Cut and Plug Ends
The Contractor shall cut abandoned utility lines and plug the ends of lines larger than 18-inch
diameter with brick and mortar, unless otherwise specified on the Plans or in the
Specifications. Abandoned facilities smaller than 18 inches in diameter shall be plugged with
concrete. The pipe shall be disposed of as unsuitable material by the Contractor.
3.5 Remove and Reconstruct - Where so indicated on the Plans or in the Specifications or as required by the Engineer, the
Contractor shall remove the utility and after passage, reconstruct it with new materials. The
Contractor shall take appropriate measures to provide temporary service for the disconnected
utility. All reconstruction work shall be in accordance with the applicable specifications.
3.6 Compaction
A.
6.
C.
Utilities Protected in Place: Contractor shall take special precautions to compact
under and around the utility to ensure that no voids are left.
Utilities Reconstructed: Prior to replacement of the utility, the trench shall be
backfilled and compacted by approved means to an elevation one foot above the
top of the ends of the utility. A cross trench of the proper width shall be excavated
for the utility and it shall be laid, backfilled, and compacted as specified herein or
as required by the Engineer.
Alternate Construction - Sand Slurw: Sand slurry consisting of one sack (94
pounds) of Portland cement per cubic yard of sand and sufficient moisture for
workability may be substituted for other backfill materials to aid in reducing
compaction difficulties. Specific methods and procedures must be submitted for
the approval of the Engineer prior to construction.
City of Carlsbad
03/04 (DBE)
END OF SECTION
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
02225 - Utility Crossings - 2 of 2
SECTION 02510 - ASPHALTIC CONCRETE PAVEMENT
PART 1 - GENERAL
1.1 Description
The Contractor shall construct asphaltic concrete pavements for roads, parking areas,
aprons, sidewalks, and other work involving asphaltic concrete, all as shown on the Plans.
Asphaltic concrete shall conform to all requirements of the latest revision of the Standard
Specifications for Public Works Construction (P.W.C.) and specified herein.
1.2 Related Work Described Elsewhere
A. Section 02200: Earthwork
B. Section 01300: Shop Drawings
1.3 Submittals
Contractor shall furnish submittals in accordance with the requirements of Section 01 300,
Shop Drawing Submittals. The following submittals are required:
_c Submit six (6) copies of a report from a testing laboratory verifying that aggregate
material is asbestos-free and conforms to the specified gradations or characteristics.
1.4 Pavrnent
Payment for the Work in this section shall be included as part of the unit price or lump sum
bid amount stated in the Proposal.
1.5 Testinq for Compaction
A. The Owner will test for compaction as described herein and in Section 02200,
Earthwork.
B. Determine the density of existing soil in place by the Sand Cone Method, ASTM
D1556.
C. Determine laboratory moisture-density relations of soils by ASTM D1557.
D. Determine the relative density of cohesionless soils by ASTM D4253 and D4254.
E. Sample backfill materials by ASTM D75.
c F. "Relative compaction" is the ratio, expressed as a percentage, of the in-place dry
density to the laboratory maximum dry density.
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03/04 (DBE)
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0251 0 - Asphaltic Concrete Pavement - 1 of 4
G. Compaction shall be deemed to comply with the specifications when no more
than one test of any three consecutive tests falls below the specified relative
compaction. The one test shall be no more than three percentage points below
the specified compaction. The Contractor shall pay the costs of any retesting of
Work not conforming to the specifications.
-
PART 2 - MATERIALS
2.1 Soil Sterilant
The sterilant shall be Oust (EPA regulation #352-401) as manufactured by E.I. DuPont
Nemours and Company (Wilmington, Delaware), or approved equal.
2.2 Amreqate Base Course
The base materials shall conform to Section 200-2.2, crushed aggregate base of the
Standard Specifications for P.W.C. The Contractor may elect to use on-site materials which
shall conform to Section 200-2.5, Processed Miscellaneous Base of the Standard
Specifications for P.W.C.
2.3 Prime Coat
Prime coat shall be liquid asphalt, Grade SC-250 as specified in Section 203-2 of the - Standard Specifications for P.W.C.
2.4 Tack Coat
If paving over existing pavement, a tack coat shall be applied, either AR1000 paving asphalt
or SS-1 h in accordance with Section 302-5.4 of the Standard Specifications for P.W.C.
2.5 Asphalt Concrete Pavement
Asphalt concrete shall consist of Type II mineral aggregate conforming to the requirements
specified in Section 203-6.3.2 of the Standard Specifications for P.W.C. using a medium
coarse Class B grading mixed with a bitumen content of 4.5% to 5.8% of the dry mineral
aggregate, bitumen shall be RC85-100 penetration paving asphalt.
2.6 Seal Coat
Seal coat shall be SS-I h asphalt emulsion.
PART 3 - EXECUTION
- 3.1 Subrrrade Preparation
Scarify 6-inches below subgrade, bring to optimum moisture content, and compact to a
relative dry density of 90%.
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03/04 (DBE)
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0251 0 - Asphaltic Concrete Pavement - 2 of 4
3.2 Soil Sterilant
Soil sterilant shall be spread uniformly upon the prepared subgrade at the rate of 10 to 12
ounces of dry sterilant per acre, in accordance with the manufacturer's recommendations,
from outside of curb to opposite outside of curb for the full width of roadways or parking area
to be paved or surfaced.
c
3.3 Aaareqate Base Course
Base material shall be furnished, placed and compacted for asphalt concrete pavements as
shown on the Plans and specified herein.
The spreading and compacting shall conform to Section 301-2 of the Standard Specifications
for P.W.C.
3.4 Prime Coat
After completion of the subgrade, a prime coat of liquid asphalt, specified in 2.2, shall be
pressure-spray applied at a rate of approximately 0.25 gallons per square yard. In the event
an aggregate base is specified, the prime coat shall be applied after completion of the base
course. Liquid asphalt shall be prevented from spraying on adjacent ground, structures,
curbing and fencing.
3.5 Tack Coat
Over existing pavement, a tack coat shall be applied in accordance with Section 302-5.3 of
the Standard Specifications for P.W.C.
3.6 Asphaltic Concrete Pavement
Materials and workmanship for asphalt concrete shall conform to the applicable provisions of
Section 203-6 of the Standard Specifications for P.W.C. and the following provisions:
Asphaltic concrete pavement shall be spread in one course by means of a Barber-
Greene paving machine, or approved equal. It shall be spread to a depth to achieve a
compacted thickness as shown on the Plans. The completed surface shall be
thoroughly compacted, smooth and true to grade and cross-section, and free from ruts,
humps, depressions and irregularities.
When a straight edge is laid on the finished surface and parallel to the centerline, the
surface shall not vary more than 1/8-inch in 10-feet.
3.7 Seal Coat
A seal coat of mixing type emulsion liquid asphalt shall be applied to all asphaltic concrete
pavements. The emulsion shall be SS-1 h and shall be applied at the rate of 0.1-gallon per
square yard. The Contractor shall have the option of closing the sealed area to traffic for at
least 7-days or blotting with sand and sweeping with the area being open to traffic as soon as
cover material is laid.
_-
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
0251 0 - Asphaltic Concrete Pavement - 3 of 4
3.8 Adiust Valve Box Rings and Covers -
The Contractor shall adjust all valve box rings and covers to grade within 30 days after final
paving of each street in which the pipelines are installed.
END OF SECTION
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic 8, Recycled Water Transmission Mains
0251 0 - Asphaltic Concrete Pavement - 4 of 4
SECTION 03300
CONCRETE CONSTRUCTION
PART 1 -GENERAL
1.1 Description
The Work under this section includes all cast-in-place concrete, complete.
1.2 Related Work Described Elsewhere
The Contractor shall refer to the following Specification section(s) for additional requirements:
A. Shop Drawing Submittals: 01300
B. Testing and Inspection: 01 41 0
1.3 Submittals
Contractor shall furnish submittals in accordance with the requirements of Section 01 300, Shop
Drawing Submittals. The following submittals are required:
A. The mix design shall be submitted for review and approved before placing of any - concrete.
B. The Contractor shall submit reinforcing Shop Drawings and placing drawings for all
reinforcing. Placing drawings shall indicate all openings, including additional
reinforcing at openings and corner bar arrangements at intersecting beams, walls,
and footings as indicated in the Plans.
C. The Contractor shall submit a certified mill copy of mill tests on each heat showing
physical and chemical analysis of reinforcing steel.
D. The Contractor shall submit a proposed sequence of placing concrete, showing
proposed beginning and ending of individual placements. Placement of concrete
shall be consistent with indicated construction joints.
1.4 Payment
A. Measurement: If concrete is a pay item in the Contract Documents, the
measurement shall be in accordance with the dimensions shown on the Plans.
cc
B. Payment: Payment shall be at the bid price per cubic yard in place, complete,
including forming, reinforcement, and such embedded items as are shown on the
Plans. Payment for concrete construction for which no pay item is provided shall be
considered included as part of the lump-sum or unit-price bid amount for which such
Work is appurtenant thereto.
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03300 Concrete Construction - 1 of 18
PART 2 - MATERIALS
2.1 General
A. Cement: Cement shall be Portland cement, Type II, conforming to ASTM C150
(unless otherwise specified).
B. Aggregates: Aggregates shall conform to ASTM C33 and shall be free from any
substances that will react with the cement alkalies.
C. Reinforcement: Reinforcement shall conform to ASTM A61 5, Grade 40 or 60. Tie
wire shall be annealed wire not lighter than 16 gauge. Wire fabric shall conform to
ASTM A185.
D. Waterstops: Waterstops shall be of polyvinyl material. The material shall be
resistant to chemical action with portland cement, shall be resistant to alkalies, and
shall not be affected by mildew or fungus. It shall show no effect when immersed for
ten days in a 10% solution of sulfuric or hydrochloric acids, saturated lime solution, or
salt water. All waterstops shall be such that any cross section will be dense,
homogeneous, and free from porosity and other imperfections. They shall be
symmetrical in shape. When tested in accordance with the applicable test methods
of Federal Standard No. 601, the material shall meet the following requirements:
Tensile strength, psi, minimum 2,000
Elongation, ultimate, percent, minimum 250
Compression set, percent, maximum 30
Tensile strength after accelerated aging
80
Water absorption, percent by weight, maximum 0.5%
(48 hours, 70°C, 300 psi) percent, minimum
Durometer hardness, Shore A 70-80
E. Water: Water should be clean and potable.
F. Admixtures: All concrete shall contain Master Builders Pouolith polymer-type water-
reducing admixture and an air-entraining admixture (Type MBVR), to prevent
segregation, improve workability, and reduce the quantity of mixing water, both in
strict accordance with the manufacturer's recommendations. Resulting entrained air
shall be 3% to 5%. Where controlled setting and/or controlled rate of hardening is
required, the admixtures shall be a formulation that provides this control without loss
in strength when compared with the normal setting formulation. The manufacturer
shall make available at no cost upon 72 hours notice, the services of a qualified full-
time field representative to assure proper use of the admixture.
G. Forms: Form lumber shall conform to specified paragraphs in the Standard Grading
Rules No. 16 of the West Coast Lumber Inspection Bureau effective September 1 ,
1970. Plywood shall be Douglas fir, Class 1, Exterior B-B concrete panels,
conforming to U.S. Product Standard PSI-66 and shall be edge sealed. I_
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03300 Concrete Construction - 2 of 18
H. Premolded Expansion Joint Filler: Premolded expansion joint filler shall be
preformed, non-extruding-type joint filler constructed of closed cellular sponge rubber
of firm texture conforming to ASTM D1752, Type I.
I. Curing Compound: Curing compound shall conform to ASTM C309.
J. Joint Sealant: The joint sealant shall be a two part, gray, non-staining, non-sagging,
polyurethane sealant, which cures at ambient temperature to a firm, flexible, tear-
resistant rubber. The sealer shall be resilient and have excellent recovery
characteristics after extended periods of compression or elongation. Sealant shall be
PRC 270 or approved equal.
Technical Requirements
Consistency Gun Grade
Tack Free Time 24 hours at 75°F and 50% R.H.
Pot Life 1 to 3 hours
Hard ness 30 Shore A, *5
Elongation 750%
Shrinkage Negligible
Tensile Strength, ASTM D412
Peel Strength on Concrete
Temperature Service Range
325 psi
12 P.L.I. Cohesive
-40°F to 175°F
Joint primer shall be compatible with sealant. Joint backup material shall be closed
cell polyethylene rod, 3/4-inch diameter. Bond breaker tape shall be compatible with
sealant.
K. Epoxy Bonding Compound: Epoxy bonding compound shall be Concresive 1001 LPL
and shall be applied in accordance with manufacturer's instructions.
2.2 Concrete Requirements
A. Classes of Concrete: Concrete shall be of three classes, referred to as Class A,
Class B, and Class C.
Anchors, thrust blocks, encasements, cradles, surface slope protection, cut off walls,
and other similar items shall be constructed of a minimum of Class B Concrete.
Class C concrete may be used as fill for unauthorized excavation, thrust blocks and
pipe encasement where approved by the Owner's Representative.
All other concrete shall be Class A.
B. Strength Requirements: Class A concrete shall not be less then 3,000 psi
compressive strength at 28 days and contain not less than six sacks of cement per
cubic yard of concrete.
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03300 Concrete Construction - 3 of 18
2.3
Class B concrete shall not be less than 2,500 psi compressive strength at 28 days
and contain not less than five sacks of cement per cubic yard of concrete. -
Class C concrete shall not be less than 2,000 psi compressive strength at 28 days
and contain not less than four sacks of cement per cubic yard of concrete.
C. Mix Design: The mix designs shall be prepared at the Contractor's expense by an
independent inspection and testing laboratory acceptable to the Owner's
Representative in accordance with Section 01 41 0, Testing and Inspection and shall
show the expected strength and corresponding slump and all ingredient weights and
other physical properties necessary for the design mix. Mix design shall be submitted
for review and approved in accordance with Section 01300, Shop Drawing
Submittals, before placing of any concrete.
Aggregate size shall be as follows:
Sections 8-inches or less in thickness shall be 3/4-inch maximum (combined
gradation).
Sections greater than 8-inches shall be 1 %-inches maximum.
Mix design for pumped concrete shall produce a plastic and workable mix. The
percentage of sand in the mix shall be based on the void content of the coarse
aggregate. -
D. Slump: Vertical wall sections and columns shall be four to five inches. Slabs,
beams, and footings shall be three to four inches.
E. Workability: Concrete shall be of such consistency and composition that it can be
worked readily into the forms and around the reinforcement without excessive
spading and without permitting the materials to segregate or free water to collect on
the surface.
The proportions shall be adjusted to secure the lowest water-cement ratio which is
consistent with good workability, a plastic, cohesive mixture, and one which is within
the specified slump range.
To avoid unnecessary changes in consistency, the aggregate shall be obtained from
a source which will ensure uniform quality, moisture content, and grading during any
single day's operation. Materials shall be handled in such a manner that variations in
moisture content will not interfere with production of concrete of the specified degree
or uniformity and slump.
Formwork
- A. Design of Forms: The Contractor shall be responsible for the design and
construction of forms. Forms shall be designed on the basis of deflection and stress
and shall be adequately braced. The allowable deviation in all exposed finished
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03300 Concrete Construction - 4 of 18
c
surfaces shall not exceed 1/8-inch in ten feet. All concrete shall be formed, unless
shown otherwise on the Plans.
B. Classes of Forms: Class I forms shall have smooth surface plywood, 5/8-inch
minimum thickness. Face and edges of forms shall be coated with a two-coat system
of one component polyurethane coating applied by roller at the rate of 500 square
feet per gallon.
Class II forms shall be metal or smooth planed boards or plywood in good condition,
with boards free from large or loose knots with tongue and groove or ship lap joints.
Forms shall be oiled.
C. Location of Forms: Class II forms may be used for exterior concrete surfaces which
are below one foot of finish grade. Class I forms shall be used for all other surfaces.
D. Tolerances: The following table indicates tolerances or allowable variations from
dimensions or positions of all structural concrete work:
Maximum Tolerance
Sleeves and inserts +1/4" - 1/8"
Projected ends of anchor bolts +1/4" - 0.0"
Anchor bolt setting +1/16" - 1/16"
Concrete walls and slabs +1/8" - 1/8" in 10-feet
Finished concrete, all locations +1/4" - 1/4" in 10-feet
not listed above
Regardless of the tolerances listed above, it shall be the responsibility of the
Contractor to limit deviations in line and grade to tolerances which will permit proper
installation and operation of mechanical equipment piping.
E. Removal of Forms and Shoring: The following table indicates the minimum allowable
time after the last cast concrete is placed before forms or shoring may be removed:
Sides of footings 24 hours
Walls and columns 48 hours
Vertical sides of beams, girders, and similar members 48 hours
Slabs, beams and girders 10 days
Shoring for slabs, beams, and girders 21 days
Forms shall not be removed from concrete which has been placed with outside air
temperature below 50°F without first determining by cylinder tests if the concrete has
properly set without regard for time. No heavy loading on green concrete will be
permitted. Immediately after forms are removed, the surface of the concrete shall be
carefully examined and any irregularities in the surface shall be repaired and finished
as specified hereinafter.
