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HomeMy WebLinkAboutCCL Contracting Inc; 2011-08-26; PWS11-43UTIL (4)f CITY OF CARLSBAD San Diego County California CONTRACT DOCUMENTS, GENERAL PROVISIONS, SUPPLEMENTAL PROVISIONS, AND TECHNICAL SPECIFICATIONS FOR Buena Vista Lift Station Force Main (VC-4) CONTRACT NO. 55081 BID NO. PWS11-43UTIL c BOOK 2 OF 2 SECTION 03300 CAST-IN-PLACE CONCRETE PART 1 - GENERAL 1.01 DESCRIPTION This section specifies cast-in-place concrete which consists of furnishing all material, mixing and transporting equipment, and performing all labor for the proportioning, mixing, transporting, placing, consolidating, finishing, and curing of concrete in the structure. 1.02 QUALITY ASSURANCE A. QUALITY CONTROL BY CONTRACTOR: To demonstrate conformance with the specified requirements for cast-in-place concrete, the Contractor shall provide the services of an independent testing laboratory which complies with the requirements of ASTM E329. The testing laboratory shall sample and test concrete materials as specified in paragraphs 03300-2.01, 2.02, and 3.15. Costs of testing laboratory services shall be borne by the City of Carlsbad. B. BASIS FOR QUALITY: Cast-in-place concrete shall conform to the requirements of ACI301, except as modified herein. C. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization, or if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued, or replaced. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-1 Reference Title AASHTO T210 ACI211.1 ACI214 ACI301 ACI304 ACI 304.2 ACI 305R ACI 306R ACI 350 ACI 350.1 ASTMC31 ASTMC33 ASTMC39 ASTM C40 ASTMC42 ASTMC88 ASTMC94 ASTM Cl 17 ASTMC131 ASTMC136 ASTMC142 ASTMC143 ASTMC150 ASTMC157 ASTM C172 ASTMC231 ASTMC260 ASTMC309 ASTM C494 ASTM C595 Aggregate Durability Index Selecting Proportions for Normal, Heavy Weight and Mass Concrete Evaluation of Strength Test Results of Concrete Structural Concrete for Buildings Measuring, Mixing, Transporting, and Placing Concrete Placing Concrete by Pumping Methods Hot Weather Concreting Cold Weather Concreting Code Requirements for Environmental Engineering Concrete Structures Tightness Testing of Environmental Engineering Concrete Structures Making and Curing Concrete Test Specimens in the Field Concrete Aggregates Compressive Strength of Cylindrical Concrete Specimens Organic Impurities in Fine Aggregate for Concrete Obtaining and Testing Drilled Cores and Sawed Beams of Concrete Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate Ready-Mixed Concrete Materials Finer Than 75-^m (No. 200) Sieve in Mineral Aggregates by Washing Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine Sieve Analysis of Fine and Coarse Aggregates Clay Lumps and Friable Particles in Aggregates Slump of Portland Cement Concrete Portland Cement Length Change of Hardened Cement Mortar and Concrete Sampling Freshly Mixed Concrete Air Content of Freshly Mixed Concrete by the Pressure Method Air-Entraining Admixtures for Concrete Liquid Membrane-Forming Compounds for Curing Concrete Chemical Admixtures for Concrete Blended Hydraulic Cements ^___ BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 CAST-IN-PLACE CONCRETE 03300-2 Reference Title ASTMC618 ASTM C881 ASTMC1059 ASTMC1567 ASTM D75 ASTM D2419 ASTM E329 CRD-C572 IBC Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Portland Cement Concrete Epoxy-Resin-Base Bonding Systems for Concrete Latex Agents for Bonding Fresh to Hardened Concrete Potential Alkali Reactivity of Aggregates (Mortar Bar Method) Sampling Aggregates Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate Inspection and Testing Agencies for Concrete, Steel, and Bituminous Materials as Used in Construction U.S. Corps of Engineer's Specifications for Polyvinylchloride Waterstop International Building Code with local amendments 1.03 SUBMITTALS The following information shall be provided in accordance with Section 01300: 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check- marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks (*0 shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. 2. Each proposed mix design showing (a) the expected strength, (b) corresponding slump before and after the introduction of mid- or high-range water-reducing admixtures, (c) weights and test results of the ingredients, and (d) other physical properties necessary to review each mix design for conformance with these specifications. Mix design proposed shall be sealed by a Professional Engineer registered in the State of California. 3. Product literature and technical data for aggregates and pozzolan. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 CAST-IN-PLACE CONCRETE 03300-3 4. Product literature, technical data and dosage of all proposed admixtures including, but not limited to, air entraining, water reducing and/or retarding admixtures. 5. Anticipated average delivery time from batch plant to site. If this time exceeds the limit specified in paragraph 3.02, include proposed method to extend set time without deleterious effects on final product. Engineer reserves the right, in their sole discretion, to accept or reject such proposed methods. 6. Curing program description in sufficient detail to demonstrate acceptable strength, finish and crack control as specified. 7. Product literature and technical data for waterstops, curing compounds, bonding compounds, surface sealers and hardeners. 8. Neoprene bearing pad sample, 4 inches x 4 inches; material data sheets verifying conformance with specification; shop drawing of each bearing pad showing splice locations, if any, and description of manufacturing and splice procedure. 9. Report of the most recent inspection of testing laboratory facilities by the Cement and Concrete Reference Laboratory of the National Bureau of Standards. The report shall note deficiencies mentioned in the report of that inspection have been corrected. The evidence of inspection shall be provided prior to beginning the work of this section. 10. Sample panels of formed wall surfaces, if required, are specified in Sections 03100. Samples of concrete floor and slab finishes are specified in paragraph 3.12 E. 1.04 REGULATORY REQUIREMENTS, SPECIAL INSPECTION A. GENERAL: Special Inspection of concrete work shall be performed by the Special Inspector under contract with the City of Carlsbad and in conformance with the IBC Chapter 17. Special Inspectors) and laboratory shall be acceptable to the City of Carlsbad in their sole discretion. Special Inspection of concrete is in addition to, but not replacing, other inspections and quality control requirements herein. Where sampling and testing required herein conforms to Special Inspection standards, such sampling and testing need not be duplicated. B. CONCRETE WORK TO RECEIVE SPECIAL INSPECTION: All structural concrete work shall receive Special Inspection in accordance with IBC Section 1701.5, including subsections 1. Concrete; 2. Bolts Installed in Concrete; 4. Reinforcing Steel; and 11. Piling. Structural concrete includes all elements which resist code-defined loads and whose failure would impact life safety. Non-structural sitework concrete does not require Special Inspection. Anchor bolts and anchors installed in hardened concrete require Special Inspection unless otherwise noted on the drawings. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 . 03300-4 PART 2 -- PRODUCTS 2.01 MATERIALS A. CEMENT: Portland cement shall be ASTM C150, Type II or Type V, low alkali, containing less than 0.60 percent alkalis. Portland-pozzolan cement shall be ASTM C595, Type IP(MS), interground, low alkali. B. AGGREGATES: 1. GENERAL: Except as modified herein, fine and coarse aggregates shall conform to ASTM C33. Fine and coarse aggregates shall be regarded as separate ingredients. Aggregates shall be non-reactive and shall be washed before use. Tests for size and grading of fine and coarse aggregates shall be in accordance with ASTM C136. Combined aggregates shall be well and uniformly graded from coarse to fine sizes to produce a concrete that has optimum workability and consolidation characteristics. The final combined aggregate gradation shall be established during the design mix. When sources of aggregates are changed, test reports shall be provided for the new material. The tests specified shall be performed prior to commencing concrete work. 2. FINE AGGREGATE: Fine aggregate shall be hard, dense, durable particles of either sand or crushed stone regularly graded from coarse to fine. Gradation shall conform to ASTM C33. For classes of concrete which will be used in liquid retaining structures, fine aggregate shall not exceed 40 percent by weight of combined aggregate total, except for concrete with coarse aggregate of less than maximum size 1/2 inch. Variations from the specified gradations in individual tests will be acceptable if the average of three consecutive tests is within the specified limits and the variation is within the permissible variation listed below: U.S. standard sieve size 30 and coarser 50 and finer Permissible variation in individual tests, percent 2 0.5 Other tests shall be in accordance with the following specifications: Test Amount of material Test method ASTM C 117 Requirements 3 percent passing No. 200 sieve maximum by weight BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-5 Test Reactivity Sand equivalent Test method ASTMC1567 ASTM D2419 Requirements Less than 0.10% expansion in 14 days Minimum 75 COARSE AGGREGATE: Coarse aggregate shall be hard, angular (not river washed), dense and durable gravel or crushed rock free from injurious amounts of soft and friable particles, alkali, and organic matter. Other deleterious substances shall not exceed the limits listed in ASTM C33, Table 3. Gradation of each coarse aggregate size specified in paragraph 03300-2.02 A shall conform to ASTM C33, Table 2. Before and during field trial mixes, the Contractor may make minor adjustments to the above gradation to produce the specified concrete. During progress of the work, variations from the specified gradations will be acceptable in individual tests if the average of three consecutive tests is within the specified limits. Other tests shall be in accordance with the following specifications: Test Durability index Soundness Amount of material Abrasion Clay lumps and friable particles Reactivity Test method AASHTOT210 ASTM C88 ASTM C 117 ASTMC131 ASTM C 142 ASTMC1567 Requirements Minimum 75 10 percent maximum loss with sodium sulfate 1.0 percent maximum passing No. 200 sieve by weight 35 percent maximum loss after 500 revolutions in Los Angeles machine 4.5 percent maximum by weight Less than 0.10% expansion in 14 days. C. POZZOLAN: Pozzolan shall be Class N, natural pozzolan, or Class F, fly ash, conforming to ASTM C618. Fly ash pozzolan shall contain less than 1 percent by weight carbon and less than 3 percent by weight sulfur trioxide. Pozzolan supplied during the life of the project shall have been formed at the same single source. The pozzolan color shall not substantially alter the resulting concrete from the normal gray color and appearance. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 CAST-IN-PLACE CONCRETE 03300-6 D. ADMIXTURES: 1. GENERAL: Admixtures shall be compatible with the concrete and with each other. Calcium chloride or admixtures containing calcium chloride are not acceptable. Admixtures shall be used in accordance with the manufacturer's recommendations and shall be added separately to the concrete mix. 2. WATER REDUCING ADMIXTURES AND RETARDERS: Water reducing retarders shall conform to ASTM C494, Type D. Candidate manufacturers include Degussa Admixture Systems, Pozzolith 300R; Sika Chemical Corp., Plastiment; Euclid Chemical Co., Eucon Retarder 75; or equal. Water reducing admixtures shall conform to ASTM C494, Type A. Candidate manufacturers include Degussa Admixture Systems, Pozzolith 322N; SIKA Chemical Corp., Plastocrete 161; Euclid Chemical Co., Eucon WR89; or equal. The water reducing retarders and admixtures shall reduce the water required by at least 11 percent for a given concrete consistency and shall comply with the water/cement ratio standards of ACI 211.1. Retarder dosage shall result in set time consistent with paragraph 3.02. 3. HIGH RANGE WATER REDUCING ADMIXTURES AND RETARDERS: High range water reducing (superplasticizing) retarders shall conform to ASTM C494, Type G. Candidate manufacturers include Sika Chemical Corp., Sikament 10ESL; Euclid Chemical Co., Eucon 537; or equal. High range water reducing (superplasticizing) admixtures shall conform to ASTM C494, Type F. Candidate manufacturers include Degussa Admixture Systems, Glenium 3000NS; Sika Chemical Corp., Sikament FF or 86; Euclid Chemical Co., Eucon 37; or equal. 4. AIR ENTRAINING AGENT: Air entraining agent shall conform to ASTM C260. Candidate manufacturers include Degussa Admixture Systems, MB-AE 90; Sika Chemical Corp., AEA-15; Euclid Chemical Co., AEA-92 or equal. The air entraining agent added shall produce, in accordance with ASTM C260, an entrained air content specified in paragraph 03300-2.02 A for each class of concrete. 5. SHRINKAGE REDUCING ADMIXTURE: Candidate manufacturer is Degussa Admixture Systems, Tetraguard AS20. E. WATER: Water for washing aggregate, for mixing and for curing shall be free from oil and deleterious amounts of acids, alkalis, and organic materials; shall not contain more than l,OOOmg/L of chlorides as Cl, nor more than 1300 mg/L of sulfates as SO4i and shall not contain an amount of impurities that may cause a change of more than 25 percent in the setting time of the cement nor BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-7 a reduction of more than 5 percent in the compressive strength of the concrete at 14 days when compared with the result obtained with distilled water. Additionally, water used for curing shall not contain an amount of impurities sufficient to discolor the concrete. 2.02 CONCRETE CHARACTERISTICS A. MIX PROPORTIONING: Concrete shall be normal weight concrete composed of specified cement, pozzolan, admixtures, aggregates and water proportioned and mixed to produce a workable, strong, dense, and impermeable concrete. The Contractor may substitute interground Portland-pozzolan cement conforming to ASTM C595, containing the specified amount of pozzolan in lieu of Portland cement and pozzolan. Pozzolan may be omitted in concrete exposed to normal atmospheric conditions and concrete not in contact with the ground or liquid. Water/cement ratio is based on the combined contents of cement and pozzolan in a given mix proportion. Concrete shall be provided in accordance with the following: Concrete class A B C-l C-2 D-l D-2 Ee F ASTM coarse aggregate size 2 467d 467d 67 8 8 467d - Maximum water/ cement ratio 0.42 0.45 0.40 0.35 0.42 0.40 - — Pozzolan, percent by weight of cementitious materials3 18-20 18-20 18-20 18-20f 0 18-20 18-20f 18-20f Air content (percent) 5.5C 5.5C 5.5C 0 0 4.5C 0 0 Minimum1* 28- day compressive strength, psi 4500 3000 4500 6000 4000 4500 2000 500g Slump Range min-max/admixh (inches) 1-2/4 3-4/5 3-4/5 3-4/5 2.5-3.5/5 3-4.5/6 4-8/8 4-8/8 Pozzolan content may be included in cementitious fraction. Compressive strength shall be determined at the end of 28 days based on test cylinders made and tested in accordance with ASTM C39. Plus or minus 1.5 percent. Adjust as required for floors to receive monolithic finish. ASTM coarse aggregate gradation 57 may be substituted at Contractor's option. Concrete encasement for electrical conduit shall contain 3 pounds of red oxide per sack of cement. Pozzolan use optional for this class of concrete. Minimum 28-day compressive strength shall be 500 psi and maximum 28-day compressive strength shall be 1,000 psi. Min and max represent slump due to water only. Admix refers to recommended maximum slump for the mix after the incorporation of water reducing admixtures. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 CAST-IN-PLACE CONCRETE 03300-8 B. USE: Concrete shall be provided by class for the corresponding use listed as follows: Type of use Class of concrete Concrete greater than 36 inches thick Sitework, non-structural concrete (sidewalks, curbs, pavers, etc.) Typical cast-in-place structural concrete Precast concrete Topping concrete Wall starter course Pipe bedding and encasement, electrical conduit encasement (duct banks) and concrete fill Encasement of reinforcement extension for future construction A B C-l C-2 D-l D-2 E C. CONTROL TESTS: 1. GENERAL: Before beginning concrete work, the Contractor shall determine the proper proportions of materials for each class of concrete. The mix shall consist of specified cement, pozzolan, admixtures, aggregate and water. Methods for selecting and adjusting proportions of the ingredients shall be in accordance with ACI 211.1. Verification of mix characteristics for submittal may be achieved using either the Batch Plant Mix Design method or Historical Data method. Concrete shall not be placed in the field prior to review and acceptance of mix proposed. 2. BATCH PLANT MIX DESIGN: Each class of concrete and/or mix verified by this method shall be manufactured in a 1 cubic yard quantity at the batch plant which will supply concrete to the project. Testing, data and reporting shall conform to ACI318 Section 5.3. At a minimum, twelve standard test cylinders shall be cast and cured as specified for the field concrete for each mix. Four cylinders from each batch shall be tested at age 7 days, 14 days, and 28 days, or as required to comply with ACI318 Section 5.3 and demonstrate an acceptable mix is proposed for use. Additional cylinders may be cast and tested at 56 days at the option of the manufacturer; however, specified compressive strength evaluation will be based on 28-day results only. 3. HISTORICAL DATA: When sufficient historical data for a particular mix design is available which is identical or substantially similar to that proposed for use, Contractor may substitute use of this data in lieu of a laboratory mix design. Historical data, reports and analysis shall conform to ACI318 Section 5.3, except as modified herein. Historical mix design proportions for which data are submitted may vary from the specified mix within the following limits: (a) f c as specified or up to 500 psi above; (b) W/C ratio as specified or lower; (c) pozzolan content within 5 percent of that specified; (d) maximum coarse aggregate size may not vary smaller, but gradation of coarse aggregate may vary; BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-9 (e) fine aggregate fraction within +0/ 5 percent of that specified; and (f) slump after introduction of admixtures +0/-1 inch. Use of historical mix design data does not allow modification of the project mix specifications herein without the express review and acceptance of the Engineer. 4. SHRINKAGE: Process structures are intended to be watertight, and are designed and detailed with an expected drying shrinkage limit of 0.03 percent in the laboratory and 0.04 percent in the field, as tested by ASTM C157 with "California amendments." The concrete mix design specifications are intended to limit drying shrinkage, and therefore verification testing of that characteristic is not specified. In particular, coarse aggregate size, gradation and quality, and total cementitious material content of the mix are important variables. Contractor is encouraged to consider mix designs which minimize total cementitious materials content while still achieving specified compressive strength. Substitution of smaller coarse aggregate, for example gradation 67 replacing 467, shall not be allowed for process structures unless that proposed mix demonstrates drying shrinkage at or below the limits and based on test data described herein. The California amendments will be provided by Engineer upon request. Should Contractor request such substitution, they shall timely conduct and report tests, which typically take over 35 days to complete. Contractor shall not claim or charge any additional expense to the City of Carlsbad for either the testing or associated project delays. Concrete shall not be placed hi the field prior to acceptance of the field trial mix. 2.03 WATERSTOPS A. POLYVINYL CHLORIDE (PVC): PVC waterstops shall be manufactured from virgin polyvinyl chloride conforming to the Corps of Engineers Specification No. CRD-C572. Unless otherwise specified or noted on the drawings, waterstops in construction joints shall be 6-inch flat center/ribbed sides/0.375 inch thick, Greenstreak 679, Vinylex R6-38, or equal. Waterstops in expansion joints shall be 9 inch center-bulb/ribbed sides/0.375 inch thick, Greenstreak 696, Vinylex RLB9-38, or equal. B. EXPANDING (HYDROPHILIC) WATERSTOPS: Expanding waterstops shall be bentonite-free and made from unvulcanized rubber. Acceptable products include SikaSwell or SikaSwell Profile by SIKA, and Ultra Seal by Adeka. Equivalents approved by the Engineer are acceptable. These are allowable for use only where indicated on the drawings or accepted in writing by the Engineer. Provide adhesive approved by the waterstop manufacturer where required due to geometry, irregular surface conditions, or as recommended by the manufacturer. Unless otherwise shown on the drawings, use Adeka Ultra Seal MC-2010MN where 3/8" x W waterstops are called for and Adeka Ultra Seal MC- 2005T where 3/16" x 3/4" waterstops are called for. Both of these waterstops MUST be placed between two mats or curtains of steel reinforcement. Where only one mat or curtain of reinforcement is present, use Adeka Ultra Seal KBA-1510FP. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-10 2.04 SEALANTS AND JOINT FILLERS Sealants and preformed joint fillers shall be as specified in Sections 07900 and 07905. 2.05 BONDING COMPOUNDS Epoxy resin bonding compounds to be used for wet areas shall conform to ASTM C881 Types IV or V, Class A, B, or C depending on temperature at use, and Grade to suit geometry and installation circumstances. Acceptable products include: Degussa Building Systems, Concresive Paste SPL or 1490 as applicable; Sika Chemical Corporation Sikadur 35 or Sikadur 32, as applicable; or equal. Non-epoxy bonding compounds may be used in dry areas for non-structural bonding or as specifically noted on the drawings only and shall conform to ASTM C1059 Type II. Acceptable products include: Burke by Edoco, Acrylic Bondcrete; ChemMasters, Cretelox; or equal. Bonding compounds shall be applied in accordance with the manufacturer's instructions. 2.06 EPOXY FOR CRACK INJECTION Epoxy for crack injection shall be a two-component, moisture insensitive, high modulus, injection grade, 100 percent solids, blend of epoxy-resin compounds. The consistency shall be as required to achieve complete penetration in hairline cracks and larger. Material shall conform to ASTM C881 Type 1 Grade 1, such as Sika Corporation Sikadur 52, Adhesivesv Technology Corporation SLV 300 series, or equal approved by the Engineer. 2.07 CHEMICAL GROUT FOR CRACK INJECTION Chemical (hydrophobic polyurethane) grout shall be used at the Engineer's discretion as an alternative to the injection of the epoxy grout for sealing crack and voids in structures intended to be watertight. Chemical grout shall be De Neef "Hydro Active Cut" by De Neef Construction Chemicals or SikaFix HH by Sika Corporation, or equal approved by the Engineer. Chemical grout injection tube system, if shown on the drawings, shall be De Neef "Injecto System" by De Neef Construction Chemicals or equal. Equivalent systems shall be submitted to the Engineer for review. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-11 2.08 RETARDANT Retardant for exposing aggregates for unformed surfaces in construction joints shall be Sika Rugasol-S, Horn Aggretex-H, Burke Company True Etch Surface Retarder, or equal. Retardant shall be applied in accordance with manufacturer's instructions sufficient to assure a minimum penetration of 1/8 inch. 2.09 SURFACE HARDENER A. MODERATE DUTY HARDENER: Moderate duty surface hardener shall be premixed, non-colored, nonmetallic Degussa Building Systems, Mastercron; A. C. Horn Inc., Durafax; Burke Company Non-Metallic Floor Hardener; or equal. Surface hardener shall be applied in accordance with manufacturer's instructions, and shall be applied in an amount of at least 0.75 pounds per square foot for commercial, light duty traffic and 1.25 pounds per square foot for heavy duty traffic and process spaces. Product and/or application procedure shall be compatible with specified or modified air contents for the class of concrete hardened. B. HEAVY DUTY HARDENER: Heavy-duty surface hardener shall be emery aggregate dry shake applied during slab finishing. Candidate manufacturers include L&M Construction Chemicals, Emeryplate FF; or equal. Apply conforming to manufacturer's recommendations at a minimum rate of 1.5 pounds per square foot, and adjusted for the specific floor traffic and use anticipated. Product and/or application procedure shall be compatible with specified or modified air contents for the class of concrete hardened. C. HARDENER FOR HARDENED CONCRETE: Monolithic finish for moderate duty may utilize an alkaline siliconate solution to harden, densify, and seal the surface. Candidate manufacturers include L&M Construction Chemicals, Seal Hard, or equal. Proposed product shall be approved by City of Carlsbad after review of similar floors so-treated for at least 2 years. 2.10 CURING AND SEALING COMPOUNDS Curing and sealing compound shall be Degussa Building Systems, Masterseal; Sonneborn, Kure and Seal; A. C. Horn Inc., Horn Clearseal EMI 80; Burke Company Spartan-Cote WB Cure Seal Hardner; or equal, conforming to ASTM C309. Curing compound shall be clear and shall be applied in accordance with the manufacturer's instructions, except as otherwise specified. Curing and sealing compound shall be certified compliant with final finish systems. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-12 Curing compound for use in potable water storage and conveyance structures shall be NSF 61 approved. Provide only resin curing compound Euclid Chemical Company "Pliocure", Unires 150, or equal approved by the Engineer. 2.11 TRENCH DRAINS Trench drains may be either field formed and cast, with compatible grate as specified below, or utilize a manufactured trench drain system. Trench drain systems shall be pre-engineered, manufactured systems that conforms to the design loading requirements of AASHTO H-20 in traffic areas or 300 pounds per square foot elsewhere and with the following minimum requirements: A. A method of forming a round or V-bottom channel pre-sloped to a minimum of 0.5 percent (1/16-inch per foot) installed in sections. See drawings for channel cross section or size. If not shown, assume 12 inches wide and deep (nominal) and confirm with Engineer. B. An aluminum frame with stainless steel anchors at 45 degrees into the surrounding concrete. Aluminum shall be coated to prevent direct concrete contact as specified elsewhere. C. An aluminum grate conforming to Federal Specification RR-F-621C. D. A locking device which directly connects the grate to the frame. Candidate manufacturers include: MultiDrain Systems, Atlanta, Georgia, (800) 433-1119; ABT, Inc., Troutman, North Carolina, (800) 438-6057; or approved equal. 2.12 NEOPRENE BEARING AND SEAL PADS Bearing and seal pads and rod shall be composed of 100 percent chloroprene (neoprene), 50 Durometer A, and conform to Division II, Section 18 of AASHTO Standard Specifications for Highway Bridges. Pads and rods shall conform to geometry as shown on the drawings. All bearing and seal pads and rods shall be one-piece manufactures, or factory spliced using a process proven gas-tight in repeated similar applications. Glues and adhesives shall not be used to bond pieces together. Deliver to job site in protective containers or packaging and maintain the integrity of the pad/rod through construction. 2.13 PRODUCT DATA The following product data shall be provided in accordance with Section 01300. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-13 A. MANUFACTURER'S DATA: Copies of manufacturer's data shall be provided for the following: 1. Cement 2. As-delivered concrete strength, slump, temperature, and air content 3. Final laboratory report. B. READY-MIXED CONCRETE TRUCK DELIVERY TICKETS: Each load of ready-mixed concrete delivered to the job site shall be accompanied by a delivery ticket showing the information listed in ASTM C94, Section 16. PART 3 « EXECUTION 3.01 GENERAL The City of Carlsbad is defining the quality of cast-in-place concrete by specifying in this part some of the means, methods, techniques, sequences, and procedures for construction of cast-in- place concrete. The Contractor, without relinquishing authority and responsibility for supervision and direction of the work, agrees to follow the specified means, methods, techniques, sequences, and procedures. 3.02 CONCRETE Concrete shall be truck-mixed, ready-mixed concrete conforming to the applicable portions of ASTM C94. Materials shall be proportioned by weighing. Pozzolan shall be introduced into the mixer with cement and other components of the concrete mix; pozzolan shall not be introduced into a wet mixer ahead of other materials or with mixing water. Water shall be introduced at the time of charging the mixer; additional water may be introduced within 45 minutes from charging the mixer, provided the specified slump is not exceeded; or the Contractor shall be responsible for producing concrete of the specified characteristics. Contractor shall arrange with the testing laboratory for inspection as required to comply with these specifications. Concrete shall be delivered to the site and discharge shall be completed within one (1) hour after introduction of water to the mixture. Extension of allowable time beyond this limit requires a Contractor proposed remedial action plan to be reviewed and accepted by the Engineer. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-14 3.03 CONVEYING AND PLACING CONCRETE A. CONVEYING CONCRETE: Concrete shall be conveyed from the mixer to the forms in accordance with ACI 301 and ACI 304. Concrete which has segregated in conveying shall be removed from the site of the work. B. PLACING CONCRETE: 1. GENERAL: Concrete shall be placed in accordance with ACI 301 and ACI 304 as applicable. 2. PLACING CONCRETE BY PUMPING: Concrete may be placed by pumping at Contractor's discretion according to ACI 304 and ACI 304.2. Use of pumping shall not, however, be cause to change or relax specified mix design characteristics, in particular coarse aggregate size and gradation. Slump shall be measured at the hose discharge, except as follows. Initial slump testing in each pour shall occur at both the pumping unit inlet hopper and hose discharge. Slump loss in pumping, measured between the inlet hopper and the hose discharge, shall not exceed 1 inch. After this criteria has been satisfied, slump may be measured at the inlet hopper with allowable slump increased by the earlier measured difference, not to exceed 1 inch. Before starting each pumping operation, the pump and line shall be primed with a cement slurry to lubricate the system. Cement slurry shall be wasted outside the forms. Hose tip shall be equipped with a safety chain for recovery in case of hose blowout during pumping, and in no case shall hose or accessories remain in the freshly placed concrete. Proper tremie placing techniques and equipment shall be used for all pump placed concrete. Pump discharge system shall remain full of concrete from pump to discharge point at all times. Concrete pumping shall not occur until Engineer has verified that the proper equipment is available, in particular, the tremie plug. Should the discharge line become open, with significant zones empty of concrete, then the pumping shall cease and the line re-primed with tremie plug installed before continuing the pour. 3. PLACING CONCRETE IN HOT WEATHER: In hot weather (above 85 degrees F), concrete shall be placed in accordance with ACI 305R. 4. PLACING CONCRETE IN COLD WEATHER: In cold weather (below 45 degrees F), concrete shall be placed in accordance with ACI 306R. 5. STARTER COURSE AT WATERSTOPS: When placing concrete in wall forms for water retaining structures over eight (8) feet in height, without form windows, and which have a waterstop at the bottom of the form, a starter course of Class D-2 concrete BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-15 shall be placed to a depth of approximately twelve (12) inches and thoroughly consolidated. Subsequent lift(s) of concrete shall be placed onto this starter course within ten (10) minutes of the starter course placement, and the two lifts shall be thoroughly consolidated together to result in a dense, continuous, watertight structure with no cold joint. Contractor shall provide adequate pumping and consolidating equipment and personnel to achieve the time limit specified herein. 6. PLACING CONCRETE UNDER WATER: When placing concrete under water, concrete shall be placed in accordance with ACI 304, Chapter 8, Tremie Concrete C. CONSOLIDATING CONCRETE: Concrete shall be consolidated in accordance with ACI 301. Concrete placing shall be suspended if proper consolidation is not being secured until proper consolidation can be achieved. For wall pours in excess of eight (8) feet tall by fifteen (15) feet long, two consolidation devices each with a two man crew shall be utilized, minimum. 3.04 CURING AND SEALING A. GENERAL: Concrete curing shall be completed by water curing or by using a clear membrane curing compound or by a combination of both methods. Repairs or treatment of concrete surfaces shall be coordinated so that interruption of the curing will not be necessary. Concrete surface temperature shall be maintained between 50 degrees F and 80 degrees F for at least 5 days. Curing concrete in hot weather (above 85 degrees F) shall be in accordance with ACI305R. Curing concrete in cold weather (below 45 degrees F) shall be in accordance with ACI306R. B. WATER CURING: When water curing is used, concrete shall be kept wet continuously for a minimum of 10 days after placement. Absorptive mats or fabric may be used to retain moisture during the curing period. Unless otherwise specified, water curing shall be used in hot weather for water containment structures. Forms shall be covered and kept moist. The forms shall be loosened, as soon as possible without damage to the concrete, and provisions made for curing water to run down inside them. During form removal, care shall be taken to provide wet cover to newly exposed surfaces. At the end of the specified curing period, the covering shall be left in place without wetting for several days. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-16 C. CURING COMPOUND: When curing compound is used, it shall be applied as soon as the concrete has set sufficiently so as not to be marred by the application or immediately following form removal for vertical and other formed surfaces. Preparation of surfaces, quantities used, application procedures, and installation precautions shall be followed in strict compliance with the manufacturer's instructions. Curing compound shall not be used on concrete surfaces to be coated, waterproofed, moisture proofed, tiled, roofed, or where other coverings are to be bonded, unless the curing compound is compatible with the final finish covering or it is removed prior to covering. 3.05 PROTECTION Concrete shall be protected from injurious action by sun, rain, flowing water, frost and mechanical injury, and shall not be allowed to dry out from the time it is placed until the expiration of curing periods. Steel toweled slabs shall be protected with craft paper, 6 mil thick polyethylene membrane, or other similar waterproof material for at least 2 weeks after placement. Joints between adjacent strips of the paper shall be sealed. Float or broom finished slabs need be protected after curing only in areas subject to damage during construction. Arrangements for covering, insulating, and protecting concrete in cold weather shall be in accordance with ACI306R. 3.06 CONSTRUCTION JOINTS A. GENERAL: Concrete in each unit of construction shall be placed continuously. Before new concrete is placed on or against concrete which has set, forms shall be retightened and the surface of the set concrete shall be cleaned of foreign matter. Watertight joints shall be provided as specified in paragraph 03300-3.09. B. CONSTRUCTION: Construction joints shall be formed as specified. A rough surface of exposed concrete aggregates shall be produced using a surface retardant at construction joints, including joints between slab and topping concrete. The limit of the treated surfaces shall be 1 inch away from the joint edges. Within 24 hours after placing, retarded surface mortar shall be removed either by high pressure water jetting or stiff brushing or combination of both so as to expose coarse aggregates. A rough surface of exposed aggregate may also be produced by sandblasting followed by high pressure water jetting. Sandblasting, if used, shall remove 1/8 inch of laitance BUENA VISTA LIFT STATION FORCE MAIN (VC-4) . CAST-IN-PLACE CONCRETE AUGUST 2010 03300-17 film and shall expose coarse aggregate to ensure adequate bond and watertightness at the construction joints. C. LOCATIONS: Construction joint locations shall be as follows: 1. Walls exceeding 50 feet in length shall be cast in panels not to exceed 30 feet hi length. Where the number of panels is three or more, the panels shall be cast in an alternating pattern, unless 5 days have elapsed between casting of adjoining panels. Joints are not allowed within the lesser of 10 feet or 25 percent of the wall length from any corner unless specifically detailed thus on the drawings. 2. Joints in beams or girders shall be located at or near the midpoint between supports. 3. Joints in the members of a floor system shall be made at or near the center of the span. 4. Joints in walls and columns shall be at the underside of floors, slabs, beams or girders and at the tops of footings or floor slabs. Joints in columns shall be perpendicular to the axis. 5. Slabs panels shall be cast in checkerboard patterns not to exceed 40 feet in length and not to exceed 900 square feet in area, with maximum 1 V4 to 1 ratio of side lengths. Minimum lapsed time between placing adjacent panels shall be 72 hours. This requirement may be waived if slab joints are specifically detailed on the drawings, both plan for locations and in detail for construction. 6. With approval of the Engineer, non-water retaining floor slabs-on-grade may utilize sawcut control joints as detailed on the drawings. For cases not detailed, stop half of the typical reinforcing crossing joint locations, provide trim bars each side joint, sawcut slab to 25 percent of its depth while green, and complete the joint by cleaning and filling with sealant specified in Section 07900 after curing. Vertical construction joints shall be grooved at exposed faces. Grooves subjected to wetting or weather shall be caulked with joint sealer as specified. Reinforcing steel and welded wire fabric shall be continued across construction joints. Girders and floor slabs shall not be constructed over columns or walls until at least one hour has elapsed to allow for shrinkage in the column or wall. No joint will be allowed between a slab and a beam or girder unless otherwise specified. Joints shall be perpendicular to the main reinforcement. Waterstops shall be provided in construction joints at locations as specified in paragraph 03300-3.09. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-18 3.07 INSERTS AND EMBEDMENTS A. INSERTS: Where pipes, castings or conduits are to pass through structures, the Contractor shall place such pipes or castings in the forms before placing the concrete, or he may provide openings in the concrete for subsequent insertion of such pipes, castings or conduits. Such openings shall be provided with waterstops and V-shaped construction joint as shown and shall have a slight flare to facilitate grouting and permit the escape of entrained air during grouting. Additional reinforcement shall be provided around openings as shown. Grout fill around inserts shall be non-shrink grout as specified in Section 03600. Horizontal conduits and pipes, where shown in structural slabs and beams, shall be placed between the top and bottom layers of reinforcement. Spacing and size limitations shall conform to ACI318 Section 6.3 unless specifically approved otherwise by the Engineer. Such conduits and pipes shall not run directly beneath a column or, if used, its steel base plate. B. EMBEDMENTS: Gate frames, gate thimbles, special castings, channels or other miscellaneous metal parts that are to be embedded in the concrete shall be set and secured in the forms prior to concrete placement. Unless otherwise specified, anchor bolts and inserts shall be embedded in concrete as shown. The Contractor shall provide inserts, anchors or other bolts necessary for the attachment of piping, valves, metal parts and equipment. Nailing blocks, plugs, strips, and the like necessary for the attachment of trim, finish, and similar work shall be provided. Voids in sleeves, inserts and anchor slots shall be filled temporarily with readily removable material to prevent the entry of concrete into the voids. Operators or sleeves for gate or valve stems shall be positioned to clear reinforcing steel, conduit and other embedments, and to align accurately with equipment. 3.08 EXPANSION JOINTS Expansion joints shall be as shown. Reinforcement or other embedded metal items bonded to the concrete shall not extend through expansion joints. Waterstops shall be provided in expansion joints as specified in paragraph 03300-3.09. 3.09 WATERSTOPS Waterstops shall conform to ACI 301. Waterstops shall be securely held in position during placing of concrete. If, after placing concrete, waterstops are materially out of position or shape, the surrounding concrete shall be removed, the waterstop reset, and concrete replaced in accordance with paragraph 03300-3.10. Waterstops shall be provided at the following joints: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-19 1. Expansion joints in structures. 2. Joints in parts of structures exposed to ground or water on one side and occupied by non-submerged equipment or by personnel on the other. 3. Wall and slab joints of tanks and channels subject to water pressure. Waterstops shall be provided from 6 inches above high water level to structural foundation slab or footing, or as otherwise noted on the drawings. Field splices shall be heat fused welded butt splices only and shall be acceptable only in straight sections. Lapping of splices or joining by any means other than heat fused welding shall not be allowed. Crosses, tees, and other shapes used for changes of direction, intersections, and transitions shall be factory fabricated. Hydrophilic waterstops shall be installed according to manufacturer's recommendations. Surfaces of concrete shall be prepared to required level/plumb and smoothness as required by manufacturer. Form and finish concrete placed first with contact surface requirements in mind, or grind surface if necessary. Provide bonding adhesive if required for the particular product, or if surface conditions warrant. Note restrictions on use described in paragraph 03300-2.03 B. 3.10 MODIFICATION OF EXISTING CONCRETE A. GENERAL: Structural dimensions related to or controlled by previously constructed or existing structures shall be verified in the field by the Contractor prior to concrete work. B. CUTTING OR CORING CONCRETE: Surfaces exposed to view shall be neatly saw cut to a depth of 1 inch prior to removing the existing concrete. New openings in existing concrete shall be cut 2 inches oversize, coated with epoxy bonding compound and re-finished with profiling mortar to the required opening size. Existing joint edge shall be ground to create a chamfer matching those used adjacent, where occurs. Hidden or other surfaces shall receive a Vz inch radius tooled joint between new and existing concrete. Grind existing to imitate tooled edge. Unless specifically notified otherwise, Contractor shall investigate concrete to be drilled, cored or sawcut to determine location of existing reinforcing steel. Penetrations shall be located so as to clear existing reinforcing steel if possible. Unless otherwise detailed on the drawings, or where not possible to avoid reinforcing steel, consult Engineer as to acceptability of cutting reinforcing steel and provide new reinforcing systems as directed. Locating methods include chipping to expose reinforcing steel, ground penetrating radar, X-ray, or magnetic flux devices. Locates of existing reinforcing shall be paid for by the Contractor. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-20 C. JOINING NEW CONCRETE TO EXISTING: Existing concrete surfaces to be joined with new concrete shall be thoroughly cleaned, and roughened by abrasive blasting, bush hammering or other method to achieve !4-inch amplitude surface. Existing metalwork, embeds or other interfering items shall be removed. In typical cases, coat existing surface with epoxy bonding compound just prior to placement of new concrete. In restricted access situations or for large quantity work, review need for epoxy bonding agent with Engineer if not specifically required by notes or details on the drawings. D. DOWELS: Dowels to be installed in existing concrete shall utilize drilled holes, properly brushed and air- cleaned, and epoxy based adhesive, as per Section 03600. When the holes are horizontal, they shall be drilled slightly downward (approx 15 degrees). When overhead holes are required, capsule anchors shall be used. Installation and Special Inspection shall conform to ICBO Evaluation Report or comparable agency certification. Adhesive anchored dowels shall not be used where developed reinforcing requires full transfer of force to adjoining reinforcing unless approved by the Engineer of Record, or where restricted in Section 03600. E. WATERSTOPS: Where a PVC waterstop between new and existing concrete is required, Contractor shall cut a suitable groove in the existing concrete and install waterstop with epoxy based adhesive unless otherwise noted on the drawings. Waterstop shall be securely braced and supported during installation and to the completion of adhesive curing. 3.11 FORMED SURFACE FINISHES A. REPAIR OF SURFACE DEFECTS: Surface defects, including tie holes, minor honeycombing or otherwise defective concrete shall be repaired in accordance with ACI 301. Areas to be patched shall be cleaned. Minor honeycombed or otherwise defective areas shall be cut out to solid concrete to a depth of at least 1 inch. The edges of the cut shall be perpendicular to the surface of the concrete. Patches on exposed surfaces shall be finished to match the adjoining surfaces after they have set. Patches shall be cured as specified for the concrete. Finished surfaces shall be protected from stains and abrasions. Finishes shall be equal in workmanship, texture, and general appearance to that of the adjacent concrete. Concrete with honeycombing which exposes the reinforcing steel or with defects which affect structural strength shall be corrected. B. FORMED SURFACE FINISHING: Formed surfaces shall be finished as soon as practicable after form removal and repair of surface defects. Finishes shall be as follows. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-21 1. FINISH A: Finish A shall be a grout clean finish in accordance with ACI301, Section 10.3.2 except that ALL FORM FINS AND OTHER PROTRUSIONS SHALL BE COMPLETELY REMOVED TO THE FINAL SURFACE. Surfaces shall be lightly sandblasted prior to sacking. For interior areas not exposed to moisture or weather, water used in the mortar shall be mixed with a PVA bonding compound as recommended by the manufacturer. Finish A shall be provided for painted and unpainted surfaces; surfaces of stair wells; interior surfaces of equipment rooms, galleries and tunnels; operations areas; exposed channels and tanks from 1 foot below minimum water surfaces and up; and permanently exposed vertical and sloped surfaces, such as pipe chases. 2. FINISH B: Finish B shall be the same as Finish A, except that the final burlap rubbing may be omitted, providing the steel trowel scraping removes the loose buildup from the surface. Finish B shall be provided for waterproof and moistureproof coated surfaces. 3. FINISH C: Finish C shall be a finish which has surface imperfections less than 3/8 inch in any dimension. Surface imperfections greater than 3/8 inch shall be repaired or removed and the affected areas shall be neatly patched. Finish C or smoother shall be provided for interior surfaces of wet wells, tanks and channels from 1 foot below minimum water surfaces and down and otherwise unfinished interior surfaces. 4. FINISH D: Finish D shall be the finish for surfaces which may be left as they come from the forms, except that tie holes shall be plugged and defects greater than 1/2 inch in any dimension shall be repaired. 3.12 SLAB FINISHES A. GENERAL: The finishes specified herein include surface finishes, treatments and toppings for floors and slabs. Dry cement shall not be used on new concrete surfaces to absorb excess moisture. Edges shall be rounded to a radius of 1/2 inch. Joints shall be grooved to a radius and depth of 1/4 inch each. Finishes shall match the sample panels provided under paragraph 03300-1.03. Floors shall be sloped to drain uniformly within a room or space. Unless otherwise specified, slope shall be a minimum of 1/8 inch per foot toward nearest dram. Where finish is not specified, floor slabs shall receive steel troweling. Use of floor drains with only locally depressed slabs shall be coordinated with Engineer if detailed on the drawings, and restricted to locations specifically noted. B. FLOAT FINISH: Float finish shall conform to ACI 301, Section 5.3.4.2.b. Floating shall be performed with a hand or power-driven float. Floating of any one area shall be the minimum necessary to produce the finish specified. Floating shall compact and smooth the surface and close any BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-22 cracks and checking of surfaces. Float finish shall be applied to surfaces of channel and tank bottom slabs and to footings. C. STEEL TROWEL FINISH: Steel trowel finish shall conform to ACI 301, Section 5.3.4.2.C. Immediately after final troweling, the surface shall be cured and protected as specified in paragraphs 03300-3.04 and 03300-3.05. Steel trowel finish shall be provided on floors unless specified otherwise. Surface hardener shall be troweled into the finished surface where monolithic surface is specified. D. BROOMED FINISH: Broomed finish shall conform to ACI 301, Section 5.3.4.2.d. Broomed finish shall be provided for walks, tops of tanks, slabs-on-grade exposed to atmosphere, and where otherwise indicated or specified, E. SAMPLES OF CONCRETE FLOOR FINISHES: A sample concrete panel, 2 feet by 2 feet, representative of each specified finish, shall be provided to the Engineer. The panels shall be representative of the workmanship and finishes required. Samples shall be approved in field prior to the start of such work. 3.13 TOPPING CONCRETE A. SUBFLOOR FINISH: Slabs to receive topping, tile or grout as shown shall be float finished to required elevations. Immediately following the final finishing, the slab shall be treated with a retardant. B. TOPPING CONCRETE: These requirements shall apply to the placement of normal concrete topping, with or without surface hardener, on a cured concrete substrate. Slabs to receive topping concrete shall have an exposed aggregate subfloor finish as specified in paragraph 03300-3.13 A, or have a 14 inch amplitude roughened surface using abrasive blast or raked finish after floating. Dirt, laitance and loose aggregate shall be removed. The cleaned base shall be kept wet for a period of 24 hours prior to the application of topping. Excess water shall be removed, and a neat cement grout shall be applied and brushed into the surface of the base. The cement grout shall not be allowed to dry and shall be spread within 15 minutes of the topping placement. The topping shall then be placed to grade, compacted by rolling or tamping, and floated. The surface shall be tested with a straightedge to detect high and low spots of over 1/8 inch in 10 feet which shall be eliminated. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-23 Surface hardener shall be incorporated where specified. When the floor has hardened sufficiently, it shall receive a steel trowel finish. Structural, non-exposed topping may be float finished only. 3.14 RELATED SURFACES A. MONOLITHIC SURFACING: Monolithic surfacing shall be provided on floor areas as specified. Monolithic surfacing shall consist of a steel trowel finish hardened with a moderate duty surface hardener as specified in paragraph 03300-2.09 A unless otherwise noted on the drawings. Surface hardener shall be applied in accordance with the manufacturer's recommendations and directions. Adjust air content of concrete to receive monolithic surfacing to limits recommended by the hardener manufacturer. B. STAIR TREAD: Stair tread shall be constructed with nonskid nosing as specified in Section 05530. Tread shall have a steel trowel finish with moderate duty surface hardener and shall have a slope of 1/8 inch per foot toward the front. Ends of treads shall have a 1/16 to 1/8 inch cut between concrete and metal tread to allow for expansion. C. FINISHING OF UNFORMED SURFACES: 1. RELATED UNFORMED SURFACES: Tops of walls or buttresses, horizontal offsets, and similar unformed surfaces occurring adjacent to formed surfaces shall be struck smooth after concrete is placed and shall be floated to a texture reasonably consistent with that of the adjacent formed surfaces. Final treatment of formed surfaces shall continue uniformly across the unformed surfaces. 2. PAVEMENTS AND SIDEWALKS: The surfaces of the concrete shall be screeded to grade and sloped to drain. After screeding, the surface shall receive a broomed finish as specified in paragraph 03300-3.12 D. Edges and expansion joints shall be rounded to a radius of Vi inch. Joints shall be grooved to a radius and depth of 1/4 inch each. 3.15 FIELD SAMPLING AND TESTS A. GENERAL: Field sampling and testing shall be performed by the independent testing laboratory specified in paragraph 03300-1.02 A. Samples of aggregates and concrete shall be taken at random locations and at such times to represent the quality of the materials and work throughout the project. The laboratory shall provide the necessary labor, materials and facilities for sampling the aggregate and for casting, handling and storing the concrete samples at the site of work. Aggregates shall BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-24 be sampled in accordance with paragraph 03300-3.15 B not less than 30 days prior to the use of such aggregates in the work. The minimum number of samples and tests are specified in paragraph 03300-3.15 C. B. SAMPLING: 1. AGGREGATES: a. GENERAL: Fine and coarse aggregates shall be sampled in accordance with ASTM D75. Samples shall be taken at the discharge gates of the bins feeding the weigh hopper. The Contractor shall provide safe and suitable facilities for obtaining samples. Samples shall be obtained at the concrete batch plant at the frequency specified in paragraph 03300-3.15 C. Sampling shall be repeated when the source of material is changed or when unacceptable deficiencies or variations from the specified requirements of materials are found in testing. Aggregate samples shall be tagged and their sources identified. b. COARSE AGGREGATE: A sample weighing between 50 and 60 pounds shall be taken after the batch plant is brought up to full operation. The samples shall be taken so that a uniform cross section, accurately representing the materials on the belt or in the bins, is obtained. c. FINE AGGREGATE: Samples shall be taken as specified for coarse aggregate. The samples shall be taken for sieve analysis of fine aggregate and specific gravity tests. Samples of sand shall be taken when the sand is moist. 2. CONCRETE: Samples of plastic concrete shall be obtained in accordance with ASTM C172. Samples for pumped concrete shall be taken at the hose discharge point, or as specified earlier in 3300-3.03B. 2. Samples for other concrete shall be taken at the hopper of concreting equipment or transit mix truck. C. TESTING: 1. AGGREGATE: A minimum of one test of coarse aggregate per 400 cubic yards of concrete and a minimum of one test of fine aggregate per 200 cubic yards of concrete used shall be made to confirm continuing conformance with specifications for gradation, cleanliness and sand equivalent. A maximum of one test per day of each aggregate is required. The full test program is required before source changes will be accepted. 2. CONCRETE: a. STRENGTH TESTS: The strengths specified for the design mix shall be verified by the testing laboratory during placement of the concrete. Verification shall be accomplished by testing standard cylinders of concrete samples taken at the job site. Standard cylinders shall represent the concrete placed in the forms. One set of six standard cylinders shall be cast of each class of concrete for each 100 cubic yards or BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-EM-PLACE CONCRETE AUGUST 2010 03300-25 less or for each 4,000 square feet of surface area placed per day. Casting, handling and curing of cylinders shall be in accordance with ASTMC31. Additional cylinders shall be provided when an error in batching is suspected. For the first 24 hours after casting, the cylinders shall be kept moist in a storage box constructed and located so that its interior air temperature will be between 60 and 80 degrees F. At the end of 24 hours, the cylinders shall be transported to the testing laboratory. Testing of specimens for compressive strength shall be in accordance with ASTM C39. Tests shall be made at 7 and 28 days from time of casting. Two test cylinders from each group of six shall be tested at the end of 7 days and two shall be tested at the end of 28 days. The fifth and sixth cylinders shall be tested at the end of 56 days if the 28-day strength reports below specification. A strength test shall consist of the average strength of two cylinders cast from material taken from a single load of concrete. If one cylinder in a set of two shows evidence of low strength due to improper sampling, casting, handling or curing, the result of the remaining one cylinder may be used if approved by the Engineer. The average of any three consecutive 28-day strength test results of the cylinders representing each class of concrete for each structure shall be equal to or greater than the specified strength and not more than 10 percent of the strength test results shall have values less than the specified 28-day strength for the total job concrete. No individual strength test result shall be less than the specified strength by more than 500 pounds per square inch. Certified reports of the test results shall be provided directly to the Engineer. Test reports shall include sufficient information to identify the mix used, the stationing or location of the concrete placement, and the quantity placed. Slump, air content, temperature of concrete, and ambient temperature shall be noted. The 28-day strength test results shall be evaluated in accordance with ACI214. Quality control charts showing field test results shall be included with the test results for each class of concrete in each major structure. Charts shall be prepared in accordance with ACI 214. Quality control charts shall be maintained throughout the entire job and shall be available for the Engineer's inspection at any time. If the 28-day test results fall below the specified compressive strength for the class of concrete required for any portion of the work, adjustment in the proportions, water content, or both, shall be made as necessary at the Contractor's expense. Changes and adjustments shall be reported in writing to the Engineer. If compressive test results indicate concrete in place may not meet structural requirements, tests shall be made to determine if the structure or portion thereof is structurally sound. Tests may include, but not be limited to, cores in accordance with ASTM C42 and any other analyses or load tests acceptable to the Engineer. Costs of such tests shall be borne by the Contractor. b. TESTS FOR CONSISTENCY OF CONCRETE. The slump shall be as specified when measured in accordance with ASTM C143. Samples for slump determination BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-26 shall be taken from the concrete during placing. Tests shall be made at the beginning of concrete placement operation and at subsequent intervals to insure that the specification requirements are met. Slump tests shall also be performed whenever standard cylinders are cast. c. TESTS FOR TEMPERATURE AND AIR CONTENT: Temperature tests shall be made at frequent intervals during hot or cold weather conditions until satisfactory temperature control is established. Whenever standard cylinders are cast, temperature tests shall be performed. Air content shall be as specified when measured in accordance with ASTM C231. Air content shall be measured whenever standard cylinders are cast. D. FINAL LABORATORY REPORT: A final report, prepared by the testing laboratory, shall be provided at the completion of all concreting. This report shall summarize the findings concerning concrete used in the project and provide totals of concrete used by class and structure. Final quality control charts for compressive strength tests for classes of concrete specified in each major structure shall be included. The report shall also include the concrete batch plant's coefficient of variation and standard deviation results for each class of concrete as determined in accordance with ACI214. 3.16 REPAIR OF DAMAGED CONCRETE, CRACKING: A. REPAIR METHODS: Damaged or excessively cracked concrete shall be repaired by one of the following methods: 1. Fill the joint or crack by drilling holes to the affected area, install injection ports and force epoxy or chemical grout (expanding urethane) into the joint under pressure. The material type, whether epoxy or chemical grout shall be made by the Engineer. After injection and cure, ports, sealing mix and surface generally shall be cleaned and worked to match the specified finish. 2. Fill cracks with low viscosity epoxy, applied by pouring/flooding crack zone until cracks are filled. Prepare surface and cure according to manufacturer's recommendations. At a minimum, prepare surface to result in a clean, dry surface and with no visible detrimental material in cracks to be filled. Conform to temperature limitations for epoxy to be used. Finish to match adjacent areas. 3. Cut a bevel groove 3/8 to 1/2 inch in width and depth, and caulk with sealant in accordance with manufacturer's instructions. This repair method is only to be used where expressly allowed by the Engineer. Groove and caulk shall be applied on wet or hydrostatic pressure side of surface where occurs. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-EM-PLACE CONCRETE AUGUST 2010 03300-27 B. METHODS, WHERE USED: 1. Repair Method 1 shall be used for all cracks in walls, surfaces sloped 1:1 or greater, beams, columns, slabs, overhead surfaces and generally for liquid retaining surfaces. Need for repair depends upon crack width, location, and surface conditions under service conditions. Engineer shall determine repair need in their sole discretion. 2. Repair Method 2 may be utilized in lieu of Method 1 for slabs which receive a raked finish. Method 2 may also be used with Engineer's approval for exposed trowelled and broomed finishes after review of conditions, degree of exposure to public, and proposed repair product and installation. Finish shall substantially match adjacent surfaces. 3. Repair Method 3 shall be limited to dry-surface slabs, walls subject to less than three feet of liquid pressure, or as specifically directed by the Engineer. Method 3 is not an equivalent repair method to Methods 1 or 2 which shall be considered the standards. 3.17 BEARING AND SEAL PADS A. GENERAL: Seal pads are intended to result in a gas-tight and liquid tight seal between surfaces and may also serve as bearing pads. Bearing pads are intended primarily to transmit structural loads between two structural elements. A seal pad is intended to seal by dead load compressive force or mechanical clamping force as detailed. The seal pad may be bonded to one or both surfaces to maintain uniformly tight contact with the pieces contacting it. Neoprene materials may not be compatible with coatings applied later, and the Contractor shall verify that the particular coating(s) proposed for use are: (a) contact compatible without neoprene breakdown; or (b) mask off neoprene which may be exposed to the coating to prevent contact. B. CONCRETE CONTACT: Neoprene pads shall bear against clean, smooth existing concrete. Existing concrete shall be aggressively cleaned with high-pressure hydro-blast (3,500 psi) equipment. Cracks shall be epoxy grouted as specified above. Surface irregularities greater than 1/16 inch shall be roughened to 1/4-inch amplitude and then patched using an epoxy bonding agent and either polymer concrete or profiling mortar as specified in Section 03600. Patch material shall be allowed to cure before installing pad. Seal pad, as indicated on the drawings, shall be bonded to existing concrete prepared as above. Bonding agent shall be as recommended by the pad manufacturer, and shall not allow shear sliding of the pad either with or without load normal to its surface. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-28 C. METAL SURFACE CONTACT: Neoprene pads with metal to metal contact shall be 1/4 inch minimum thickness or as shown on the drawings; Compression is achieved by tightening connection bolts to specified torque determined by: (a) the equipment manufacturer; or (b) structural specifications on the drawings; or (c) minimum 1/16 turn past "snug tight" as defined by AISC Steel Construction Manual, 13th Edition. Bolts shall be tightened in multiple steps, proceeding around the joint to result in a uniform compression of the pad. Contact surfaces shall be clean, smooth, and not evidence harmful sharp edges or chemicals. Certain pieces of equipment may have gasket specifications particular to that piece of equipment, and the Contractor is referred to those Sections of the specifications for detailed requirements. Hatches and other metal surfaces in contact with concrete shall be protected by coatings as specified in specification 09900. 3.18 WATERTIGHTNESS, TESTING AND REPAIR A. WATER RETAINING CONCRETE TANKS AND CHANNELS: Concrete tanks, basins, reservoirs and channels which have walls or slabs subjected to hydrostatic pressure shall be tested for watertightness. The tests shall be made after the structure is complete and the concrete has achieved its specified 28-day strength, but prior to application of waterproofing coating or backfilling. Testing shall consist of filling the tank or channel with water to the maximum operating water surface for at least 72 hours and then visually inspecting the dry side of all walls and base perimeter of slab for evidence of leakage. Damp spots, leakage, or seepage revealed by the test, including those caused by shrinkage of concrete, honeycombed areas, construction joints, or other sources shall be repaired by Method 1, paragraph 03300-3.16-A.l. Damp spots are defined as spots from which water that can be picked up on dry hand. The Contractor shall re-test tanks or channels which have been repaired to check the suitability of repairs. Water required for testing and re-testing shall be provided by the Contractor and disposed of so as not to create a nuisance. All liquid retaining or conveying concrete structures must also meet maximum leakage criteria set forth in ACI350.1 as follows: Structure Type Cylindrical water and wastewater storage tanks and reservoirs other than digesters Digesters Rectangular basins and tanks Concrete paved reservoirs and channels ACI 350.1 Designation HST-025 SHT-050 HST-050 HST-100 Tightness Criterion 0.025% per day 0.050% per day (surcharged hydrostatic test) 0.050% per day 0.10% per day Note: All damp spots on or leakage through walls or wall-to-slab joints shall be repaired as described above. Leakage equal to or less than the values shown in the table above is permitted only through the base slab or mat foundation. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 CAST-IN-PLACE CONCRETE 03300-29 Volume loss shall be measured by measuring the vertical distance from the water surface to a fixed point on the tank above the water surface taking into account evaporation from open surfaces. If the drop in water surface in the 24-hour period exceeds the values given in the table above, exclusive of evaporation, the leakage shall be considered excessive and shall be remedied. 