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03300 Concrete Construction - 5 of 18
F. Waterstops: Waterstops shall be of the shapes and dimensions shown on the Plans.
Waterstops shall be properly heat-spliced at ends and intersections to ensure
continuity. Splicing shall be in accordance with the manufacturer's instructions.
Forms for construction joints shall be constructed in such a manner as to prevent
injury to waterstops. Waterstops shall be securely held in position in the construction
joints by wire ties, continuous bars, and rings as indicated. Waterstops shall be
installed in all construction joints in hydraulic structures and in all joints subjected to
groundwater.
2.4 Reinforcing (Non-Prestressed)
A. General Requirements: All reinforcing steel shall be delivered to the site bundled and
tagged with identifying tags. All reinforcing steel shall be bent cold and shall be bent
in accordance with the details on the Plans and as recommended in ACI 315.
Reinforcing steel, before being positioned, shall be free from loose mill and rust scale
and from coating that may destroy or reduce the bond. Where there is delay in
depositing concrete, reinforcement steel shall be reinspected and cleaned when
necessary by abrasive sandblasting.
Reinforcing steel shall not be straightened or rebent in a manner that will injure the
material. Bars with bends not shown on the Plans shall not be used.
PART 3 - EXECUTION
3.1 Concrete Construction
A. Mixing: Concrete shall be site mixed or ready mixed and shall conform to the
following requirements:
Site Mixed Concrete: The mixing equipment shall be capable of combining the
aggregates, cement, and water within the specified time into a thoroughly mixed and
uniform mass and discharging the mixture without segregation.
Mixing shall be done in a batch mixer of approved type which will ensure a uniform
distribution of the materials throughout the mass. The equipment at the mixing plant
shall be so constructed that all materials, including the water entering the mixing
drum, can be accurately proportioned and controlled. The cement and aggregate
shall be proportioned by weight.
Each entire batch shall be discharged before recharging. The volume of the mixed
materials per batch shall not exceed the manufacturer's rated capacity of the mixer.
Mixing time shall be as follows:
For mixer of a capacity of one cubic yard or less, 1 -1/2 minutes after batching is -_ completed.
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03300 Concrete Construction - 6 of 18
.-
_I-
For mixers of capacities larger than one cubic yard, the time of mixing shall be
1-1/2 minutes plus 30 seconds for each additional 1/2 cubic yard capacity or
fraction thereof in excess of one cubic yard.
The mixer shall revolve at a uniform rate as specified by the manufacturer for the
mixing equipment.
Ready-Mixed Concrete: Ready-mixed concrete shall conform to ASTM C94 with the
following additional requirements:
Water shall not be admitted to the mix until the drum has started revolving. The right
is reserved to increase the required minimum number of revolutions or to decrease
the designated maximum number of revolutions allowed, if necessary, to obtain
satisfactory mixing, and the Contractor will not be entitled to additional compensation
because of such increase or decrease.
The retempering of concrete or mortar which is partially hardened will not be
permitted.
B. Conveying: Concrete shall be conveyed from the mixer to the place of final deposit
by methods which will prevent the separation or loss of the materials. Equipment for
chuting, pumping, and pneumatically conveying concrete shall be of such size and
design as to ensure a practically continuous flow of concrete at the delivery end
without separation of the materials. Chutes and devices for conveying and depositing
concrete shall be so designed and used that the concrete shall be directed vertically
downward when discharged from the chute or conveying device. Chutes for
conveying concrete shall be kept thoroughly cleaned by washing and scraping.
C. Placing: Placement of concrete shall be consistent with indicated construction joints.
Wye walls at the top of hydraulic structures shall be placed monolithic with the main
structural wall. After review of the proposed sequence of placing concrete, this
sequence shall be adhered to, except when specifically permitted otherwise by the
Owner's Representative. The Contractor shall notify the Owner's Representative of
his readiness, not just his intention to place concrete in any portion of the Work. This
notification shall be such time in advance of the operation as the Owner's
Representative deems necessary for him to make final inspection of the preparations
at the location of the proposed concrete placing. All forms, steel, screeds, anchors,
ties, and inserts shall be in place before the Contractor's notification of readiness is
given to the Owner's Representative.
Concrete shall not be placed until all reinforcement is securely and properly fastened
in its correct position and loose form ties at construction joints have been retightened,
nor until all dowels, bucks, sleeves, hangers, pipes, conduits, bolts, wires, ceiling
insert, and any other fixtures required to be embedded therein have been placed and
adequately anchored, nor until the forms have been cleaned and coated as specified.
Subgrade shall be moistened and forms shall be wetted before concrete is placed.
Concrete shall be deposited at or near its final position to avoid segregation caused
by rehandling or flowing. Concrete shall not be deposited in large quantities in one
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03300 Concrete Construction - 7 of 18
place and worked along the forms with a vibrator or shovel. No concrete shall be
dropped freely into place from a greater height than six feet in unexposed Work and
four feet in exposed Work. Tremies shall be used where the drop exceeds these
limits.
-.
In order to assure that there will be no interruption in continuous placing, the
Contractor shall have available standby concrete mixing equipment ready for use in
case of breakdown or he shall make arrangements, satisfactory to the Owner's
Representative, with the supplier of concrete, if transit mix concrete is being used so
that the Owner's Representative may be assured that once placement is started, it
can be completed without interruption. The vibrating equipment, including standby
equipment, shall be at the site and tested in the presence of the Owner's
Representative during the day preceding the planned day of placement.
Appropriate mechanical vibration shall be used in placing concrete to eliminate rock
pockets and voids, to consolidate each layer with that previously placed, to
completely embed reinforcing bars and fixtures and to bring just enough fine material
to exposed surfaces to produce a smooth, dense, and even texture. Vibrators shall
be of the high-frequency internal type and the number in use shall be ample to
consolidate the incoming concrete to a proper degree within 15 minutes after it is
deposited in the forms. In all cases, at least two vibrators shall be available at the
site. The use of external vibrators for consolidating concrete will be permitted when
the concrete is otherwise inaccessible for adequate consolidating, provided the forms
are constructed rigidly enough to resist displacement or damage from external
vibration and the vibrators are approved by the Owner's Representative. -
Concrete shall be placed solidly against the forms so as to leave no voids, with
measures taken to ensure that all concrete is compact. If for any reason the surfaces
or interiors indicate voids or are in any way defective, such concrete shall be repaired
as directed by the Owner's Representative. Defective Work shall be repaired as
specified hereinafter.
No concrete shall be placed during rainstorms. Concrete placed immediately before
rain shall be protected to prevent rain water from coming in contact with it. Sufficient
protective covering shall be kept on hand at all times for this purpose.
1. Placing Temperatures
a. Hot Weather: When the weather is such that the temperature of the
concrete as placed would exceed 90°F, the Contractor shall employ ice or
other effective means of cooling the concrete during mixing and
transportation so that the temperature of the concrete as placed will not
exceed 90°F.
Precautions shall be taken when placing concrete during hot weather to
eliminate early or "flash" setting of concrete. This includes protection of
reinforcing from direct sunlight to prevent heating of reinforcing, placing
concrete during cooler hours of the day and the proper and timely application
of specified curing methods.
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All cracks that occur in line with reinforcing bars due to "flash" setting of
concrete shall be repaired by the Contractor at his own expense. These
cracks are in addition to the cracks defined in Subsection 3.4, Repair of
Defective Concrete.
There will be no additional reimbursement to the Contractor for costs
incurred for placing concrete in hot weather.
b. Cold Weather: Suitable equipment for enclosing and heating freshly placed
concrete and maintaining the required curing conditions shall be furnished by
and at the expense of the Contractor and shall be approved by the Owner's
Rep resentat ive.
When the temperature of the surrounding atmosphere is 40°F or, as
determined by the Owner's Representative, is likely to fall below this
temperature, the mixing water shall be heated to but not exceed 140°F.
Under no circumstances shall the heated water be permitted to come in
contact with the cement before the cement is added to the batch.
Concrete, when placed in the forms during cold weather, shall have a
temperature of not less than 55°F. All materials shall be free from ice, snow,
and frozen lumps before entering the mixer.
The air and forms in contact with the concrete shall be maintained at
temperatures about 40°F for at least the first five days and above 35°F for
the remainder of the curing period. Reinforcing shall be protected and shall
be maintained at temperatures about 50°F until concrete is placed around
the bars. The temperature protection equipment, the curing water and the
removal of forms shall be handled and applied so that ambient and concrete
surface temperatures, as indicated by suitable thermometers installed
outside of the concrete and two inches inside the surface of the concrete,
may be determined by direct observation. All thermometers shall be
furnished by the Contractor. There will be no additional reimbursement
made to the Contractor for costs incurred for placing concrete during cold
weather.
D.
_-
Pumping Concrete: Equipment: Pump size shall be based on rate of concrete
placement, length of delivery pipe or hose, aggregate size, mix proportions, vertical
lift and slump of concrete.
Minimum inside diameter of pipe or hose shall be based on the maximum aggregate
size as follows:
3/4-inch maximum aggregate
1 %-inch maximum aggregate
2-inches minimum ID
4-inches minimum ID
Aluminum pipes shall not be used for delivery of concrete to the forms.
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Pumping: Before pumping is started, the delivery pipe or hose shall be primed by
pumping mortar through the line using five gallons of mortar for each 50-feet of
delivery line.
-
E. Construction Joints: Construction joints shall be made only where shown on the
Plans, unless otherwise permitted by the Owner's Representative. In case of
emergency, construction joints shall be placed as directed by the Owner's
Representative. After the pour has been completed to the construction joint and the
concrete has hardened, the entire surface of the joint shall be thoroughly cleaned of
surface laitance, loose or defective concrete and foreign material. Clean aggregate
shall be exposed by sandblasting the surface of construction joints before the new
concrete is placed. Except when otherwise shown on the Plans, after the surfaces
have been prepared to the satisfaction of the Owner's Representative, all horizontal
construction joints shall be covered with a layer of mortar approximatelytwo inches in
thickness and shall be spread uniformly and worked thoroughly into all irregularities of
the surface. The mortar shall have the same proportions of cement and sand as the
regular concrete mixture. The water-cement ratio of the mortar in place shall not
exceed that of the concrete to be placed upon it and the consistency of the mortar
shall be suitable for placing and working.
Where indicated on the Plans, expansion joints shall be provided with continuous
edge reservoirs which shall be filled with a joint sealant. The material used for
forming the reservoirs shall be left in place until immediately before the grooves are
cleaned and filled with joint sealant. After removing edge forms from the reservoir, all
grout, loose concrete, and fins shall be removed after which the slots shall be
sandblasted. The reservoirs shall be allowed to become thoroughly dry, after which
they shall be blown out and immediately thereafter, they shall be primed and filled
with the expansion joint sealant and back-up materials. The primer used shall be
supplied by the same manufacturer supplying the joint sealant.
-.
Construction joints shall be keyed, unless otherwise detailed. Keyways shall be
formed by beveled strips or boards placed at right angles to the direction of shear.
Except where otherwise shown on the Plans or specified, keyways shall be at least
1%-inches in depth over at least 25% of the area of the section.
When it is necessary to make a joint because of an emergency, reinforcing steel shall
be furnished and placed across the joint as directed by the Owner's Representative.
Furnishing and placing such reinforcing steel shall be at the Contractor's expense.
F. Embedded Items: Anchor bolts and all other embedded items shall be set accurately
and held securely in position in the forms until the concrete is placed and set. All
special castings, channels, or other metal parts that are to be embedded in the
concrete shall be approved prior to and again after installation. All nailing blocks,
plugs, strips, etc., necessary for the attachment of trim, finish and similar work, shall
be approved prior to installation by the Contractor.
Aluminum surfaces to be embedded or which are in contact with concrete shall,
before installation, be given one coat of zinc chromate primer in accordance with
4
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03300 Concrete Construction - 10 of 18
United States Joint Army-Navy Specification JAN-P-735 or the equivalent. The paint
shall be allowed to dry before the aluminum is placed in contact with the concrete.
Submerged aluminum surfaces in contact with concrete or masonry shall receive one
heavy coat of alkali-resistant bituminous paint in accordance with U.S. Military
Specification MIL-P-6883. The paint shall be applied as it is received from the
manufacturer without addition of any thinner.
G. Curing: All concrete shall be cured for not less than 14 days after placing, in
accordance with the methods specified herein for the different parts of the Work and
described in detail in the following paragraphs:
Surface to be Cured Method
Unstripped wooden forms 1
Vertical and horizontal construction joints
and walls
Surfaces requiring architectural finish or
which are to be plastered or tiled or upon
which concrete topping is to be placed
All concrete surfaces not specifically
provided for elsewhere in this subsection
Method 1 :
Method 2:
Method 3:
Method 4:
City of Carlsbad
03/04 (DBE)
2
3
4
Wooden forms shall be wetted immediately after concrete has been
placed and shall be kept wet with water until removed. The exposed
concrete surfaces shall then be cured by Method 2, 3 or 4.
The surface shall be covered with burlap mats which shall be kept wet
with water for the duration of the curing period.
The surface shall be kept wet with water for the duration of the curing
period. This shall be accomplished by keeping the forms wet prior to
stripping and by means of an approved combination of fog nozzlers,
soaker-type hoses, handsprinkling, and burlap or other types of mats.
No curing compound may be applied to surfaces cured under Method 3.
The surface shall be sprayed with a liquid curing compound which will
not affect the bond of paint to the concrete surface. It shall be applied in
accordance with the manufacturer's instructions at a maximum coverage
rate of 300-square feet per gallon in such a manner as to cover the
surface with a uniform film which will seal thoroughly. The exterior
surfaces of buried portions of partially buried walls shall be given two
additional coats of curing compound at the specified coverage rate,
making three coats in all.
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03300 Concrete Construction - 1 1 of 18
Surfaces which are to receive Method 4 curing shall be reviewed prior to placement
with respect to anticipated weather conditions and placement procedures, whereby
Method 3 curing may be required as directed by the Owner's Representative.
-
Where the curing compound method is used, care shall be exercised to avoid
damage to the seal during the curing period. Should the seal be damaged or broken
before the expiration of the curing period, the damaged portions shall be repaired
immediately by the application of additional curing compound.
Whenever curing compound may have been applied to surfaces against which
concrete subsequently is to be placed and to which it is to adhere, the curing
compound shall be entirely removed by sandblasting prior to the placing of new
concrete.
Where curing compound is specified, it shall be applied immediately after completion
of the finish on unformed surfaces and within two hours after removal of forms on
formed surfaces. Repairs required to be made to formed surfaces shall be made
within the said two hour period; provided, however, that any such repairs which
cannot be made within the said two hour period shall be delayed until after Method 3
has been applied. When repairs are to be made to an area on which curing
compound has been applied, the area shall first be sandblasted to remove the curing
compound, after which repairs shall be made as specified hereinafter.
H. Installation of Pipelines Through Concrete -
1. Pipes in Place: whenever a pipeline of any material terminates at the surface or
continues through a structural wall, slab, or sump, the Contractor shall, where
possible, install in advance of placing concrete the fitting or special casting
required for the particular installation. Welding of wall flanges to reinforcing steel
shall not be permitted and shall be cause for rejection.
2. Formed Openings: Whenever any run of pipe is installed subsequent to
placement of concrete, the Contractor shall accurately position the required
opening in the concrete for such pipelines. Openings shall be of sufficient size to
permit final alignment of pipelines and fittings without deflection or offsets of any
kind and to allow adequate space for satisfactory packing where pipe passes
through the wall to ensure water tightness around openings so formed. The
boxes or cores shall be provided with continuous keyways to hold the filling
material in place, and they shall have a slight flare to facilitate grouting and the
escape of entrained air during grouting. Formed openings shall be provided with
reinforcement as indicated on the Plans.
3. Non-shrink Grout: Non-shrink grout shall be Master builders "MASTERFLO" 71 3
grout or approved equal. Grout shall not contain any ferrous materials.
- Before placing the grout, concrete surfaces shall be abrasive cleaned and shall
be coated with an epoxy bonding compound.
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03300 Concrete Construction - 12 of 1 8
I.
.-
4. Placing of Grout: The pipe, castings, or conduits, as specified, shall be grouted
in place by pouring in grout under a head of at least four inches. The grout shall
be poured or rammed into place to fill completely the space between the pipes,
castings, or conduits and the sides of the openings so as to obtain water
tightness through the wall itself. The grouted area shall then be water cured.
Surface Finishes: Concrete surface finishes shall be in accordance with the concrete
finish schedule indicated below:
CONCRETE FINISH SCHEDULE
Finish Area
F- 1
F-2
F-3
Exterior walls below grade not exposed to water.
Exterior and interior walls exposed to water.
Walls of structures or buildings exposed to view.
Underside of formed floors or slabs.
Slabs and floors to be covered with concrete.
Slabs and floors not water bearing.
Slabs and floors which are water bearing.
Slabs and floors of structures or buildings exposed
to view (includes sidewalks).
Exposed edges of slabs, floors, and wall tops.
s- 1
s-2
s-3
s-4
E- 1
The following finishes shall be used for vertical concrete surfaces and for underside
of formed slabs:
Finish F-1 :
Finish F-2:
Finish F-3:
,-
City of Carlsbad
03/04 (DBE)
No special treatment other than repair of defective concrete and filling
depressions deeper than 1/2-inch and filling tie holes.