3.19 CLEANUP Upon completion of the work and prior to final inspection, the Contractor shall clean all concrete surfaces. The cleaning procedures shall be as follows: After sweeping with an ordinary broom to remove the loose dirt, the surface shall be flushed with clean water. Final scrubbing by hand or machine shall follow. Floors that have curing and sealing compound shall be cleaned of loose dirt and debris by sweeping with ordinary brooms. They shall then be washed and mopped with clean water. Finally, one additional coat of the same clear curing and sealing compound shall be applied in the same manner as specified. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) CAST-IN-PLACE CONCRETE AUGUST 2010 03300-30 SECTION 03400 PRECAST CONCRETE PART 1 - GENERAL 1.01 DESCRIPTION A. Scope: This section specifies the materials and labor required for the manufacture and erection of precast concrete. B. Type: Precast concrete includes precast storm drains and trench drains within the Buena Vista Lift Station yard. 1.02 QUALITY ASSURANCE A. General: 1. The Contractor shall provide certification from the precast concrete manufacturer mat the materials and manufacture of precast work supplied conforms to these specifications. The certification shall be signed by an officer of the manufacturer's corporation. 2. The responsibility for furnishing and installing precast concrete conforming to the specifications is solely that of the Contractor. B. Testing Laboratory: All testing shall be performed by recognized independent laboratories specializing in the particular test to be performed, and conforming to the requirements of the National Bureau of Standards and ASTM E329. C. Reference Standards: 1. The appropriate reference standards are specified in specification Sections 03200 and 03300 of this project manual, and the following documents. They are part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PRECAST CONCRETE AUGUST 2010 03400-1 Reference Title ^**r' ACI318 Building Code Requirements for Reinforced Concrete AWS D1.1 Structural Welding Code - Steel AASHTO Standard Specification for Highway Bridges MNL-116 Prestressed Concrete Institute's Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete Products, third edition 1.03 SUBMITTALS A. In accordance with specification Section 01300 and in addition to the requirements of that section, the following submittals shall be provided: 1. Concrete Mix: Prior to casting any precast elements, concrete mix design shall be submitted to the Engineer for acceptance. 2. Shop Drawings: Four copies of shop drawings shall be provided showing product location, fabrication details, number identification marks, reinforcement, connection details including field installed anchor sizes and locations, if required, openings, loose or embedded items and inserts, dimensions and relationship to adjacent materials in sufficient detail to cover manufacture, handling, and erection. Shop drawings shall be accompanied by a letter signed by a California Registered Civil or Structural Engineer, certifying that, the shop drawings submitted represent construction which meets or exceeds the requirements of the Contract Documents and the requirements of codes and agencies having jurisdiction over the Work. 1.04 LABELING A. Each panel or member shall have an identification mark indicating its location in the structure as shown on the placing diagrams and date of casting. 1.05 HANDLING AND STORAGE A. Unless specified otherwise herein, fabrication, handling and erection of precast elements shall be in accordance with the recommendations made by ACI318 and ACI Committee 533. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PRECAST CONCRETE AUGUST 2010 03400-2 B. Precast elements shall be properly supported off the ground to avoid damage during curing, storage, handling and hauling. Lateral support shall be sufficient to prevent bowing, warping, or permanent set due to creep. Edges of the units shall be adequately protected by padding or other means to prevent staining, chipping or spelling of concrete. Lifting devices shall have a minimum safety factor of 4. PART 2-PRODUCTS 2.01 PERFORMANCE AND DESIGN REQUIREMENTS A. Concrete mix design and compressive strength shall meet or exceed that as specified for Class C-2 concrete in specification Section 03300. B. Design live loads for structural precast units are given on the Drawings. Design seismic criteria are given on Drawing 2-S-l. The Contractor shall furnish the precast supplier with locations and loads of mechanical equipment. The precast units shall be designed for the actual mechanical equipment to be supplied. 2.02 PRECAST CONCRETE MATERIALS A. Cement: Concrete in contact with soil or liquids shall be formulated using Type II or Type V Portland Cement conforming to ASTM C150. Concrete not in contact with soil or liquids may be formulated using Type I or Type III Portland cement. Cement shall contain less than .60% alkalies and shall be from one source throughout the entire project. B. Aggregates: Aggregates for normal weight concrete shall conform to ASTM C33 with a maximum size of 3/i-inch. C. Water: Water shall be clean, potable, free from injurious amounts of oil, alkalies, organic materials and other deleterious substances. D. Admixture: Admixture shall be Pozzolith 300-R manufactured by Master Builders, Plastiment manufactured by Sika Chemical Corp., or equal. Admixture shall be used in strict accordance with manufacturer's recommendations. Calcium chloride or any admixture containing calcium chloride shall not be used. E. Reinforcing Steel: Reinforcing steel shall conform to ASTMA615, including supplementary requirements, and shall be Grade 60 except that bars to be welded shall be Grade 40 or ASTM A706. F. Embedded Items and Anchorage Devices: All embedded items, inserts, and anchorage devices exposed to view, moisture or weather shall be hot-dipped galvanized steel. Anchorage devices shall be fabricated from ASTM A36 steel. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PRECAST CONCRETE AUGUST 2010 03400 - 3 G. Penetrations: All required penetrations and openings larger than 6 inches in diameter or 6 inches square shall be formed in place at the time of casting. Additional reinforcing shall be added where required to meet loading requirements. Openings and penetrations smaller than 6 inches may be core drilled. H. Molds: 1. Material from which molds are to be fabricated shall be steel, concrete, fiberglass, reinforced plastic or wood. The selection of materials for molds shall be at the manufacturer's option, except that wood shall not be used without the express approval of the Engineer. All elements shall be cast in molds of rigid construction, accurate in detail with precise corners and arises, and designed to provide a close control of dimensions and details as indicated on the drawings. 2. Prior to casting of precast elements, molds shall have all surface joints, radii, corners, etc., filled, ground, filed, straightened or otherwise removed to provide a finished concrete surface that is smooth and dense, free of honeycombing, large air pockets, offsets, sinkages, or other irregularities. I. Parting Compound: All molds shall be coated with parting compound to facilitate removal of elements from molds. Parting compound shall be non-petroleum, nonstaining and shall be of a nature and composition not deleterious to concrete. 2.03 PRODUCT DATA A. The following information shall be provided: 1. Laboratory Test Reports: Before delivery of materials, three copies of the reports of the tests specified herein shall be provided. Test reports on previously tested materials shall be accompanied by the manufacturer's statement that the previously tested material is the same type, quality, manufacture, and make as that proposed for use in this project. Test reports are required for the following: 1. Cement 2. Aggregates 3. Pozzolan 4. Admixtures 5. Curing compounds 6. Waterstops 7. Concrete mix designs o BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PRECAST CONCRETE 03400-4 2.04 UTILITY TRENCH (Not Used) A. Provide a precast concrete underground utility trench system as manufactured by Trenwa, Inc. (Patent#2862367); 1419 Alexandria Pike; Fort Thomas, KY 41075. The manufacturer must have experience in design and fabrication of similar products and with facilities for fabricating them with the quality specified herein and without delay to the specified schedule. B. The precast components shall be designed to conform to requirements stated in ASTM C857-07 "Practice for Minimum Structural Design Loading for Underground Precast Concrete Utility Structures, ASTM C858-07 "Specifications for Underground Precast Concrete Utility Structures" and ACI-318 "Building Code Requirements for Reinforced Concrete". C. Product Description: 1. The trench system will consist of precast concrete U-shaped bases and removable covers equivalent to Trenwa's One Piece trench system to be installed in earth trenches with covers extending above the surrounding crushed rock surface. 2. The trench system will be designed to support at least 9,000 pound G.V.W. for pickup trucks and light duty utility vehicles. 3. The trench shall have an interior clear cross sectional area of 20" wide x 15" deep. 4. The precast U-shaped bases for the trench will be furnished in standard 10 foot lengths, except that special lengths will be furnished where required by the layout on the drawings. The U-shaped bases will be solid bottom. 5. The precast trench covers will be furnished in lightweight sections, sized to permit removal by a single person. The covers will have slots for lifting tools and will be made of fiber and steel reinforced concrete. 6. The precast trench system shall be designed and constructed so that neither the covers, nor temporary side-to-side braces need to be installed to facilitate installation or subsequent machine backfilling and tamping. 2.04 TRENCH DRAIN A. Provide an in line trench trench drain as shown on the drawings. Trench drains shall be 12-Inch internal width, Type S300K with cast iron grates as manufacured by ACO Polymer Products or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PRECAST CONCRETE AUGUST 2010 03400-5 B. The trench drain body shall be made from polyester resin binder reinforced by mineral aggregates and fillers and shall be designed to conform to requirements stated in ASTM C857-07 PART 3 - EXECUTION 3.01 INSTALLATION A. Casting: 1. Casting shall be accomplished by methods and equipment that are in conformance with generally acceptable systems for this type of Work. All precast concrete shall be manufactured by a plant thoroughly experienced in this type of Work. The manufacturer shall meet all production schedules. Surfaces on which units are cast shall be level and free from any imperfections detrimental to the surface appearance of the finished units. Parting compound shall be applied evenly as per manufacturer's recommendations. 2. Concrete shall be so handled as to prevent segregation of materials and shall be continuously vibrated during casting, either internally or externally, to achieve proper compaction, finish and distribution of concrete. All precautions must be taken to keep the reinforcing steel in the proper location during placing and consolidation of^ the concrete. Unless shown otherwise and except at concrete faces exposed to soil or liquids, all reinforcing steel shall have a minimum cover of %-inch. At concrete faces exposed to soil or liquids, cover shall be 1-1/2 inches minimum. Embedded items shall be accurately placed and maintained in their proper location during the casting operation. Special inserts or other devices for handling of panels for the convenience of the manufacturer shall not be exposed to view after members are erected. Embedded anchors, inserts, plates, angles and other cast-in items shall have sufficient anchorage and embedment for design requirements. 3. Casting, bowing, warpage and dimensional tolerances shall be in accordance with MNL-116, Third Edition. B. Curing: All precast units shall be steam cured for a period of at least 12 hours. Fog spraying may be used when reviewed by the Engineer. Precast elements shall not be removed from molds for a minimum period of 12 hours after casting, or until concrete has attained a minimum compressive strength of 3,500 pounds per square inch, whichever governs. After removal from the forms, curing by steam or fog spraying shall be continued until concrete has attained specified strength and confirmed by standard tests. Curing procedures shall be consistent and uniform throughout the entire project. C. Welding: The quality of material and fabrication of all welded connections shall conform to the latest AISC "Specification for the Design, Fabrication and Erection of Structural Steel for Buildings." All weldments shall be made in accordance with the applicable BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PRECAST CONCRETE AUGUST 2010 03400-6 provisions of AWS. All welding, other than tacks, shall be done by certified welders. All units shall be protected from damage by field welding or cutting operations. Noncombustible shields shall be provided as necessary for this purpose. D. Joints and Joint Sealants: 1. In all instances, the edges of precast concrete units and of adjacent material shall be sound, smooth, clean and free of all contaminants prior to joint treatment. 2. Sealant and primer shall be supplied by the same manufacturer and the primer, when required, shall be as recommended for the particular sealant used. All sealant compounds shall be delivered to the job in the manufacturer's original sealed containers with labels intact and shall be applied in strict accordance with the manufacturer's recommendations. Sealant shall be as specified in specification Section 07900 of these specifications. E. Waterproofing and Moistureproofing 1. Waterproofing and moistureproofing shall be as specified in section 07100 3.02 ERECTION A. Any errors or misalignment in the structure, which would prevent the proper setting of the elements shall be corrected by the Contractor before the erection is commenced. Erection shall be supervised and performed by workmen skilled in this type of Work. Each element shall be set in the proper position, carefully plumbed and anchored securely to the structural frame. Adjustments or changes in connections, which could involve additional stresses in the products or connections, shall not be permitted without approval of the Engineer. All bearing surfaces shall be true to line and grade. Erection tolerances shall be in accordance with MNL-116. All joints shall be uniform and straight. 3.03 CLEANING AND REPAIRING A. After installation, precast elements shall be protected from all damage until final acceptance by the Engineer. Precast units with cracks, spalls, and other defects shall be subject to rejection. Units reviewed for repair shall be repaired to the satisfaction of the Engineer. 3.04 ALTERNATIVE DESIGN A. The Contractor may offer an alternative design for any precast element. Such design shall be comparable in terms of strength, deflection, finish and all other design criteria BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PRECAST CONCRETE AUGUST 2010 03400 - 7 indicated. Complete drawings prepared and sealed by a civil or structural engineer registered in the State of California where applicable shall be submitted to the Engineer for his review in accordance with specification Section 01300 of this project manual. No alternative design will be permitted, unless it has been specifically accepted in writing by the Engineer. If an alternative design is accepted, all expenses resulting there shall be borne by the Contractor. ** END OF SECTION** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PRECAST CONCRETE AUGUST 2010 03400-8 SECTION 03600 GROUT PART 1-GENERAL 1.01 DESCRIPTION This section specifies grout for column and other structural support bases, equipment bases, crack repair, surface repair and uses other than masonry. 1.02 QUALITY ASSURANCE A. QUALITY CONTROL BY CONTRACTOR: To demonstrate conformance with the specified requirements for grout, the Contractor shall provide samples for analysis to an independent testing laboratory provided by the City of Carlsbad in accordance with Section 4 of the General Provisions. B. SPECIAL INSPECTION: Where Special Inspection is specified, noted on the drawings, required by Code or product manufacturer, the City of Carlsbad shall provide the services of a qualified Special Inspector according to Section 4 of the General Provisions. C. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference Title BUENA VISTA LIFT STATION FORCE MAIN (VC-4) GROUT AUGUST 2010 03600-1 Reference ASTM C33 ASTM C40 ASTMC88 ASTM Cl 17 ASTMC136REVA ASTMC150 ASTMC289 ASTMC881 ASTM C1107 ASTMD2419 Title Concrete Aggregates Organic Impurities in Fine Aggregates for Concrete Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate Material Finer Than 75 |im (No. 200) Sieve in Mineral Aggregates by Washing Sieve Analysis of Fine and Coarse Aggregates Portland Cement Potential Reactivity of Aggregates (Chemical Method) Epoxy-Resin-Base Bonding Systems for Concrete Packaged Dry, Hydraulic-Cement Grout (Nonshrink) Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate 1.03 SUBMTTTALS The following information shall be provided in accordance with Section 01300: 1. Complete product literature and installation instructions for epoxy grout (all uses) and cementitious non-shrink grout. 2. Current ICBO Evaluation Report, or equivalent in other jurisdictions, for adhesives used for dowel and anchor setting. PART 2-PRODUCTS 2.01 MATERIALS A. CEMENT: Portland cement shall be ASTM C150, Type II or Type V, low alkali, containing less than 0.60 percent alkalies. B. AGGREGATE: 1. GENERAL: Aggregate shall be nonreactive and shall be washed before use. When sources of aggregate are changed, test reports shall be provided for the new material. The tests specified shall be performed prior to commencing grout work. 2. FINE AGGREGATE: Fine aggregate shall be hard, dense, durable particles of either sand or crushed stone regularly graded from coarse to fine and shall conform to ASTM C33 as modified herein. When tested in accordance with ASTM C136, gradation shall BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 GROUT 03600-2 be such that 100 percent by weight will pass a standard No. 8 mesh sleeve and no less than 45 percent by weight will pass a standard No. 40 mesh sieve. Variation from the specified gradations in individual tests will be acceptable if the average of three consecutive tests is within the specified limits and the variation is within the permissible variation listed below: U.S. standard sieve size 30 or coarser 50 or finer Permissible variation in individual tests, percent 2 0.5 Other tests shall be in accordance with the following specifications: Test Organic Impurities Amount of Material Passing No. 200 Sieve Soundness Reactivity Sand Equivalent Test method ASTM C40 ASTMC117 ASTMC88 ASTMC289 ASTMD2419 Requirements Color lighter than standard 3% maximum by weight 10% maximum loss with sodium sulfate Innocuous aggregate Minimum 80 C. ADMIXTURES: 1. GENERAL: Admixtures shall be compatible with the grout. Calcium chloride or admixtures containing calcium chloride are not acceptable. Admixtures shall be used in accordance with the manufacturer's recommendations and shall be added separately to the grout mix. 2. ACCEPT ABLE ADMIXTURES: Acceptable products including water reducing, water reducing and retarding, and superplasticizing are specified in Section 03300. Contractor shall select as appropriate for the use intended and in conformance with manufacturer's recommendations and these specifications. 3. LUBRICANT FOR CEMENT PRESSURE GROUTING: Lubricant additive for cement pressure grouting shall be Intrusion Prepakt Intrusion Aid, Sika Intraplast N, or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 GROUT 03600-3 D. WATER: s*\ Water for washing aggregate, for mixing and for curing shall be free from oil and deleterious amounts of acids, alkalies, and organic materials; shall not contain more than 1000 mg/1 of chlorides as Cl, nor more than 1300 mg/1 of sulfates as 864; and shall not contain an amount of impurities that may cause a change of more than 25 percent in the setting time of the cement nor a reduction of more than 5 percent in the compressive strength of the grout at 14 days when compared with the result obtained with distilled water. Additionally, water used for curing shall not contain an amount of impurities sufficient to discolor the grout. 2.02 GROUT A. DRYPACK GROUT: Drypack grout shall be a mixture of approximately one part cement, 1-1/2 to 2 parts fine aggregate, water reducing retarder, and sufficient water to make a stiff workable mix. B. CEMENTITIOUS NONSHRINK GROUT: Cementitious nonshrink grout is available with both metallic and nonmetallic aggregate. Metallic aggregate grout shall be Master Builders Embeco 636, Burke Company Metallic Spec Grout, Sonnoborn Ferrolith G Redimix, or equal. Nonmetallic aggregate grout shall be Five Star Products, Inc. Five Star Grout, Master Builders Masterflow 713, Burke Company Non- Ferrous, Non-Shrink Grout, Hi-Flow Grout by Euclid Chemical Company, or equal. C. EPOXY GROUT FOR EQUIPMENT MOUNTING: Epoxy grout for equipment mounting shall be a non-cementitious, resin based, muli-component formulation. Epoxy grout shall be flowable, with shrinkage minimized to achieve minimum 98% effective bearing area. Acceptable products include: Masterflow 648 CP Plus by Masterbuilders; Sikadur 42 by Sika Corporation; E3-G by Euclid Chemical Company; or equal. D. EPOXY GROUT FOR CRACK REPAIR AND DOWEL ANCHORAGE: Except as noted below, epoxy grout shall be a high modulus, two-component, moisture insensitive, 100 percent solids, thermosetting modified polyamid epoxy compound. The consistency shall be a paste form capable of not sagging in horizontal or overhead anchoring configurations. Material shall conform to ASTM C881, Type IV, Grade 3, and shall have a heat deflection temperature in excess of 130 degrees F. Candidate manufacturers include Master Builders Concresive Standard Paste or SPL, and Sika Corporation Sikadur Hi-Mod Series, or equal. Epoxy for pressure grouting/crack injection shall be a two-component, moisture insensitive, high modulus, injection grade, 100 percent solids, blend of epoxy-resin compounds. The consistency shall be as required to achieve complete penetration in hairline cracks and larger. BTJENA VISTA LIFT STATION FORCE MAIN (VC-4) GROUT AUGUST 20 10 03600-4 Material shall conform to ASTM C881, Type 1, Grade 1. Candidate manufacturers include Sika Corporation Sikadur 52, Master Builders SCB ConcresiVe 1300 series, and Adhesive Technology Corporation SLV 300 series, or equal. E. POLYMER CONCRETE (PROFILING MORTAR): Polymer concrete (profiling mortar) for resurfacing or patching shall consist of a liquid binder and dry aggregate mixed together to make a mortar or grout of a consistency as required for the application. The liquid binder shall be a chemical and oil resistant, stress relieved, low modulus, moisture insensitive, two-component epoxy-resin compound. The consistency shall be similar to lightweight oil for proper mixing with aggregate. Material shall conform to ASTM C881, Type 3, Grade 1. Candidate manufacturers include Sika Corporation Sikadur Lo-Mod series, Master Builders Concresive 1490, and Adhesive Technology Corporation 400 series, or equal. Alternatively, polymer concrete may be a one-component, shrinkage compensated, polymer- modified cement based mortar, with or without fiber reinforcement. Candidate manufacturers include Master Builders R300 series, or equal. The aggregate shall be oven dry in sealed packages until time of mixing, and shall be of size and consistency compatible with recommendations of manufacturer of liquid binder for intended application. R ADHESIVE FOR DOWEL AND ANCHOR SETTING: Adhesive for setting dowels and anchoring connection/baseplate bolts may either be tube applied or capsule style. Adhesive shall evidence approval for the use intended by ICBO certification report or other recognized and Code compliant agency. Tube-applied adhesive shall be a modified epoxy formulation. Acceptable products include HY150 by Hilti, SET Adhesive by Simpson Strong-Tie Company, or equal. Adhesive resin capsules shall consist of sealed glass or foil capsules containing premeasured amounts of a polyester or vinylester resin, quartz sand aggregate and a hardener contained in a separate vial within the capsule. Acceptable adhesive capsule products include HVU by Hilti, Needle Capsule or Chem-Stud by Powers-Rawl, or equal. Capsule adhesives shall utilize the same manufacturer's insert stud with chisel point, or Contractor shall demonstrate through submittal to the Engineer that the substitute proposed substantially meets or exceeds the geometric and material properties of same. 2.03 PRESSURE GROUTING EQUIPMENT Pressure grouting equipment shall include a mixer and holdover agitator tanks and shall be designed to place grout at pressures up to 50 psi. Gages shall be provided to indicate pressure used. The mixer shall be provided with a meter capable of indicating to one-tenth of a cubic foot the volume of grout used. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) GROUT AUGUST 2010 03600-5 2.04 PRODUCT DATA The following information shall be provided in accordance with Section 01300. A. MANUFACTURER'S DATA: Manufacturer's data shall be provided for the following: 1. Bonding compounds 2. Pressure grout 3. Retardants 4. Polymer concrete B. LABORATORY TEST REPORTS: Test reports on previously tested materials shall be accompanied by the manufacturer's statement that the previously tested material is the same type, quality, manufacture, and make as that proposed for use in this project. Test reports are required for the following: 1. Cement 2. Aggregates 3. Retardants 4. Bonding compounds 5. Epoxy resin C. EVIDENCE OF TESTING LABORATORY COMPETENCE: The Contractor shall require that the laboratory provide directly to the Engineer evidence of the most recent inspection of its facilities by the Cement and Concrete Reference Laboratory of the National Bureau of Standards. The evidences shall show that deficiencies mentioned in the report of that inspection have been corrected. The evidence of inspection shall be provided prior to delivery of materials to the job site. PART 3--EXECUTION 3.01 GENERAL Bonding compound for use with grout is specified in Section 03300. Primer, if required for polymer concrete, shall be provided per manufacturer's recommendation. o BUENA VISTA LIFT STATION FORCE MAIN (VC-4) GROUT AUGUST 2010 03600-6 3.02 DRYPACK GROUT Drypack grout shall be used for small or shallow built-up surfaces and minor repairs. Surfaces required to be built up with drypack grout shall be roughened by brushing, cleaned, and coated with the bonding compound specified in paragraph 03300-2.05 before the application of the grout. The drypack grout shall be applied immediately following the application of the bonding compound in bands or strips to form a covering of the required thickness. The covering shall be smooth. Construction joints in the grout shall be sloped and shall be cleaned and wetted before application is resumed. Drypack grout shall be cured in accordance with Section 03300. Grout shall not be placed during freezing weather unless adequate protection is provided. 3.03 CEMENTITIOUS NONSHRINK GROUT Nonshrink, cementitious, nonmetallic aggregate grout shall be used for column base plates, structural bearing plates, and all locations where the general term "non-shrink grout" is indicated on the drawings. Use of this grout to support the bearing surfaces of machinery shall be as specified in Section 11002 or as detailed on the Drawings for specific locations or pieces of equipment. If guidance in not provided in locations noted above, use of non-shrink grout for equipment mounting shall be limited to equipment less than 20 horsepower or 1,000 pounds. Grout shall be placed and cured in accordance with manufacturer's instructions. 3.04 EPOXY GROUT FOR EQUIPMENT MOUNTING Prepare concrete surfaces of equipment pads as indicated in details on the Drawings and as required by the epoxy grout manufacturer. Epoxy grout for equipment mounting shall be placed and cured in accordance with the requirements of Section 11002, details on the Drawings, and in strict conformance with manufacturer's recommendations. 3.05 EPOXY GROUT FOR CRACK REPAIR AND DOWEL ANCHORAGE Epoxy grout shall be used for repairing cracks by pressure grouting or gravity flow, repairing structural concrete, and may be used for setting reinforcing dowels or anchor bolts into holes for grouting. Concrete shall be primed in accordance with the grout manufacturer's instructions. Use of epoxy grout for anchorage of bolts or reinforcing dowels shall be subject to the following conditions: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) GROUT AUGUST 2010 03600-7 1. Use shall be limited to locations where exposure, on an intermittent or continuous basis, to acid concentrations higher than 10 percent, to chlorine gas, or to machine or diesel oils, is extremely unlikely. 2. Use shall be limited to applications where exposure to fire or exposure to concrete or rod temperature above the product's heat deflection temperature or 120 degrees F (whichever is less) is extremely unlikely. Overhead applications (such as pipe supports) because of the above concerns, shall be disallowed. 3. Approval from Engineer for specific application and from supplier of equipment to be anchored, if applicable. 4. Anchor diameter and grade of steel shall be per contract documents or per equipment supplier specifications. Anchor shall be threaded or deformed full length of embedment and shall be free of rust, scale, grease, and oils. 5. Embedment depth and hole diameter shall be as specified. 6. Holes shall have rough surfaces, such as can be achieved using a rotary percussion drill. 7. Holes shall be blown clean with compressed air and be free of dust or standing water prior to application of grout. 8. Anchor shall be left undisturbed and unloaded for full curing period.. 9. Anchors shall not be placed in concrete below 25 degrees F. 3.06 ADHESIVE CAPSULES Adhesive resin capsules may be used for setting and anchoring reinforcing dowels or anchor bolts into predrilled holes in concrete. Use of the adhesive resin capsules for anchorage of reinforcing dowels or bolts shall be as specified in paragraph 05501-3.03. 3.07 PRESSURE GROUTING Prior to grouting, systems and holes to be grouted shall be washed clean. Washing is not required for grouting soil voids outside pipe cylinders or casing pipes. Grouting, once commenced, shall be completed without stoppage. In case of breakdown of equipment, the Contractor shall wash out the grouting system sufficiently to ensure fresh grout and adequate bond and penetration will occur upon restarting the grouting operation. Grout pressure shall be maintained until grout has set. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) GROUT AUGUST 2010 03600-8 SECTION 05501 ANCHOR BOLTS PART 1» GENERAL 1.01 DESCRIPTION This section specifies anchor bolts complete with washers and nuts. Unless otherwise specified, anchor bolts shall be type 304 stainless steel. 1.02 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference ANSIA58.1 ASTM A36/A36M ASTM A307 ASTM A320/A320M UBC Title Minimum Design Loads for Buildings and Other Structures Structural Steel Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength Alloy-Steel Bolting Materials for Low Temperature Service Uniform Building Code BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 ANCHOR BOLTS 05501-1 PART 2 » PRODUCTS 2.01 GENERAL Anchor bolt holes in equipment support frames shall not exceed the bolt diameters by more than 25 percent, up to a limiting maximum oversizing of 1/4 inch. Unless otherwise specified, minimum anchor bolt diameter shall be 1/2 inch. Tapered washers shall be provided where mating surface is not square with the nut. Expansion, wedge, or adhesive anchors set in holes drilled in the concrete after the concrete is placed will not be permitted in substitution for anchor bolts except where otherwise specified. Upset threads shall not be acceptable. 2.02 MATERIALS Anchor bolt materials shall be as specified in Table A. Table A. Anchor Bolt Materials Material Steel bolts Fabricated steel bolts Stainless steel bolts, nuts, washers Expansion anchors Wedge anchors Adhesive anchors Specification ASTMA307,GradeA ASTM A36 ASTM A320, Type 304a HILTI-BOLT, McCulloch Industries, or equal ITT, Phillips Drill Co., or equal. HILTI-HVA, PARABQND Capsule, or equal "Use Type 316 where specified. 2.03 DESIGN Anchor bolts for equipment frames and foundations shall be designed in accordance with the California Building Code, latest edition for the appropriate seismic zone of the Carlsbad locality. o BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 ANCHOR BOLTS 05501-2 2.04 PRODUCT DATA The following information shall be provided in accordance with Section 01300 for all bolt systems not cast-in-place: 1. Data indicating load capacities. 2. Chemical resistance. 3. Temperature limitations. 4. Installation instructions. 5. Evaluation report for expansion and wedge type anchors as specified in paragraph 05501-3.04. PART 3 « EXECUTION 3.01 GENERAL Fieldwork, including cutting and threading, shall not be permitted on galvanized items. Dissimilar metals shall be protected from galvanic corrosion by means of pressure tapes, coatings or isolators. Grouting of anchor bolts with nonshrink or epoxy grouts, where specified, shall be in accordance with Section 03600. 3.02 CAST-IN-PLACE ANCHOR BOLTS Anchor bolts to be embedded in concrete shall be placed accurately and held in correct position while the concrete is placed or, if specified, recesses or blockouts shall be formed in the concrete and the metalwork shall be grouted in place in accordance with Section 03300. The surfaces of metalwork in contact with concrete shall be thoroughly cleaned. After anchor bolts have been embedded, their threads shall be protected by grease and the nuts run on. 3.03 ADHESIVE ANCHOR BOLTS Use of adhesive or capsule anchors shall be subject to the following conditions: 1. Use shall be limited to locations where exposure, on an intermittent or continuous basis, to acid concentrations higher than 10 percent, to chlorine gas, or to machine or diesel oils, is extremely unlikely. 2. Use shall be limited to applications where exposure to fire or exposure to concrete or rod temperature above 120 degrees F is extremely unlikely. Overhead applications (such as pipe supports) because of the above concerns, shall be disallowed. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) ANCHOR BOLTS AUGUST 2010 0550U3 3. Approval from Engineer for specific application and from supplier of equipment to be anchored, if applicable. 4. Anchor diameter and grade of steel shall be per contract documents or per equipment supplier specifications. Anchor shall be threaded or deformed full length of embedment and shall be free of rust, scale, grease, and oils. 5. Embedment depth shall be as specified. Adhesive capsules of different diameters may be used to obtain proper volume for the embedment, but no more than two capsules per anchor may be used. When installing different diameter capsules in the same hole, the larger diameter capsule shall be installed first. Any extension or protrusion of the capsule from the hole is prohibited. 6. All installation recommendations by the anchor system manufacturer shall be followed carefully, including maximum hole diameter. 7. Holes shall have rough surfaces, such as can be achieved using a rotary percussion drill. 8. Holes shall be blown clean with compressed air and be free of dust or standing water prior to installation. 9. Anchor shall be left undisturbed and unloaded for full adhesive curing period. 10. Concrete temperature (not air temperature) shall be compatible with curing requirements of adhesives per adhesive manufacturer. Anchors shall not be placed in concrete below 25 degrees F. 3.04 EXPANSION ANCHORS Use of expansion or wedge type anchors shall be subject to conditions 2, 3, 4, 6, 7, and 8 specified in paragraph 05501-3.03. The Contractor shall supply the Engineer with the current evaluation report from the International Conference of Building Officials for the particular brand of expansion anchors to be used. **END OF SECTION** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) ANCHOR BOLTS AUGUST 2010 05501-4 SECTION 05503 ACCESS HATCHES PART 1« GENERAL 1.01 SUMMARY A. Section Includes: 1. Aluminum access hatches suitable for AASHTO H20-44 loading. 1.02 REFERENCES A. Trade and Technical Association Standards: 1. "Structural Aluminum" published by National Association of Architectural Metal Manufacturers (NAAMM). 2. "Welding Aluminum" published by American Welding Society (AWS). 1.03 SUBMITTALS A. Submit in accordance with Section 01300. B. Product Data: Fully describe all items proposed for use. C. Shop Drawings: Show dimensions, attachments, inserts and relationship of work to adjoining construction. 1.04 QUALITY ASSURANCE A. Regulatory Requirements: 1. Applicable Occupational Safety and Health Regulations, 2. California Building Code, latest Edition. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) ACCESS HATCHES AUGUST 2010 05503-1 1.05 GUARANTEE A. Furnish a written guarantee effective for a period of 2 years after final acceptance of the project that floor hatches shall be free of defects in material and workmanship for a period of (25) twenty-five years from the date of purchase. Should a part fail to function in normal use within this period, manufacturer shall furnish a new part at no charge. PART 2 - PRODUCTS 2.01 ACCESS HATCHES A. Access Hatches shall be dual double-leaf, rated for H-20 loading. A removable center beam shall be installed to allow for complete access. B. Double Leaf: Bilco Model "JD-AL H20"; Babcock-Davis Model B-FGA; U.S.F. Fabrication Model THD; or equal. C. Door Leaves: 44-inch (6.35 mm) thick aluminum, diamond pattern, reinforced as required to withstand H-20 loading. D. Frame: 44-inch (6.35 mm) thick aluminum channel with anchor flange around perimeter. .^ E. Doors: Equip with spring operators and an automatic hold-open arm with a positive *""** automatic latch that will secure the door in the open position until the release handle is activated. Provide snaplock with removable handle. Provide aluminum recessed hasp to door and frame where required for padlock. Provide recessed padlock enclosure. Maximum lifting effort for each door shall be less than 30 Ibs. F. Provide stainless steel hold-open pin through holes in hold-open arms to insure against accidental hatch closure. Attach pin to hatch with a short stainless steel chain to prevent loss. G. Safety Chain: Provide a stainless steel safety chain between double leaf doors at opposite end from latch. H. All hardware: Stainless steel throughout, minimum Type 304. I. Dissimilar metals and aluminum in contact with concrete shall be protected by two coats of System E-3 epoxy in accordance with specification 09900 J. Finish: Mill finish aluminum with bituminous coating applied to the exterior portion of the frame and anchors. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) ACCESS HATCHES AUGUST 2010 05503-2 SECTION 05505 MISCELLANEOUS METAL WORK PART 1 - GENERAL 1.01 DESCRIPTION This section specifies miscellaneous metalwork, which consists of custom fabricated steel metalwork other than structural metalwork. Vandal-resistant stainless steel framed with stainless steel expanded metal panels for air-vacuum release valves as well as cans for air-vacuum release valves are covered under this section. 1.02 QUALITY ASSURANCE A. GENERAL: Shop and field welding shall conform to the requirements of the AISC Manual of Steel Construction. The use of salvaged, reprocessed or scrap materials will not be permitted. B. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference AISC Manual of Steel Construction Title American Institute of Steel Construction, Manual of Steel Construction, Allowable Stress Design-9th Edition BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS METALWORK AUGUST 2010 05505-1 Reference ASTM A36/A36M ASTM A48 ASTM A283/A283M ASTM A307 ASTMA320/A320M ASTM A500 Tide Structural Steel Gray-Iron Castings Low and Intermediate Tensile Strength Carbon Steel Plates, Shapes and Bars Carbon Steel Externally Threaded Standard Fasteners Alloy-Steel Bolting Materials for Low Temperature Service Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes _ PART 2-PRODUCTS 2.01 MATERIALS Materials for miscellaneous metalwork are specified in Table A. Table A, Materials for Miscellaneous Metalwork Material Nonstructural steel bars, angles, clips, and similar items Iron castings Structural steel tubing Steel bolts (except flanges and anchor bolts) Stainless steel Specification ASTM A36 or ASTM A283 ASTM A48 ASTM A500, Grade B ASTM A307, Grade A ASTM A320, Type 304 2.02 FABRICATION A. GENERAL: Holes shall be punched 1/16 inch larger than the nominal size of the bolts, unless otherwise specified. Whenever needed, because of the thickness of the metal, holes shall be subpunched and reamed or shall be drilled. Fabrication including cutting, drilling, punching, threading and tapping required for miscellaneous metal or adjacent work shall be performed prior to hot-dip galvanizing. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 MISCELLANEOUS METALWORK 05505-2 B. SEAT ANGLES, SUPPORTS AND BRACKETS: Seat angles over slide gate guides shall be welded to the guides. Seat angles for grating, supports for floor plates, clips for precast panels and brackets for piping shall be steel, hot-dip galvanized after fabrication unless otherwise specified. C. POWER DRIVEN PINS: Power driven pins may be used in interior locations of nonprocess areas. Pins shall be heat treated steel alloy in accordance with AISI 1062 or 4063 and shall be zinc-plated. Pins shall have capped or threaded heads capable of transmitting the loads the shanks are required to support. Pins that are connected to steel shall have longitudinal serrations around the circumference of the shank. Complete information describing pin capacities and connections shall be provided to the Engineer. Proposed use and locations shall be approved by the Engineer prior to their use. D. IRON CASTINGS: Castings shall be as specified on the drawings. Castings weighing less than 100 pounds shall be hot-dip galvanized after machining. Castings weighing greater than 100 pounds shall be galvanized where specified. E. OTHER MISCELLANEOUS STEEL METALWORK: Other miscellaneous steel metalwork including embedded and nonembedded steel metalwork, hangers and inserts shall be as specified on the drawings and shall be hot-dip galvanized after fabrication. F. ENCLOSURES FOR AIR-VACUUM RELEASE VALVES: Enclosures for air-vacuum release valves shall be provided as shown on the drawings. Air- vacuum valves on the Jefferson Street Bridge shall be installed in new, vandal-resistant stainless steel cages constructed of stainless steel frames with expanded metal panels. Cages shall be rigidly affixed to the bridge structure using Type 304 stainless steel fasteners. Air vacuum valves installed elsewhere shall meet the City of Cralsbad Engineering Standards. PART 3--EXECUTION 3.01 INSTALLATION A. GENERAL: Fieldwork shall not be permitted on galvanized items. Drilling of bolts or enlargement of holes to correct misalignment will not be allowed. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS METALWORK AUGUST 2010 05505-3 Dissimilar metals shall be protected from galvanic corrosion by means of pressure tapes, coatings or isolators. Metalwork to be embedded in concrete shall be placed accurately and held in correct position while the concrete is placed or, if specified, recesses or blockouts shall be formed in the concrete. The surfaces of metalwork in contact with or embedded in concrete shall be thoroughly cleaned. If accepted, recesses may be neatly cored in the concrete after it has attained its design strength and the metalwork grouted in place. Embedments shall be as specified in Section 03300. B. SEAT ANGLES, SUPPORTS AND GUIDES: Seat angles for grating and supports for floor plates shall be set so that they are flush with the floor and also maintain the grating and floor plates flush with the floor. C. POWER DRIVEN PINS: Power driven pins shall be set by a craftsman who is certified by the manufacturer. Pins shall be driven in one initial movement by an instantaneous force that has been selected to attain the required penetration. Driven pins shall conform to the following: Material penetrated by pin Concrete Steel Penetrated material's minimum thickness 16D 1/4 inch Penetration of pin's shank in supporting material 6D minimum Steel thickness plus 2D Minimum space from center of pin' s shank to edge of penetrated matl. 14D 4D Minimum pin spacing 20D 7D V****" Where D = pin shank diameter. When required by the Engineer, pullout tests shall be carried out by the Contractor to prove the effectiveness of the anchorage and the capacity of the pin. 3.02 CLEANING After installation, damaged surfaces of shop primed metals shall be cleaned and touched up with the same material used for the shop coat. Damaged surfaces of galvanized metals shall be repaired as specified in Section 05910. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 MISCELLANEOUS METALWORK 05505-4 SECTION 05910 HOT-DIP ZINC COATING PART 1« GENERAL 1.01 DESCRIPTION This section specifies hot-dip zinc coating. 1.02 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has. been superseded by a version with a later date, discontinued or replaced. Reference ASTMA123 ASTM A143 ASTM A153 ASTM A384 ASTM A385 ASTM A780 MILSPEC DOD-P-21035 Title Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement Zinc Coating (Hot-Dip) on Iron and Steel Hardware Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies Providing High-Quality Zinc Coatings (Hot-Dip) Repair of Damaged Hot-Dip Galvanized Coatings Paint, High Zinc Dust Content, Galvanizing Repair BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 HOT DIP ZINC COATING 05910-1 PART 2-PRODUCTS 2.01 MATERIALS A. ZINC COATING: Zinc coating material shall be as specified in ASTM A153. B. ZINC DUST-ZINC OXIDE COATING: Zinc dust-zinc oxide coating shall conform to MILSPEC DOD-P-21035. Coating shall be as manufactured by Z.R.C. Chemical Products Co., Galvicon Co., or equal. 2.02 FABRICATION REQUIREMENTS Fabrication practices for products to be galvanized shall be in accordance with applicable portions of ASTM A143, A384 and A385. 2.03 PRODUCT DATA The following information shall be provided in accordance with Section 01300: 1. Zinc dust-zinc oxide coating manufacturer's product data showing conformance to the specified product. 2. Manufacturer's recommendation for application of zinc dust-zinc oxide coating. 3. Coating applicator's Certificate of Compliance that the hot-dip galvanized coating meets or exceeds the specified requirements of ASTM A123 or A153, as applicable. PART 3 -- EXECUTION 3.01 APPLICATION Steel members, fabrications and assemblies shall be galvanized after fabrication in accordance with ASTM A123. Unless otherwise specified, steel items weighing 100 pounds or less shall be hot-dip zinc coated. Anchor bolts and nuts 5/8 inch and larger shall be hot-dip zinc coated in accordance with ASTM A153. Anchor bolts and nuts smaller than 5/8 inch and all other bolts, screws, nuts, washers and other minor steel fasteners shall be mechanically zinc coated as specified in Section 05911. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HOT DIP ZINC COATING AUGUST 2010 05910-2 3.02 COATING REQUIREMENTS Coating weight shall conform with paragraph 5.1 of ASTM A123 or Table 1 of ASTM A153, as appropriate. 3.03 REPAIR OF DEFECTIVE GALVANIZED COATING Where zinc coating has been damaged after installation, substrate surface shall be first cleaned and then repaired with zinc dust-zinc oxide coating in accordance with ASTM A780. Application shall be as recommended by the zinc dust-zinc oxide coating manufacturer. Coating shall consist of multiple coats to dry film thickness of 8 mils. Items not physically damaged, but which have insufficient or deteriorating zinc coatings, and items damaged in shipment or prior to installation, shall be removed from the project site for repair by the hot-dip zinc coating method. ** END OF SECTION** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HOT DIP ZINC COATING AUGUST 2010 05910-3 SECTION 05911 MECHANICAL ZINC COATING PART 1« GENERAL 1.01 DESCRIPTION This section specifies mechanically applied zinc coating. This coating shall be used on steel fasteners including bolts, screws, nuts, and washers. Anchor bolts are coated as specified in Section 05910. Electroplated corrosion protection is not an acceptable substitute for mechanical zinc coating. 1.02 QUALITY ASSURANCE A. ZINC COATING THICKNESS: Coating thickness shall be Class 50 as specified in ASTM B695. B. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference ASTM A153 ASTM B695 Title Zinc Coating (Hot-Dip) on Iron and Steel Hardware Coatings of Zinc Mechanically Deposited on Iron and Steel BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 MECHANICAL ZINC COATING 05911-1 PART 2 "PRODUCTS 2.01 MATERIALS The coating material shall be as specified in ASTM A153. 2.02 PRODUCT DATA In accordance with Section 01300, information shall be provided that describes materials and method of coating used. PART 3 » EXECUTION 3.01 FIELD REPAIR Damaged surfaces of zinc coated metals shall be repaired as specified in Section 05910. *** END OF SECTION *** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 MECHANICAL ZINC COATING 05911-2 SECTION 07100 WATERPROOFING AND MOISTUREPROOFING PART 1» GENERAL 1.01 DESCRIPTION This section specifies waterproofing and moistureproofing of concrete surfaces and below grade masonry surfaces. All buried concrete structures shall receive exterior waterproofing and moistureproofing in accordance with this section. PART 2 « PRODUCTS 2.01 MATERIALS A. WATERPROOFING AND MOISTUREPROOFING COATINGS: Waterproofing and moistureproofing coating shall be PVC lining where shown on the drawings or epoxy resin. Acceptable epoxy resin products are Tnemec Series 69, Ameron Amercoat 385, and International Protective Coatings Intergard 760 HS. Each of these is a polyamidoamine epoxy. B. WATERPROOFING MEMBRANE: 1. MEMBRANE: Waterproofing membrane shall be Bituthene as manufactured by W. R. Grace and Company, Jiffy Seal as manufactured by Protecto Wrap Co., or equal. Volclay Panels or Bentonize bentonite system are acceptable alternates except where membrane is required between concrete slabs or where there is concrete over waterproofing membrane. 2. PROTECTIVE BOARD: Protective board shall be 1/2-inch asphalt impregnated celotex insulation board. C. MOISTUREPROOFING UNDERLAY: 1. PLASTIC MEMBRANE: Plastic membrane for moistureproofing underlay shall be polyethylene film with a thickness of 6 mils. 2. PRESSURE SENSITIVE TAPE: Pressure sensitive tape shall be 2-inch wide polyethylene tape. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) WATERPROOFING AND MOISTUREPROOFING AUGUST 2010 07100-1 PART 3 - EXECUTION 3.01 CONSTRUCTION A. WATERPROOFING COATING: 1. LOCATION: Waterproofing coating shall be applied to the water side of walls and bottoms of channels or tanks which are common with rooms, tunnels or galleries to be occupied by equipment, piping, conduit, or personnel. 2. SURFACE PREPARATION: New concrete to be waterproofed shall have aged at least 28 days and allowed to dry to a moisture content recommended by the coating manufacturer. Loose concrete and laitance shall be removed from new concrete surfaces by abrasive blasting. Voids and cracks shall be repaired as specified in Section 03300. 3. APPLICATION: Two or more coats at manufacturers' recommended dry film thickness. Total dry film thickness shall be minimum 16 mils, final coat shall be black. Drying time between coats shall be as recommended by the coating manufacturer. B. MOISTUREPROOFING COATING: 1. LOCATION: Moistureproofing coating shall be applied to the earth side of concrete or masonry walls which are below grade and are common with rooms, tunnels or galleries to be occupied by equipment, piping or personnel. Moistureproofing coating is not required for walls to be provided with waterproofing membrane or for walls that are poured directly against an excavated surface. 2. SURFACE PREPARATION: Preparation of concrete shall conform to paragraph 07100-3.01 A.2. Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repointed. Loose or splattered mortar shall be removed by scrapping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing. Muriatic acid shall not be used. After cleaning, masonry surfaces shall be sealed or filled with sealer or block filler compatible with the specified primer. Sealer or filler shall dry a minimum of 48 hours prior to application of prime coat. 3. APPLICATION: One or more coats shall be applied at the manufacturer's recommended dry film thickness. The number of finish coats shall be sufficient to produce a total dry film thickness of at least 16 mils. Drying time between coats shall be as recommended by the coating manufacturer. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) WATERPROOFING AND MOISTUREPROOFING AUGUST 2010 07100-2 C. WATERPROOFING MEMBRANE: /"*», 1. LOCATION: Waterproofing membrane shall be applied to surfaces as specified. 2. SURFACE PREPARATION: Concrete surfaces to receive waterproofing membrane shall be clean, dry and free of voids, spalled areas, loose aggregate, and sharp protrusions, with no coarse aggregate visible. 3. APPLICATION: Waterproofing membrane shall be applied in accordance with the manufacturer's recommendations. Surfaces shall be clean and primed prior to application of the membrane. The manufacturer's representative shall be present during initial application to certify that the Contractor's procedures comply with manufacturer's specifications. Pipes or conduits entering structures shall be watertight. The protective board shall be placed directly against the membrane prior to backfilling. Where the membrane is turned up from the base of the walls, at angles in walls, and at any other place where the membrane may be subjected to unusual strain, strips consisting of two additional plies of membrane shall be applied. D. MOISTUREPROOF1NG UNDERLAY: 1. LOCATION: Unless otherwise specified, moistureproofing underlay shall be provided ^^ under concrete floors or floating slabs-on-grade including those deposited on drain rock. ^^j 2. SURFACE PREPARATION: Backfilled surfaces to receive moistureproofing underlay shall be leveled off and smoothed over to minimize contact with sharp edges. 3. APPLICATION: At joints, moistureproofing membrane shall be lapped 6 inches and sealed with pressure sensitive tape. Where pipes and conduits pass through the membrane, they shall be wrapped tightly with separate sheets of membrane which shall then be sealed with tape to the main membrane. Reinforcing steel or wire mesh shall be supported by chairs with flat bases to protect the membrane. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) WATERPROOFING AND MOISTUREPROOFING AUGUST 2010 07100-3 SECTION 07900 SEALANTS PART 1« GENERAL 1.01 DESCRIPTION This section specifies sealants for manholes, vaults, and other structures. All joints between adjacent structures, concrete or asphalt pavement shall be sealed in accordance with this section. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference FEDSPEC TT-S-00230C FEDSPEC TT-S-00227E Title Sealing Compound: Elastomeric Type, Single Component Sealing Compound: Elastomeric Type, Multi-Component PART 2-PRODUCTS 2.01 POLYURETHANE SEALANT A. ACCEPTABLE PRODUCTS: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) SEALANTS AUGUST 2010 07900-1 Acceptable products shall be Sikaflex by Sika Chemical Corporation, Vulkem by Mameco International, U-Seal Joint Sealant by Burke Company, or Rubber Calk by Products Research and Chemical Corporation. B. GENERAL: Polyurethane sealants shall conform to FEDSPEC TT-S-0230C for one-component systems and FEDSPEC TT-S-00227E for two-component systems. Polyurethane sealant shall be one of the following two types. 1. SELF-LEVELING: Self-leveling polyurethane sealant shall be Type I, Class A as specified by the FEDSPECs referenced above. 2. NONSAG: Nonsag polyurethane sealant shall be Type II, Class A as specified by the FEDSPECs referenced above. C. PRIMER: Primer shall be as recommended by the sealant manufacturer. D. BACKER ROD OR BACKER TAPE: Backer rod shall be open cell polyethylene or polyurethane foam. Rod shall be cylindrical unless otherwise specified. Backer tape shall be polyethylene or polyurethane with adhesive on one side. 2.02 MASTIC SEALANT A. GENERAL: Mastic joint sealant shall consist of a blend of refined asphalts, resins and plasticizing compounds, reinforced with fiber. Sealant shall be compatible with joint fillers and shall be pressure grade. B. PRIMER: Primer shall be as recommended by the mastic sealant manufacturer. 2.03 PRODUCT DATA The following information shall be provided in accordance with Section 01300: 1. Manufacturer's product data showing conformance to the specified products. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) SEALANTS AUGUST 20 10 07900-2 2. Manufacturer's recommendations for storage, handling and application of sealants and primers. PART 3 « EXECUTION 3.01 GENERAL Sealants and primers shall be applied according to the sealant manufacturer's recommendations. Polyurethane sealants shall be used on all expansion joints and specified construction joints. Joints and spaces to be sealed shall be clean, dry and free of dust, loose mortar, concrete and plaster. Additional preparation of joints and spaces shall be provided in accordance with manufacturer's recommendations. Primer shall be applied only to the surfaces that will be covered by the sealant. 3.02 POLYURETHANE SEALANTS A. GENERAL: Nonsag polyurethane sealants shall be used on vertical joints. Self-leveling polyurethane sealants shall be used on horizontal joints. B. JOINT DIMENSIONS: Unless otherwise specified, joints and spaces to be filled shall be constructed to the following criteria. Joints and spaces shall have a minimum width of 1/4 inch and a maximum width of 1 inch. The depth of the sealant shall be one-half the width of the joint, but in no case less than 1/4 inch deep. Sealant depth shall be measured at the point of smallest cross section. When joints exceed the depth requirements, backing rod shall be inserted to provide the joint depth specified. If the joint sealant depth is within the specified tolerances, backer tape shall be placed in the bottom of the joint. 3.03 MASTIC SEALANT A. JOINT DIMENSIONS: Joints to be sealed shall be 2 inches deep, 1 inch wide at the top, and 3/4 inch wide at the base. ** END OF SECTION** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) SEALANTS AUGUST 2010 07900-3 SECTION 09900 TABLE OF CONTENTS PARTI-GENERAL 3 1.01 DESCRIPTION 3 A. SCOPE: 3 B. DEFINITIONS: 3 1.02 QUALITY ASSURANCE 4 A. REFERENCES: 4 B. STANDARDIZATION: 6 C. QUALITY CONTROL REQUIREMENTS: 7 D. INSPECTION AT HOLD POINTS 8 1.03 DELIVERY AND STORAGE 9 1.04 SUBMITTALS: 9 1.05 RESPONSIBILITIES OF THE CTR ..11 A. COATING SYSTEM INSTALLATION TRAINING 11 B. COATING SYSTEM INSPECTION 11 C. FINAL REPORT , 12 PARTI-PRODUCTS 13 2.01 MATERIALS 13 2.02 PRODUCT DATA 14 PARTS-EXECUTION 15 3.01 COATINGS 15 A. GENERAL: 15 B. SHOP AND FIELD COATS: 15 C. APPLICATION LOCATION REQUIREMENTS: 15 3.02 PREPARATION 16 A. GENERAL: 16 B. BLAST CLEANING: 16 C. SOLVENT CLEANING: 17 D. METALLIC SURFACES: 18 E. CONCRETE SURFACES: 18 F. MASONRY SURFACES: 20 G. FIBERGLASS REINFORCED PLASTIC (FRP) SURF ACES: 20 3.03 APPLICATION 20 A. WORKMANSHIP: 20 B. COATING PROPERTIES, MIXING AND THINNING: 21 C. ATMOSPHERIC CONDITIONS: 21 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-1 •^^^jr TABLE OF CONTENTS (Continued) D. CONCRETE SUBSTRATE TEMPERATURES: 22 E. PROTECTION OF COATED SURFACES: 22 F. METHOD OF COATING APPLICATION: 22 G. FILM THICKNESS AND CONTINUITY: 23 H. SPECIAL REQUIREMENTS: 23 I. ELECTRICAL AND INSTRUMENTATION EQUIPMENT AND MATERIALS: 24 J. SOLUBLE SALT CONTAMINATION OF METALLIC SUBSTRATES: 24 3.04 CLEANUP 24 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) 25 Coating System Identification: E-l 27 Coating System Identification: E-2 29 Coating System Identification: E-4 31 Coating System Identification: E-7 33 Coating System Identification: EA-1 34 Coating System Identification: EU-1 36 Coating System Identification: L-2 38 Coating System Identification: M-l 39 Coating System Identification: M-2 41 3.06 COATING SYSTEMS SCHEDULE (FINISH SCHEDULE) 42 3.07 INSPECTION AND TESTING BY THE CITY OF CARLSBAD 45 3.08 FINAL INSPECTION 46 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-2 SECTION 09900 COATING SYSTEMS PART 1-GENERAL 1.01 DESCRIPTION A. SCOPE: This Section 09900 specifies coating systems, surface preparations, and application requirements for coating systems. B. DEFINITIONS: Specific coating terminology used in this Section 09900 is in accordance with definitions contained in ASTM D16, ASTM D3960, and the following definitions: 1. Coating System Applicator (CSA): A generic reference to the specialty subcontractor or subcontractors retained by the Contractor to install the coating systems specified in this Section 09900. ^ 2. Coating System Manufacturer (CSM): Refers to the acceptable coating system *m*r manufacturer, abbreviated as the CSM. 3. Coating System Manufacturer's Technical Representative(s) (CTR): Refers to the technical representative(s) of the acceptable Coating System Manufacturer and is abbreviated as CTR. 4. Dry Film Thickness (DFT): The primer or coating film's thickness following curing and drying. Dry film thickness is measured in mils or thousandths of an inch (0.001 inch) and is abbreviated DFT. 5. Field Coat: The application or the completion of application of the coating system after installation of the surface at the site of the work. 6. Hold Point: A defined point, specified in this Section 09900, at which work shall be halted for inspection. 7. Shop Coat: One or more coats applied in a shop or plant prior to shipment to the site of the work, where the field or finishing coat is applied. 8. Tie Coat: An intermediate coat used to bond different types of paint coats. Coatings used to improve the adhesion of a succeeding coat. ^^ BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 20 10 09900-3 9. Touch-Up Painting: The application of paint on areas of painted surfaces to repair marks, scratches, and areas where the coating has deteriorated to restore the coating film to an unbroken condition. 10. Volatile Organic Compound (VOC) Content: The portion of the coating that is a compound of carbon, is photochemically reactive, and evaporates during drying or curing, expressed in grams per liter (g/1) or pounds per gallon (Ib/gal). 11. Wet Film Thickness (WFT): The primer or coating film's thickness immediately following application. Wet film thickness is measured in mils or thousandths of an inch (0.001 inch) and is abbreviated WFT. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued, or replaced. Reference Title ANSI/NSF61 ANSIB74.18 ASTMD16 ASTM D2200 (SSPC-V1) ASTM D4787 ASTM D5162 Drinking Water System Components Health Effects Grading of Certain Abrasive Grain on Coated Abrasive Material Standard Terminology for Paint, Related Coatings, Materials, and Applications Pictorial Surface Preparation Standards for Painting Steel Surfaces Standard Practice for Continuity Verification of Liquid or Sheet Linings Applied to Concrete Substrates Standard Practice for Discontinuity (Holiday) Testing of Nonconductive Protective Coating on Metallic Substrates BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-4 Reference Title ASTM E337 ASTM D3359 A ASTM D3960 ASTM D4262 ASTM D4263 ASTMD4414 ASTMD4417 ASTMD4541 ASTM Fl 869 FS 595b ICRI 03732 NAPF 500-03 NAPF 500-03-04 NAPF 500-03-05 SSPC SSPC-PA Guide 3 SSPC SP1 SSPC SP2 SSPC SP3 SSPC SP5 SSPC SP6 SSPC SP7 SSPC SP10 SSPCSP11 Standard Test Method for Measuring Humidity With a Psychrotneter Standard Test Methods for Measuring Adhesion by Tape Test Standard Practice for Determining Volatile Organic Compound (VOC) Content of Paints and Related Coatings Standard Test Method for pH of Chemically Cleaned or Etched Concrete Surfaces Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method Standard Practice for Measurement of Wet Film Thickness by Notch Gages Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel Standard Test Methods for Pull-Off Strength of Coatings Using Portable Adhesion Testers Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride Federal Standard Colors Guideline for Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, and Polymer Overlays Surface Preparation Standard for Ductile Iron Pipe and Fittings in Exposed Locations Receiving Special External Coatings and/or Special Internal Linings Abrasive Blast Cleaning for Ductile Iron Pipe Abrasive Blast Cleaning for Cast Ductile Iron Fittings Paint Application Specification No. 1. A Guide to Safety in Paint Application Solvent Cleaning Hand Tool Cleaning Power Tool Cleaning White Metal Blast Cleaning Commercial Blast Cleaning Brush-Off Blast Cleaning Near- White Blast Cleaning Power Tool Cleaning to Bare Metal _ BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-5 Reference SSPC SP12 SSPC SP13 SSPC-PA-2 SSPC-TR2/ NACE6G198 SSPC-TU-3 SSPC-TU-4 SSPC V2 SSPC-Guidell Title Surface Preparation and Cleaning of Metals by Waterjetting Prior to Recoating Surface Preparation of Concrete Measurement of Dry Coating Thickness with Magnetic Gages Wet Abrasive Blast Cleaning Overcoating Field Methods for Retrieval and Analysis of Soluble Salts on Substrates. Systems and Specifications: Steel Structures Painting Manual, Volume 2 Guide for Coating Concrete B. STANDARDIZATION: Materials and supplies provided shall be the standard products of CSMs. Materials in each coating system shall be the products of a single CSM. The standard products of CSMs other than those specified may be acceptable when it is demonstrated to the Engineer that they are equal in composition, durability, usefulness, and convenience for the purpose intended. Requests for consideration of CSMs other than those specified in this Section 09900 will be considered, provided the following minimum conditions are met. Such requests are not a substitution for submittals after the alternative CSMs have been considered and accepted. 1. The proposed coating system shall use an equal or greater number of separate coats to achieve the required total dry film thickness. 2. The proposed coating system shall use coatings of the same generic type as that specified including curing agent type. 3. Requests for consideration of products from CSMs other than those specified in this Section 09900 shall include information listed in paragraph 09900-1.04, Items 1, 2, and 3, demonstrating that the proposed CSM's product is equal to the specified coating system. 4. The Contractor and the proposed alternative CSM shall provide a list of references for the proposed product where the coating of the same generic type has been applied. The reference list shall include the project name, city, state, owner, phone number of owner; coating system reference and number from this Section 09900; type of facility in which it was used, generic type, and year coating was applied. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-6 C. QUALITY CONTROL REQUIREMENTS: 1. The Contractor is responsible for the workmanship and quality of the coating system installation. Inspections by the Engineer will not relieve or limit the Contractor's responsibilities. 2. The Contractor's methods shall conform to requirements of this specification and the standards referenced in this Section 09900. Changes in the coating system installation requirements will be allowed only with the written acceptance of the Engineer before work commences. 3. Only personnel who are trained by the CTR specifically for this contract or who are approved by the CSM specifically for this contract shall be allowed to perform the coating system installation specified in this Section 09900. 4. Contaminated, outdated, diluted materials, and/or materials from previously opened containers shall not be used. 5. For repairs, the Contractor shall provide the same products, or products recommended by the CSM, as used for the original coating. 6. The Contractor shall identity the points of access for inspection by the City of Carlsbad or the Engineer. The Contractor shall provide ventilation, ingress and egress, and other means necessary for the Engineer's personnel to safely access the work areas. 7. The Contractor shall conduct the work so that the coating system is installed as specified and shall inspect the work continually to ensure that the coating system is installed as specified. Coating system work that does not conform to the specifications or is otherwise not acceptable shall be corrected as specified. 8. The Contractor shall complete the Coating System Inspection Checklist, Form 09900- A, included in Section 01999, for coating system installations. Follow the sequential steps required for proper coating system installation as specified and as listed in the Coating System Inspection Checklist. For each portion of the work, install the coating system and complete sign-ofifs as specified prior to proceeding with the next step. After completing each step as indicated on the Coating System Inspection Checklist, the Contractor shall sign the checklist indicating that the work has been installed and inspected as specified. 