Repair of defective concrete, removal of fins, filling depressions 1/4-inch
or deeper and filling tie holes. Finish 2 shall be a preparation finish for
surfaces receiving Finish 3.
Upon completion of Finish F-2, fill all depressions and air holes with
mortar. Predampen surfaces and then spread a slurry consisting of one
part cement (including an appropriate quantity of white cement) and 1-
1/2 parts sand passing the No. 16 sieve, by damp loose volume, over
the surface with clean burlap pads or sponge rubber floats. Any surplus
shall be removed by scraping and then rubbing with clean burlap (sack
finish).
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03300 Concrete Construction - 13 of 18
After proper and adequate vibration and tamping, the following finishes shall be used
for horizontal concrete surfaces:
Finish S-1 Screeded to grade and left without special finish.
Finish S-2 Smooth steel trowel finish.
Finish S-3 Steel trowel finish free from trowel marks. The finish shall be smooth
and free of all irregularities. (Note shall be made where moving
mechanical equipment is located).
Finish S-4 Steel trowel finish without local depressions or high points and shall be
given a light hair-broom finish. Stiff bristle brooms or brushes shall not
be used. Brooming shall be parallel to slab drainage.
Finish E-1 : Exposed edges of all slabs, floors and tops of walls shall be edged with
a 1/4-inch radius edger or chamfered as shown on the Plans.
Edges shall include any line where placement is stopped. All wall and slab surfaces
at edges shall be protected against concrete spatter and shall be thoroughly cleaned
upon completion of each placement or adjacent placement of concrete.
3.2 Form Construction Requirements
A. All forms shall be true in every respect to the required shape and size, shall conform
to the established alignment and grades, and shall be of sufficient strength and
rigidity to maintain their position and shape under the loads and operations incident
to placing and vibrating the concrete.
B. Suitable and effective means shall be provided on all forms for holding adjacent
edges and ends of panels and sections tightly together and in accurate alignment so
as to prevent the formation of ridges, fins, offsets, or similar surface defects in the
finished concrete. The forms shall be tight in order to prevent the loss of mortar and
fines during placing and vibration of the concrete.
C. Cleanout and inspection openings shall be provided at the bottom of each lift of
forms. The size, number, and location of such openings is subject to the approval of
the Owner's Representative.
D. Exterior corners in concrete members shall be provided with 3/4-inch chambers.
Re-entrant corners in concrete members shall not have fillets, unless otherwise
shown on the Plans. Adequate and suitable means shall be provided for removing all
forms without injury to the surface of the finished concrete.
E. A sufficient number of forms shall be provided to permit a reasonable and
coordinated rate of progress to be maintained. If, in the opinion of the Owner's
Representative, additional forms are required to maintain the necessary progress,
such additional forms shall be provided.
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03300 Concrete Construction - 14 of 18
F. Where metal rod ties extending through the concrete are used to support or to
strengthen forms, the rod ties shall remain embedded and shall terminate not less
than one inch back from the formed face or faces of the concrete. The maximum
diameter of removable cones for rod ties shall not exceed one inch, and all such
fasteners shall be such as to leave holes of conical shape for reaming and patching.
Wire ties for holding forms will not be permitted. No form-tying device or part thereof
or other than metal shall be left embedded in the concrete, nor shall any be removed
in such a manner as to leave a hole extending entirely through the concrete member.
The use of form or form-tying methods which cause spalling of the concrete upon
form stripping or tie removal will not be permitted. Form ties shall be provided with
integral waterstops. All vertical surfaces of concrete members shall be formed,
except where the placement of the concrete against the ground is called for on the Plans or explicitly authorized by the Owner's Representative. The dimensions of
concrete members shown on the Plans apply to formed surfaces, except where
otherwise indicated, and not less than one inch of concrete shall be added where
concrete is permitted to be placed against trimmed undisturbed ground in lieu of
forms. Such permission will be granted only for members of comparatively limited
height and where the character of the ground is such that it can be trimmed to the
required lines and will stand securely without caving or sloughing.
G.
c
Forms shall be maintained at all times in good condition, particularly as to size,
shape, strength, rigidity, tightness, and smoothness of surface. Forms, when in
place, shall conform to the established alignment and grades. Before concrete is
placed, the forms shall be thoroughly cleaned. The surfaces of all Class I forms shall
be treated with a bond breaker as specified hereinbefore. Class II forms shall be
treated with a non-staining mineral oil or other lubricant approved by the Owner's
Representative. Any excess lubricant shall be satisfactorily removed before placing
the concrete. In addition, all plywood not treated with the bond breaker specified
above, shall be given a preliminary oil treatment by the form manufacturer or shall be
oiled by the Contractor at least two weeks in advance of its use as forms. Care shall
be exercised to keep form oil off the surface of steel reinforcement and other metal
items to be embedded in concrete.
H. Forms may be reused if they are in good condition and if approved by the Owner's
Representative. In determining the extent to which forms may be reused, particular
attention shall be given to maintaining a uniform surface texture on all exposed
concrete surfaces. Light sanding between uses will be required wherever necessary,
in the opinion of the Owner's Representative, to obtain such uniform texture. Unused
tie rod holes shall be plugged with corks, shaved flush, and sandpapered on the
concrete surface side. Patching of forms other than filling tie rod holes will not be
permitted, except in the case of Class II forms. The use of metal patching discs on
Class I forms will not be permitted.
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3.3 Reinforcinrr (Non-Prestressed) -
A. Placing: Reinforcement steel shall be accurately positioned in accordance with the
Plans and secured by using annealed wire ties or suitable clips at intersections and
shall be supported by concrete or metal supports, spacers or metal hangers. Metal
clips or supports shall not be placed in contact with the forms. Tie wires shall be bent
away from the forms in order to provide the specified concrete coverage. Bars,
additional to those shown on the Plans, which may be found necessary or desirable
by the Contractor for the purpose of securing reinforcement in position, shall be
furnished and installed by the Contractor at his own expense. All reinforcement shall
be placed a minimum of 2-inches clear of any metal pipe or fittings.
Reinforcing dowels, where required or ordered, shall be set in place prior to placing
concrete; they shall not be pressed into the concrete after the concrete has been
placed.
Wire mesh used for reinforcement shall be rolled flat before placing concrete and
shall be supported and tied to prevent movement during concrete placement. Dowels
for masonry walls shall be accurately positioned to occur at reinforced block cells.
The Owner's Representative shall approve all dowel locations prior to placing of any
concrete.
B. Splices: When it is necessary to splice reinforcement at points other than shown on
the Plans, the splice shall be 36 bar diameters. Unless otherwise shown, splices in
horizontal bars shall be staggered with splices 36 bar diameters with 18-inches
minimum. Laps of wire mesh shall be one width of wire spacing, and adjoining
sheets shall be securely tied together with No. 14 tie wire, one tie for each two
running feet. Wires shall be staggered and tied in such a manner that they cannot
slip.
.-
3.4 Repair of Defective Concrete
A. General: As soon as forms are removed, all surfaces shall be carefully examined
and all rough sections, rock pockets, and defective areas shall be removed and
replaced.
The material used for repair purposes shall consist of a cement mortar composed of
one part cement well mixed with three parts sand by volume and only enough water
so that the mortar will ball together when molded by slight pressure of the hands.
The mortar shall be thoroughly compacted into place. Sand shall pass a No. 16
sieve.
Defective surfaces to be repaired shall be cut back from true line a minimum depth of
one inch over the entire area. Feathered edges shall be avoided. All surface laitance
or soft material, and not less than 1/32-inch depth of the surface film from all sound
concrete, shall be removed by means of an efficient sandblast. -_
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03300 Concrete Construction - 16 of 1 8
.-
E-
Dry-pack mortar shall be placed and packed in layers having a compacted thickness
of 3/8-inch. Surfaces of each layer shall be scratched to promote bonding of next
layer.
Before the mortar is applied, the surfaces of the sandblasted concrete shall be
coated with an epoxy bonding compound.
Major defective area repairs are defined as follows:
1. Areas of more than one foot square and deeper than the reinforcing steel.
2. Major repair areas shall be filled with pneumatically-applied concrete after
surfaces have been sandblasted.
For major repairs, the filling shall be reinforced and doweled securely to the old
concrete. The exposed surface shall be neatly finished to match the surface and
texture of the adjacent concrete. All patches shall be cured by Method 2.
Holes left by tie-rod cones shall be reamed with suitable toothed reamers so as to
leave the surfaces of the holes clean and rough. These holes then shall be repaired
in an approved manner with mortar and epoxy and cured in accordance with the
requirements of the curing section of the Specifications. Other imperfections having
a depth greater than their least surface dimension shall not be reamed, but shall be
repaired in an approved manner with epoxy bonding compound and dry packed
mortar.
All repairs shall be built up and shaped in such a manner that the completed surface
will conform to the finish requirements of this specification using approved methods
which will not disturb the bond or cause sagging or horizontal fractures. Surfaces of
said repairs shall receive the same kind and amount of curing treatment as required
for the concrete in the unrepaired section.
B. Cracks in Hydraulic Structures: Concrete cracks greater than 1/64-inch in width shall
be repaired by cutting out a square edge joint 1/2-inch wide by one inch deep,
preparing all exposed surfaces of the joint, installing a back-up rod, priming of the
joint and application of the polyurethane joint sealant in accordance with the joint
sealant section of this specification.
Alternate methods of crack repair used by the Contractor which utilize epoxy
adhesive injection methods shall be subject to the approval of the Owner's
Representative.
Full height vertical cracks and full width horizontal cracks greater than the above-
specified width shall be assumed to occur and the Contractor shall make allowance in
his bid for the repair of specified cracks.
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03300 Concrete Construction - 17 of 18
3.5 Enforcement of Concrete Strength Requirements
A. Compressive Strength: Compressive strength shall be determined at the end of
seven days and 28 days on standard six by 12-inch test cylinders in accordance with
ASTM C39. The compressive strength shall not be less than 3,000 psi for Type A
concrete and 2,000 psi for Type C concrete at 28 days.
-
B. Concrete Cylinders: The Owner's Representative will take three concrete cylinders
for each 50 cubic yards of concrete and each day's pour. The Contractor shall
furnish the concrete and cylinders for such tests. Cylinders will be cured under job
conditions. Slump tests will be in accordance with ASTM C143.
C. Cylinder Tests: If any cylinders fail to meet the strength requirements for the portion
of the structure in which the concrete is used, core tests will be taken at the
Contractor's expense to demonstrate the adequacy of the concrete in place.
If both core tests and cylinder tests fail to meet the Specifications, the concrete shall
be considered defective and shall be replaced or adequately strengthened in a
manner satisfactory to the Engineer.
END OF SECTION
-..
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03300 Concrete Construction - 18 of 18
SECTION 09870
TAPE WRAP AND CONCRETE MORTAR COATING _-
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. Shop Drawings Submittals: 01 300
8. Earthwork: 02200
C. Painting and Coating: 09900
D. c Petrolatum Wax Tape Coating: 09902
E. Cement Mortar Lined Steel Pipe: 15076
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
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.
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09870 - Tape Wrap and Concrete Mortar Coating - 1 of 9
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.
PART 2 - MATERIALS
2.1
2.2
2.3
2.4
Polvethvlene Tape Coatinq
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
primed 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.
3.
Plant cold-applied tape for special sections, connections and fittings, and
plant repairs of cold-applied tape
Field joint, field coated fittings and repair of field cold-applied tape.
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 #lo39 primer.
Storage Primer
A. Storage primer on the exposed steel at the tape cutbacks shall be Polyken
#924.
Plant Applied Polyethvlene Tape System, Polyken YGlll (80 mil)
A.
B.
Liquid adhesive shall be Polyken #lo39 primer.
Anti-corrosion inner layer tape shall be Polyken #989 (20 mil), black.
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03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09870 - Tape Wrap and Concrete Mortar Coating - 2 of 9
C.
D.
First mechanical outer layer tape shall be Polyken #955 (30 mil), gray.
Second mechanical outer layer tape shall be Polyken #956 (30 mil), white.
c
E. Reinforced cement mortar shield 3/4" thick.
F. Weld Stripping Tape shall be Polyken #933 (25 mil), if required.
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 #lo39 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 Polvethvlene
.- Tape
A. Primer shall be Polyken #1029.
B. Joint filler tape to be Polyken #939.
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 Polvethylene 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.
c 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.
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ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09870 - Tape Wrap and Concrete Mortar Coating - 3 of 9
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)
B. Perform the entire coating operation at a single facility/manufacturer operation
by experienced workers skilled in the application of polyethylene tapes and
cement mortar coating under qualified supervisors. Do not allow additional
offsite handling following initial set-up of pipe sections from applications of
primer to mortar coating.
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.
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.
^4 D.
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
6, Commercial Blast Cleaning.
achieve a prepared surface equal to that which is specified in SSPC SP- -
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09870 - Tape Wrap and Concrete Mortar Coating - 4 of 9
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 .O mil, but not exceeding 3.0 mils. Measure the anchor pattern or profile
of the blasted surface using comparator tape as specified herein.
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 blasted 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.
c 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 reprimed.
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.
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H. Inner layer tape application:
City of Carlsbad
03/04 (DBE)
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.
2. The application of tension shall be such that the width of tape will be
reduced between 1% 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 6,000 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.
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09870 - Tape Wrap and Concrete Mortar Coating - 6 of 9
I. Mechanical outer layer tape application.
1.
2.
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.
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 3/4" thick in accordance
with Section 15076, paragraph 2.9.
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.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09870 -Tape Wrap and Concrete Mortar Coating - 7 of 9
Fittinqs 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 l-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.
3.4 Tape Application to Fittings. Specials and Pipe Joints (Field)
.-_ A. Filler tape shall be used to fill voids on fittings, specials, welds, and pipe joints.
B. All bell and spigot joints, lap joints, and other locations where voids will
otherwise exist shall be provided specially shaped filler tape applied after
priming.
C. Field pipe joints shall be prepared as required by the paragraph entitled "Pipe
Surface Preparation," except that shop blasted surfaces that have been coated
with a storage primer or an epoxy coating may be power-tool cleaned instead of
abrasive-blast cleaned. The power tool cleaning shall be done in accordance
with SSPC-SP2: Pipe ends not effectively protected with a storage primer shall
be abrasive blasted to SSPC-SP6.
D. The tape system for pipe joints is shown in Section 2.6.
3.5 Inspection of Tape Coating
Perform all tape coating work in accordance with AWWA C209 Section 5.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09870 - Tape Wrap and Concrete Mortar Coating - 8 of 9
3.6 Protectinq Coated Pipe
IC
A. The CONTRACTOR shall protect all coated surfaces from damage prior to and
during the pipe installation in accordance with these specifications.
€3. 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
.-
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09870 - Tape Wrap and Concrete Mortar Coating - 9 of 9
SECTION 09900
PAINTING AND COATING
PART1 - 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 section(s) for additional requirements:
A. Shop Drawing Submittals: 01300 B. Testing and Inspection: 01410
1.3 Submittals
Contractor shall furnish submittals in accordance with the requirements of Section 01 300, 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.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09900 - Painting and Coating - 1 of 10
C. Submit certification that all coatings conform to applicable local Air Quality
Management District rules and regulations for products and application.
-
1.4 Pavment
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
A.
B.
C.
D.
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
E. I. DuPont de Nemours & Company, Los
Tnemec Company, Inc., Kansas City, MO, Angeles, CA
641 41
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.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09900 - Painting and Coating - 2 of 10
2.2 Valves
IC
A.
c
B.
C.
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.
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.
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.
2.
3.
4.
Apply powdered thermosetting epoxy per the manufacturer's application
recommendations to a thickness of 10 to 12 mils.
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.
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.
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.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09900 - Painting and Coating - 3 of 10
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.
.---
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 Submerned
A.
B.
C.
D.
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.
Surface Preparation: All metal surfaces shall be field sandblasted according to
SSPC-SP-10 (near white blast cleaning).
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.
.-4
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.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09900 - Painting and Coating - 4 of 10
.~
- 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
H. 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).
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 32-1 21 5 Tneme-Grip or
Sinclair 7113 Wash Primer applied at 0 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)
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09900 - Painting and Coating - 5 of 10
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 Devtar 221 (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
General
A. The Contractor shall arrange with the Owner's Representative in accordance with
Section 01410, Testing and Inspection, so that all surface preparation may be
inspected and approved prior to the application of any coatings.
B. 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.
Workmanship
A.
B.
C.
D.
It is the intent of the Specifications 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 over all 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.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic 8, Recycled Water Transmission Mains
09900 - Painting and Coating - 6 of 10
,-
c
E. 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.
F. 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 surfaces Pipe interior* Brass and copper tubing, Metal letters Shafts
submerged* Mortar-coated pipe and fittings Stainless steel
Buried pipe 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.
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 9O"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 50°F or expected
to drop below 50°F within 24 hours.
c.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09900 - Painting and Coating - 7 of 10
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 A1 59.1) 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.