9. The Contractor shall provide written daily reports that present, in summary form, test data, work progress, surfaces covered, ambient conditions, quality control inspection test findings, and other information pertinent to the coating system installation. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-7 D. INSPECTION AT HOLD POINTS The Contractor shall conduct inspections at Hold Points during the coating system installation and record the results from those inspections on Form 09900-A. The Contractor shall coordinate such Hold Points with the Engineer such that the Engineer may observe Contractor's inspections on a scheduled basis. The Contractor shall provide the Engineer a minimum of two (2) hours of notice prior to conducting Hold Point Inspections. The Hold Points shall be as follows: 1. Environment and Site Conditions. Prior to commencing an activity associated with coating system installation, the Contractor shall measure, record, and confirm acceptability of ambient air temperature and humidity as well as other conditions such as proper protective measures for surfaces not to be coated and safety requirements for personnel. The acceptability of the weather and/or environmental conditions within the structure shall be determined by the requirements specified by the CSM of the coating system being used. 2. Conditions Prior to Surface Preparation. Prior to commencing surface preparation, the Contractor shall observe, record, and confirm that oil, grease, and/or soluble salts have been eliminated from the surface. 3. Monitoring of Surface Preparation. Spot checking of degree of cleanliness, surface profile, and surface pH testing, where applicable. In addition, the compressed air shall be checked to confirm it is free from oil and moisture. 4. Post Surface Preparation - Upon completion of the surface preparation, the Contractor shall measure and inspect for proper degree of cleanliness and surface profile as specified in this Section 09900 and in the CSM's written instructions. 5. Monitoring of Coatings Application - The Contractor shall inspect, measure, and record the wet film thickness and general film quality (visual inspection) for lack of runs, sags, pinholes, holidays, etc. as the application work proceeds. 6. Post Application Inspection - The Contractor shall identify defects in application work including pinholes, holidays, excessive runs or sags, inadequate or excessive film thickness and other problems as may be observed. 7. Post Cure Evaluation - The Contractor shall measure and inspect the overall dry film thickness. The Contractor shall conduct a DFT survey, as well as perform adhesion testing, holiday detection, or cure testing as required based on the type of project and the specific requirements in this Section 09900 and/or in the CSM's written instructions. 8. Follow-up to Corrective Actions and Final Inspection. The Contractor shall measure and reinspect corrective coating work performed to repair defects identified at prior BUENA VISTA LIFT STATION FORCE MAIN (VCM) COATING SYSTEMS AUGUST 2010 09900-8 Hold Points. This activity also includes final visual inspection along with follow-up tests such as holiday detection, adhesion tests, and DFT surveys. 1.03 DELIVERY AND STORAGE Materials shall be delivered to the job site in their original, unopened containers. Each container shall be properly labeled. Materials shall be handled and stored to prevent damage to or loss of label. Labels on material containers shall show the following information: 1. Name or title of product. 2. CSM's batch number. 3. CSM's name. 4. Generic type of material. 5. Application and mixing instructions. 6. Hazardous material identification label. 7. Shelf life expiration date. Materials shall be stored in enclosed structures and shall be protected from weather and excessive heat or cold in accordance with the CSM's recommendations. Flammable materials shall be stored in accordance with state and local requirements. Containers shall be clearly marked indicating personnel safety hazards associated with the use of or exposure to the materials. Material Safety Data Sheets (MSDS) for each material shall be provided to the Engineer. The Contractor shall store and dispose of hazardous waste according to federal, state and local requirements. This requirement specifically addresses waste solvents and coatings. 1.04 SUBMITTALS: Provide in accordance with Section 01300: 1. A copy of this specification section, with addendum updates included, and referenced and applicable sections, with addendum updates included, with each paragraph check- marked (X) to indicate specification compliance or marked to indicate requested deviations from specification requirements or those parts which are to be provided by the Contractor or others. Check marks shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 20 10 09900-9 the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined shall signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for requested deviations to the specification requirements shall be cause for rejection of the entire submittal and no further submittal material will be reviewed. 2. CSM's current printed recommendations and product data sheets for coating systems including: a. Volatile organic compound (VOC) data b. Surface preparation recommendations. c. Primer type, where required. d. Maximum dry and wet mil thickness per coat. e. Minimum and maximum curing time between coats, including atmospheric conditions for each. f. Curing time before submergence in liquid. g. Thinner to be used with each paint, h. Ventilation requirements. i. Minimum atmospheric conditions during which the paint shall be applied. j. Allowable application methods. k. Maximum allowable moisture content. 1. Maximum shelf life. 3. Affidavits signed and sealed by an officer of the CSM's corporation, attesting to full compliance of each coating system component with current and promulgated federal, state, and local air pollution control regulations and requirements. 4. Material Safety Data Sheets (MSDS) for materials to be delivered to the job site, including coating system materials, solvents, and abrasive blast media. 5. List of cleaning and thinner solutions allowed by the CSMs. 6. Storage requirements including temperature, humidity, and ventilation for Coating System Materials as recommended by the CSMs. 7. CSM's detailed, written instructions for coating system treatment and graphic details for coating system terminations in the structures to be coated including pipe penetrations, metal embedments, gate frames, and other terminations to be determined from the contract drawings. This information shall also include detail treatment for coating system at joints in concrete. 8. The Contractor and CSA shall provide a minimum of five project references each including contact name, address, and telephone number where similar coating work has been performed by their companies in the past five years. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-10 1.05 RESPONSIBILITIES OF THE CTR The Contractor shall retain or obtain the services of the CTR to be on site to perform the Contractor and/or CSA application training and to periodically inspect and verify that the application personnel have successfully performed surface preparation, filler/surface application, coating system application, and Quality Control Inspection in accordance with this Section 09900. This inspection is in addition to the inspection performed by the Contractor in accordance with this Section 09900. A. COATING SYSTEM INSTALLATION TRAINING 1. Provide a minimum of 8 hours of classroom and off site training for application and supervisory personnel (both the Contractor's and CSA's). Provide training to a minimum of two supervisory personnel from the CSA and one supervisor from the Contractor. Alternatively, the CTR shall provide a written letter from the CSM stating that the application personnel (listed by name) who shall perform coating work are approved by the CSM without further or additional training. 2. One CTR can provide training for up to fourteen application personnel and three supervisory personnel at one time. The training shall include the following as a minimum: a. A detailed explanation of mixing, application, curing, and termination details. b. Hands-on demonstration of how to mix and apply the coating systems. c. A detailed explanation of the ambient condition requirements (temperature and humidity) and surface preparation requirements for application of the coating system as well as a detailed explanation of re-coat times, cure times, and related ambient condition requirements. d. When training is performed, the CTR shall provide a written letter stating that training was satisfactorily completed by the personnel listed by name in the letter. B. COATING SYSTEM INSPECTION While on site to periodically inspect and verify, the CTR shall perform the following activities as and when they are applicable at the time of the CTR's site visits to confirm acceptability arid conformance with the specifications: 1. Inspect ambient conditions during various coating system installation at hold points for conformance with the specified requirements. 2 Inspect the surface preparation of the substrates where the coating system will terminate or will be applied for conformance to the specified application criteria. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-11 3. Inspect preparation and application of coating detail treatment (for example, terminations at joints, metal embedments in concrete, etc.). 4. Inspect application of the filler/surface materials for concrete and masonry substrates. 5. Inspect application of the primers and finish coats. 6. Inspect coating systems for cure. 7. Review adhesion testing of the cured coating systems for conformance to specified criteria. 8. Review coating system continuity testing for conformance to specified criteria. 9. Inspect and record representative localized repairs made to discontinuities identified via continuity testing. 10. Conduct a final review of completed coating system installation for conformance to the specifications. 11. Prepare and submit a site visit report following each site visit. C. FINAL REPORT Upon completion of coating work for the project, the CTR shall prepare a final report. That report shall summarize daily test data, observations, drawings, and photographs in a report to be submitted in accordance with paragraph 09900-2.02. Include substrate conditions, ambient conditions, and application procedures, observed during the CTR's site visits. Include a statement that the completed work was performed in accordance with the requirements of this Section 09900. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-12 PART 2-PRODUCTS 2.01 MATERIALS Notwithstanding the listing of product names in this Section 09900, the Contractor shall provide affidavits, signed and sealed by an officer of the CSM's corporation, attesting to full compliance of each coating system component with current and promulgated federal, state, and local air pollution control regulations and requirements. No coatings shall be applied to a surface until such time as the specified affidavits have been submitted and have been reviewed and accepted. Failure to comply with this requirement shall be cause for rejection and removal of such materials from the site. The following list specifies the material requirements for coating systems. Coating systems are categorized by generic name followed by an identifying abbreviation. If an abbreviation has a suffix number, it is for the purpose of identifying subgroups within the coating system. Coating Systems E-5 and E-6 shall be NSF 61 certified. Coating System j Manufacturer Primer Coat(s)Finish Coat(s) Epoxy Coatings E-l E-2 E-4 E7 PPG PMC Carboline ICI Paints Sherwin Williams Tnemec PPG PMC Carboline ICI Paints Sherwin Williams Tnemec PPG PMC Carboline ICI Paints Sherwin Williams Tnemec PPG PMC Carboline ICI Paints Sherwin Williams Tnemec Amerlock 2/400 Series Carboguard 890 Devran 224 Macropoxy 646 CA Series V69 Amerlock 2/400 Series Carboguard 890 Bar-Rust 236 Macropoxy 646 CA Series V69 Amerlock 2/400 Series Carboguard 890 Bar-Rust 236 Macropoxy 646 CA Series V69 Amerlock 400 Sanitile 120 Bar-Rust 236 Macropoxy 646 CA Series V69 Amerlock 2/400 Series Carboguard 890 Devran 224 Macropoxy 646 CA Series V69 Amerlock 2/400 Series Carboguard 890 Bar-Rust 236 Macropoxy 646 CA Series V69 Amerlock 2/400 Series Carboguard 890 Bar-Rust 236 Macropoxy 646 CA Series V69 Amerlock 400 Sanitile 120 Bar-Rust 236 Macropoxy 646 CA Series V69 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-13 Coating System Manufacturer Primer Coat(s) | Finish Coat(s) Specialty Epoxy Linings EA-1 Carboline Sauereisen Tnemec Plasite 4550S Sewergard210S Series 435 Plasite 4550S Sewergard210S Series 435 Epoxy Polyurethane EU-1 Ameron Carboline Sherwin Williams Tnemec Primer Coat(s) N/A N/A N/A N/A Intermediate Coat(s) Amerlock 400 Carboguard 890 Macropoxy 646 100 Series V69 Amershield VOC Carbothanel34VOC Hi Solids Polyurethane 100 Series 1075 Latex Acrylic L-2 PPG PMC Carboline ICI Paints Sherwin Williams Tnemec Amercoat 220 Sanitile 120 UHGripper3210 SherCryl Series 1028 or 1029 Amercoat 220 Carbociylic 3359 DTM Dulux Pro 4206 SherCryl Series 1028 or 1029 Miscellaneous M-l M-2 Carboline Denso Trenton PPG PMC Carboline ICI Paints Sherwin Williams Tnemec Carbowrap Tape Paste Denso Paste Waxtape Primer Amerlock 400 Carbomastic615HS Bar-Rust 231 Duraplate 235 Series 135 Carbowrap Petrolatum Tape Densyl Tape #1 Wax Tape Amerlock 400 Carbomastic615HS Bar-Rust 231 Duraplate 235 Series 135 2.02 PRODUCT DATA 1, Prior to application of coatings, submit letter(s) from the CTR(s) identifying the application personnel who have satisfactorily completed training as specified in paragraph 09900-1.05 or a letter from the CSM stating, that personnel who shall perform the work are approved by the CSM without need for further or additional training. 2. Submit reports specified in paragraph 09900-1.02 C.10 and 09900-1.05 B.12 when the work is underway. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-14 3. Submit the Coating System Inspection Checklists, using Form 09900-A, included in Section 01999, for the coating work. 4. CTR final report in accordance with paragraph 09900-1.05 C. PART 3-EXECUTION 3.01 COATINGS A. GENERAL: Coating products shall not be used until the Engineer has accepted the affidavits specified in paragraph 09900-1.04 and 2.01, the Engineer has inspected the materials, and the CTR has trained the Contractor and CSA in the surface preparation, mixing and application of each coating system. B. SHOP AND FIELD COATS: 1. SHOP APPLIED PRIME COAT: Except as otherwise specified, prime coats may be shop-applied or field-applied. Shop-applied primer shall be compatible with the specified coating system and shall be applied at the minimum dry film thickness recommended by the CSM. Data sheets identifying the shop primer used shall be provided to the on-site coating application personnel. Adhesion tests shall be performed on the shop primer as specified in paragraph 09900-3.01B.3. Damaged, deteriorated and poorly applied shop coatings that do not meet the requirements of this Section 09900 shall be removed and the surfaces recoated. If the shop primer coat meets the requirements of this Section 09900, the field coating may consist of touching up the shop prime coat and then applying the finish coats to achieve the specified film thickness and continuity. 2. FIELD COATS: Field coats shall consist of one or more prime coats and one or more finish coats to build up the coating to the specified dry film thickness. Unless otherwise specified, finish coats shall not be applied until other work in the area is complete and until previous coats have been inspected. 3. ADHESION CONFIRMATION: The Contractor shall perform an adhesion test after proper cure in accordance with ASTM D3359 to demonstrate that (1) the shop applied prime coat adheres to the substrate, and (2) the specified field coatings adhere to the shop coat. Test results showing an adhesion rating of 5 A on immersed surfaces and 4A or better on other surfaces shall be considered acceptable. C. APPLICATION LOCATION REQUIREMENTS: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 20 10 COATING SYSTEMS 09900-15 1. EQUIPMENT, NONIMMERSED: Items of equipment, or parts of equipment which are not immersed in service, shall be shop primed and then finish coated in the field after installation with the specified or acceptable color. If the shop primer requires topcoating within a specified period of time, the equipment shall be finish coated in the shop and then touch-up painted after installation. 2. EQUIPMENT, IMMERSED: Items of equipment, or parts and surfaces of equipment which are immersed when in service, with the exception of pumps and valves, shall have surface preparation and coating work performed in the field. Coating systems applied to immersed equipment shall be pinhole free. 3. STEEL WATER TANKS: The interior surfaces of steel water tanks or reservoirs shall have surface preparation and coating work performed in the field. 3.02 PREPARATION A. GENERAL: Surface preparations for each type of surface shall be in accordance with the specific requirements of each coating specification sheet (COATSPEC) and the following. In the event of a conflict the COATSPEC sheets shall take precedence. Surfaces to be coated shall be clean and dry. Before applying coating or surface treatments, oil, grease, dirt, rust, loose mill scale, old weathered coatings, and other foreign substances shall be removed. Oil and grease shall be removed before mechanical cleaning is started. Where mechanical cleaning is accomplished by blast cleaning, the abrasive used shall be washed, graded and free of contaminants which might interfere with the adhesion of the coatings. The air used for blast cleaning shall be sufficiently free of oil and moisture to not cause detrimental contamination of the surfaces to be coated. Where deemed necessary, a NACE International certified coatings inspector, provided by the City of Carlsbad, will inspect and approve surfaces to be coated before application of a coating. Surface defects identified by the inspector shall be corrected by the Contractor. Cleaning and painting shall be scheduled so that dust and spray from the cleaning process shall not fall on wet, newly painted surfaces. Hardware, hardware accessories, nameplates, data tags, machined surfaces, sprinkler heads, electrical fixtures, and similar uncoated items which are in contact with coated surfaces shall be removed or masked prior to surface preparation and painting operations. Following completion of coating, removed items shall be reinstalled. Equipment adjacent to walls shall be disconnected and moved to permit cleaning and painting of equipment and walls and, following painting, shall be replaced and reconnected. B. BLAST CLEANING: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-16 When blast cleaning is required to achieve the specified surface preparation the following requirements for blast cleaning materials and equipment shall be met: 1. Used or spent blast abrasive shall not be reused on this project. 2. The compressed air used for blast cleaning shall be filtered and shall contain no condensed water and no oil. Moisture traps shall be cleaned at least once every four hours or more frequently as required to prevent moisture from entering the supply air to the abrasive blasting equipment. 3. Oil separators shall be installed just downstream of compressor discharge valves and at the discharge of the blast pot discharges. These shall be checked on the same frequency as the moisture traps as defined in item 3 above. 4. Regulators, gauges, filters, and separators shall be in use on compressor air lines to blasting nozzles times during this work. 5. An air dryer or desiccant filter drying unit shall be installed which dries the compressed air prior to blast pot connections. This dryer shall be used and maintained for the duration of surface preparation work. 6. The abrasive blast nozzles used shall be of the venturi or other high velocity type supplied with a minimum of 100 psig air pressure and sufficient volume to obtain the blast cleaning production rates and cleanliness/specified. 7. The Contractor shall provide ventilation for airborne particulate evacuation (meeting pertinent safety standards) to optimize visibility for both blast cleaning and inspection for the substrate during surface preparation work. 8. If, between final surface preparation work and coating system application, contamination of prepared and cleaned metallic substrates occurs, or if the prepared substrates' appearance darkens or changes color, recleaning by water blasting, reblasting and abrasive blast cleaning shall be required until the specified degree of cleanliness is reclaimed. 9. The Contractor is responsible for dust control and for protection of mechanical, electrical, and other equipment adjacent to and surrounding the work area. C. SOLVENT CLEANING: Any solvent wash, solvent wipe, or cleaner used, including but not limited to those used for surface preparation in accordance with referenced Society for Protective Coatings (SSPC) specifications, shall be of the emulsifying type which emits no more than 2.8 Ib/gal (340 g/1) VOCs, contains no phosphates, is biodegradable, removes no zinc, and is compatible with the specified primer. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-17 ^-^3 Clean cloths and clean fluids shall be used in solvent cleaning. D. METALLIC SURFACES: Metallic surfaces shall be prepared in accordance with applicable portions of surface preparation specifications of the Society for Protective Coatings (SSPC) specified in each coating system. The profile depth of the surface to be coated shall be 20 to 25 percent of the coating dry film thickness as measured by Method C of ASTM D4417. Blast particle size shall be selected by the Contractor to produce the specified surface profile. The solvent in solvent cleaning operations shall be as recommended by the CSM. Preparation of metallic surfaces shall be based upon comparison with SSPC-VIS 1-89 (ASTM D2200), and as described. If dry abrasive blast cleaning is selected and to facilitate inspection, the Contractor shall, on the first day of cleaning operations, abrasive blast metal panels to the standards specified. Plates shall measure a minimum of 8-1/2 inches by 11 inches. Panels meeting the requirements of the specifications shall be initialed by the Contractor and the Engineer and coated with a clear non-yellowing finish. One of these panels shall be prepared for each type of abrasive blasting and shall be used as the comparison standard throughout the project. Blast cleaning requirements for steel, ductile iron, and stainless steel substrates are as follows: 1. Steel piping shall be prepared in accordance with SSPC SP-6 (Commercial Blast Cleaning) and primed before installation. Ductile iron piping surfaces including fittings shall be prepared in accordance with NAPF 500-03, NAPF 500-03-04, and NAPF 500-03-05. 2. Stainless steel surfaces shall be abrasive blast cleaned to leave a clean uniform appearance with a minimum surface profile of 1.5 to 2.5 mils which is uniform. 3. Remove traces of grit, dust, dirt, rust scale, friable material, loose corrosion products or embedded abrasive from substrate by vacuum cleaning prior to coating application. 4. Care must be taken to prevent contamination of the surface after blasting from worker's fingerprints, deleterious substances on workers * clothing, or from atmospheric conditions. 5. Ambient environmental conditions in the enclosure must be constantly monitored and maintained to ensure the degree of cleanliness is held and no "rust back" occurs. E. CONCRETE SURFACES: 1. Inspection of concrete surfaces prior to surface preparation and surface preparation of concrete surfaces other than concrete floors shall be performed in accordance with SSPC-SP13 (also called NACE 6). BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-18 2. The surface profile for prepared concrete surfaces to be coated shall be evaluated by comparing the profile of the prepared concrete with the profile of graded abrasive paper, as described in ANSI B74.18 or by comparing the profile with the ICRI 03732 (surface profile chips). Surface profile requirements shall be in accordance with the CSM's recommendations. 3. Surface cleanliness of prepared concrete substrates shall be inspected after cleaning, preparation, and/or drying, but prior to making repairs or applying a coat in the coating system. If concrete surfaces are repaired, they shall be reinspected for surface cleanliness prior to application of the coating system. 4. Surface preparation of concrete substrates shall be accomplished using methods such as dry abrasive blast cleaning, high, or ultra high pressure water blast cleaning in accordance with SSPC-SP-13. The selected cleaning method shall produce the requirements set forth below. a. A clean substrate that is free of calcium sulfate, loose coarse or fine aggregate, laitance, loose hydrated cement paste, and otherwise deleterious substances shall be achieved. Blast cleaning and other means necessary shall be used to open up air voids or "bugholes" to expose their complete perimeter. Leaving shelled over, hidden air voids beneath the exposed concrete surface is not acceptable. Concrete substrate must be dry prior to the application of filler/surface or coating system materials. Acceptable surface preparation must produce a concrete surface pH of 8.0 to 11.0 to be confirmed by surface pH testing. If after surface preparation, the surface pH remains below 8.0, perform additional water blasting, cleaning, or abrasive blast cleaning until additional pH testing indicates an acceptable pH level. b. Following inspection by the Contractor of the concrete surface preparation, thoroughly vacuum clean concrete surfaces to be coated to remove loose dirt, and spent abrasive (if dry blast cleaning is used) leaving a dust free, sound concrete substrate. Debris produced by blast cleaning shall be removed from the structures to be coated and disposed of legally off site by the Contractor. 5. Should abrasive blast cleaning or high or ultrahigh pressure water blasting not remove degraded concrete, chipping or other abrading tools shall be used to remove the deteriorated concrete until a sound, clean substrate is achieved which is free of calcium sulfate, loose coarse or fine aggregate, laitance, loose hydrated cement paste, and otherwise deleterious substances. Concrete substrates must be dry prior to the application of filler/surfacers or coating system materials. 6. Surface cleanliness of prepared concrete substrates shall be inspected after cleaning, preparation, and/or drying, but prior to application of coating materials. If concrete 3 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-19 surfaces are repaired, they shall be reinspected for surface cleanliness prior to application of the coating system. 7. Moisture content of concrete to be coated shall be tested in accordance with ASTM D4263, Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method and ASTM F 1869, Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride. The ASTM D4263 plastic sheet test shall be conducted at least once for every 500 sq. ft. of surface area to be coated. For concrete surfaces to be coated which are on the negative or back side of concrete walls or structures exposed to soils (back filled) or immersed, and waterproofed in accordance with Section 07100, perform calcium chloride tests in accordance with ASTM F-1869 once for each 500 sq. ft. of surface area to be coated. F. MASONRY SURFACES: 1. Prepare masonry surfaces such as Concrete Masonry Units (CMU) to remove chalk, loose dirt, dried mortar splatter, dust, peeling or loose existing coatings, or otherwise deleterious substances to leave a clean, sound substrate. 2. Be certain masonry surfaces are dry prior to coating application. If pressure washing or low pressure water blast cleaning is used for preparation, allow the masonry to dry for at least 5 days under dry weather conditions or when the minimum ambient temperature is 70oF prior to coating application work. G. FIBERGLASS REINFORCED PLASTIC (FRP) SURFACES: Prepare FRP surfaces by sanding to establish uniform surface roughness and to remove gloss from the resin in the FRP. Next, vacuum clean to remove loose FRP dust, dirt, and other materials. Next, solvent clean using clean white rags and allow solvent to completely evaporate before application of coating materials. 3.03 APPLICATION A. WORKMANSHIP: 1. Coated surfaces shall be free from runs, drips, ridges, waves, laps, and brush marks. Coats shall be applied to produce an even film of uniform thickness completely coating corners and crevices. 2. The Contractor's equipment shall be designed for application of the materials specified. Compressors shall have suitable traps and filters to remove water and oils from the air. A paper blotter test shall be performed by the Contractor when requested by the Engineer to determine if the air is sufficiently free of oil and moisture to not produce deteriorating effects on the coating system. The amount of BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-20 oil and moisture in spray air shall be less than the amount recommended by the CSM. Spray equipment shall be equipped with mechanical agitators, pressure gages, and pressure regulators, and spray nozzles of the proper sizes. 3. Each coat of paint shall be applied evenly and sharply cut to line. Care shall be exercised to avoid overspraying or spattering paint on surfaces not to be coated. Glass, hardware, floors, roofs, and other adjacent areas and installations shall be protected by taping, drop cloths, or other suitable measures. 4. Coating applications method shall be conventional or airless spray, brush or roller, or trowel as recommended by CSM. 5. Allow each coat to cure or dry thoroughly, according to CSM's printed instructions, prior to recoating. 6. Vary color for each successive coat for coating systems when possible. 7. When coating complex steel shapes, prior to overall coating system application, stripe coat welds, edges of structural steel shapes, metal cut-outs, pits in steel surfaces, or rough surfaces with the primer coat. This involves applying a separate coat using brushes or rollers to ensure proper coverage. Stripe coat via spray application is not permitted. B. COATING PROPERTIES, MIXING AND THINNING: Coatings, when applied, shall provide a satisfactory film and smooth even surface. Glossy undercoats shall be lightly sanded to provide a surface suitable for the proper application and adhesion of subsequent coats. Coating materials shall be thoroughly stirred, strained, and kept at a uniform consistency during application. Coatings consisting of two or more components shall be mixed in accordance with the CSM's instructions. Where necessary to suit the conditions of the surface, temperature, weather and method of application, the coating may be thinned as recommended by the CSM immediately prior to use. The volatile organic content (VOC) of the coating as applied shall comply with prevailing air pollution control regulations. Unless otherwise specified, coatings shall not be reduced more than necessary to obtain the proper application characteristics. Thinner shall be as recommended by the CSM. C. ATMOSPHERIC CONDITIONS: Coatings shall be applied only to surfaces that are dry, and only under conditions of evaporation rather than condensation. Coatings systems shall not be applied during rainy, misty weather, or to surfaces upon which there is frost or moisture condensation. During damp weather, when the temperature of the surface to be coated is within 10°F of the dew point, forced dehumidification equipment may be used to maintain a temperature of minimum 40°F and 10°F above the dew point for the surfaces to be coated, the coated surface, and the atmosphere in contact with the surface. These conditions shall be BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-21 maintained for a period of at least 8 hours or as recommended by the CSM. Where conditions causing condensation are severe, dehumidification equipment, fans, and/or heaters shall be used inside enclosed areas to maintain the required atmospheric and surface temperature requirements for proper coating application and cure. D. CONCRETE SUBSTRATE TEMPERATURES: When the surface temperatures of the concrete substrates to be coated are rising or when these substrates are in direct sunlight, outgassing of air from the concrete may result in bubbling, pinhole formations, and/or blistering in the coating system. As such, the application of the coating system in such locations shall be postponed until the cooler evening hours or other measures shall be taken to prevent such rising substrate temperatures. Should bubbles, pinholes, or discontinuities form in the applied coating system material, they shall be repaired as recommended by the CSM. E. PROTECTION OF COATED SURF ACES: Items which have been coated shall not be handled, worked on, or otherwise disturbed, until the coating is completely dry and hard. After delivery at the site, and upon permanent erection or installation, shop-coated metalwork shall be recoated or retouched with specified coating when it is necessary to maintain the integrity of the film. F. METHOD OF COATING APPLICATION: 1. Where two or more coats are required, alternate coats shall contain sufficient compatible color additive to act as indicator of coverage, or the alternate coats shall be of contrasting colors. Color additives shall not contain lead, or lead compounds, which may be destroyed or affected by hydrogen sulfide or other corrosive gas, and/or chromium. 2. Mechanical equipment, on which the equipment manufacturer's coating is acceptable, shall be touch-up primed and coated with two coats of the specified coating system to match the color scheduled. Electrical and instrumentation equipment specified in Divisions 16 and 17 shall be coated as specified in paragraph 09900-3.03 I. 3. Coatings shall not be applied to a surface until it has been prepared as specified. The primer or first coat shall be applied by brush to ferrous surfaces that are not blast- cleaned. Coats for blast-cleaned ferrous surfaces and subsequent coats for nonblast- cleaned ferrous surfaces may be either brush or spray applied. After the prime coat is dry, pinholes and holidays shall be marked, repaired in accordance with CSM's recommendations and retested before succeeding coats are applied. Unless otherwise specified, coats for concrete and masonry shall be brushed or rolled. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-22 G. FILM THICKNESS AND CONTINUITY: ^ ^Mtf^1 1. WFT of the first coat of the coating system and subsequent coats shall be verified by the Contractor, following application of each coat. 2. The surface area covered per gallon of coating for various types of surfaces shall not exceed those recommended by the CSM. The first coat, referred to as the prime coat, on metal surfaces refers to the first full paint coat and not to solvent wash, grease emulsifiers or other pretreatment applications. Coatings shall be applied to the thickness specified, and in accordance with these specifications. Unless otherwise specified, the average total thickness (dry) of a completed protective coating system on exposed metal surfaces shall be not less than 1.25 mils per coat. The minimum thickness at any point shall not deviate more than 25 percent from the required average. Unless otherwise specified, no less than two coats shall be applied. 3. In testing for continuity of coating about welds, projections (such as bolts and nuts), and crevices, the Engineer shall determine the minimum conductivity for smooth areas of like coating where the dry mil thickness has been accepted. This conductivity shall be the minimum required for these rough or irregular areas. Pinholes and holidays shall be recoated to the required coverage. 4. The ability to obtain specified film thickness is generally compromised when brush or roller application methods are used and, therefore, more coats are needed to be ^% applied to achieve the specified dry film thickness. ^^ 5. Contractor shall apply a complete skim coat of an appropriate filler/surfacer material over the entire substrate prior to application of the coating system if, after completion of surface preparation, the surface profile or roughness of concrete or masonry substrates cannot be hidden or covered by the coating system's film thickness and/or if there are frequent open air voids and "bugholes" in the concrete substrate that cannot be filled by the coating system. The Contractor shall consult with the CSM for the appropriate filler/surfacer material and application recommendations to ensure compatibility with the coating system. H. SPECIAL REQUIREMENTS: Before erection, the Contractor shall apply all but the final finish coat to interior surfaces of roof plates, roof rafters and supports, pipe hangers, piping in contact with hangers, and contact surfaces which are inaccessible after assembly. The final coat shall be applied after erection. Structural friction connections and high tensile bolts and nuts shall be coated after erection. Areas damaged during erection shall be hand-cleaned or power-tool cleaned and recoated with primer coat prior to the application of subsequent coats. Touch-up of surfaces shall be performed after installation. Surfaces to be coated shall be clean and dry at the time of application. Except for those to be filled with grout, the underside of equipment bases and supports that have not been galvanized shall be coated with at least two coats of primer ^-^ specified for system E-2 prior to setting the equipment in place. Provide coating system i BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-23 - terminations at leading edges and transitions to other substrates in accordance with the CSM's recommendations or detail drawings. I. ELECTRICAL AND INSTRUMENTATION EQUIPMENT AND MATERIALS: Electrical and instrumentation equipment and materials shall be coated by the equipment manufacturer as specified below. 1. FINISH: Electrical equipment shall be treated with zinc phosphate, bonderized or otherwise given a rust-preventive treatment. Equipment shall be primed, coated with enamel, and baked. Minimum dry film thickness shall be 3 mils. Unless otherwise specified, instrumentation panels shall be coated with system E-l for indoor mounting and system U for outdoor mounting. Before final acceptance, the Contractor shall touch up scratches on equipment with identical color coating. Finish shall be smooth, free of runs, and match existing finish. Prior to touching up scratches, Contractor shall fill them with an appropriate filler material approved by the CSM. 2. COLOR: Exterior color of electrical equipment shall be FS 26463 (ANSI/NSF 61) light gray. Interior shall be painted FS 27880 white. Nonmetallic electrical enclosures and equipment shall be the equipment manufacturer's standard grey color. Exterior color of instrumentation panels and cabinets mounted indoors shall be FS 26463 light gray; unless otherwise specified, exterior color for cabinets mounted outdoors shall be FS 27722, white. Cabinet interiors shall be FS 27880, white. J. SOLUBLE SALT CONTAMINATION OF METALLIC SUBSTRATES: Contractor shall test in accordance with SSPC-TU-4 metallic substrates to be coated that have been exposed to sea water or coastal air or to industrial fallout of particulate or other sources of soluble chlorides (such as waste water exposure). If testing indicates detrimental levels of soluble salts, the Contractor shall clean and prepare these surfaces. 3.04 CLEANUP Upon completion of coating, the Contractor shall remove surplus materials, protective coverings, and accumulated rubbish, and thoroughly clean surfaces and repair overspray or other coating-related damage. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-24 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating systems for different types of surfaces and general service conditions for which these systems are normally applied are specified on the following COATSPEC sheets. Surfaces shall be coated in accordance with the COATSPEC to the system thickness specified. Coating systems shall be as specified in paragraph 09900-3.06, Coating System Schedule. In case of conflict between the schedule and the COATSPECS, the requirements of the schedule shall prevail. Coating Specification Sheets included in Table 09900A are included this paragraph 09900- 3.05. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-25 Table 09900A Coating Specification Sheets Coating System ID Coating Material Surface Service Condition E-l E-2 E-4 E-7 EA-1 EU-1 L-2 M-l M-2 Epoxy Epoxy Epoxy Epoxy Blended Amine Cured Epoxy Zinc-epoxy- polyurethane system Metal Metal Concrete, masonry, plaster, gypsum board Plastic Metal Latex Petrolatum based mastic or wax based wrapping tapes Epoxy mastic or equal Ferrous Metal, exposed piping, valves, apputenences and above grade tanks, color to match existing PVC and CPVC pipe Metal Ferrous Metal Interior; exterior, covered, not exposed to direct sunlight, non-corrosive exposure. Immersed, nonpotable; non-immersed, moderately corrosive environment, color required. Interior Interior; exterior covered, not exposed to direct sunlight. Immersed, nonpotable; non-immersed, corrosive environment, color not required especially for headspace environments that are corrosive due to biogenic sulfide corrosion. Exterior, exposed to direct sunlight, moderately corrosive non-immersed. Exterior, direct sunlight exposure. Below grade (buried) or where little to no surface preparation can be performed on piping or structural steel. Interior, corrosive environment, confined enclosures, where minimal surface preparation is possible. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-26 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: E-l Coating Material: Epoxy Surface: Metal Service Condition: Surface Preparation: General: Ferrous Metal: Nonferrous and Galvanized Metal: Interior; exterior, covered, not exposed to direct sunlight, non-corrosive exposure. Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and spot primed with the primer specified. Shop epoxy primed surfaces shall require light abrasive blasting prior to receiving finish coats. Bare ferrous metal surfaces shall be prepared in accordance with SSPC SP-6 (Commercial Blast Cleaning). Ferrous metal with rust bleeding shall be cleaned in accordance with SSPC SP-1 (Solvent Cleaning). Areas of rust penetration shall be spot blasted to SSPC SP-10 (Near White Blast) and spot primed with the specified primer. For ductile iron surfaces, refer to the requirements in paragraph 09900-3.02 D. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning). IH^^P BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-27 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: E-l (continued) Application: General: Ferrous Metal: Nonferrous and Galvanized Metal: System Thickness: Coatings: Primer: Finish: Field Prime coat may be thinned and applied as recommended by the CSM, provided the coating as applied complies with prevailing air pollution control regulations. Prime coats shall be an epoxy primer compatible with the specified finish coats and applied in accordance with the written instructions of the CSM. Nonferrous and galvanized metal shall be cleaned prior to the application of the prime coat in accordance with SSPC SP-1 (Solvent Cleaning). 10 mils dry film. One coat at CSM's recommended dry film thickness. One or more coats at CSM's recommended dry film thickness per coat to the specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-28 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: E-2 Coating Material: Epoxy Surface: Metal Service Condition: Surface Preparation: Ferrous Metal: Nonferrous and Galvanized Metal: Application: General: Ferrous Metal: Immersed, nonpotable; non-immersed, moderately corrosive environment, color required. Ferrous metal surfaces shall be prepared in accordance with SSPC SP-5 (White Metal Blast Cleaning). Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning) or SSPC-SP-3 (Power Tool Cleaning). Damaged shop coating shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and spot primed with the primer specified. Shop epoxy primed surfaces shall require light abrasive blasting prior to receiving finish coats if the maximum recoat time for the primer has been exceeded. For ductile iron surfaces, refer to the requirements in paragraph 09900-3.02 D. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning). Galvanized steel with this E-2 coating system shall not be used in immersion service in wastewater. Field Prime coat may be thinned and applied as recommended by the CSM, provided the coating as applied complies with prevailing air pollution control regulations. Prime coat shall be an epoxy primer compatible with the specified finish coats. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-29 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: E-2 (continued) Nonferrous and Galvanized Metal: Nonferrous and galvanized metal, non-immersed, shall be coated prior to the application of the prime coat with a grease emulsifying agent in accordance with the CSM's written instructions. Nonferrous metal to be immersed shall not be painted. Galvanized metal shall not be immersed even if it is painted. System Thickness: 16 mils dry film. Coatings: Primer: One coat at CSM's recommended dry film thickness. Finish: Two or more coats at CSM's recommended dry film thickness per coat to the specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-30 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: E-4 Coating Material: Epoxy Surfaces: Concrete, masonry, plaster, gypsum board. Service Condition: Interior Surface Preparation: Concrete: Masonry: Plaster: Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the CSM. Moisture content may be tested by the Engineer with a Delmhorst Instrument Company moisture detector, or equal. Loose concrete, form oils, surface hardeners, curing compounds and laitance shall be removed from surfaces, and voids and cracks shall be repaired as specified in Section 03300. After cleaning, air voids or bugholes in the concrete shall be filled with a surfacer or block filler compatible with the specified primer and finish coats. Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repointed. Loose or splattered mortar shall be removed by scrapping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Muriatic acid shall not be used. After cleaning, exterior masonry surfaces shall be sealed or filled with a sealer or block filler compatible with the specified primer. Plaster surfaces shall be dry and clean and free from grit, loose plaster, and surface irregularities. Cracks and holes shall be repaired with acceptable patching materials, keyed to existing surfaces, and sandpapered smooth. Surfaces shall be cleaned with clean water by washing and scrubbing to remove foreign and deleterious substances. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-31 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: Application: System Thickness: Coatings: Primer: Finish: E-4 (continued) Field Block Filler shall be a multiple component epoxy block filler or an acrylic based or waterborne epoxy based block filler and shall dry a minimum of 48 hours prior to primer application or as required by the CSM. Prime coat shall be thinned and applied as recommended by CSM, provided the coating as applied complies with prevailing air pollution control regulations. Drying time between coats shall be as recommended by CSM. 10 mils dry film, excluding block filler and sealer. One coat at CSM's recommended dry film thickness. One or more coats at CSM's recommended dry film thickness per coat to the specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-32 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: E-7 Coating Material: Epoxy Surface: Plastic Service Condition: Surface Preparation: Application: System Thickness: Coatings: Interior; exterior covered, not exposed to direct sunlight. Plastic shall be prepared in accordance with SSPC SP-1 (Solvent Cleaning) and light sanding to produce a uniform surface roughness on the plastic. Field 5 mils dry film. One or more coats at CSM's recommended dry film thickness per coat to the specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-33 •<*,- 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: EA-1 Coating Material: Blended Amine Cured Epoxy Surface: Metal Service Condition: Surface Preparation: Ferrous Metal: Nonferrous and Galvanized Metal: Application: General: Immersed, nonpotable; non-immersed, corrosive environment, color not required especially for headspace environments that are corrosive due to biogenic sulfide corrosion. Ferrous metal surfaces shall be prepared in accordance with SSPC SP-5 (White Metal Blast Cleaning). Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning surfaces in accordance with SSPC SP-11 (Hand Tool Cleaning). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and spot primed with the primer specified. Shop epoxy primed surfaces shall require light abrasive blasting and blow down cleaning prior to receiving finish coats. Cast iron surfaces to be coated shall be abrasive blast cleaned to a clean, gray uniform metal appearance free of variations in color and loose materials. Ductile iron surfaces shall be prepared in accordance with paragraph 09900-3.02 D. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning). Galvanized metal should generally not be used in these environments. Field Prime coat may be thinned and applied as recommended by the CSM, provided the coating as applied complies with prevailing air pollution control regulations. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-34 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: EA-1 (continued) Ferrous Metal: System Thickness: Coatings: Primer: Finish: Drying time between coats shall be as specified by the CSM for the site conditions. If the maximum recoat time is exceeded, surface preparation shall require solvent washing, light abrasive blasting, or other procedures per CSM's instructions. If shop priming is required or field priming is necessary, the prime coat shall be an epoxy primer compatible with the specified coating system. Generally, the EA-1 coating system is self-priming and does not require a primer unless there is a special reason to prime the steel to hold the blast cleaning from rusting back. 25-30 mils dry film. One coat at CSM's recommended dry film thickness only if required by special circumstances. One or more coats at CSM's recommended dry film thickness per coat to the specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-35 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: EU-1 Coating Material: Zinc-Epoxy-Polyurethane System Surface: Ferrous Metal Service Condition: Surface Preparation: General: Ferrous Metal: Application: General: Ferrous Metal: Exterior, exposed to direct sunlight, moderately corrosive, non-immersed. Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-3 (Power Tool Cleaning) and recoated with the primer specified. Bare ferrous metal surfaces shall be prepared in accordance with SSPC SP-6 (Commercial Blast Cleaning). Ductile iron surfaces to be coated shall be abrasive blast cleaned in accordance with paragraph 09900-3.02 D. Ferrous metal with rust bleeding shall be cleaned in accordance with SSPC-SP-11 (Power Tool Cleaning to Bare Metal). Areas of rust penetration shall be spot blasted to SSPC SP-10 (Near White Blast) and spot primed with the specified primer. Field Prime coat may be thinned and applied as recommended by the CSM, provided the coating as applied complies with prevailing air pollution control regulations. Prime coats shall be a zinc rich epoxy or polyurethane primer compatible for use with urethane finish coats and applied in accordance with written instructions of the CSM. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-36 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: EU-1 (continued) System Thickness: Coatings: Primer: Intermediate: Finish: 3 to 4 mils of zinc rich primer, one intermediate epoxy coat at 5 to 6 mils and one finish coat of polyurethane at 2 to 3 mils DFT. One coat at CSM's recommended dry film thickness. One coat at CSM's recommended dry film thickness. One coat at CSM's recommended dry film thickness per coat to meet the specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-37 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: L-2 Latex PVC and CPVC pipe. Exterior, direct sunlight exposure. Coating Material: Surface: Service Condition: Surface Preparation: Application: System Thickness: Coatings: Primer: Finish: Plastic pipe shall be cleaned with solvent compatible with the specified primer and sanded to uniformly roughen surfaces. Field 3 mils dry film. One coat at CSM's recommended dry film thickness. One or more coats at CSM's recommended dry film thickness per coat to the specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-38 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: M-l Coating Material: Petrolatum based mastic or wax based wrapping tapes. Surfaces: Metal Service Condition: Surface Preparation: Application: Below grade (buried) or where little to no surface preparation can be performed on piping or structural steel. Remove loose scale, rust, dirt, excessive moisture, or frost from the surface in accordance with SSPC SP-2 (Hand Tool Cleaning). All surfaces shall be hand rubbed or brushed with a priming paste recommended by the CSM. Sharp projections such as threads, irregular contours, or badly pitted areas shall receive a liberal amount of priming paste to ensure maximum protection of metal throughout. On irregular shaped surfaces, i.e., nuts, bolts, flanges, valves, etc., the Contractor shall use either of the following systems recommended by the CSM. A. OR: B. Apply recommended mastic by hand in sufficient quantity to build an even contour over entire surface. The Contractor shall pay particular attention to ensure that folds and air pockets within the mastic layer are thoroughly pressed out prior to subsequent application of tape. An extra layer of tape shall be cut and carefully molded around sharp projections, nuts, bolts, etc., before final application of tape, in order to meet specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-39 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification: M-l (Continued) Tape shall be spirally wrapped with a 55 percent overlap and sufficient tension and pressure to provide continuous adhesion without stretching the tape. Edges of tape must be continuously smoothed and sealed by hand during wrapping. On vertical application, contractor shall begin at bottom and proceed upward creating a weather board overlap. System Thickness: Smooth contours shall have a minimum thickness of 50 mils while nuts, bolts, and sharp projections shall be 100 mils. Tape: Number and types of tape wraps shall be in accordance with the CSM's written instructions. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-40 3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating System Identification; M-2 Coating Material: Epoxy mastic or equal Surface: Ferrous Metal Service Condition: Surface Preparation: Ferrous Metal: Application: General: System Thickness: Coatings: Prime: Finish: Interior, corrosive environment, confined enclosures, where minimal surface preparation is possible. All uncoated ferrous metal surfaces shall be prepared in accordance with SSPC SP-3 (Power Tool Cleaning), or SSPC-SP-11 (Power to Cleaning to Bare Metal) prior to assembly. Shop primed ferrous metal surfaces and fabricated assemblies shall be clean and dry prior to the application of field coats. Following assembly, the Contractor shall smooth welds and prominences using power tools prior to the application of the field applied coatings. Field Prior to the application of field applied coatings, welds, back-to-back angles, sharp or rough edges and weld splatter shall be brushed with the specified prime coat and allowed to cure overnight. 15 mils dry film. One coat of the CSM's recommended dry film thickness. One or more coats of CSM's recommended dry film thickness per coat to the specified system thickness. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-41 3.06 COATING SYSTEMS SCHEDULE (FINISH SCHEDULE) Specific coating systems, colors, and finishes for rooms, galleries, piping, equipment, and other items which are coated or have other architectural finishes are specified in the following coating system schedule. Unless otherwise specified in the coating system schedule, the word "interior" shall mean the inside of a building or structure, and the word "exterior" shall mean outside exposure to weather elements. Location Description Surface Coating System Identification Color General: Alt surfaces not specified by area or structure 1. Equipment and Metal Appurtenances a. Equipment, non immersed, unless otherwise specified 1) Indoors 2) Outdoors b. Equipment, immersed, unless otherwise specified c. Existing equipment 1) Not damaged nor modified by work hi this contract 2) Damaged or modified by work in this contract a) Indoors b) Outdoors d. Electrical switchgear panels, unit substations, motor control centers, power transformers, distribution centers, and relay panels; indoors and outdoors e. Instrumentation panels, graphic indicating panels, indicating and transmitting field panels, unless otherwise specified 1) Indoors 2) Outdoors f. Existing electrical and instrumentation panels 1) Not damaged by work in this contract 2) Damages to outside surfaces by work in this contract E-l EU-1 E-2 Uncoated E-l (see paragraph 09900-3.02) EU-1 without primer (see paragraph 09900-3.02) See paragraph 09900-3.03 I See paragraph 09900-3.03 I See paragraph 09900-3.03 I Uncoated FS 25051 Blue FS 20040 Brown Beige Match existing color Match existing color ANSI 61 Grey (outside) FS 27880 White (inside) FS 26306 Grey (outside) FS 27880 White (inside) FS 27722 White (outside) FS 27880 White (inside) BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-42 Location Description Surface Coating System Identification Color a) Indoors b) Outdoors E-l (see paragraph 09900-3.02 F) EU-1 without primer (see paragraph 09900-3.02 F) 2. Conduit, Piping and Ductwork a. Ferrous, non ferrous and galvanized piping, and appurtenant hangers and supports, non immersed, unless otherwise specified. 1) Indoors - noncorrosive 2) Outdoors - noncorrosive 3) Indoors - in corrosive environment 4) Buried piping b. Ferrous piping, appurtenant and supports, immersed c. Conduit, outlet and junction boxes, lighting transformers, lighting, communication and small power panels, control stations, piping, lagged ductwork, appurtenant hangers, clamps, and supports on coated surfaces, unless otherwise specified. 1) Indoors 2) Outdoors d. Conduit, outlets and junction boxes, lighting transformers, lighting, communication and small power panels, control stations, piping, lagged ductwork, appurtenant hangers, clamps and supports on uncoated surfaces, unless otherwise specified 1) Indoors 2) Outdoors e. Existing conduit, outlet and junction boxes, lighting transformers, lighting communication and small power panels, control stations, piping, lagged ductwork, appurtenant hangers, clamps, and supports 1) Not damaged nor modified by work in this contract 2) Damaged or modified by work in this contract a) Indoors E-l EU-1 EA-1 M-lorM-2 E-2 E-l EU-1 E-l EU-1 FS 26306 Grey FS 26306 Grey (Electrical) FS 27722 White (Instrumentation) Uncoated E-l (see paragraph 09900-3.02 F) FS 25051 Blue FS 20040 Brown To be determined Not required To be determined Match background color Match background color FS 25051 Blue FS 20040 Brown Match existing color BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-43 Location Description Surface Coating System Identification Color b) Outdoors f. Racked conduits and cable trays g. Insulated pipe jacketing h. Plastic, fiberglass and flexible conduit and piping 1) Unless otherwise specified 2) PVC and CPVC Piping a) Exposed to direct sunlight b) Not exposed to direct sunlight EU-1 without primer (see paragraph 09900-3.02 F) Uncoated Uncoated Uncoated L-2 L-2 E-7 Match existing color FS 25051 Blue FS 25051 Blue FS 25051 Blue 3.. Concrete, Grout, Masonry and Plaster a. Immersed tank and channel walls and bottoms unless otherwise specified b. Outside concrete walls below grade common with dry area or room c. Concrete equipment bases unless otherwise specified ___^ Uncoated In accordance with Section 07100) E-4 4. Precast Concrete Metalwork Fasteners, anchors, supports, etc.EU-1 5. Other a. Tanks 1) Steel tanks unless otherwise specified a) Inside of tanks b) Outside of tank (1) Indoors (2) Outdoors b. Pipe, ductwork, equipment and appurtenances made from fiberglass, plastic, rubber, including flexible hose, conduit, and plastic coated tubing, in areas not exposed to view (indoors) (metal hangers and supports are coated with E-l) c. Buried, sleeve-type and flanged pipe, couplings, valves, mechanical and electrical penetrations E-2 E-l EU-1 Uncoated M-l or M-2 Match equipment color Match wall FS 25051 Blue FS 25051 Blue Manufacturer's color BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 COATING SYSTEMS 09900-44 3.07 INSPECTION AND TESTING BY THE CITY OF CARLSBAD W A. Inspection by the City of Carlsbad or others does not limit the Contractor's or CSA's responsibilities for quality workmanship or quality control as specified or as required by the CSM's instructions. Inspection by the City of Carlsbad is in addition to any inspection required to be performed by the Contractor. B. The City of Carlsbad may perform, or contract with an inspection agency to perform, quality control inspection and testing of the coating work covered by this Section 09900. These inspections may include the following: 1. Inspect materials upon receipt to ensure that are supplied by the CSM. 2. Inspect to verify that specified storage conditions for the coating system materials, solvents and abrasives are provided. 3. Inspect and record findings for the degree of cleanliness of substrates. 4. Inspect and record the pH of concrete and metal substrates. 5. Inspect and record substrate profile (anchor pattern). *^^^h, 6. Measure and record ambient air and substrate temperature. ^X 7. Measure and record relative humidity. 8. Check for the presence of substrate moisture in the concrete. 9. Inspect to verify that correct mixing of coating system materials is performed in accordance with CSM's instructions. 10. Inspect, confirm, and record that the "pot life" of coating system materials is not exceeded during installation. Inspect to verify that recoat limitations for coating materials are not exceeded. 11. Perform adhesion testing. 12. Measure and record the thickness of the coating system. 13. Inspect to verify proper curing of the coating system in accordance with the CSM's instructions. 14. Perform holiday or continuity testing for immersed coatings or coatings exposed to aggressively corrosive conditions. _ O BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 ' 09900-45 3.08 FINAL INSPECTION A. Contractor shall conduct a final inspection to determine whether coating system work meets the requirements of the specifications. B. The Engineer will subsequently conduct a final inspection with the Contractor to determine the work is in conformance with requirements of the contract documents. C. Any rework required shall be marked. Such areas shall be recleaned and repaired as specified at no additional cost to the City of Carlsbad. *** END OF SECTION *** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) COATING SYSTEMS AUGUST 2010 09900-46 SECTION 09902 PETROLATUM WAX TAPE COATING PART 1 - GENERAL 1.01 SCOPE This section covers the work necessary to furnish and install petrolatum wax tape coating on buried ferrous materials including pipe flanges, bolted fittings and couplings, valves and other buried pipeline appurtenances, complete, as shown or specified. 1.02 SUBMITTALS DURING CONSTRUCTION Submit manufacturer's technical product data, details, installation instructions and general product recommendations. 1.03 PRODUCT IDENTIFICATION The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired only. Products of other manufacturers will be considered in accordance with the Contract Documents. PART 2 - MATERIALS 2.01 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. 2.02 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- 1 00° F • Flash Point 350° F minimum BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PETROLATUM WAX TAPE COATING AUGUST 20 10 09902-1 • Approximate Coverage 1 gal/100 square feet • Color Brown The primer shall be Trenton Wax-Tape Primer or equivalent. 2.03 WAX TAPE Two types of petrolatum wax tape shall be available from the manufacturer: one type for buried installations and another type for above-ground installations. Buried Installations: The covering material shall be a plastic-fiber felt tape, saturated with a blend of petrolatum, plasticizers, and corrosion inhibitors that is easily formable over irregular surfaces. The tape shall have the following properties: • Color: Brown • Saturant Pour Point 115° - 125°F • Thickness 70-90 mils • Dielectric Strength 170 volts/mil • Tape Width 6 inches • Wax tape shall be Wax-Tape #1 as manufactured by The Trenton Corporation (Ann Arbor, Michigan), or approved equal. 2.04 OUTER COVERING The primed and wax-tape wrapped surface shall be wrapped with a plastic tape covering consisting of three (3) layers of 50 gauge, clear, polyvinylidene chloride, high cling membranes wound together as a single sheet. The material shall have the following properties: • Width 6 inches • Thickness 1.5 mils • Dielectric Strength 2000 volts/mil • Water Absorption Negligible • Color Clear The outer covering shall be Trenton Poly-Ply or approved equal. 2.05 OTHER PETROLATUM WAX TAPE SYSTEM COMPONENTS Any components not listed above, but required for a complete petrolatum wax tape coating system as recommended for this application by the manufacturer shall be provided at no additional cost to City of Carlsbad. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PETROLATUM WAX TAPE COATING AUGUST 2010 09902-2 PART 3 - EXECUTION 3.01 GENERAL The petrolatum wax tape system shall be installed in conformance with the manufacturer's recommendations. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PETROLATUM WAX TAPE COATING AUGUST 2010 09902-3 SECTION 09961 FUSION-BONDED EPOXY LININGS AND COATINGS PART 1 - GENERAL 1.01 DESCRIPTION This section includes materials, application, and testing of one part, fusion bonded, heat cured, thermosetting, 100% solids epoxy linings and coatings on steel, cast iron, and ductile- iron equipment, such as valves, flexible pipe couplings, slide gates, and structural steel, and ductile-iron and steel pipe. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Coating Systems: 09900. B. Piping Systems: 15050. 1.03 SUBMITTALS A. Submit shop drawings in accordance with the Subsection 01300. B. Submit manufacturer's catalog literature and product data sheets, describing the physical and chemical properties of the epoxy coating. Describe application and curing procedure. PART 2 - MATERIALS 2.01 PIPING AND EQUIPMENT SURFACES A. The Contractor shall require the equipment suppliers to provide equipment that is free of salts, oil, and grease to the coating applicator. B. The Contractor shall require pipe suppliers to provide bare pipe that is free of salts, oil, and grease to the coating applicator. 2.02 SHOP-APPLIED EPOXY LINING AND COATING Lining and coating shall be a 100% solids, thermosetting, fusion-bonded, dry powder epoxy resin: Scotchkote 134 or 206N, Lilly Powder Coatings "Pipeclad 1500 Red," H. B. Fuller 1F- 3003, or equal. Epoxy lining and coating shall meet or exceed the following requirements: FUSION-BONDED EPOXY BUENA VISTA LIFT STATION FORCE MAIN (VC-4) LININGS AND COATINGS AUGUST 2010 09961-1 Hardness (minimum) Barcol 17 (ASTM D 2583) "^ Rockwell 50 ("M" scale) ^*r Abrasion resistance 1,000 cycles; 0.05 gram removed (maximum value) 5,000 cycles: 0.115 gram removed ASTM D 1044, Tabor CS 17 wheel, 1,000-gram weight Adhesion (minimum) 3,000 psi (Elcometer) Tensile strength 7,300 psi (ASTM D 2370) Penetration 0 mil (ASTM G 17) Adhesion overlap shear, 1/8- 4,300 psi, ASTM D 1002 inch steel panel, 0.010 glue line Impact (minimum value) 100 inch-pounds (Gardner 5/8-inch diameter tup) 2.03 FIELD-APPLIED EPOXY COATING FOR PATCHING Use a two-component, 80% solids liquid resin, such as Scotchkote 306. 2.04 PAINTING AND COATING OF GROOVED-END AND FLEXIBLE PIPE COUPLINGS Line and coat couplings the same as the pipe. Color shall match the color of the pipe fusion <^\ epoxy coating. ^^ PART 3 - EXECUTION 3.01 SHOP APPLICATION OF FUSION-BONDED EPOXY LINING AND COATING- GENERAL A. Grind surface irregularities, welds, and weld spatter smooth before applying the epoxy. The allowable grind area shall not exceed 0.25 square foot per location, and the maximum total grind area shall not exceed 1 square foot per item or piece of equipment. Do not use any item, pipe, or piece of equipment in which these requirements cannot be met. B. Remove surface imperfections, such as slivers, scales, burrs, weld spatter, and gouges. Grind outside sharp corners, such as the outside edges of flanges, to a minimum radius of 1/4 inch. C. Uniformly preheat the pipe, item, or piece of equipment prior to blast cleaning to remove moisture from the surface. The preheat shall be sufficient to ensure that the surface temperature is at least 5°F above the dew point temperature during blast cleaning and inspection. _ 3 FUSION-BONDED EPOXY BUENA VISTA LIFT STATION FORCE MAIN (VC-4) LININGS AND COATINGS AUGUST 2010 09961-2 D. Sandblast surfaces per SSPC SP-5. Protect beveled pipe ends from the abrasive blast cleaning. E. Apply a phosphoric acid wash to the pipe, item, or piece of equipment after sandblasting. The average temperature, measured in three different locations, shall be 80°F to 130°F during the acid wash procedure. The acid wash shall be a 5% by weight phosphoric acid solution. The duration in which the acid is in contact with the surface shall be determined by using the average temperature as tabulated below: Contact Time Pipe Temperature (°F) (seconds) 80 52 85 45 90 36 95 33 100 28 105 24 110 21 130 10 After the acid wash has been completed, remove the acid with demineralized water having a maximum conductivity of 5 micromhos/cm at a minimum nozzle pressure of 2,500 psi. F. Apply lining and coating by the electrostatic spray or fluidized bed process. Minimum thickness of lining or coating shall be 15 mils. Heat and cure per the epoxy manufacturer's recommendations. The heat source shall not leave a residue or contaminant on the metal surface. Do not allow oxidation of surfaces to occur prior to coating. Do not permit surfaces to flash rust before coating. 3.02 SHOP APPLICATION OF FUSION-BONDED EPOXY LINING AND COATING TO PIPE-ADDITIONAL REQUIREMENTS A. Apply lining and coating per AWWA C213 except as modified herein. B. Grind 0.020 inch (minimum) off the weld caps on the pipe weld seams before beginning the surface preparation and heating of the pipe. 3.03 QUALITY OF LINING AND COATING APPLICATIONS The cured lining or coating shall be smooth and glossy, with no graininess or roughness. The lining or coating shall have no blisters, cracks, bubbles, underfilm voids, mechanical damage, discontinuities, or holidays. FUSION-BONDED EPOXY BUENA VISTA LIFT STATION FORCE MAIN (VC-4) LININGS AND COATINGS AUGUST 2010 09961-3 3.04 FACTORY TESTING OF COATING-GENERAL A. Test linings and coatings with a low-voltage wet sponge holiday detector. Test pipe linings and coatings per AWWA C213, Section 5.3.3. If the number of holidays or pinholes is fewer than one per 20 square feet of coating surface, repair the holidays and pinholes by applying the coating manufacturer's recommended patching compound to each holiday or pinhole and retest If the number of pinholes and holidays exceeds one per 20 square feet of coating surface, remove the entire lining or coating and recoat the item or pipe. B. Measure the coating thickness at three locations on each item or piece of equipment or pipe section using a coating thickness gauge calibrated at least once per eight-hour shift. Record each measured thickness value. Where individual measured thickness values are less than the specified minimum thickness, measure the coating thickness at three additional points around the defective area. The average of these measurements shall exceed the specified minimum thickness value, and no individual thickness value shall be more than 2 mils below or 3 mils above the specified minimum value. If a section of the pipe, item, or piece of equipment does not meet these criteria, remove the entire lining or coating and recoat the entire item or piece of equipment. 3.05 FACTORY TESTING OF LINING AND COATING OF PIPE-ADDITIONAL REQUIREMENTS Check for coating defects on the weld seam centerlines. There shall be no porous blisters, craters, or pimples lying along the peak of the weld crown. 3.06 FIELD REPAIRS Patch scratches and damaged areas incurred while installing fusion bonded epoxy coated items with a two-component, 80% solids (minimum), liquid epoxy resin. Wire brush or sandblast the damaged areas per SSPC SP-10. Lightly abrade or sandblast the coating or lining on the sides of the damaged area before applying the liquid epoxy coating. Apply a two-part epoxy coating to defective linings and coatings to areas smaller than 20 square inches. Patched areas shall overlap the parent or base coating a minimum of 0.5 inch. If a defective area exceeds 20 square inches, remove the entire lining and coating and recoat the entire item or piece of equipment. Apply the liquid epoxy coating to a minimum dry-film thickness of 15 mils. ** END OF SECTION ** •^^f FUSION-BONDED EPOXY BUENA VISTA LIFT STATION FORCE MAIN (VC-4) LININGS AND COATINGS AUGUST 2010 09961-4 SECTION 11000 EQUIPMENT GENERAL PROVISIONS PART 1 - GENERAL 1.01 Work OF THIS SECTION A. The Work of this Section includes providing general requirements for the Work of applicable Sections of these Specifications. Unless there are more restrictive requirements in the individual Sections, the provisions of this Section shall apply. B. The Work of this Section applies to the Work of the following Sections: 1. Section 11060 Electric Motors 2. Section 11346 Submersible Sump Pump 1.02 RELATED SECTIONS A. The Work of the following Sections applies to the Work of this Section. Other Sections of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this Work. 1. Section 01300 Submittals 2. Section 01660 Equipment and System Performance and Operational Testing 3. Section 05505 Miscellaneous Metalwork 4. Section 09900 Coating Systems 5. Section 16000 General Requirements for Electrical Work 6. Section 16030 Electrical Acceptance Testing 7. General Provisions Section 4 - Control of Materials 1.03 CODES A. The Work of this Section shall comply with the current editions of the following codes as adopted by the City of San Diego Municipal Code: 1. Uniform Mechanical Code (UMC) 2. Uniform Plumbing Code (UPC) 3. Uniform Fire Code (UFC) 4. National Electrical Code (NEC) 5. Uniform Building Code (UBC) 6. California Building Code 1.04 SPECIFICATIONS AND STANDARDS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-1 A. Except as otherwise indicated, the applicable standards of the following organizations apply to the Work of this Section: 1. American Society for Testing and Materials (ASTM) 2. American Public Health Association (APHA) 3. American National Standards Institute (ANSI) 4. American Society of Mechanical Engineers (ASME) 5. American Water Works Association (AWWA) 6. American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE) 7. American Welding Society (AWS) 8. National Fire Protection Association (NFPA) 9. National Electrical Manufacturers Association (NEMA) 10. Antifriction Bearing Manufacturers Association (ABMA) 11. American Gear Manufacturers Association (AGMA) B. The current editions of the following apply to the Work of this Section: 1. ABMA 9 Load Ratings and Fatigue Life for Ball Bearings 2. ABMA 11 Load Ratings and Fatigue Life for Roller Bearings 3. ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800 4. ANSI B16.5 Pipe Flanges and Flanged Fittings, Steel, Nickel Alloy, and Other Special Alloys 5. ANSIB46.1 Surface Texture 6. ANSI S12.6 Method for the Measurement of the Real-Ear Attenuation of Hearing Protectors 7. ANSI/ASME B1.20.1 General Purpose Pipe Threads (Inch) 8. ANSVASMEB31.1 Power Piping 9. ANSI/AWWAD100 Welded Steel Tanks for Water Storage 10. AWWA C206 Field Welding of Steel Water Pipe 11. ASTM A 48 Specification for Gray Iron Castings 12. ANSI A 58.1 Minimum Design Loads for Buildings and Other Structures 13. ASTM A 108 Specification for Steel Bars, Carbon, Cold-Finished, Standard Quality BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-2 14. ANSI/NFPA 70 National Electrical Code 15. MIL STD 167-2 Mechanical Vibrations of Shipboard Equipment (Reciprocating Machinery and Propulsion System and Shafting) 1.05 SHOP DRAWINGS AND SAMPLES A. The following shall be submitted in compliance with Section 01300: 1. Manufacturer's product data including catalogue cuts. 2. Equipment name, identification number and specification numbers. 3. Shop drawings showing details, dimensions, anchorage details, and installation of equipment with all special fittings, appurtenances and required clearances. 4. Shipping weights. 5. Calculations of equipment anchorage forces and anchorage details. 6. Certification that the single manufacturer accepts the indicated unit responsibilities. 7. Parts list with materials of construction by ASTM reference and grade. 8. List of at least 5 installations and telephone numbers, where identical equipment has been used. 9. Documentation of experience of specialist who will perform torsional and vibration analysis. 10. Torsional and lateral vibration analysis reports. 1.06 OWNER'S MANUAL A. In addition to the requirements of paragraph 01300-1.05, the following shall be included in the Owner's Manual submittal in compliance with Section 01300: 1. Manufacturer's catalog including installation instructions. 2. Manufacturer's operating and maintenance procedures including lubricating instructions. 3. Manufacturer's certification that products comply with the indicated requirements. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-3 4. Certification that products have been factory-tested and found to conform with the contract requirements. 5. Certification that the Work has been field-tested and the Work complies with the indicated requirements. 6. Equipment tolerances 7. Electrical data including control and wiring diagrams. 8. Address and telephone number of local service representative. 1.07 SERVICES OF MANUFACTURER A. Inspection, Startup, and Field Adjustment: An authorized service representative of the manufacturer shall visit the site and witness the following: 1. Installation of the equipment. 2. Inspection, checking, and adjusting the equipment. 3. Startup and field-testing for proper operation. 4. Performing field adjustments to ensure that the equipment installation and operation comply with the Specifications. B. Instruction of City of Carlsbad's Personnel: 1. An authorized service representative of the manufacturer shall instruct the City of Carlsbad's personnel in the operation and maintenance of the equipment, including step- by-step troubleshooting with necessary test equipment. Training shall be specific to the models of equipment provided. 2. The representative shall have at least one year of qualified experience in training covering the relevant subjects described in paragraph 11000-1.7B.1. A resume for the representative shall be submitted to the Engineer. 3. Training shall be scheduled a minimum of 3 weeks in advance of the first session. 4. Proposed training material and a detailed outline of each lesson shall be developed in accordance with the requirements specified in Section 01300, and submitted to the Engineer for review. Comments from the Engineer shall be incorporated into the material. 5. Training materials shall remain with the trainees. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-4 6. The City of Carlsbad may videotape the training sessions for later use with the City of Carlsbad's personnel. C. Local Service; The manufacturer shall have a local service agency (within 50 miles of the site) which maintains properly trained personnel and adequate spare parts and is able to respond and complete repairs within 24 hours. 1.08 FACTORY INSPECTION AND TESTING A. The Contractor shall be responsible for all costs associated with inspection and testing of materials, products, or equipment at the place of manufacture. This shall include costs for travel, meals, lodging, and car rental for two City of Carlsbad-designated inspectors for the number of days indicated to complete such inspections or observations, if the place of manufacture, fabrication and factory testing is more than fifty (50) miles outside the geographical limit of the City. The Contractor shall not be responsible for salary or salary- related costs of the inspectors. The Contractor shall comply with the requirements of Section 4 of the General Provisions. B. Product Testing: Products shall be tested at the factory for compliance with the indicated requirements. The Contractor shall provide the Engineer a written notification of testing dates at least 2 weeks in advance of testing, unless more advance notice is specified elsewhere. 1.09 FIELD TESTING A. Testing: Products shall be field-tested for compliance with the indicated requirements. B. Witnesses: The City of Carlsbad and the Engineer (at the option of either) reserve the right to witness field tests. 1.10 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. Materials delivered onsite without an approved submittal for verification shall be rejected and payment withheld. B. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. C. Protection of Equipment: Equipment shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage. Equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Motors, BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-5 electrical equipment, and other equipment with anti-friction or sleeve bearings shall be stored in weather tight storage facilities prior to installation. For extended storage periods, plastic equipment wrappers shall not be used to prevent accumulation of condensate in gears and bearings. Gears and bearings to be stored for extended periods shall be containerized suitable for export shipment. D. Investigation of Failed Products: Prior to disposal of failed products, the Contractor shall investigate the causes of failure and submit a report to the Engineer, who will subsequently direct the Contractor for disposal. 1.11 UNIT RESPONSIBILITY A. Equipment systems made up of two or more components shall be provided as a unit by the manufacturer of the driven equipment. The manufacturer of the driven equipment shall assume the unit responsibility. Unless otherwise indicated, the Contractor shall cause each system component to be furnished by the manufacturer with unit responsibility. The extent of the manufacturer's responsibilities shall include engineering the specified equipment, preparation of all submittal materials, coordinating manufacture and procurement, compatibility and shipment of all specified components, design of all equipment supports, providing installation and testing specialists to assist the Contractor in completing the installation and commissioning the equipment, furnishing factory certified specialists to train the City of Carlsbad's staff, and the production and submission of specified operation and maintenance manuals. The Contractor is responsible to the City of Carlsbad for performance of all systems as indicated. The Contractor shall ensure the submittal of a Certificate of Unit Responsibility signed by the manufacturer with unit responsibility. PART 2 - PRODUCTS 2.01 GENERAL A. General: Only products meeting the indicated requirements shall be provided. B. Manufacturers: Products shall be new, of current manufacture, and shall be the products of reputable manufacturers specializing in the manufacture of such products. C. Products: Materials shall be suitable for the intended purpose and free of defects and shall be recommended by the manufacturer for the application indicated. D. No Endorsement: The listing of a manufacturer shall not be construed as an endorsement of a particular manufacturer's product, nor shall it be construed that a named manufacturer's standard product will comply with the indicated requirements. No preference is implied by the order of listing of named manufacturers, and the listings are not intended to be comprehensive. The manufacturer listings are only an indication that the City of Carlsbad BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 20 10 11000-6 and Design Consultant believe that the named manufacturers are capable of producing equipment and products which will satisfy the indicated requirements. 2.02 GENERAL REQUIREMENTS A. Noise Level: When in operation, no piece of equipment shall exceed the OSHA noise level requirements for a one hour exposure. B. Service Factors: Service factors shall be applied in the selection and design of mechanical power transmission components where so indicated in individual Sections. When not indicated there, minimum service factors shall be 1.25. C. Welding: Except as otherwise indicated, welding shall comply with ANSI/AWWA D100 and AWWA C206 and the following: 1. Composite fabricated steel assemblies which are to be erected or installed inside a hydraulic structure, including any fixed or movable structural components of mechanical equipment, shall have continuous seal welds and shall prevent entrance of air or moisture. 2. Welding shall be by the metal-arc method or gas-shielded arc method described in the American Welding Society's "Welding Handbook" as supplemented by other AWS standards. Qualification of welders shall comply with AWS Standards. 3. In assembly and during welding, the component parts shall be clamped, supported, and restrained to minimize distortion and for control of dimensions. Weld reinforcement shall comply with the AWS code. Upon completion of welding, weld splatter, flux, slag, and burrs left by attachments shall be removed. Welds shall be repaired to produce a workmanlike appearance with uniform weld contours and dimensions. Sharp corners of material which is to be painted or coated shall be ground to a minimum of 1/32-inch on the flat. E. Identification of Equipment Items: Each item of equipment shall have an indelible, legible identifying mark corresponding to the equipment number indicated. F. Vibration Level: (Not Used) G. Shop Fabrication: Shop fabrication shall be performed in accordance with the shop drawings. H. Tolerances: The variation in length of members without machine finished ends and which are to be framed shall not exceed 1/16-inch for members 30 feet or less and shall not exceed 1/8-inch for members over 30 feet. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-7 I. Machine Finish: The type of finish shall be the most suitable for the application in micro- inches complying with ANSI B46.1. The following finishes shall be used: 1. Surface roughness of surfaces in sliding contact shall not exceed 63 micro-inches. 2. Surface roughness shall not exceed 250 micro-inches except where a tight joint is indicated. 3. Surface roughness for other mechanical parts shall not exceed 500 micro-inches. 4. Surface roughness of contact surfaces of shafts and stems which pass through stuffing boxes and contact surfaces of bearings shall not exceed 32 micro-inches. H. Seismic Design: (Not Used) 2.03 EQUIPMENT SUPPORTS AND FOUNDATIONS A. Equipment Supports: Equipment supports, anchors, and restrainers shall be designed for static, dynamic, wind, and seismic loads. The design horizontal peak ground acceleration shall be the greater of that indicated in the Geotechnical Report or as required by the UBC for seismic Zone 4. Unless otherwise indicated, seismic design importance factors shall be in accordance with Table 16-K of the UBC. Determination of seismic forces and load combinations shall follow procedures in the UBC. B. Equipment Foundations: Unless otherwise indicated, equipment foundations shall conform to the requirements of Division 3. 2.04 SHAFTING A. General: All shafting shall be continuous between bearings and shall be sized properly to transmit the power required. Keyways shall be provided in accordance with standard practice. B. Materials: Shafting materials shall be selected for the type of service and torque transmitted and the effect of corrosive gases, moisture, and fluids shall be considered. Unless otherwise specified, materials shall conform to the following: 1. Low carbon cold-rolled steel shafting: ASTM A 108, Grade 1018. 2. Medium carbon cold-rolled shafting: ASTM A 108, Grade 1045. 3. Corrosion-resistant shafting: stainless steel or Monel, whichever is most suitable for the intended service. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-8 4. Extended shafting: carbon fiber/resin composite. C. Differential Settlement; Where differential settlement between the driver and the driven equipment is indicated, an extension shaft with 2 sets of universal type couplings shall be provided. 2.05 BEARINGS A. Bearings shall conform to the standards of the Anti-Friction Bearing Manufacturers Association, Inc. (ABMA). B. Bearing selection shall include the following criteria: fitting practice, mounting, lubrication, sealing, static rating, and housing strength. C. Re-lubricatable type bearings shall be equipped with an Alemite type hydraulic grease fitting in an accessible location. D. All lubricated-for-life bearings shall be factory-lubricated with the manufacturer's best recommended grease to insure maximum bearing life and best performance. E. Except where otherwise indicated, bearings for process equipment shall be selected for a minimum L-10 life expectancy of 50,000 hours for intermittent service and 100,000 hours for continuous service, in accordance with ABMA 9 or 11. Anti-friction bearings for pumps with discharge nozzle sizes 14 inches in diameter or greater, or pumps with a shaft diameter greater than 4 inches, shall be selected for an L-10 life expectancy of 100,000 hours in accordance with ABMA 9 or 11. Bearings for other elements in the rotating system such as motors, intermediate shaft bearings, right-angle gears, and flywheel bearings shall be selected using the same criteria as specified for the driven equipment, but not less than 50,000 hours. This requirement supersedes any specified bearing life in the detailed specification sections. Bearing selection shall be based upon the worst combination of continuous duty operating conditions specified and shall include both steady state and transient loads. Commercially manufactured appliances and small package heating and air conditioning equipment shall be furnished with bearings with L-10 life expectancy of not less than 20,000 hours in accordance with ABMA 9 or 11. Calculations supporting the selection of bearing sizes shall be included in the City of Carlsbads Manual. F. Bearing housings shall be of cast iron or steel and the bearing mounting arrangement shall be in accordance with the published standards of the manufacturer. Split-type housings may be used. G. Unless otherwise indicated, sleeve-type bearings shall have a Babbitt or bronze liner. 2.06 GEARS AND GEAR DRIVES (Not Used) BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-9 A. Except as otherwise indicated, gears shall be of the helical or spiral-bevel type, designed and manufactured in accordance with AGMA Standards, with a minimum service factor of 1.7, a minimum L-10 bearing life of 60,000 hours at the worst combination of specified operating conditions, in accordance with ABMA 9 or 11, and a minimum efficiency of 94 percent. Worm gears shall not be used. B. Gear speed reducers or increasers shall be of the enclosed type, oil- or grease-lubricated and fiilly sealed, with a breather to allow air to escape but keep dust and dirt out. The casing shall be of cast iron or heavy duty steel construction with lifting lugs and an inspection cover for each gear train. An oil level sight glass and an oil flow indicator shall be provided and installed for easy reading. C. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation. D. Material selections shall comply with AGMA values and the manufacturer's recommendations. Input and output shafts shall be properly designed for the service and load requirements. Gears shall be computer-matched for minimum tolerance variation. The output shaft shall have 2 positive seals to prevent oil leakage. E. Oil level and drain location shall be readily accessible. Oil coolers or heat exchangers with all required appurtenances shall be included where indicated. F. Where gear drive input or output shafts connect to couplings or sprockets, the gear drive manufacturer shall supply matching key. 2.07 DRIVE CHAINS (Not Used) A. Power drive chains shall be commercial type roller chains complying with ANSI standards and of materials best suited for the process fluid. B. A chain take-up or tightener shall be provided in every chain drive arrangement. G. A minimum of one connecting or coupler link shall be provided with each length of roller chain. 2.08 SPROCKETS (Not Used) A. General: Sprockets shall be used in conjunction with chain drives and chain-type material handling equipment. B. Materials: Except as otherwise indicated, sprockets shall comply with the following: 1. Sprockets with 25 teeth or less, normally used as a driver, shall be medium carbon steel in the 0.40 to 0.45 percent carbon range. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-10 2. Type A and B sprockets with 26 teeth or more, normally used as driven sprockets, shall be minimum 0.20 percent carbon steel. 3. Large diameter sprockets with Type C hub shall be cast iron conforming to ASTM A 48, Class 30. C. Sprockets shall be accurately machined to ANSI Standards. Sprockets shall have deep hardness penetration in tooth sections. D. Finish bored sprockets shall be provided complete with keyseat and set screws. E. Sprockets shall be of the split type or shall be provided with taper-lock bushings. F. Idler sprockets shall be provided with brass or Babbitt bushings, complete with oil hole and axial or circumferential grooving. Steel collars with set screws in both sides of the hub shall be provided. 2.09 V-BELT DRIVES (Not Used) A. V-belts and sheaves shall be of the best commercial grade and shall conform to ANSI, MPTA, and RMA Standards. B. Sheaves shall be machined from gray cast iron. C. Sheaves shall be statically balanced. In applications where excessive vibration is expected, sheaves shall be dynamically balanced. Sheaves operating at belt speeds exceeding 6,500 fpm shall be of materials and construction recommended by the manufacturer. D. Sheaves shall be provided complete with taper-lock or QD bushings as required. E. Finish bored sheaves shall be provided complete with keyseat and set screws. F. Sliding motor bases shall be provided to adjust the tension of V-belts. 2.10 DRIVE GUARDS (Not Used) A. Power transmission, prime movers, machines, shaft extensions, and moving machine parts shall be guarded. Unless otherwise indicated for corrosive environment, the guards shall be constructed of minimum 10 gauge expanded, flattened steel with smooth edges and corners, galvanized after fabrication and securely fastened. Where required for lubrication or maintenance, guards shall have hinged and latched access doors. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 EQUIPMENT GENERAL PROVISIONS 11000-11 2.11 FLEXIBLE CONNECTORS AND DUAL PIPE COUPLINGS A. Flexible connectors shall be installed in piping connections to engines, blowers, compressors, and other vibrating equipment in accordance with the requirements of the ANSIB31.1. B. Dual pipe couplings, separated by an 18-inch pipe spool unless otherwise indicated, shall be installed on the suction and discharge of all pumps - inboard of the isolation valves. Dual pipe couplings, separated by not less than two pipe diameters nor more than 5 feet, shall be installed on all piping where it exits a structure. Couplings shall be restrained where required. Dual flexible pipe joints may be used where indicated in buried pipe applications in lieu of dual pipe couplings. Flexible connectors are not permitted where dual pipe couplings are specified. 2.12 INSULATING CONNECTIONS A. Insulating bushings, unions, couplings, and flanges, shall comply with the requirements of Section 15050. 2.13 GASKETS AND PACKINGS A. Gaskets shall comply with the requirements of Section 15050. B. Packing around valve stems and reciprocating shafts shall be of compressible material, compatible with the fluid being used. Chevron-type "V" packing shall be Garlock No. 432, John Crane "Everseal," or equal. C. Packing around rotating shafts (other than valve stems) shall be "O"-rings, stuffing boxes, or mechanical seals, as recommended by the manufacturer. 2.14 TOOLS AND SPARE PARTS A. Tools: The Work includes one complete set of special tools recommended by the manufacturer for maintenance and repair of each separate type of equipment; tools shall be stored in tool boxes, and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box. B. Spare Parts: All equipment shall be furnished with the manufacturers' recommended spare parts, as indicated in the individual equipment Sections. Spare parts shall be tagged by project equipment number and identified as to part number, equipment manufacturer, and subassembly component (if appropriate). Spare parts subject to deterioration such as ferrous metal items and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts with individual BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-12 weights less than 50 pounds and dimensions less than 2 feet wide, or 18 inches high, or 3 feet in length shall be stored in a wooden box with hinged wooden cover and locking hasp. Hinges shall be strap type. The box shall be painted and identified with stenciled lettering stating the name of the equipment, equipment numbers, and the words "spare parts." A neatly typed inventory of spare parts shall be taped to the underside of the cover. 2.15 NAMEPLATES A. Equipment nameplates of stainless steel shall be engraved or stamped and fastened to the equipment in accessible locations with stainless steel screws or drive pins. Nameplates shall contain the manufacturer's name, model, serial number, size, characteristics, and appropriate data describing the machine performance ratings. 2.16 OVERLOAD PROTECTION A. General: Where indicated, mechanical or electronic overload protection devices shall be installed on equipment. B. Mechanical System: The overload protection shall be a mechanical device designed to provide reliable protection in the event of excessive overload. It shall be a ball detent type designed for long term repeatability and life. It shall be infinitely adjustable by a single adjusting nut which shall be tamper proof, and incorporate a torque monitoring and control system. It shall activate an alarm set for 85 percent, and a motor cutout switch set for 100 percent of maximum continuous running torque. A visual torque indicator shall be provided and oriented so that it may be read from the walkway. The dial shall be calibrated from 0 to 100 percent of maximum continuous running torque. The design of the torque limiter should initiate the mechanical disengagement of the drive upon overload. Each unit shall be suitable for outdoor and corrosive environments with a protective finish, corrosion inhibiting lubricants and a stainless steel cover. C. Electronic System: Overload protection may be an Electronic Torque Monitoring Control System capable of displaying torque, rpm's, one level of overload, and two levels of overload of the drive system. It shall incorporate a time-delay for startup and a voltage monitoring and compensation circuit for up to 15 percent variation. The overload device shall have an enclosure suitable for outdoor installation at temperatures of 0-70 degrees C, and relative humidity up to 95 percent. A visual torque dial shall be provided and oriented so that it can be easily read from the walkway. The torque monitoring system shall be calibrated to include: alarm and shut down the system in the event the torque drops to 50 percent of normal running; alarm at 85 percent of maximum continuous running torque and shut down the motor at maximum continuous running torque of the equipment. The system shall be calibrated at the factory of the BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-13 equipment manufacturer and it shall be capable of monitoring twice the maximum continuous running torque of the equipment. D. Definition: For the purpose of these Specifications, "maximum continuous running torque" shall be defined as the lesser of: the motor continuous running torque rating, the gear drive continuous running torque rating, or the driven mechanism continuous running torque rating, not exceeding a service factor of 1.0. E. Manufacturers: Overload protection devices shall be manufactured by the following (or equal): 1. American Autogard Corporation 2. Ferguson Machine Company 2.17 ANCHOR BOLTS, NUTS AND WASHERS A. Unless otherwise indicated, anchor bolts, nuts and washers for anchoring equipment to foundations and connecting bolts for equipment assemblies supported by other assemblies shall conform to the requirements of Section 05501. Unless otherwise specified, the Contractor shall provide Type 316 stainless steel anchor bolts and washers, and Type 416 stainless steel or other corrosion resistant, non-galling alloy nuts. In ferrous chloride and ferric chloride containment areas, unless otherwise specified, provide Hastelloy C or Alloy 276 anchor bolts, nuts, washers and connecting bolts. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 EQUIPMENT GENERAL PROVISIONS 11000-14 PART 3 - EXECUTION 3.01 INSTALLATION A. General: Products and equipment shall be installed in accordance with the manufacturer's written installation instructions, the requirements of this Section, the requirements of the individual equipment specifications, and as indicated. B. Alignment: Journeymen millwrights shall perform alignment of equipment furnished under this Section and any referencing section. Carpenters, laborers or any other trades are specifically excluded from performing this work. In locations where such trades are not available, the Contractor shall retain the services of a firm specializing in this type of work to perform the setting and alignment work. The Contractor shall submit the qualifications of the proposed firm to the Engineer for acceptance prior to performing the work. The Engineer shall personally witness final alignment procedures for each item of equipment as a condition precedent to beginning any work required under Section 01660. C. Lubricants: The Contractor shall provide for each item of mechanical equipment a supply of the lubricant required for the commissioning period. Lubricants shall be of the type recommended by the equipment manufacturer and shall be products of the City of Carlsbad's current lubricant supplier. The Contractor shall limit the various types of lubricants by consolidating them, with the equipment manufacturer's approval, into the least number of different types. Not less than 90 days before the date shown in his construction schedule for starting, testing and adjusting equipment, the Contractor shall provide the City of Carlsbad with three copies of a list showing the required lubricants, after consolidation, for each item of mechanical equipment. The list shall show estimated quantity of lubricant needed for a full year's operation, assuming the equipment will be operating continuously. 