3.5 Procedures for the Application of Coatinas
A. 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.
-4
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic 8t Recycled Water Transmission Mains
09900 - Painting and Coating - 8 of 10
.-
_..-
3.6
B. 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.
C. 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.
D. 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 prior to and in conjunction with the spray coat application. Apply the spray coat
over the brush coat.
E. 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.
1. 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.
2. 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 14pounds per gallon. Coating shall be of the converted epoxy, epoxy
phenolic, or urethane type and shall be manufactured by the prime coat and
finish coat manufacturer.
3. 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.
Dry-Film Thickness Testinn 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. --
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09900 - Painting and Coating - 9 of 10
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
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09900 - Painting and Coating - 10 of 10
.-
SECTION 09902
PETROLATUM WAX TAPE COATING
PART1 - 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 plans and specified herein.
1.2 Submittals During Construction
Submit manufacturer's technical product data, details, installation instructions and general
product recommendations in accordance with the requirements of Section 01 300.
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.
.c
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
Flash Point 350" F minimum
Approximate Coverage
Color Brown
1 gal/lOO square feet
rc The primer shall be Trenton Wax-Tape Primer or equivalent.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09902 - Petrolatum Wax Tape Coating - 1 of 3
2.3 WaxTape
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
Thickness 70-90 mils
Dielectric Strength 170 volts/mil
Tape Width 6 inches
Saturant Pour Point 115" - 125°F
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
Thickness
Dielectric Strength
Water Absorption
Color
6 inches
1.5 mils
2000 volts/mil
Neg I ig i ble
Clear
The outer covering shall be Trenton Poly-Ply or approved equal.
2.5 Other Petrolatum Wax Tape Svstem 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.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09902 - Petrolatum Wax Tape Coating - 2 of 3
PART 3 - EXECUTION
cl
3.1 General
The petrolatum wax tape system shall be installed in conformance with the manufacturer’s
recommendations and as shown or specified by these Contract Documents.
END OF SECTION
/--
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
09902 - Petrolatum Wax Tape Coating - 3 of 3
SECTION 13120
CATHODIC PROTECTION BY SACRIFICIAL ANODES ‘-
PART 1 - GENERAL
1.1 Scope Of Work
This section describes all materials and installation requirements to install cathodic protection
and corrosion monitoring facilities on the City of Carlsbad, 30-inch and 24-inch El Camino
Real Potable Water Transmission pipeline. The materials include sacrificial anodes, test
stations, wiring, insulating flange kits can continuity bonds. The Work also includes all
personnel, equipment, labor and incidental materials to install, activate and test these
facilities.
1.2 References
The publications listed below form a part of this specification to the extent referenced. The
publications are referred to in the text by the basic designations only.
ASTM 83-90
ASTM B8-86
ASTM C94-81
ASTM D1248
ASTM D2220
AWWA C217-90
MIL-C-18480A
(Military Specs)
NACE RPOl69-96
NACE RP0286-97
NACE RP0375-94
Soft of Annealed Copper Wire
Concentric-Lay-Stranded Copper Conductors
Ready-Mix Concrete
Polyethylene Plastics Molding and Extrusion Materials
PVC Insulation for Wire and Cable, 75’ C Operation
Cold-Applied Petrolatum Tape and Petroleum Wax Tape
Coatings for the Exterior of Special Sections, Connections,
and Fittings for Buried Steel Water Pipelines
Coating Compound, Bituminous, Solvent, Coal Tar Base
Recommended Practice “Control of External Corrosion on
Underground or Submerged Metallic Piping Systems”.
Electrical Isolation of Cathodically Protected Pipelines
Wax Coating Systems For Underground Piping Systems
UL 83-80Thermoplastic-Insulated Wires
UL 486-76 Wire Connectors and Soldering Lugs for Use with Copper
Conductors
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03/04 (DEC)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 20-Cathodic Protection - 1 of 14
1.3 Definitions
I
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:
contact between the OWNER and the CONTRACTOR.
The OWNER'S representative who is assigned to be the direct
D. INSPECTOR: The OWNER'S representative designated to have project inspection
responsibilities.
E. CORROSION ENGINEER: The individual, accepted by the OWNER but retained
by the CONTRACTOR, who is trained, experienced and qualified in the installation
and testing of cathodic protection systems for buried pipelines.
1.4 Related Work Described Elsewhere
A. Shop Drawing Submittals: 01 300
B. Petrolatum Wax Tape Coating: 09902
C. 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 magnesium anodes
2. Bare magnesium anodes
3. At-grade test boxes
4. Shunts
5. Split-bolt connectors
6. Brass tags
7. Wire and cable
8. Insulating flange kit
9. Wax tape wrap
10. Alumino-thermic weld kit
11. Weld caps and primer
12. Bitumen coating
13. Warning tape
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03/04 (DEC)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 20-Cathodic Protection - 2 of 14
c
B.
C.
D.
Qualifications: Qualifications of the CORROSION ENGINEER retained by the
CONTRACTOR for cathodic protection installation supervision and testing
purposes. The CORROSION ENGINEER shall be experienced with buried water
line cathodic protection and either be a registered professional corrosion engineer
in the State of California or a NACE International certified Cathodic Protection
Specialist.
Test Results:
1. Insulator tests
2. Continuity tests
3. Anode testing and cathodic protection performance
As-built Drawinqs: 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.
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.
I
2.1 Maqnesium Anodes
A. Backfill Method: Either pre-packaged or bare magnesium anodes can be used.
Single anodes shall be pre-packaged ingots in a permeable cloth bag in special
backfill. Clustered anodes can either be bare ingots backfilled with a slurry of
special backfill or pre-packaged ingots.
B. 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.
..--
C. 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 0.002 percent (max)
Other 0.05 percent each (rnax)
Magnesium Balance
and 0.3 percent total (max)
City Of Carlsbad 03/04 (DEC)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 2Mathodic Protection - 3 of 14
D. Open Circuit Potential: The open circuit potential of all anodes shall be between
1.65 and 1.75 volts DC versus a copper-copper sulfate reference electrode.
__
E. Ingot Size and Weight: Anodes shall be 48-pound magnesium ingots with a
trapezoidal cross section. Ingot size shall be 32 inches long.
F. 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.
2.2 Special Backfill for Pre-Packaqed or Slurrv Backfilled Anodes:
A. Composition: Low resistivity backfill mix for pre-packaged and clustered (slurry)
anodes:
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.
-
B. Pre-Packaged Backfill: Dry powder contained in a permeable cloth bag suitable
for direct burial. See soaking requirements in Section 3.0
C. Clustered Anode Backfill: Backfill\water mixture or slurry.
2.3 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.
---c 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.
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ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 20-Cathodic Protection - 4 of 14
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 26 inch by
4-inch thick reinforced concrete pad constructed of ASTM C94 Ready-Mix
concrete.
2.4 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 83 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.
2.4 Insulating Flange Kit
.c
A. Gasket. ANSI B-16.21, full faced, Type “E” phenolic material with rectangular
nitrile or Viton O-ring seal for operation between 20°F and 150°F. Gaskets shall
be 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 LI-1 G10 for operation between 2OoF and 15OoF. 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 LI-
1 G10 for operation between 2OoF and 1 5OoF.
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. All buried pipe and fitting surfaces such as valves, flanges,
couplings, adapters, insulating flanges, etc., that are not tape and mortar coated
shall be wrapped with a petrolatum wax tape coating in accordance these
specifications.
B. Standard: Wax tape materials shall be per this specification section, AWWA
C-217 and Specification Section 09902.
C. Primer. All surfaces shall be prime coated with a blend of petrolatum, plasticizer,
inert fillers, and corrosion inhibitor having a paste-like consistency.
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03/04 (DEC) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 2Mathodic Protection - 5 of 14
D. 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 s u rfaces .
-_
E. Plastic Wrap. The primed and wax-tape wrapped fitting shall have an outer
plastic tape covering or wrap consisting of 1.5 mil polyvinylidene chloride or
metallocene resin material. The tape shall have high dielectric strength, be
stretchable and be able to conform well to irregular shapes. The outer covering
shall be Trenton Poly-Ply, Denso Poly-wrap or equivalent.
2.6 Alumino-Thermic Welds
A.
6.
C.
D.
E.
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.
Weld Mold: Welds on horizontal surfaces are illustrated in the drawings. A
special mold is required for attaching welds to vertical or sloped surfaces.
Primer: Weld cap primer shall be an elastomer-resin based corrosion resistant
primer for underground services such as Royston Roybond Primer 747 or
equivalent.
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.
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 Warninq 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.
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03/04 (DEC) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 ILO-Cathodic Protection - 6 of 14
PART 3 - EXECUTION -
Corrosion protection installations shall conform to NACE Publication RPO169-92
Recommended Practice, "Control of External Corrosion on Underground or Submerged
Metallic Piping Systems". The installation of corrosion protection facilities shall be
supervised by the CORROSION ENGINEER.
3.1 Sacrificial Anodes
_-
c.
A.
B.
C.
D.
E.
F.
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. Loose or broken anode lead wire-to-anode connections
shall require complete replacement of the anode and lead wire assembly.
Location: Anodes are to be installed in augured holes placed off of the pipe the
distance shown in the drawings. Anode positions shall be as close to the pipe
stations indicated in the drawings; however they can be adjusted to facilitate
installation or to avoid interference with existing structures. Alternate anode
positions greater than 20 feet from the station specified must be approved by the
ENGINEER. The CONTRACTOR must identify final locations of all anodes on
the as-built drawings.
Offset From Pipe: Anode holes shall be offset from pipeline by 10 feet where
possible. If the desired offset places the anode close to a metallic pipeline
always place the anode between the protected pipe and the nearby pipe even if
the offset from the protected pipe is less than 10 feet. The anode shall be no
closer than 2 feet to the nearby pipe.
Handling: Care shall be taken to ensure that anodes are never lifted, supported,
transported, or handled by the lead wire. All anodes shall be lowered into the
hole using a sling or a rope.
Anode Depth: Anode hole depth shall be 12 feet. If rock in encountered when
auguring anode holes, the ENGINEER shall be consulted for direction.
Prepackaged Anodes: Single, pre-packaged anodes are installed at alternate
anode sites.
1. Packaged Anode Inspection: Each pre-packaged anode 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. Anode
ingots shall be centered within a permeable cloth bag. If the prepackaged anodes are supplied in a waterproof container or covering, that container or
covering shall be removed before installation.
2. Pre-Soaking Requirements: All prepackaged anodes shall be completely
submerged in water for 30 minutes before being placed in the hole. Once in
the 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.
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03/04 (DEC)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 20-Cathodic Protection - 7 of 14
G.
H.
I.
3. Soil Backfill: 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 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.
-
Bare (Clustered) Anodes: At clustered anode sites two bare anode ingots shall
be installed side-by-side as shown in the drawings.
1. Anode Pairs: Bare anodes can be touching in the hole. Note: Contractor
may opt to install two prepackaged anodes in the same manner to eliminate
the need for slurry; however, the hole must be large enough to allow the
prepackaged anodes to be placed vertically, side-by-side in the hole.
2. Slurry Backfill: Mix special backfill with minimum water such that the backfill
is the consistency of white glue, motor oil or syrup. Add enough water so
that the mixture can be poured. Pour the backfill such that the ingots are
covered over approximately 6 inches. Tamp with a long rod so that there are
no pockets or voids in the slurry.
3. Anode Bottom: Do not let the bottom of the anode touch the soil. Provide a
non-metallic cradle or stand-off such that the backfill completely encases the
anode ingots.
Anode Hole Backfill: After the anodes have soaked in the hole or covered with
slurry, or hole is backfilled with native trench spoil (not sand) with all stones over
1/2-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.
-
Anode Connection in Test Box: Shunts shall be attached to the cathode (pipe)
lead wires with split-bolt connectors as shown in the drawings; however, the
anode lead shall be left unconnected in the test box. The split-bolt for connecting
the anode lead to the shunt shall be securely attached to the shunt for connection
to the anode when the cathodic protection system is activated.
3.2 At-Grade Test Stations
A. Locations: At-grade corrosion monitoring test boxes shall be located just behind
the curb or pavement at the side of the road. Wire runs shall be jetted under the
pavement or trenched as directed by the Engineer. Contractor must be careful not
to damage existing utilities.
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 which may be used to protect the test wires during construction shall
be removed. -4
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131 20-Cathodic Protection - 8 of 14
_.-
-
3.3
C.
D.
E.
F.
G.
Test Wire Connections: Test leads shall be attached to the pipe or casing using
the alumino-thermic weld process as shown in the drawings. A single 18-inch
slack wire coil shall be placed at each weld.
Brass Tag Markings and Attachment: Brass 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.
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 18 inches of slack coiled inside
the test box.
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.
Concrete Pad: A 26 inch square by 4 inch thick reinforced 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.
lnsulatinq Flange Kit
A.
6.
C.
D.
Standard: Insulators shall be installed and tested in accordance with this
specification and NACE RP0286-97 Electrical Isolation of Cathodically Protected
Pipelines.
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.
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. If possible,
smaller flanges shall be pre-installed and tested above grade.
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.
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131 20-Cathodic Protection - 9 of 14
E. Alignment: Alignment pins shall be used to properly align the flange and gasket.
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.
'1
3.4
G. 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.
Wax Tape Wrap
A. Critical Installation Requirements. Wax tape primer, filler or wrap shall
completely fill all irregular surfaces and be applied 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
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. I
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131 20-Cathodic Protection - 10 of 14
PART 4 - TESTING AND INSPECTION
Y 4.1
4.2
.-
4.3
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 ohmmeter 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.
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.
Pipeline Continuitv
A.
B.
C.
Testing Requirement: Pipe reaches along which all joints are welded do not
require continuity testing. All reaches that contain one or more bonded joints or
one or more mechanical joints, such as a valve, flanges or in-line appurtenances,
shall be tested for continuity.
Responsibility: The CONTRACTOR shall measure the linear resistance of
sections of pipe that require continuity testing. All testing shall be done by the
CORROSION ENGINEER in the presence of the ENGINEER at his or her
discretion.
Method: Resistance shall be measured by the linear resistance method. A direct
current shall be impressed from one end of the test section to the other (test
station to test station) using DC power supply (battery). A voltage drop is
measured for several current levels. The resistance (R) is calculated using the
equation R = dV/I, where dV is the voltage drop and I is the current. The
resistance shall be calculated for three or four different current levels.
City Of Carlsbad
03/04 (DEC)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 2Mathodic Protection - 1 1 of 14
D. Acceptance: Acceptance is reasonable comparison of the measured resistance
with the calculated or theoretical resistance. The measured resistance shall not
exceed the theoretical resistance by more than 130%. The CONTRACTOR shall
submit calculations of the theoretical resistance and the measured value of
resistance for each section of pipe tested.
__
E. Deficiencies: If discontinuities or high resistance joints are found, it is the
CONTRACTOR’S responsibility to locate, excavate, and repair all bonds that are
found to be discontinuous. Continuity tests shall be repeated after repairs are
made.
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
CORROSION ENGINEER shall test each installed anode for wire connection
integrity and for open-circuit potential after the anodes are installed.
B. Notification for Testing: The CONTRACTOR shall notify the ENGINEER at least
five days in advance of anode installation and five days in advance of activation
and testing by the CORROSION ENGINEER. At his or her discretion, the anode
installation shall be witnessed by the ENGINEER or INSPECTOR.
Cathodic Protection Performance Test Method: The performance of the cathodic
protection system will be tested by the 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 at points at least 100 feet
away from the test station (anodes) to verify that the pipeline is fully protected.
Adequate protection shall be as defined in NACE RPO169.
-
C.
D. Test Report: The CORROSION ENGINEER shall immediately report all system
deficiencies to the ENGINEER. Upon completion of the testing, the CORROSION
ENGINEER shall submit a report to the ENGINEER 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.
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. The CONTRACTOR is not
responsible for the performance of the system if the proper materials are used
and installed correctly.
City Of Carlsbad
03/04 (DEC) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains 13120-Cathodic Protection - 12 of 14
4.5 lnsulatinq Flanqe Kits
c- A. Responsibilitv: Insulators shall be tested and certified by the Corrosion Engineer.
Testing shall be done in the presence of the Engineer and the Owner at their
discretion.
6. Test Method: The assembled flange shall be tested with an insulator testing
device (Le., Gas Electronics Model 601 Insulation Checker) specifically designed
for this purpose. Additional testing shall include measurement of pipe-to-soil
potentials, using a copper-copper sulfate reference electrode, with contacts made
to either side of the insulator.
C. Notification for Inspection: The Contractor shall notify the ENGINEER at least
five days in advance of the testing of insulator installations.
D. Acceptance: The installation shall be considered complete when the testing
device indicates that no shorts or partial shorts are present and the potentials on
either side of the insulator differ by at least 20 millivolts. 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:
ENG IN EER or INSPECTOR.
All wax tape coating applications shall be inspected by the
6. 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 insure protection of the wax tape.
E. Acceptance: Conformance with this specification section
City Of Carlsbad
03/04 (DEC) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains 131 20-Cathodic Protection - 13 of 14
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
18 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
03/04 (DEC) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
131 2Mathodic Protection - 14 of 14
SECTION 15000
GENERAL PIPING SYSTEM AND APPURTENANCES c
PART 1 - GENERAL
1.1 Description
This Section describes the requirements and procedures for piping systems (pressure pipe)
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), connections to
existing piping field touch up, grooved end or shoulder couplings, warninglidentification tape,
tracer wire, 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.
ANS181.1 -
ANSI 81.2 -
ASTM A 36/A 36M -
ASTM A 47lA 47M -
ASTM A 53 -
ASTM A 108 -
ASTM A 183 -
ASTM A 283lA 283M -
ASTM A 307 -
ASTM A 325lA 325M -
ASTM A 51 OIA 51 OM -
ASTM A 512 -
ASTM A 536 -
ASTM A 568/A 568M -
ASTM D 2000 -
ASTM F 593 -
ASTM F 594 -
AWWA C105 -
AWWA Clll -
AWWA C200 -
City of Carlsbad
03/04 (DBE)
Unified Inch Screw Threads
Gages and Gaging for Unified Inch Screw Threads
Standard Specification for Carbon Structural Steel
Standard Specification for Ferritic Malleable Iron Castings
Standard Specification for Pipe, Steel, Black and Hot-Dipped,
Zinc - Coated Welded and Seamless
Standard Specification for Steel Bars, Carbon, Cold Finished,
Standard Quality
Standard Specification for Carbon Steel Track Bolts and Nuts
Standard Specification for Low and Intermediate Tensile
Strength Carbon Steel Plates, Shapes and Bars
Standard Specification for Carbon Steel Bolts and Studs
Standard Specification for High-Strength Bolts for Structural
Steel Joints
Standard Specification for General Requirements for Wire
Rods and Course Round Wire, Carbon Steel
Standard Specification for Cold-Drawn 8uttweld Carbon Steel
Mechanical Tubing
Standard Specification for Ductile Iron Castings
Standard Specification for Steel, Sheet and Strip, Carbon,
Hot-Rolled, Structural Quality and Cold Rolled
Standard Classification System for Rubber Products in
Automotive Applications
Specifications for Stainless Steel 8olts, Hex Cap Screws, and
Studs
Specification for Stainless Steel Nuts
Polyethylene Encasement for Ductile-Iron Pipe Systems
Rubber Gasket Joints for Ductile-Iron Pressure Pipe and
Fittings
Steel Water Pipe -150 mm (6") and Larger
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 1 of 10
AWWA C203 -
AWWA C213 -
AWWA C606 -
AWWA C900 -
AWWA M11 -
AWWA -
Coal- Tar Protective Coatings and Linings for Steel Water
Pipelines - Enamel and Tape -Hot Applied
Fusion-Bonded Epoxy Coating for Interior and Exterior of
Steel Water Pipelines
Grooved and Shouldered Joints
PVC Pressure Pipe, 100 mm (4") Through 300 mm (12") for
Water Distribution
Steel Pipe -A Guide for Design and Installation
Guidelines for Distribution of Non-potable Water
A.
California Administrative Code, Title 22
NSF - National Sanitation Foundation
SSPWC - Standard Specifications for Public Works Construction
("Green book")
1.3 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.
1.4 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. The contractor shall provide a submittal to the District showing pipe layout, tie-in
details, materials, sizing and flow calculations, schedule and duration of use for each
segment, and disinfection for all high line piping prior to ordering materials. The submittal
shall be reviewed by the District Engineer prior to ordering or delivery of any materials.
1.5 Pipe Tappinq
All pipe tap (wet tap) connections to existing pressure pipelines, whether for mainline
extensions, temporary lines or service laterals, shall be incorporated into the design plans
only upon written authorization by the District. The Contractor shall provide materials and
labor to excavate, pour thrust block, backfill, compact, and repair pavement as indicated in
this Section. In some cases the contractor may perform the wet tap, only with prior approval
of the District.
1.6 Warninn/ldentification Tape
Warninghdentification tape shall be used to identify location of underground utilities and to
act as a warning against accidental dig-ins of buried utilities. Warninghdentification tape shall
be used on all underground water and recycled water mains, casings, force mains, sewer
mains, and all related appurtenances. Warninghdentification tape shall also be used on
cathodic protection wiring systems and tracer wire brought into and out of access ports.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 2 of 10
1.7 Curb Identification
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.
B.
C.
Potable water laterals shall be stamped with a letter "W".
Recycled water laterals shall be stamped with a letter "RW".
Sewer laterals to be stamped with a letter "S".
PART 2 - MATERIALS
2.1 Temporary Aboveground Pipe (Highline)
High line piping layout, materials and appurtenances shall be as indicated on the final
submittal from the shop drawing review process and shall comply with the Approved
Materials List.
2.2 Grooved End Or Shouldered Couplings For Ductile Iron Or Steel Pipe
Grooved end or shouldered couplings shall be in accordance with the Approved Materials
List and as described below:
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.
ZI
B. Bolts in exposed service shall conform to ASTM A 183, 69 MPa (10,000 psi)
tensile strength.
2.3 Warninn/ldentification Tape
Warningidentification tape shall be as indicated below and in accordance with the Approved
Materials List.
A. Tape shall consist of one layer of aluminum foil laminated between two colored
layers of inert plastic film (non-metallic) formulated for prolonged underground
use that will not degrade when exposed to alkalies, acids and other destructive
substances commonly found in soil. The lamination bond should be strong
enough that the layers cannot be separated by hand.
B. Tape shall be puncture-resistant and shall have an elongation of two times its
original length before tearing or separating.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 3 of 10
C. Tape shall bear a continuous, printed message every 16- to 36- inches warning
of the installation buried below. Tape shall be colored to identify the type of
utility intended for identification. Printed message and tape color shall be as
follows:
-
Printed Messaqe Tape Color
Caution: Waterline Buried Below Blue
Caution: Recycled Waterline Buried Below Purple
Caution: Sewerline Buried Below Green
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.
D. Tape shall be minimum 5 mil thick x 6" wide with a printed message on one
side.
2.4 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. -
PART 3 - EXECUTION
3.1 Temporary Aboveground Pipe (Highline)
A.
B.
C.
D.
E.
City of Carlsbad
03/04 (DBE)
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, under District
observation.
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.
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.
Valves shall be installed at 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.
The Contractor shall be responsible for disinfecting all high line, connections, -
flushing, and assisting the District in taking water samples for bacteriological
testing in accordance with Section 15040.
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 4 of 10
_-
3.2
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.
Connections To Existinq Facilities
The Contractor shall furnish the tee, valves and all other materials as called for in the
Standard Specifications and plan details in accordance with the Approved Materials List for
cut-in installations (and wet taps, where permitted). The Contractor shall provide all
equipment and labor required for the excavation and installation of the connection including
but not limited to thrust blocks, backfill and pavement replacement. The Contractor shall
provide the labor for service change-overs and connections to existing facilities under District
observation. Emergency standby equipment or materials may be required of the Contractor
by the District.
r_ Cut-in tee (or wet tap, where permitted) 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 02225 for protection of existing
facilities. Contractor shall record the following information on as-built drawings:
1.
2.
3.
4.
5.
6.
7.
Pipe size, outside diameter and circumference.
Pipe material such as PVC, Ductile-Iron, Steel or ACP.
Pipe class and/or pressure rating.
Elevation and horizontal position (coordinates).
Location of collars, pipe bells, fittings or couplings, within five feet of
proposed tie-in, if found.
Potential conflicts with existing utilities.
Location of system valves which may be required to shut down or
minimize flow to existing pipeline.
c
B. A plan shall be submitted to the District by the Contractor which details the
findings of the pothole activities and indicates specifically how the tie-in will be
made and what materials will be used. Additionally, the Contractor shall
indicate which system valves may need to be shut down during the construction
of the connection. This plan must be reviewed by District staff and
authorization given in writing to proceed.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 5 of 10
C. To facilitate the proposed connection and allow for slight adjustments in
alignment and thrust blocks for testing, the Contractor shall leave a minimum
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 10' if
conditions warrant, or if directed by the Engineer.
D. The new pipeline shall have successfully passed pressure testing and
disinfection and bacteriological testing in accordance with Section 15040 prior
to proceeding with the connection to the existing pipeline.
E. After the District Engineer has given approval to proceed with the connection,
the Contractor shall schedule with the District for the cut-in or wet tap
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 seven (7) working
days notice prior to any proposed excavation or shutdown of existing
mains or services. Scheduling shall be subject to approval by the District.
3. The District Engineer 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.
If progress in completing the connection within the time specified 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.
-
4. -
F. Contractor may proceed with excavation only when pothole has been
completed, materials have been approved and delivered, cut-in or wet tap
installation has been scheduled and a copy of the approved traffic control plan
has been supplied to the District Engineer.
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.
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 District Engineer.
The Contractor shall de-water existing mains where cut-in installations
are required in the presence of the Engineer and in accordance with
Section 15040 and 02200. The Contractor shall be prepared to deal with
leaking valves and water from those valves to complete the shutdown.
Contractor shall be responsible for any and all damage resulting from
unauthorized operation of existing District facilities.
2.
3.
Only District personnel are authorized to operate existing valves. The -
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 6 of 10
4. In areas where cut-ins are to be performed the Contractor shall line the
bottom of the trench with 12" to 18" of 3/4" rock and install a 12" to 16"
deep sump for dewatering the trench bottom.
The District shall perform the following work for cut-in and wet taps
installations:
a. 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.
b. Wet taps (when authorized): Disinfect and install the tapping saddle
and tapping valve and perform tapping operations.
After the District has performed cut-in or tapping operations, and the
District 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:
5.
6.
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 03300.
d. Completing all backfill and compaction of the trench in accordance
with Section 02200.
e. Repairing or replacing pavement as necessary in accordance with
agency of jurisdiction requirements.
c
3.3 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 recommendations for bolt torque using a properly
calibrated torque wrench.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 7 of 10
3.4 Warninghdentification Tape
I. Warninghdentification 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 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 24" for continuous coverage.
C. Tape shall be installed prior to placement of the Trench Zone Backfill.
3.5 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 indicated
below and in accordance with the Standard Drawings: -
A. Abandonment in place:
1.
2.
3.
4.
5.
6.
7.
8.
Existing pipe 4" and smaller shall have a short section of pipe removed
and pipe ends encased in concrete.
Existing pipe 6" through 14" shall be cut and plugged with concrete or as
indicated on plans.
Existing pipe 16" and larger shall be entirely filled by pressure-grouting
or by blown sand to a bulkhead as indicated on plans.
Existing pipe ends shall be filled with concrete in accordance with the
Standard Drawings.
All valves shall be turned to the closed position.
Gate wells shall be cut 24" below grade and filled with concrete or
removed and replaced with compacted backfill.
Water service corporation stops shall be closed. Meter boxes and curb
stops shall be removed.
Water services to be abandoned that are connected to pipelines that will
remain in service shall be abandoned in-place in accordance with the
Standard Drawings.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 8 of 10
.-
9. Sewer laterals shall be cut and plugged with concrete at the main as
directed by the District Engineer for the specific circumstance and
material type identified.
Sewer manholes 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 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.
10.
B. Removal by excavation:
1.
2.
Existing pipe and appurtenances shall be removed from the ground as
indicated on the Approved Plans or as directed by the District Engineer.
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 concurrence from the agency having disposal
jurisdiction with respect to disposal sites.
Backfill, compaction, and surface repair of all excavations for removal of
pipe and appurtenances shall be made in accordance with the Approved
Plans, Section 02200 of the Standard Specifications, and the Standard
Drawings.
4.
3.7 Salvaae
When the Contractor is required to remove existing pipe and appurtenances, or portions
thereof, from the ground, such materials 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.
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.
B.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15000 - General Piping System and Appurtenances - 9 of 10
3.8 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 above.
B. Existing service laterals or appurtenances shall be connected to new pipelines
as shown on the Approved Plans or as directed by the District Engineer in
accordance with the Standard Drawings.
END OF SECTION
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
1 5000 - General Piping System and Appurtenances - 10 of 10
,--
SECTION 15040
TEST1 NG, FLUSH1 NG AND DlSl N FECTlO N
PART 1 - GENERAL
1.1 Description
This section designates the requirements for field testing, flushing and disinfection of all water
mains intended for the conveyance of potable water or recycledheclaimed water under pressure.
Where the words "potable water" are used to describe a process, the Contractor shall assume
that process applies fully to recycled or reclaimed water mains. The Contractor shall furnish all
labor, materials (including water), tools, and equipment necessary to provide and complete field
testing, flushing and disinfection as specified. All pipelines shall be tested for watertightness by
subjecting each section to Hydrostatic Pressure and Leakage Tests in accordance with the
applicable requirements of AWWA C600 and the Carlsbad Rules and Regulations for
Construction of Potable Water Mains, except as modified herein.
It shall be the Contractor's sole responsibility to plan his construction activities to allow and
facilitate testing, flushing and disinfection of all sections of potable water lines. It shall be the
Contractor's sole responsibility to obtain any and all permits required to carry out the Work
specified herein.
.- 1.2 Related Work Described Elsewhere
The Contractor shall refer to the following Specification section(s) for additional requirements:
A. Shop Drawing Submittals: 01 300
B. Testing and Inspection: 01410
1.3 Submittals
Contractor shall furnish submittals in accordance with the requirements of Section 01 300, Shop
Drawing Submittals. The following submittals are required:
A. The Contractor shall submit a detailed plan showing how the Contractor intends to
test, flush and disinfect the pipeline and Dechlorinate the water from flushing, prior to
the submittal of Shop Drawings for the steel pipe.
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.
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03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15040 - Testing, Flushing and Disinfection - 1 of 5
PART 2 - MATERIALS
2.1 General
The Contractor shall furnish all labor, water, chemicals, and equipment necessary for completing
the disinfection process and for obtaining, transporting and testing samples as specified herein.
The use of chlorine solutions is anticipated as the active disinfecting agent. The Contractor shall
be solely responsible for the safe and proper handling of the chlorine compounds or other
hazardous chemicals utilized. Only chlorine from a hypochlorite solution or a gas-to-solution
injector will be allowed. Direct injection of chlorine gas is prohibited. Hypochlorite solutions must
be pre-mixed and fed to tanks or piping and not placed dry. Containers and equipment used in
sampling must be clean and free of contamination. Sampling bottles shall be furnished by the
testing lab and they will collect samples. All water mains above 12 inches in diameter shall
require the chlorine gas method applied by a certified chlorination company.
PART 3 - EXECUTION
3.1 General
Do not allow chlorinated water to remain in contact with the internal waterway ports of pumps,
valves, and sensor line assemblies for longer than is necessary.
3.2 Pressure Testing --.L
A. Procedure: After the pipe and all appurtenances have been laid and sufficiently
backfilled for required restraint, they shall be subjected to a four hour hydrostatic
pressure test. This test shall consist of applying to the pipeline a pressure of 50 psi in
excess of the designated working pressure specified by the class of pipe, unless
otherwise specified on the Plans or in the Specifications, at the point of test
application. For pipe sizes in excess of 16-inch diameter, they 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 50 psi. in excess of the working pressure. Pressure
shall be maintained for an eight (8) hour duration and shall be re-pumped when it falls
to an amount of 5 p.s.i. Pressure tests or a retest shall be conducted subsequent to
any trench backfill compactive effort with heavy duty compacting equipment having
an overall weight in excess of 100 pounds.
Some hydraulic equipment such as buttetfly valves have a maximum working water
pressure less than the test pressure. The Contractor shall apply a minimum back
pressure on these closed devices equal to the difference between the test pressure
and the rated pressure of the device.
The test shall be made prior to connecting the new line with existing pipe and mains.
The test shall further be conducted with valves open, and the open ends of pipes,
valves, and fittings suitably closed. Valves shall be operated and checked prior to the
test period. No leakage shall be allowed when testing across any valves.
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03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15040 - Testing, Flushing and Disinfection - 2 of 5
.-
B.
C.
D.
E.
Maximum Length of Pipe: Maximum length of pipe to be included in any one test
shall be no more than 2,500-feet or the distance between valves, whichever is
greater. The Contractor shall provide suitable test bulkheads, blocking, and fittings to
permit such sectionalizing.
Preparation: The test shall be applied at an approved outlet or fitting located within
an elevation of 5-feet of the lowest point of the pipe section to be tested. The
Contractor shall provide and later securely plug such fittings. The line shall be filled
slowly and maintained at operating pressure for a period of at least 24 hours prior to
testing to satisfy any system water absorption. While filling and immediately prior to
testing, all air shall be expelled from the pipeline. Where air valves or other suitable
outlets are not available, approved taps and fittings shall be provided at all high
points and later securely plugged.
Pressure Testing: After the 24-hour soak period, the pressure in the pipeline shall be
pumped up to the specified test pressure. When the test pressure has been
reached, the pumping shall be discontinued until the pressure in the line has dropped
5-psi, at which time the pressure in the pipeline shall again be pumped up to the
specified test pressure. This procedure shall be repeated until eight hours have
elapsed from the time the specified test pressure was first applied. At the end of this
period, the pressure shall be pumped up to the specified test pressure for the last
time.
Leakage: Leakage shall be considered as the total quantity of water pumped into the
pipeline during the eight hour period, including the amount required in reaching the
specified test pressure for the final time. Leakage shall not exceed the rate as
specified for the type of pipe material being tested. If the leakage exceeds the rate,
as specified elsewhere, the Contractor shall, at his own expense, locate and make all
repairs as necessary until the leakage is within the specified allowance. Allowable
leakage for piping having threaded, brazed, welded, flange or mechanical joint shall
be zero.
The test shall be repeated until the leakage does not exceed the specified leakage
rate. All visible leaks shall be repaired regardless of the amount of leakage.
3.3 Flushinq
All potable water mains and services shall be flushed with potable water (or water as otherwise
approved by the Owner and regulatory agencies) after completion of construction and prior to
disinfection. The Contractor shall provide a sufficient number of suitable outlets at the end@) of
the line(s) being flushed in addition to those required by the Plans to permit the main to be
flushed with water at a velocity of at least 2.5-feet per second over its entire length. The outlets
provided shall meet the requirements for fittings as specified for the type of main constructed.
The velocity through outlets and fittings shall not exceed 25 fps during the flushing operation.
Drainage facilities shall be constructed such that the water lines cannot be contaminated through
,- the flushing outlet.
The Contractor shall be solely responsible for providing a source of water for flushing and the
methods for discharge of the water, including all associated costs and permits.
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15040 - Testing, Flushing and Disinfection - 3 of 5
3.4 ,-.
A. Procedure: After pressure testing and prior to acceptance of the Work, the entire
pipeline, including all valves, fittings, hydrants, service laterals, and other
accessories, shall be disinfected in accordance with AWWA C651 and Carlsbad
Rules and Regulations for Construction of Potable Water Mains.
B. Disinfection - Potable Water Mains: After flushing, all mains and services shall be
disinfected with chlorine gas (as provided in Subsection 2.1) solution, which shall be
water mixed and introduced into the mains to produce a dosage of not less than 50
mg/l nor more than 100 mg/l in all sections of the pipeline and appurtenances.
Treated water shall be retained with system for a minimum period of 24-hours and
shall produce at the end of the retention period a chlorine residual of not less than 25
mg/l in all sections being disinfected. If the tests are not satisfactory, the Contractor
shall provide additional disinfection at his expense as required until all tests are to the
satisfaction of the Owner. During the disinfection process, all valves, hydrants, and
other accessories shall be operated. After chlorination, the water shall be flushed
from the line at its extremities until the replacement water tests are equal chemically
and bacteriologically to those of the permanent source of supply. The placing of HTH
capsules or powder in pipe sections during the laying process WILL NOT be
considered adequate disinfection, The Contractor shall keep adequate chlorine
residual testing and indicating apparatus available on the site during the entire
disinfection period. After final flushing, the flushing fittings shall be plugged with
devices intended for this purpose at the pressure class of the pipe. Where water
main is coated, plugs and outlets shall be similarly coated.
-.
C. Discharge of Chlorinated Water
1. Disposal or discharge to sewer systems, storm drains, drainage courses or
surface waters of chlorinated water is prohibited. All chlorinated water shall be
de-chlorinated prior to discharge.
2. The reducing agent for neutralization shall be applied to the water as it exits the
piping system. The Contractor shall monitor the chlorine residual during the
discharge operations. Total residual chlorine limits in these locations, and for the
discharge of de-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
4
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 Contractor will perform all
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15040 - Testing, Flushing and Disinfection - 4 of 5
necessary tests to ensure that the total residual chlorine effluent limitations listed
above are met.
4. If a suitable point of discharge can not be found for the de-chlorinated or the
neutralized water, the Contractor shall haul the flushed water to a site suitable for
discharge. The Contractor shall include all costs for the discharge of chlorinated
water into his bid.
5. In locations where no hazard to the environment is evident based on the joint
examination describe above, the de-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.
D. Bacteriologic Samples:
1. One sample of water for the specified bacteriologic test shall be taken from each
end of the disinfected main (located downstream of the point of introduction of
chlorine disinfectant). For mains over 2,500-feet in length, additional samples
shall be taken at intermediate points in such a manner that at least one
additional sample is taken for each 2,500-feet of main.
2. An independent, State-certified laboratory will petform bacteriological sampling
and testing of all new system installations. The testing methodology employed
by the laboratory shall be as set forth in "Standards 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
laboratory will analyze the samples for the presence of coliform bacteria and
heterotrophic-type bacteria (heterotrophic plate count). Proper chain of custody
procedures shall be followed in the handling of the water samples. The
evaluation criteria employed by the District for a passing test sample is as follow:
a. Coliform bacterial: no positive sample
b. Heterotrophic plate count (HPC): 500 colony forming units/ml or less.
E. Redisinfection
If the initial disinfection fails to produce satisfactory coliform bacteriological test results,
the pipeline system shall be re-chlorinated, flushed and re-sampled. If the initial test
result of the heterotrophic plate count is greater than 500 units/ml the system shall be re-
flushed and re-sampled. If the second set of samples does not produce satisfactory
results for the heterotrophic plate count, the pipeline system shall be re-chlorinated]
flushed, and re-sampled. The chlorination, flushing and sampling procedure shall
continue until satisfactory results are obtained. Re-disinfection and retesting shall be at
the Contractor's expense. --
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15040 - Testing, Flushing and Disinfection - 5 of 5
SECTION 15056
DUCTILE IRON PIPE AND FllTlNGS
PART 1 - GENERAL
1.1 Description
This section designates the requirements for the manufacture and installation of ductile iron pipe,
abbreviated DIP, to be furnished and installed by the Contractor at the location and to the lines
and grades shown on the Plans as herein specified.
1.2 Related Work Described Elsewhere
The Contractor shall refer to the following Specification section(s) for additional requirements:
A. Shop Drawing Submittals: 01300
B. Testing and Inspection: 01410
C. Earthwork: 02200
D. Concrete Construction: 03300
E. Painting and Coating: 09900
F. Testing, Flushing, and Disinfection: 15040
1.3 Submittals
The Contractor shall furnish submittals in accordance with Section 01 300, Shop Drawing
Submittals. 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:
Lay Diagrams and Schedule
Protective Coatings and Linings
Dimensional Checks
Pressure Ratings
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.
City of Carlsbad
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15056 - Ductile Iron Pipe and Fittings - 1 of 6
1.4 Pavment
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.
PART 2 - MATERIALS
2.1 Pipe
Ductile iron pipe and fittings shall be manufactured in accordance with ANSI 21.50,
AWWA C150 and ANSI 21 51, AWWA C151, and shall be of the sizes and thickness classes
shown on the Plans. Unless otherwise specified, size four inch (4") through six inch (6") DIP
shall be thickness Class 52, while size eight inch (8") and larger shall be thickness Class 50.
Unless otherwise specified, pressure class pipe may be substituted for thickness class pipe
according to the following schedule:
Pipe Diameter
Under 16-inch
16 to 18-inch
20 to 24-inch
30 to 36-inch
42 to 60-inch
Minimum Pressure Class
Not Allowed
250
300
250
200
2.2 Coatings
All pipe fittings shall be shop coated with one prime coat of asphaltic coating approximately I-mil
thick in accordance with ANSI A21.51 , AWWA C151. All pipe and fittings above ground or in
vaults shall be painted in accordance with Section 09900, Painting and Coatings.
2.3 Linings
Unless otherwise noted on the Plans or elsewhere in the Specifications, all pipe and fittings shall
be cement-mortar lined.
A. Cement-Mortar Lining: All pipe and fittings shall be double thickness cement-mortar
lined in accordance with ANSI A21.4 or AWWA C104. All cement shall be type II
unless otherwise specified.
a.
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03/04 (DBE)
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15056 - Ductile Iron Pipe and Fittings - 2 of 6
2.4 Joints And Accessories
Unless otherwise shown on the Plans, all joints shall be the push-on type joint. Joints and
accessories shall conform to the requirements and dimensions specified in ANSI A21.11,
AWWA Clll.
F
2.5 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 Section 03300, Concrete Construction. 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.
2.6 Restrained Joints
The restrained joints shall be a special push-on type joint unless otherwise specified that is
designed to provide longitudinal restraint in lieu of a concrete thrust block. Restrained joints are
required for fittings larger than 12-inch diameter with a deflection of 1 1 %io or greater and where
indicated on plans. The length of the restrained joints shown on the Plans is the minimum
required length. The Contractor shall select an approved restrained joint and then use it
exclusively for all of the Work. Restrained joints for push-on joint pipe installations shall be U.S.
Pipe "TR-FLEX" pipe or approved equal.
-
Restraint of field cut pipe shall be kept to a minimum. But when necessary, unless otherwise
specified, restraint of field cut pipe shall be provided by the use of U.S. Pipe's "TR-FLEX" pipe
field weldments, or approved equal.
2.7 Fittings
Fittings for ductile iron pipe shall be manufactured in accordance with ANSI A21 .lo,
AWWA C110 or C153. They shall be made of ductile iron and the letters "DI" or "DUCTILE" shall
be cast on them, unless otherwise specified. Fitting joints shall be in accordance with
ANSI A21.11, AWWA C1 1 1 , and shall be of the push-on type. Mechanical joint fittings will not
be permitted unless otherwise specified on the Plans.
2.8 Pipe Lenqths
Pipe lengths shall be as specified in ANSI A21.51, AWWA C151, except where shorter lengths
are required to fit horizontal and vertical alignment. Combined horizontal and vertical deflections
at any rubber gasket or flexible coupling joints shall not exceed eighty percent (80%) of the
maximum deflection recommended by the manufacturer.
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15056 - Ductile Iron Pipe and Fittings - 3 of 6
2.9 Flanqes
Flanges shall be ductile iron, Class 125, unless otherwise shown on the Plans, screwed-on type
in accordance with ANSI A21.15, AWWA C115, for pipe, and integrally cast for fittings in
accordance with ANSI A21.10, AWWA C110 and shall be flat face. Gaskets shall be 1/8-inch
thick minimum in accordance with AWWA C115 and shall have a minimum rated working
pressure equal to 350 psi at 180°F. Drop-in type gaskets with holes prepunched shall be used
where both flanges are flat face. Where adjoining flange is steel, the steel flange shall be flat
face.
2.1 0 Bolts and Nuts
Bolts and nuts shall be cadmium plated and shall conform to ASTM A307, Grade B. Washers
shall be provided for each nut and shall be the same material as each nut. All buried flanges,
bolts, and nuts shall be encased in wax tape per Section 09902.
All bolt threads shall be lubricated with non-oxide grease. Flange faces shall be wire brushed
and cleaned prior to joining each flange.
2.1 1 Warninq Tape
Use marking tape consisting of one layer of aluminum foil laminated between two colored layers
of inert plastic film. The lamination bond should be strong enough that the layers can not be
separated by hand. Tape shall be a minimum of 5 mils thick and 6 inches wide. Elongation shall
be a minimum of 600-percent. Tape shall bear a continuous, printed, message every 16 to 36
inches warning of the installation buried below. Tape shall be selected from the District's
Approved Materials List.
-
PART 3 - EXECUTION
3.1 General
Ductile iron pipe and fittings shall be assembled in accordance with the applicable sections of
AWWA C600, "Installation of Gray and Ductile Cast-Iron Water Mains and Appurtenances" and
as specified herein.
3.2 Transportation
Transportation shall be by competent haulers and accomplished in a manner that will avoid
damage to the pipe, its lining, or coating. The Contractor shall unload by mechanical means,
such as a crane or backhoe, or by rope and skids, as recommended by the manufacturer. In
using skids, pipes must be prevented from striking other pipe. No dropping of pipe from trucks
will be allowed.
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15056 - Ductile Iron Pipe and Fittings - 4 of 6
3.3 Earthwork
-c
Excavation and backfill, including the pipe bedding, shall conform to the provisions of Section
02200, Earthwork.
3.4 General Installation Procedures and Workmanship
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 location 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 within 3 inches horizontally and 1 inch
vertically of the lines and grades on the Plans. Fittings shall be supported independently of the
pipe.
Cutting and machining of the pipe shall be accomplished in accordance with the pipe
manufacturer's standard procedures for this operation and in accordance with AWWA C600.
Pipe shall not be cut with a cold chisel, standard iron pipe cutter, nor any other method that may
fracture the pipe or will produce ragged, uneven edges.
Pipe shall be carefully handled to prevent damage to the lining and coating. Cable, rope, or
other devices used for lowering fittings into the trench shall be attached around the exterior of
the fitting for handling. Under no circumstances shall the cable, rope, or other device be
attached through the fitting's interior for handling. --
No joint shall be backfilled until it has been observed by the Owner's Representative. Sufficient
trench space shall be left open in the vicinity of each joint to permit visual observation around the
entire periphery of the joint.
3.5 Plastic Film Wrap
To protect the pipe from corrosion, ductile-iron pipe and fittings buried underground shall be
protected with two plastic film wraps in accordance with ANSI A21.5 and AWWA C105. Each
wrap shall be a loose 8-mil thick polyethylene tube. All joints between plastic tubes shall be
wrapped with 2-inch wide polyethylene adhesive tape, Polyken 900, Scotchrap 50, or approved
equal. Installation of plastic film shall conform to AWWA C105. Unless otherwise specified,
plastic film wraps shall not be installed on sections of pipe which are to be concrete encased,
installed within casings, or through concrete slope anchors.
3.6 Warning Tape
After the pipe zone and the first 12 inches in the trench zone have been backfilled and
compacted, place the marking tape on the compacted backfill and center over the pipe. Run
tape continuously along the trench and tie ends of tape together. Wrap marking tape around
valve box extension pipes and continue along pipe.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15056 - Ductile Iron Pipe and Fittings - 5 of 6
3.7
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.
Preventing Foreign Matter from Entering the Pipe
1.
3.8 Damaqed Pipe or Fittings
Damaged pipe or fittings shall be removed upon discovery and without delay from the Project
Site.
3.9 Leakaqe Test
A. General
All pipelines shall be tested in accordance with Section 15040, Testing, Flushing and
Disinfection, and the applicable provisions of AWWA C600, except as modified
herein.
B. Allowable Leakage
No pipe installation will be accepted if the leakage is greater than that determined by
the following formula:
.--..
S D F7
133,200 L=
in which L =
S =
D =
P =
the allowable leakage, in gallons per hour
length of pipe tested, in feet
nominal diameter of the pipe, in inches
average observed test pressure of the pipe being tested, as is
shown on the Plans or specified in Section 0141 0, Testing and
Inspection, in pounds per square inch gauge, based on the
elevation of the lowest point in the line or section under test and
corrected to the elevation of the test gauge.
The test pressure shall be 50 psi in excess of the designated working pressure
specified for the class of pipe unless the test pressure is shown on the Plans or
specified elsewhere in the Specifications.
3.1 0 Disinfection
Disinfection shall be in accordance with Section 15040, Testing, Flushing and Disinfection. --
END OF SECTION
City of Carlsbad
03/04 (DBE)
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ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains 15056 - Ductile Iron Pipe and Fittings - 6 of 6
SECTION 15064
POLYVINYL CHLORIDE PRESSURE PIPE AND Fli'TlNGS (AWWA C900) -
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 for both
potable and recycled water.
Specifications for related Work are as follows:
AWWA C900 PVC Pressure Pipe
ANSI A21.10
AWWA C110
AWWA C153
AWWA Manual M23
Ductile Iron and Gray-Iron Fittings
Ductile Iron and Gray-Iron Fittings
Ductile Iron Compact Fittings
Pipe Design and Installation
1.2 Related Work Described Elsewhere
The Contractor shall refer to the following Specification section(s) for additional
.- requirements:
A. Shop Drawing Submittals: 01300
B. Testing and Inspection: 01 41 0
C. Earthwork: 02200
D. Concrete Construction: 03300
E. Testing, Flushing and Disinfection: 15040
1.3 Submittals
The Contractor shall furnish submittals in accordance with Section 01 300, Shop Drawing
Submittals. 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. c
B. Payment by the linear foot shall be for each diameter and for each pipe strength
designation measured horizontally over the pipe centerline.
City of Carlsbad
03/04 (DBE)
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15064 - PVC Pressure Pipe and Fittings (AWWA C900) - 1 of 5
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 4000 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 .I 0,
AWWA C110 or C153. All fittings shall be made of ductile iron and the letters "DI" 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 Service 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.
2.5 Warning Tape --L
Use marking tape consisting of one layer of aluminum foil laminated between two colored
layers of inert plastic film. The lamination bond should be strong enough that the layers can
City of Carlsbad
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15064 - PVC Pressure Pipe and Fittings (AWWA C900) - 2 of 5
not be separated by hand. Tape shall be a minimum of 5 mils thick and 6 inches wide.
Elongation shall be a minimum of 600-percent. Tape shall bear a continuous, printed,
message every 16 to 36 inches warning of the installation buried below.
-
For potable water, the tape shall be blue in color with the wording that indicates “Potable
Waterline Below” or other appropriate wording as approved by the District.
For Reclaimed/Recycled water application, the tape shall be the color purple with the wording
that indicates “Reclaimed Waterline below” or other appropriate wording as approved by the
Engineer or District. Tape shall be selected from the District’s Approved Materials List.
PART 3 - EXECUTION
3.1 Pipe Lenqths
Laying lengths shall be 20-feet with the manufacturer’s option to supply up to 15% random
(minimum length 1 O-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 for recycled water,
the pipe shall be purple in color. 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 Section
02200, Earthwork.
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.
-
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15064 - PVC Pressure Pipe and Fittings (AWWA C900) - 3 of 5
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.
3.5 Longitudinal Bendinq
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 Section 03300, Concrete Construction. 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 Preventinq Foreiqn Matter from Enterina the Pipe
--4 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
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15064 - PVC Pressure Pipe and Fittings (AWWA C900) - 4 of 5
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.
-
3.10 Leakaqe Test
A. General: All pipelines shall be tested in accordance with Section 15040, Testing,
Flushing and Disinfection, except as modified herein.
8. Allowable Leakage: The following table shall be used for allowable leakage for
C900 PVC Pressure Pipe:
Pipe size
(inches)
6
8”
1 0”
1 2”
AI Iowa b I e I ea kag e
gals/4hrs/lOOO’ of pipe
0.5
0.66
0.83
0.99
Unless otherwise specified on the Plans or in Section 01410, Testing and
Inspection, the test pressure shall be 75 psi in excess of the designated working
pressure specified for the class of pipe being tested.
/c 3.1 1 Disinfection
Disinfection shall be in accordance with Section 15040, Testing, Flushing and Disinfection.
END OF SECTION
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15064 - PVC Pressure Pipe and Fittings (AWWA C900) - 5 of 5
c-
SECTION 15066
POLYVINYL CHLORIDE WATER TRANSMISSION PIPE
AND FllTlNGS (AWWA C905)
PART 1 - GENERAL
1.1 Description
This section designates the requirements for the manufacture and installation of polyvinyl
chloride, abbreviated PVC, water transmission 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 C905
ANSI 21.10
AWWA C110
AWWA C153
AWWA Manual M23
PVC Water Transmission Pipe
Ductile Iron and Gray Iron Fittings
Ductile Iron and Gray Iron Fittings
Ductile Iron Compact Fittings
PVC Pipe Design and Installation
1.2 Related Work Described Elsewhere
- The Contractor shall refer to the following Specification section(s) for additional requirements:
A. Shop Drawing Submittals: 01300
B. Earthwork: 02200
C. Concrete Construction: 03300
D. Testing, Flushing and Disinfection: 15040
1.3 Submittals
The Contractor shall furnish submittals in accordance with Section 01 300, Shop Drawing
Submittals. 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 C905, the Plans and Specifications.
1.4 Pavment
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.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15066 - PVC Pressure Pipe and Fittings (AWWA C905) - 1 of 5
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 C905 Section 2.1 (Basic Materials), with an established
hydrostatic design basis (HDB) equal to or greater than 4000 psi for water at 73.4 degrees F
(230C). Elastomeric gaskets shall comply with the requirements of AWWA C905 Sections 2.1.3
(Elastomeric Gaskets) and 2.1.4 (Gaskets and Lubricants).
2.2 Pipe
PVC water transmission pipe, 14-inch through 30-inch, shall be manufactured in accordance with
AWWA C905, and shall be of the sizes and dimension ratios (DR) shown on the Plans. If a
pressure class is called for on the Plans, it shall mean the pressure rating (PR) as defined in
AWWA C905. The pipe shall have integral bell and spigot joints with elastomeric gaskets in
accordance with AWWA C905 Section 3 (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 18 or 25 or as shown on the drawings.
The pipe shall be manufactured by J.M. Manufacturing Company, Certainteed Corporation,
Pacific Western Extruded Plastics Company or approved equal.
2.3 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 C905
Section 4.7 (Marking Requirements).
For potable water applications, the pipe shall be white or blue in color and the seal of the testing
agency that verified the suitability of the material for potable water service shall be included.
For Recycled or Reclaimed water applications, the pipe shall be purple in color and contain the
markings of "Caution: Reclaimed Water - Do Not Drink - Peligro Aqua lmpura - No Beber" or
other appropriate markings as approved by the Engineer or District.
2.4 Fittinas
All fittings for PVC water transmission 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 "DI"
or "DUCTILE" shall be cast on them, unless otherwise specified. Bell size shall be for Class 165
and Class 235 cast-iron equivalent PVC water transmission pipe, including the rubber-ring
retaining groove.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15066 - PVC Pressure Pipe and Fittings (AWWA C905) - 2 of 5
2.5 Service Saddles
Service saddles for AWWA C905 PVC water transmission pipe shall not be allowed unless
specifically called for on the Plans.
,.-
2.6 Warning Tape
Use marking tape consisting of one layer of aluminum foil laminated between two colored layers
of inert plastic film. The lamination bond should be strong enough that the layers can not be
separated by hand. Tape shall be a minimum of 5 mils thick and 6 inches wide. Elongation shall
be a minimum of 600-percent. Tape shall bear a continuous, printed, message every 16 to 36
inches warning of the installation buried below.
For Reclaimed/Recycled water application, the tape shall be the color purple with the wording
that indicates "Reclaimed Waterline below" or other appropriate wording as approved by the
Engineer or District. Tape shall be selected from the District's Approved Materials List.
PART 3 - EXECUTION
3.1 Pipe Lengths
Laying lengths shall be 20-feet with the manufacturer's option to supply up to 15% random
(minimum length 1 0-feet) sections.
3.2 Earthwork rc-
Excavation and backfill, including the pipe bedding, shall conform to the provisions of Section
02200, Earthwork, and AWWA C905 Section A6 installation.
3.3 General Installations Procedures and Workmanship
PVC water transmission 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 within 3 inches horizontally and 1 inch
vertically of the lines and grades on the Plans. Fittings shall be supported independently of the
<+ pipe.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15066 - PVC Pressure Pipe and Fittings (AWWA C905) - 3 of 5
3.4 Lonqitudinal Bendinq
No longitudinal bending shall be allowed in the installation of PVC water transmission pipe. All
deflections shall be accomplished by the use of joints and fittings specifically designed for use
with PVC C905 pipe and the deflections as installed shall not exceed the manufacturers written
recommendations.
-.4
3.5 Pipe Joint Assemblv
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.
Combined horizontal and vertical deflections at PVC pipe joints shall not exceed that
recommended by AWWA Manual M23 or published recommendations of the manufacturer (the
maximum total deflection allowed shall be one and one-half degrees).
3.6 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 Section 03300, Concrete Construction. 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.
3.7 Mechanical Thrust Restraint
Mechanical thrust restraint devices which transfer forces from fittings to the PVC pipe wall shall
only be permitted where piping is greater than 12-inch diameter or where indicated on plans.
3.8 Warninq Tape
After the pipe zone and the first 12 inches in the trench zone have been backfilled and
compacted, place the marking tape on the compacted backfill and center over the pipe. Run
tape continuously along the trench and tie ends of tape together. Wrap marking tape around
valve box extension pipes and continue along pipe.
3.9 Preventinq Foreiqn Matter From Enterinq 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
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15066 - PVC Pressure Pipe and Fittings (AWWA C905) - 4 of 5
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.
3.10 Leakage Test
A. General: All pipelines shall be tested in accordance with the Section 15040, Testing,
Flushing and Disinfection, except as modified herein.
B. Allowable Leakage: No pipe installation will be accepted if the leakage is greater
than that determined by the following formula:
SDfi
148,000 L=
c
in which L = the allowable leakage, in gallons per hour
S = length of pipe tested, in feet
D = nominal diameter of the pipe, in inches
P = average observed test pressure of the pipe being tested as
shown on the Plans or specified in Section 0141 0, Testing and
Inspection, in pounds per square inch gauge, based on the
elevation of the lowest point in the line or section under test and
correction to the elevation of the test gauge.
Unless otherwise specified on the Plans or in Section 01410, Testing and
Inspection, the test pressure shall be 50 psi in excess of the designated working
pressure specified for the class of pipe being tested.
3.1 1 Disinfection
Disinfection shall be in accordance with Section 15040, Testing, Flushing and Disinfection.
END OF SECTION
/--
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15066 - PVC Pressure Pipe and Fittings (AWWA C905) - 5 of 5
SECTION 15076
CEMENT-MORTAR LINED AND COATED STEEL PIPE -
PART 1 - GENERAL
1.1 Description
This section designates the requirements for steel pipe fabrication, test in shop, installation of
steel pipe, fabrication of steel sheet or plate, mill-manufactured steel pipe, bends, special
pipes with outlets, pass holes, flanges and all other fittings. Steel pipe shall conform to the
following except as modified by this Specification:
AWWA C200 Steel Water Pipe 6-inches and larger
AWWA C205 Cement-mortar protective lining and coating
AWWA C207 Steel Pipe Flanges
AWWA C208 Dimensions for Fabricated Steel Water Pipe Fittings
AWWA C209 Cold Applied Tape Coating for the Exterior of Special Sections,
Connection and Fittings for Steel Water Pipelines
Standard Qualification Procedure for Manual Welding Operators
c-
AWS
ASME Boiler and Pressure Vessel Code
AWWA C214 Tape Coatings Systems for the Exterior of Steel Water Pipeline
1.2 Related Work Described Elsewhere
The Contractor shall refer to the following Specification section(s) for additional
requirements:
A. Shop Drawing Submittals: 01300
B. Testing and Inspection: 0141 0
C. Trenching, Backfilling and Compacting: 02223
D. Structural Steel and Miscellaneous Metalwork: 051 00
E. Tape Wrap and Mortar Coating: 09870
*-- F. Painting and Coating: 09900
G. Petrolatum Wax Tape Coating: 09902
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 1 of 10
H. Cathodic Protection: 131 20
I. General Piping Systems and Appurtenances: 15000
J. Testing, Flushing and Disinfection: 15040
K. Miscellaneous Couplings, Pipe and Appurtenances: 15092
1.3 Submittals
The Contractor shall furnish submittals in accordance with Section 01 300, Shop Drawing
Submittals. 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 Diagram and Schedule
Manufacturer's tests Protective Coatings
Mill Reports or Plant Test Reports
Dimensional Checks
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 horizontal alignment, and all data on curves and bends for
both horizontal and vertical alignment. Other items of information to be included
in Layout Diagram and Schedule are pipe outside diameter, wall thickness,
location of all welded seams, working pressure, locations of bulkheads for field
hydrostatic pressure testing, location of closure piece and their lengths, location of
all pipes and specials, location of valves and other mechanical equipment, limits
of field welded joints, locations and callouts for flanges, reinforcing collars,
wrapper plates and crotch plates. Details for joints, butt straps, couplings, flanges,
bulkheads and their method of attachment to the pipeline, linings and coatings
shall be provided with Layout Diagram and Schedule.
-
The Layout Diagram and Schedule shall be submitted with a separate statement
by the manufacturer certifying that the pipe as represented in the Layout Diagram
and Schedule is in accordance with these specifications as well as exterior weld
bead requirements the requirements of Section 09870, Part 3.2 D.
B. Submit data used by the Manufacturer in manufacture and quality control,
including but not limited to affidavit of complance with AWWA C200 and C205,
certificate that cement complies with ASTM C150, and wire fabric conformance to
ASTM Standards..
-"-
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 2 of 10
C. Test reports showing the physical properties of the rubber used in the gaskets
shall be submitted.
D. Procedure qualification records shall be submitted for each welder who will be
performing the field welding and copies of their welder qualification records.
1.4 Inspection and Field Verification
A. The District’s Representative or his authorized representative will inspect
materials, fabrication, and testing of pipes and specials at the manufacturer’s
plant.
B. Where new pipelines are to be connected to existing waterlines of the District, the
Contractor shall verify in the field the location, elevation, pipe material, pipe
outside diameter, and any other characteristics of the existing waterline before
proceeding with the pipe fabrication or installation. This field verification shall be
performed in the presence of the District’s Representative. Adjust and align the
new pipeline as necessary to meet the field conditions and provide all required
material, labor and equipment to make the connection.
1.5 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. _I
B. Payment by the linear foot shall be for each diameter and for each pipe strength
designation measured horizontally over the pipe centerline.
PART 2 - MATERIALS
2.1 Pipe Design Requirements
Pipe lining and coating shall be the product of one company in the business of designing and
manufacturing cement-mortar lined, tape wrapped and mortar coated steel pipe. Use of
subcontractors or subcontracts to apply the lining and coating of the steel pipe is not allowed.
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.
rc‘ 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
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic ti Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 3 of 10
satisfy transient conditions).
Specifications or, if none is stated, the amount of cover shall be scaled from the Plans.
Design soil cover shall be as stated on the Plans or
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 (0.1 345-inch).
t= MWhere P = Design pressure, in psi plus 50 psi minimum
2s S = Steel stress at design pressure, Le., 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 6, 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.
circumferential stress in the steel shall not exceed 16,500 psi at the design pressure.
Welds may be straight or spiral seam. The
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 A1 85, "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 Rinqs
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. __
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 4 of 10
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
I ayou t sc hed u le.
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.
2.9 Protective Coatings and Linings
All exposed metal surfaces shall be painted or coated as specified in Section 09900, Painting
and Coating, except where painting is specified elsewhere and in this section.
All steel pipe and fittings for underground service shall be cement-mortar lined, taped
wrapped and cement-mortar coated in accordance with AWWA C205 and C602 unless
otherwise specified on the Plans. Tape wrap shall be in accordance with Section 09870.
Linings shall be in accordance with the table below.
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
(inches) (inches) (inches) (inches) (inches)
4- 10 12-18
20 - 44
45 - 58 60 and over
City of Carlsbad
03/04 (DBE)
1 I4 - 1 /32+ 1 I32
318 -1 I1 6+1 I8
1 12 -1 I1 6+1 I8 314 -1 I1 6+1 I8
314 -1 I1 6+1 I8
1 12
518 314 1
1 114
+1 I8
+1 I8
+1 I8
+1 I8
+1 I8
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 5 of 10
2.1 0 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.
2.1 1 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. 1
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 (Inches) Minimum Centerline Radius
30 - 48
51 - 60
Over 60
2-112 times ID
1 0-feet
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:
Fittina Diameter Ranae (Inches)
18 and under
20 - 24
26 - 36
38 - 45
48 - 54
57 - 60
63 - 72
75 - 84
City of Carlsbad
03/04 (DBE)
Minimum Thickness of Sheet or Plate
10 gauge
311 6" or 7 gauge 114"
511 6
318"
711 6"
1/2"
518"
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 6 of 10
4
...-_ 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:
Pw x ID cvl. x ID outlet
T= 36,000 x W
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.
2.12 Insulating Flange Kits
See Section 131 20 of these specifications.
2.13 Handling and Shipment
ZL
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.
2.14 Warninq Tape
Use marking tape consisting of one layer of aluminum foil laminated between two colored
layers of inert plastic film. The lamination bond should be strong enough that the layers can
not be separated by hand. Tape shall be a minimum of 5 mills thick and 6 inches wide.
Elongation shall be a minimum of 600-percent. Tape shall bear a continuous, printed
message every 16 to 36 inches warning of the installation buried below.
For potable water applications, the tape shall be blue in color with the wording that indicates
"Potable Waterline below" or other appropriate wording as approved by the Engineer or
District.
For reclaimed/recycled water applications, the tape shall be the color purple with the wording
that indicates "Reclaimed Waterline below" or other appropriate wording as approved by the
Engineer or District. Tape shall be selected from the District's Approved Materials List.
c
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 7 of 10
PART 3 - EXECUTION -
3.1 Installation
A. Trench Preparation: Earthwork shall be carried out in accordance with Section
02200, Earthwork. Pipe laying shall be scheduled so that the bell end of the pipe
faces in the direction of laying. Pipe installation on slopes steeper than 20% shall
be laid in an uphill direction. 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. Suitable bell holes shall be excavated at each joint and a
shallow lateral depression shall be scooped out half a pipe length from the last
pipe laid to allow for easy removal of the belt pipe sling and thus avoid any
movement of the pipe after it is placed on proper line and grade.
B. Joints: All field joints shall be welded joints. The pipe should be picked up well
balanced, then lowered into the trench so that the spigot end may be entered into
the bell end of the last pipe laid. Metal or wooden spacers shall be placed
against the inside shoulder of the bell of 24-inch and larger pipe to provide the
proper space between abutting ends of the pipe.
For pipe sizes smaller than 24-inches, where joints have not been pre-fabricated,
butt straps shall be used at all joint, unless indicated otherwise on the plans. The
pipe interior shall be inspected by a closed circuit television camera, to assure
quality of internal mortar. -~
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.
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
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 8 of 10
"I
_-
allowed to set before applying water. In any case, joints shall be grouted before
backfill is placed over the top of the pipe.
C. 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
1%-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.
D. Welded Joints: Welded joints shall be completed after the pipe is in final position.
Welded joints shall be either a welded Carnegie joint or a lap-welded slip joint as
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. Welders assigned to the Work shall be qualified under
the AWS standard qualification procedure.
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 or beads in the completed weld shall
be as follows:
Steel Cylinder Thickness (Inches) Fillet Weld Minimum Number of Passes
Smaller than 311 6 1
311 6 and 114 2
511 6 3
318 3
After the joints have been welded, the joint shall be grouted with cement mortar in
the same manner as specified for rubber-ring joints.
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 9 of 10
3.2
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.
Preventing Foreiqn Matter from Entering the Pipe
&
3.3 Leakaae Test
A. General: All pipelines shall be tested in accordance with Section 15040, Testing,
Flushing and Disinfection, and the applicable provisions of AWWA C600, except
as modified herein.
B. Allowable Leakage: No leakage will be allowed for welded joints. The length of
pipe with welded joints will be deducted from the total length in computing the
allowable leakage. All visible leaks must be repaired regardless of the results of
the leakage allowance measurements.
3.4 Disinfection
Disinfection shall be in accordance with Section 15040, Testing, Flushing and Disinfection. --
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic 8, Recycled Water Transmission Mains
15076 - Cement-Mortar Lined and Coated Steel Pipe - 10 of 10
SECTION 15092
MISCELLANEOUS COUPLINGS, PIPE AND APPURTENANCES -
PART 1 - GENERAL
1.1 Description
All valves, couplings, and appurtenances shall conform to requirements of the standard
dimensions and pressure classification of the immediately adjacent pipe, valve or appurtenance
as specified.
1.2 Related Work Described Elsewhere
The Contractor shall refer to the following Specification section(s) for additional requirements:
A. Shop Drawing Submittals: 01300
B. Painting and Coating: 09900
C. Petrolatum Wax Tape Coating: 09902
1.3 Submittals
Contractor shall furnish submittals in accordance with the requirements of Section 01 300, Shop
Drawing Submittals. The following submittals are required:
A. Submit Shop Drawings for all miscellaneous couplings, pipe and appurtenances.
Shop Drawings shall include listing of materials of construction, with ASTM reference
and grade, including lining and paint coating intended for use, with lining and coating
manufacturers' and paint numbers listed.
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 Gaskets, Nuts, and Bolts
Gaskets for flanged joints shall be fullface, compressed non-asbestos composition sheet
packing, graphited on both sides, "drop-in" type, boltholes prepunched, conforming to the
requirements of ANSI B16.21, 1/8-inch thick and shall be as manufactured by Crane Co., Garlock or approved equal.
Bolts and studs shall be cadmium plated and shall conform to ASTM A307, Grade B, "Steel
Machine Bolts and Nuts and Tap Holes," when a ring gasket is used and shall conform to either
ASTM A261, "Heat-Treated Carbon Steel Bolting Material" or ASTM AI 93, "Alloy-Steel Bolting
Material for High Temperature Service," when a full-face gasket is used. Bolts and nuts shall be
heavy hexagon series. Nuts shall conform to ASTM A194, "Carbon and Alloy Steel Nuts for
Bolts for High Pressure and High Temperature Service" either in Grade 1, 2 or 2H. The fit shall
be ANSI B1 .l, "Unified Screw Threads," Class 2, except that Class 3 fit shall be used in holes
.t
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15092 - Miscellaneous Couplings, Pipe and Appurtenances - 1 of 2
tapped for studs. Threads may be made by either cutting or cold forming. Between 1/4-inch and
3/8-inch shall project through the nut when drawn tight. Washers shall be provided for each nut
and shall be the same material as each nut. All buried flanges, including bolts, nuts and
washers, shall be encased in wax tape per Section 09902.
__
All bolt threads shall be lubricated with non-oxide grease. Flanged faces shall be wire brushed
and cleaned prior to joining each flange.
2.2 Wax Tape Encasement
Unless otherwise specified on the Plans, all couplings and appurtenances for underground
installation shall be encased in wax tape per Section 09902.
2.3 Paintina and Coatinq
All miscellaneous couplings, pipe and appurtenances referenced in this section shall be painted
and coated, interior and exterior, in accordance with Section 09900, Painting and Coating.
2.4 Flexible Couplings
Joints for which flexible couplings are required, shall be made with Baker, Smith-Blair, or
approved equal, flexible couplings. Gaskets shall be plain rubber gaskets. Threads on bolts or
compression collars shall be lubricated with non-oxide grease before assembling the coupling.
For cast-iron, ductile-iron or asbestos cement pipe sizes 2-inches through 16-inches, use Baker
Series 228, Smith-Blair Series 41 3, or approved equal. -
Transition couplings shall be Baker Series 21 2, Smith-Blair Series 41 3, or approved equal.
Flanged coupling adapters for cast iron or ductile iron pipe sizes 3-inches through 12-inches
shall be Baker Series 601, Smith-Blair Series 912, or approved equal. Flanged coupling
adaptors for cast or ductile iron pipe greater than 12-inches shall be Baker Series 602 or Smith-
Blair Series 91 3.
Flanged coupling adapters for steel pipe sizes 3-inches through 24-inches shall be Baker Series
602, Smith-Blair Series 91 3, or approved equal.
2.5 Pipe Unions
Screw unions may be employed on pipelines 2-1/2-inches in diameter and smaller. Pipes and
fittings made of non-ferrous metals shall be isolated from ferrous metals by nylon insulating pipe
bushings, unions or couplings manufactured by Smith-Blair, Pipe Seal and Insulator Co. or
approved equal.
PART 3 - EXECUTION (Not Applicable)
City of Carlsbad
03/04 (DBE)
END OF SECTION
ECR (PAR to Cassia) Domestic 8, Recycled Water Transmission Mains
15092 - Miscellaneous Couplings, Pipe and Appurtenances - 2 of 2
SECTION 151 00
VALVES
PART 1 - GENERAL
1.1 Description
This section includes materials, testing, and installation of manually operated valves, check
valves, air and vacuum valves, air-release valves, and combination air-release valves.
1.2 Related Work Described Elsewhere
The Contractor shall refer to the following Specification section(s) for additional requirements:
A. Shop Drawing Submittals: 01300
B. Painting and Coating: 09900
C. Petrolatum Wax Tape Coating: 09902
D. Testing, Flushing and Disinfection: 15040
1.3 Submittals
Contractor shall furnish submittals in accordance with the requirements of Section 01 300, Shop
Drawing Submittals. The following submittals are required: c.
A. Submit Shop Drawings, manufacturer's catalog data and detail construction sheets
showing all valve parts and describing material of construction by material and
specification (such as AISI, ASTM, SAE, or CDA). Submittal shall include valve
dimensions including laying lengths, dimensions and orientation of valve operators,
as installed on the valves. Submittals shall also indicate valve linings and coatings
with manufacturer's and paint numbers listed.
B. For valves requiring certified tests, submit certified test results.
1.4 Pavment
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 valves shall be new and of current manufacture. Valves shall be furnished and installed by
the Contractor at the location and in accordance with the type of ends as shown on the Plans
and as herein specified.
Valves shall be provided with stem extension if depth of valve nut exceeds 5-feet. Valve
extensions shall be pinned to the valve operating nut.
-
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15100 -Valves - 1 of 6
The manufacturer shall have manufactured tight-closing valves of the valve type intended for use
for a period of at least five years.
The Contractor shall furnish and install each specific type of valve from a single manufacturer
and use it throughout the Work.
All valves shall have a rated working pressure of at least 150 psi. All valves shall be certified to
meet the test pressure as specified and shall have a rated working pressure that exceeds the full
working pressure specified.
-
A.
B.
C.
D.
Connections: Valves shall have flanged, hub, screwed, or special connector ends as
shown on the Plans. Where not indicated, the valves shall have the same type of
connection as the pipeline in which valves are to be installed and conform to the
Specifications.
Bolts, Nuts and Washers: Bolts, nuts and washers for aboveground and buried
installations shall be cadmium plated and shall conform to ASTM A307, Grade B,
"Steel Machine Bolts and Nuts and Tap Holes," when a ring gasket is used, bolts,
nuts, and washers shall conform to either ASTM A261, "Heat-Treated Carbon Steel
Bolting Material" or ASTM A1 93, "Alloy-Steel Bolting Material for High Temperature
Service". Bolts and nuts shall be heavy hexagon series. Nuts shall conform to
ASTM A194, "Carbon and Alloy Steel Nuts for Bolts for High Pressure and High
Temperature Service" either in Grade 1,2, or 2H. The fit shall be ANSI B1.l, "Unified
Screw Threads," Class 2, except that Class 3 fit shall be used in holes tapped for
studs. Threads may be made by either cutting or cold forming. Between 1/4-inch
and 3/8-inch shall project through the nut when drawn tight.
-.
Bolts, nuts and washers for underground installations including below ground
structures shall be type 316 stainless steel. All buried bolts shall be completely
coated with non-oxide grease, or approved equal.
All aboveground bolt threads shall be lubricated with graphite and oil. Flanged faces
shall be wire brushed and cleaned prior to joining each flange.
Polyethylene Encasement: Unless otherwise specified on the Plans, all valves for
underground installation shall be encased in two layers of 8 mil polyethylene wrap in
accordance with AWWA C105.
Painting and Coating: All valves referenced in this section shall be painted and
coated, interior and exterior, in accordance with Section 09900, Painting and Coating.
2.2 Combination Air Valves
Air and vacuum release valves shall be of the combination type. The combination unit shall
serve the function of allowing air to enter or exit the pipe to alleviate excess air or vacuum
conditions in the pipe. The inlet/outlet vent shall have a 20 mesh stainless steel screen secured
with stainless steel band. The tap for the valve shall be made in a level section of pipe no closer
-
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15100 -Valves - 2 of 6
than 18-inches to a bell, coupling, joint, or fitting. No tap shall be permitted in any machined - section of A.C.P.
The Buna-N seat must be fastened to the valve cover, without distortion, for drip-tight shutoff.
The floats shall be heavy stainless steel, hermetically sealed; designed to withstand 1,000 psi.
The top plug or float shall be center guided through hex bushings for positive shutoff.
All materials of construction shall be in writing to conform to ASTM Specifications as follows:
Body & Cover Cast Iron ASTM A126 GR.B
Float Stainless Steel ASTM A240
Needle & Seat Buna-N
Plug Bronze ASTM B1 24
Leverage Frame DeIrin/Cast Iron ASTM D2133/ASTM A1 26 GR.B
A. Approved Manufacturer and Model: Combination air valves shall be APCO Models
143C, 145C, 147C, 149C, 150C, ,151 C, or approved equal.
2.3 Butterflv Valves
All butterfly valves shall be of the tight-closing, rubber-seat type, with rubber seats which are
recess mounted and securely fastened to the valve body and in full compliance with
AWWA C504. Valves shall be bubble tight at rated pressures and shall be satisfactory for
applications involving valve operation after long periods of inactivity. Valve discs shall rotate 90
degrees from the full open position to the tight shut position. Valves shall meet the full structural
requirements of the applicable classes of AWWA C504.
Valve bodies shall be constructed of cast-iron ASTM A1 26, Class B unless otherwise specified
on the Plans. Flange drilling shall be in accordance with ANSI B 16.1 standard for cast-iron
flanges. Two trunnions for shaft bearings shall be integral with each valve body. Body thickness
shall be strictly in accordance with AWWA C504.
All valve discs shall be constructed of Ni-Resist Type I or high-strength cast iron in accordance
with ASTM A48, Class 40. All disc seating edges shall be smooth and polished.
Shafts of all valves shall be turned, ground, and polished. Valve shafts shall be constructed of
18-8, Type 304 stainless steel.
Valve seats shall be of a continuous natural rubber or a synthetic rubber compound mounted on
the body and a stainless steel seat mounted on the disc. Bonded-in seats must be
simultaneously molded-in, vulcanized, and bonded to the body and the seat bond must
withstand 75-pound pull under test pressure in accordance with ASTM D429, Method B, or seats
may be mechanically retained on the disc by 18-8 Type 304 fasteners. Valve seats on valves
24-inches and larger shall be field adjustable and replaceable without dismantling operator, disc,
or shaft and without removing the valve from the line. Valves employing a complete rubber liner
will not be acceptable in any size.
Each valve shall be provided with one or more thrust bearings in accordance with AWWA C504.
Thrust bearings which utilize a ferrous metal bearing surface in direct rubbing contact with an
opposing ferrous metal surface will not be acceptable.
@--
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15100 -Valves - 3 of 6
Valves shall be fitted with sleeve-type bearings. Bearings shall be corrosion resistant and
self-lubricating. Bearing load shall not exceed 2,500 psi.
-
The use of a stop or lug cast integrally with or mechanically secured to the body for the purpose
of limiting disc travel by means of direct contact or interference with the valve disc in either the
open or closed position will not be acceptable.
Valve operators shall be designed to hold the valve in any intermediate position between fully
opened and fully closed without creeping or fluttering.
For buried service operation, valve operators shall be of the enclosed gear or screwed rod type.
Valve shall open with a counterclockwise rotation of the operator.
A. Approved Manufacturer and Model: Butterfly valves shall be Henry Pratt Company
Groundhog for buried service, M & H Model 4500, or approved equal. Manual
operator shall be Pratt MDT or approved equal.
Ductile iron body butterfly valves shall be DeZurik BAW with M-Series handwheel
actuator or approved equal.
2.4
The flanges of valves shall be flat faced per AWWA C207-86. Flanges of valves designed for a
working pressure of 200 psi or less shall be faced and drilled to a 125-pound American Standard
dimension. Flanges of all valves designed for a working pressure of greater than 200 psi shall
be faced and drilled to 250-pound American Standard dimensions.
Gate Valves and Tapping Valves
.-_
Each valve body shall be tested under a test pressure equal to twice its design water working
pressure, in accordance with AWWA (2509-87.
All interior parts of valves manufactured of bronze or brass, except valve stems, shall conform to
the requirements of ASTM 862. Gate valve stems shall be Everdur 1012, NiVee, or Silnic,
having a minimum tensile strength of 70,000 psi, a yield strength of 40,000 psi, and elongation of
at least 15 percent in 2-inches. The stem is to be visibly marked so that it meets this
requirement .
All valves connecting to mains shall be flanged on the main side, unless otherwise specified.
A. Gate Valves: Gate valves shall conform to AWWA C509-87. Gate Valves shall be
designed for a water working pressure of 200 psi and shall be iron bodied, resilient
seated, non-rising stem opening to the left, and provided with O-ring stem seal, and a
2-inch square operating nut for buried service and handwheel for above ground
service. All interior parts of gate valves, not including valve stems, shall be
constructed of bronze conforming to the requirements of ASTM B62. After the valves
are assembled and tested, the manufacturer's name or symbol, the size of the valve,
the year of manufacture, and the working water pressure shall be cast in the bonnet
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15100 -Valves - 4 of 6
or body of the valve. Gate valves shall be furnished with ends as specified on the
Plans or by the Owner’s Representative. .-
B. Approved Manufacturer and Model: Gate valves shall be American Flow Control,
American AVK, or approved equal.
C. Tapping Valves and Sleeves: Tapping valves shall conform to and be tested in
accordance with AWWA C500 with the exception of the ends and the seat rings. The
valves shall be designed for 150 psi water working pressure, and shall be iron
bodied, bottom wedging, ABlP double-disc with parallel seats, opening to the left,
provided with a 2-inch square operating nut, non-rising stem, and O-ring stem seal.
The ends shall be flanged. The flange on one end shall have slotted bolt holes to fit
all standard tapping machines. Seat rings shall be oversized to permit the use of full-
size cutters. The cast-iron tapping sleeves may be provided with mechanical joints.
D. Approved Manufacturer and Model: The tapping valve and sleeve shall be Mueller
H-600 Series for AC pipe, Romac SST with stainless steel flange or Ford ‘Fast’ with
stainless steel flange. For PVC pipe, the tapping valve shall be American Flow
Control, American AVK, or approved equal.
2.5 Miscellaneous Valves
A. Corporation Stops: Corporation stops shall be manufactured of bronze conforming to
ASTM B62. Use Ford FB700, Jones J1929, Mueller B2505 or approved equal. The
inlet fitting shall be a male iron pipe thread when used with a saddle and the outlet
connection shall be a flare type unless otherwise specified.
B. Angle Valves: Angle valves shall be all brass valves of the sizes shown on the Plans
and shall be, FordBA23-444W, FV23-777W, Jones J1964W, J1973W, or Mueller B-
24255, or approved equal. 2” ball valves should not be used on manual air release or
blow-off applications.
PART 3 - EXECUTION
3.1 Installation
A. Flanges shall be cleaned by wire brushing before installing flanged valves. Flange
bolts and nuts shall be cleaned by wire brushing, and threads coated with non-oxide
grease after tightening nuts and bolts. Flange to be double wrapped with 8 MIL
polyethylene film. Nuts shall be tightened uniformly and progressively. If flanges leak
under pressure testing, nuts and bolts shall be loosened or removed, the gasket
reseated or replaced, the bolts and nuts reinstalled or retightened, and joints
retested. Joints shall be watertight.
B. Threaded joints shall be cleaned by wire brushing or swabbing. Teflon joint compound or Teflon tape shall be applied to pipe threads before installing threaded
valves. Joints shall be watertight.
City of Carlsbad
03/04 (DBE) ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
15100 -Valves - 5 of 6
3.2. Valve Pressure Testing
Valves shall be tested at the same time that the connecting pipelines are pressure tested and in
accordance with Section 15040, Testing, Flushing and Disinfection. Any parts of valves,
operators, or control and instrumentation systems whose pressure rating is less than the test
pressure shall be isolated and protected.
-Lc
END OF SECTION
City of Carlsbad
03/04 (DBE)
ECR (PAR to Cassia) Domestic & Recycled Water Transmission Mains
151 00 - Valves: - 6 of 6