3.02 COUPLINGS A. Couplings shall be installed in accordance with the manufacturer's installation instructions. 3.03 INSULATING CONNECTIONS A. Insulating connections shall be installed in accordance with the manufacturer's instructions. 3.04 PIPE HANGERS, SUPPORTS, AND GUIDES A. Hangers, supports, and guides shall be installed in compliance with ANSI/ASME B31.1. 3.05 BOLTS AND MISCELLANEOUS METALS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) EQUIPMENT GENERAL PROVISIONS AUGUST 2010 11000-15 A. Bolts, including anchor bolts, and miscellaneous metals shall comply with paragraph 11000- 2.20 and Section 05501. 3.06 PACKAGED EQUIPMENT A. When any system is provided as pre-packaged equipment, coordination shall include space and structural requirements, clearances, utility connections, signals, outputs and features required by the manufacturer including safety interlocks. 3.07 PROTECTIVE COATING A. Equipment shall be painted and coated in accordance with Section 09900. Non-ferrous metal and corrosion-resisting steel surfaces shall be coated with grease or lubricating oil. Coated surfaces shall be protected from abrasion or other damage during handling, testing, storing, assembly, and shipping. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 EQUIPMENT GENERAL PROVISIONS 11000-16 SECTION 11002 RIGID EQUIPMENT MOUNTS PART 1-GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies minimum requirements for rigid equipment mounts (baseplates, soleplates, and mounting blocks) and their installation on equipment pads. Completed equipment supports shall consist of equipment pads, equipment anchors, and rigid equipment mounts (baseplates, soleplates, or mounting blocks) set in grout. Equipment mounting requirements of this section shall also apply to grouting and support of vavles and piping as part of the Work. Unless alternate requirements for equipment mounts are specified in the applicable equipment specification, the requirements of this section shall be applied to rigid mounts for all rotating or reciprocating equipment that is used to mix, convey, or pressurize fluids (gases and liquids). The requirements of this section shall also apply whenever referenced in specifications for other types of equipment. If conflict exists between this section and requirements of individual equipment manufacturers, the more restrictive requirements shall prevail. B. DEFINITIONS: Specific equipment mounting terminology used in this section conforms to the following definitions: 1. Baseplate: Fabricated (welded structural steel elements), cast, or plate steel base providing a common mounting element on which the legs, feet, or mounting surfaces of equipment are mounted by means of bolted connections. 2. Soleplate: A machined plate, spanning an opening in the floor or equipment pad, providing a common mounting element on which the legs, feet, or mounting surfaces of equipment are mounted by means of bolted connections. 3. Mounting Blocks: Multiple smaller baseplates on which individual legs, feet or equipment supports are mounted when equipment or drivers are not fastened to a common baseplate or sole plate. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-1 4. Equipment Pad: Concrete foundation (block or slab) supporting and elevating equipment mounts above the supporting structural floor slab or local grade. 5. Mounting Pads: Thickened or raised areas of baseplates and soleplates where the feet or mounting surfaces of mounted equipment and drivers are bolted and/or doweled to the baseplate or soleplate. 6. Leveling Blocks: Temporary steel blocks placed under baseplates, soleplates, or a mounting block at leveling positions (at equipment anchors) for the purpose of leveling baseplates, soleplates, or mounting blocks prior to grouting. 7. Shims: Thin stainless steel plates of a uniform thickness installed on top of Leveling Blocks for fine adjustment of level. Shims may also be used between equipment or drivers and baseplates, soleplates, or mounting blocks for equipment alignment purposes. 8. Wedges: Pairs of uniformly tapered metal blocks that are stacked with the tapered surfaces reversed (relative to the other wedge) so that the top and bottom surfaces of the wedges are parallel. Wedges are used between equipment pads and baseplates, soleplates, or mounting blocks for the purpose of leveling baseplates, soleplates, or mounting blocks. . 9. Mounting Stud: Threaded rod or bolts anchored to baseplates, soleplates, or mounting blocks for the purpose of mounting equipment or ancillary devices onto baseplates, soleplates, or mounting blocks. 10. Reinforcement Dowels: Steel reinforcement rods embedded in concrete, across a cold joint, for the purpose of transferring loads or force across the joint. 11. Machine Alignment Dowels: Tapered diameter rods inserted in tapered diameter holes for the purpose of aligning machinery. The practice of drilling tapered diameter holes through machinery and baseplates so that Machine Alignment Dowels may be inserted to facilitate alignment of machinery is known as Doweling. 12. Leveling Position: A location on the top of a concrete equipment pad where leveling tools and equipment will be temporarily installed or used for the purpose of leveling baseplates, soleplates, and mounting blocks prior to grouting. 13. Grout Manufacturer: Refers to the manufacturer of the epoxy grout system used for installation of rigid equipment mounts. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 20 10 RIGID EQUIPMENT MOUNTS 11002-2 14. Grout Manufacturer's Technical Representative(s): Refers to the technical representative(s) of the Grout Manufacturer. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-3 C. EQUIPMENT MOUNTING REQUIREMENTS: Unless otherwise specified, equipment and drivers shall be rigidly mounted on a common cast iron or fabricated steel baseplate or soleplate grouted into place on a concrete equipment pad. Under no circumstances shall baseplates, soleplates, or mounting blocks be grouted directly to concrete slabs or floors. Equipment that uses an interdependent equipment and driver mounting configuration (equipment that is bolted onto the driver frame and equipment that supports the driver entirely from the equipment frame) may be bolted directly on concrete or grout surfaces of equipment pads if the driver is less than five horsepower. Bolting equipment directly on concrete or grout surfaces of equipment pads is not acceptable for equipment and drivers that do not have an interdependent equipment and driver mounting configuration. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. It is a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed document, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid. If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, whether or not the document has been superseded by a version with a later date, discontinued or replaced. Reference ANSI/HI 1.4 ANSI/HI 2.4 API RECOMMENDED PRACTICE 686 ASTM E329 MIL-PRF-907E SSPC IBC Title Centrifugal Pumps - Installation, Operation and Maintenance Vertical Pumps - Installation, Operation and Maintenance Recommended Practices for Machinery Installation and Installation Design Inspection and Testing Agencies for Concrete, Steel, and Bituminous Materials as Used in Construction Anti-Seize Thread Compound, High Temperature Society for Protective Coatings Specifications, Vol. 2 2001 International Building Code (including local amendments) BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-4 B. QUALITY CONTROL BY CONTRACTOR: To demonstrate conformance with the specified requirements for rigid equipment mounts, the Contractor shall provide the services of an independent testing laboratory that complies with the requirements of ASTM E329. The testing laboratory shall sample and test equipment mount related materials as indicated in this Section (11002). Costs of testing laboratory services shall be borne by the Contractor. For equipment with drivers 20 horsepower and greater, the Contractor shall furnish the services of a grout manufacturer's technical representative that has been factory trained by the grout manufacturer. The grout manufacturer's technical representative shall perform training and quality control of epoxy grout installation for rigid equipment mounts as indicated in this section (11002). 1.03 SUBMITTALS The following information shall be provided in accordance with the submittal requirements specified in Section 01300. 1. A copy of this specification section, with addendum updates included, (referenced sections need not be included for Section 11002) with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. Copies of this specification section shall be numbered and marked (specification number and equipment number) for inclusion (filing) with the associated equipment submittal requirements. 2. Schedule of rigid equipment mount installations specified in paragraph 11002-2.01. 3. Name, employer and certificates or other information documenting compliance with the journeyman qualifications requirements for BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-5 millwrights who will install rigid equipment mounts, as specified in paragraph 11002-3.03. C. 4. Certificates or other documentation issued by the epoxy grout manufacturer that demonstrates that the grout manufacturer's technical representative has been factory trained on installation of epoxy grout for equipment mounts, as specified in paragraph 11002-1.02 B. 2. 5. Shop drawings for all equipment pads, equipment anchors, and baseplate, soleplate or mounting block details. Shop drawings shall depict size and location of equipment pads and reinforcement; equipment drains; equipment anchor, size, location, and projection; expansion joint locations; elevation of top of grout and grout thickness; elevation of top of baseplate; soleplate; or mounting block; size and location of electrical conduits; and any other equipment mounting features embedded in equipment pads. Shop drawings for equipment pads, equipment anchors, and baseplate, soleplate, or mounting blocks shall be numbered and marked (specification number and equipment number) for inclusion (filing) with the associated equipment submittal requirements. PART 2-PRODUCTS 2.01 GENERAL Prior to initiating any installation efforts, the Contractor shall produce a rigid equipment mount installation schedule containing the expected dates for installing equipment anchors and preparation of equipment pads for leveling, grouting, and final equipment anchor clamping for each item of equipment. The schedule shall list the equipment, by equipment tag number, and shall list applicable equipment specification section, motor horsepower, and name of the Contractor's representative responsible for quality control during installation of rigid equipment mounts. The schedule shall be accompanied by written verification of equipment anchor clamping torque from the manufacturer of each item of equipment to be installed with rigid equipment mounts. 2.02 CONCRETE EQUIPMENT PADS Concrete equipment pads shall be as shown in the structural details for equipment pads and equipment anchors for rigid mounted equipment. The Contractor shall submit equipment anchor calculations for all equipment with drivers 20 horsepower and greater. Equipment anchor calculations shall demonstrate that equipment anchor size, embedment, and edge distance comply with the California Building Code and are sufficient to resist the maximum lateral and vertical forces specified in paragraph 11000-2.11. Equipment BUENA VISTA LIFT STATION FORCE MAIN (VC^) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-6 anchor calculations shall be sealed by a registered structural or civil engineer licensed in the State of California. 2.03 BASEPLATES, SOLEPLATES, AND MOUNTING BLOCKS A. GENERAL: Unless otherwise specified, Type I baseplates, soleplates, and mounting blocks shall be a minimum of 1 inch thick for equipment with drivers 20 horsepower and larger. All Type I baseplates, soleplates, and mounting blocks shall have edges of surfaces bearing on grout rounded to a radius of not less than 0.25 inch. Horizontal corners of Type I baseplates, soleplates, or mounting blocks shall be rounded to a radius of not less than two inches to avoid producing stress risers on the grouted foundation. Grout pouring holes (minimum 4 inches in diameter for epoxy grout, minimum 2 !/2 inches in diameter for cementitious nonshrink grout) shall be provided in all baseplates and soleplates and all baseplates and soleplates shall have grout release holes. Mounting blocks may be grouted without grout pouring holes provided that no dimension of the mounting block (width or length) exceeds 18 inches. Grout relief or vent holes (minimum 1 inch in diameter) shall be provided in all baseplates, soleplates, and mounting blocks. Internal stiffeners shall be provided on all cast and fabricated baseplates and shall be designed to allow free flow of grout from one section of the baseplate to another. The minimum acceptable opening in cross bracing and stiffeners shall be 2-inches high by 6-inches in width. All welds shall be continuous and free from skips, blowholes, laps and pockets. Mounting holes for equipment anchors shall be drilled through baseplates, soleplates, and mounting blocks. Mounting holes for equipment anchors shall not be burned out and they shall not be open slots. All mounting studs shall be Type 316 stainless steel. An anti-seize or anti-galling compound, as specified in paragraph 11002-2.06, shall be applied to all mounting stud threads prior to installing nuts on mounting studs. Terminations requiring connections to baseplates, soleplates, or mounting blocks shall be acorn nuts welded to the under side of the baseplate or nuts welded to the underside of the baseplate and plugged with cork, plastic plugs or grease. In no case shall the fastener terminate only into the metal base. Where baseplates, soleplates, or mounting blocks are leveled using jackscrews, jackscrew threads shall be tapped in thickened pads or otherwise in sufficient metal to provide ease in adjusting level. Mounting pads for equipment shall be machined after all welding and stress relieving and shall be coplanar within 0.002 inch per foot in all directions. Mounting pads shall extend not less than 0.5 inch beyond the perimeter of the foot or mounting surface of the mounted equipment, in any direction. Equipment baseplates shall provide common support for the equipment and driver (and flywheel, if one is specified). Baseplates for equipment with drivers 20 horsepower and greater shall be furnished with eight transverse alignment (horizontal) positioning jackscrews for alignment of equipment drivers on horizontal surfaces of baseplates. Two BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-7 of the eight transverse alignment/positioning jackscrews shall be installed in perpendicular directions in a horizontal plane at the mounting position for each comer or foot of the equipment driver. (Eight additional jackscrews shall be provided for transverse alignment of the flywheel, if flywheels are specified.) B. TYPE I BASEPLATES: Type I baseplates shall be plate or fabricated structural steel baseplates with thickened steel mounting pads for doweling and bolting equipment to the baseplate. The baseplates shall be rectangular in shape for equipment other than centrifugal refrigeration machines and pump baseplates, which may be "T" or "L" shaped to accommodate the equipment drive and accessories. Baseplates for "split case pumps shall include supports for suction and discharge elbows, if required by the specified configuration. Perimeter members shall be beams with a minimum depth equal to l/10th of the longest dimension of the baseplate. Beam depth need not exceed 14 inches provided that the deflection and misalignment is kept within acceptable limits as determined by the manufacturer. C. TYPE II/III BASEPLATES: Type II and Type III baseplates, which are applicable for vibration isolation mounting, are to be specified, if warranted, based on the structural design by the engineer responsible for the surge tank. D. SOLEPLATES: Where soleplates are provided, the underside shall be scribed with the words "THIS SIDE DOWN" using welding rod material prior to milling the mounting pad for each equipment foot or mounting surface. Mounting surfaces and mounting pads on soleplates shall be milled flat to a tolerance of not less than 0.002 inch per foot in all directions. Soleplates shall be machined for an indexed fit to the mounted equipment or driver. E. MOUNTING BLOCKS: Where equipment is fabricated or cast with feet or mounting surfaces that are not fastened to a common baseplate or soleplate, as in dry-pit bottom suction pumps, the equipment may be supported on individual concrete piers or equipment pads in lieu of a common baseplate or soleplate and equipment pad. In such instances, the equipment shall be supported at the feet or mounting surfaces on individual mounting blocks, which shall be leveled and grouted into place on the individual piers or equipment pads as specified in this section. Vertical volute-type pumps weighing more than 2000 pounds shall be mounted on mounting blocks under each foot or mounting surface for the pump. All mounting blocks shall be furnished with jackscrew threads (three locations, minimum) tapped in the mounting block for the purpose of leveling mounting blocks with jackscrews. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-8 2.05 GROUT FOR EQUIPMENT PADS A. EPOXY GROUT FOR EQUIPMENT MOUNTING: Unless otherwise specified, grout for setting bearing surfaces of baseplates, soleplates, and mounting blocks on equipment pads shall be Epoxy Grout for Equipment Mounting as specified in Section 03600. Where the term epoxy grout is used in the context of details and specifications for equipment mounting it shall mean Epoxy Grout for Equipment Mounting. B. CEMENTITIOUS NONSHRINK GROUT: Cementitious Nonshrink Grout, specified in Section 03600, may be used for setting bearing surfaces of baseplates, soleplates, or mounting blocks on equipment pads where equipment drivers are 20 horsepower and smaller and the combined weight of equipment and driver is less than 1000 pounds. Where the term nonshrink grout or cementitious grout is used in the context of details and specifications for equipment mounting it shall mean Cementitious Nonshrink Grout. Training and quality control by the grout manufacturer's technical representative is not required for rigid equipment mounts installed with cementitious non-shrink grout. 2.06 EPOXY PRIMER Epoxy primer shall be a lead free, chrome free, rust inhibitive, two-component epoxy primer specifically designed for use on metal substrates and in conjunction with epoxy grout. The epoxy primer shall be a product of the epoxy grout manufacturer. 2.07 ANTI-SEIZE/ANTI-GALLING COMPOUND Anti-seize or anti-galling compound shall be a molybdenum disulfide and graphite combination in an aluminum complex base grease conforming to MIL-PRF-907E. Acceptable products include Jet Lube 550 by Jet Lube, Inc., E-Z Break by LA-CO, or equal. 2.08 PRODUCT DATA The following information shall be provided in accordance with the product data requirements specified in Section 01300: 1. Equipment anchor calculations specified in paragraph 11002-2.02. 2. Results of grout strength tests, as specified in paragraph 11002-3.03 D. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RIGID EQUIPMENT MOUNTS 11002-9 3. Completed Rigid Equipment Mount Installation Inspection Checklist Forms (11002-A), as specified in paragraph 11002-3.02 B. 4. List of Contractor's equipment installation staff that has completed epoxy grout manufacturer's grout installation training specified in paragraph 11002-3.02 A. PART 3-EXECUTION 3.01 GENERAL Grouting for installation of equipment on equipment pads shall take place prior to connecting any field piping or electrical and instrumentation systems. Unless the Engineer accepts an alternate installation procedure in writing, baseplates, soleplates, and mounting blocks shall be leveled and grouted with the equipment removed. Pumps shall be installed in accordance with this section and ANSI/HI 1.4 or ANSI/HI 2.4, as appropriate for the type of pumping equipment installed. Connecting piping with flexible connections and/or expansion joints shall be anchored such that the intended uses of these joints are maintained in the piping system without imposing strain on the equipment connections. Where an equipment manufacturer's installation requirements include a rigid connection between the machine and connecting piping systems, the Contractor shall delete any flexible coupling (including equipment connection fittings) shown on the drawings and install the equipment in the following manner, in lieu of installing the flexible coupling: 1. The equipment pad shall be prepared as shown on the details for rigid equipment mounts 2. The baseplate, soleplate, or mounting blocks supporting the equipment shall be installed, leveled, and grouted in place as specified in this section. 3. The equipment shall be installed, aligned and doweled in place. 4. The piping shall be installed and aligned to the equipment connections and the field piping connections without welding one of the joints for one section of pipe between the equipment connection and the field piping and all valving. All flanged joints shall be bolted up and pressure tested. 5. AH piping shall be fully supported by supports designed to accept their full weight and thrust forces. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-10 6. The final sections of piping shall be aligned with the equipment and field connections without the use of jacks, chain falls or other devices to force it into alignment. 7. The final piping joints shall be welded only after the previous steps have been completed and accepted by the Engineer. 3.02 EPOXY GROUT TRAINING AND QUALITY CONTROL A. EPOXY GROUT TRAINING Prior to commencing rigid equipment mount installation work on equipment pads, the Contractor shall furnish the services of a grout manufacturer's technical representative to conduct a training school for the workers that will be using the epoxy grout for rigid equipment mount installations.. The school shall be not less than 4 hours in length and shall cover all aspects of using the products, from mixing to application. This requirement, however, shall not be construed as relieving the Contractor of overall responsibility for this portion of the work. The epoxy grout manufacturer shall furnish a list of school attendees that have been satisfactorily trained to perform epoxy grout installation for equipment mounting. B. EPOXY GROUT QUALITY CONTROL For equipment with drivers 20 horsepower and greater, the epoxy grout manufacturer's technical representative shall provide quality control services for epoxy grout installation in rigid equipment mounts. The epoxy grout manufacturer's technical representative shall be on site to inspect and verify that the application personnel have successfully performed surface preparation, epoxy grout application, and Quality Control Inspection in accordance with these specifications for a representative portion of the epoxy grout installation work. Specifically, the epoxy grout manufacturer's technical representative shall perform the following services for at least one rigid equipment mount installation for each equipment type and size: 1. Inspect ambient conditions during various phases of epoxy grouting installation for conformance with the epoxy grout manufacturer's requirements. 2. Inspect the surface preparation of concrete substrates onto which epoxy grout materials are to be applied, for conformance to the specified application criteria, including but not limited to substrate profile, degree of cleanliness, and moisture. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-11 3. Inspect the surface preparation of the metallic substrates onto which the epoxy primer is to be applied. 4. Inspect the epoxy-primed metallic substrate for coverage and adhesion. 5. Inspect preparation and application of epoxy grout form work for conformance to the specifications. 6. Inspect and record that the "pot life" of epoxy grout materials is not exceeded during installation. 7. Inspect epoxy grout for cure. 8. Inspect and record that localized repairs made to grout voids are in conformance with the specification requirements. 9. Conduct a final review of completed epoxy grout installation for conformance to these specifications. 10. Attest to conformance of the Contractor's work by signing appropriate entries in the "Rigid Equipment Mount Inspection Checklist," form 11 002- A in Section 01 999. 3.03 INSTALLATION A. CONCRETE EQUIPMENT PAD PREPARATION: After the concrete is fully cured, the top of the equipment pad shall be roughened by chipping the surface. Chipping shall remove all laitance and defective or weak concrete and result in a rough surface profile with a 0.25 inch minimum amplitude. Chipping shall expose broken aggregate without dislodging unbroken aggregate from the cement matrix and shall not cause fractures below the concrete surface. Leveling surfaces of the concrete that have been finished smooth and level for baseplate, soleplate, or mounting block leveling at equipment anchors shall be protected from damage during chipping. A light duty, hand held pneumatic chipper with a chisel type tool shall be used for chipping the equipment pad concrete surface. Abrasive blast, bush-hammer, jack hammers with sharp chisels, heavy chipping tools, or needle gun preparation of concrete surfaces to be grouted is not acceptable. Prior to leveling activities, satisfactory removal of defective or weak concrete shall be demonstrated in the presence of the Engineer by operating the chipper on the chipped concrete surface at locations identified by the Engineer. The chipped surface of the concrete shall be such that the final baseplate, soleplate, or mounting block elevation results in the grout manufacturer's recommended grout thickness between the surface of the equipment pad and the lower baseplate flange, underside of the soleplate or BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-12 underside of mounting block. All dust, dirt, chips, oil, water, and any other contaminants shall be removed and the surface protected with plastic sheeting until grout is installed. Concrete equipment pad surfaces that have been finished smooth and level for use as leveling positions shall be protected from damage during chipping activities. Alternatively, leveling positions may be restored on chipped surfaces. Leveling positions shall be restored by installing leveling blocks or leveling plates for jackscrews on a high compressive strength epoxy putty (Philadelphia Resins, Phillybond Blue 6A, or equal). Leveling blocks and leveling plates Shall be installed level on the epoxy putty. B. BASEPLATES, SOLEPLATES, AND MOUNTING BLOCKS: All surfaces of baseplates, soleplates, and mounting blocks to be in contact with epoxy grout shall be cleaned to SSPC SP-6 and shall be primed with epoxy primer within 8 hours of cleaning. C. LEVELING: All machinery shall be mounted and leveled by journeyman millwrights. Precision surveying equipment shall be used for leveling. Machinists* spirit levels will not be permitted for leveling purposes for any baseplate, soleplate, or mounting block with a plan dimension greater than 4 feet. Baseplates and mounting blocks shall be leveled to a maximum tolerance of 0.002 inch per foot or as otherwise required by the equipment manufacturer, if more stringent. Soleplates shall be leveled to 0.0005 inch per foot or as otherwise required by the equipment manufacturer, if more stringent. An anti-seize or anti-galling compound specified in paragraph 11002-2.06 shall be applied to all equipment anchor threads prior to beginning baseplate, soleplate, or mounting block leveling. All baseplates, soleplates, and mounting blocks shall be leveled against steel surfaces (jackscrew plates, leveling blocks, leveling nuts, support plates, or other steel surfaces). Use of other materials for leveling purposes is strictly and specifically prohibited. Unless otherwise specified, baseplates, mounting blocks, and soleplates shall be leveled as indicated in the leveling details. Leveling equipment and tools shall be stainless steel leveling blocks and shims, steel wedges, or jackscrews bearing on leveling plates. Leveling nuts may be used for leveling baseplates and soleplates weighing less than 200 pounds. The use of leveling nuts for leveling mounting blocks is not permitted. After baseplates, soleplates, or mounting blocks have been leveled on the leveling equipment, the Contractor shall clamp the baseplates, soleplates, or mounting blocks in position by installing the equipment anchor nuts and washers. Clamping torque shall be less than the final clamping torque specified in paragraph 11002-2.01, but sufficient to hold the baseplate, soleplate, or mounting block in position. The Contractor shall verify BUENA VISTA LIFT STATION FORCE MAIN (VC-4) ' RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-13 that the correct level and position of the baseplate, soleplate, or mounting block has been maintained after clamping on the leveling equipment. Leveling blocks shall be stainless steel, four inches square and 1-1/2 inches thick with an open-ended slot terminating in the center for the equipment anchor. Leveling blocks shall be machined flat on all horizontal surfaces and placed under the baseplate or soleplate at each equipment anchor. Shims shall be pre-cut stainless steel, slotted for removal after grouting, and shall extend not less than three inches beyond the baseplate, soleplate or mounting block. Leveling blocks and shims shall be coated with a light oil just prior to beginning the leveling and grouting work. Shims shall be placed so the tabs on the shims are easily accessible. D. GROUTING: Grout forms shall be built of minimum 0.75 inch thick waterproof plywood and shall be securely braced (minimum brace size shall be two-by-four lumber). Forms shall be designed for a minimum of 6 inches hydrostatic head above the final elevation of the grout, to assist in flow during installation. Equipment mounting grout shall be furnished with expansion joints installed at four to six foot intervals, perpendicular to the centerline of baseplates. Forms shall be coated with three coats of paste wax on all areas that will come in contact with the grout to prevent the grout from bonding to the forms. Forms shall be waxed before assembly to prevent accidental application of wax to surfaces where the grout is to bond. Before any forms are installed, all concrete surfaces that will contact epoxy grout shall be free from any foreign material, such as oil, sand, water, wax, grease, etc. Forms shall be liquid-tight. Any open spaces or cracks in forms, or at the joint between forms and the foundation, shall be sealed off, using sealant, putty, or caulking compound. All outside vertical and horizontal edges of the grout shall have 45 -degree chamfers as indicated in the equipment anchor details for rigid equipment mounts. Match chamfers in concrete portions of the equipment pad. Block outs shall be provided at all shimming and leveling positions to allow removal of leveling equipment and tools after the grout has cured. Jackscrews shall be coated with a light oil or other acceptable bond-breaking compound prior to grouting. The 45-degree perimeter chamfer strip shall be located at the final elevation of the grout. The final elevation of the grout on baseplates with exposed I-beam or C- channel supports shall be at the top of the lower support flange. The top of the grout, on all other baseplates soleplates, and mounting blocks, shall be at least 1.0 inch above the bottom or underside of the baseplate, soleplate, or mounting block and shall not be higher than the top of the baseplate, soleplate, or mounting block. The grout's final elevation shall not be so high as to bond the equipment anchor nut and washer. The resin and hardener for epoxy grout for equipment mounting shall be mixed in accordance with the epoxy grout manufacturer's recommendations. Epoxy grout shall be placed at the center of one end of the baseplate or soleplate and worked toward the BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-14 ends in such a manner as to force the air out from beneath the baseplate or soleplate and out the vent holes, to eliminate voids. Epoxy grout shall be placed in a manner that avoids air entrapment, using a head box to pour grout into the grout holes. When the head box is moved to the next grout hole, a 6-inch high standpipe shall be placed over the grout hole and filled with grout. Use of vibrating tools and/or jarring (rapping or tapping) forms to facilitate grout flow is not permitted during placement of epoxy grout. The Contractor shall exercise care to never allow the grout to fall below the baseplate level once the grout has made contact with the baseplate. Grout placement shall be continuous until all portions of the space beneath the baseplate, soleplate, or mounting block have been filled. Subsequent batches of grout shall be prepared so as to be ready when the preceding batch has been placed. Under no circumstances shall the grouting operation be halted because of lack of grout mix. After the entire baseplate is full, 6-inch high standpipes shall be maintained over each grout hole, to continue purging of air. When the grout has started to take an initial set (typically this is determined by a noticeable increase in temperature and no flow of grout at the vent holes) the standpipes shall be removed and excess grout cleaned from all surfaces. Where the cavity under a baseplate or mounting block extends above the elevation of the top of the bolting flange for the baseplate or mounting block, grouting may be completed in two pours. Under these circumstances, the first grout pour shall be continuous until the lower face of the bolting flange for the baseplate or mounting block is submerged in grout a minimum of one inch. The second grout pour shall be completed with standpipes and air purges as specified in the previous paragraph. Grout forms shall be checked for leaks throughout grout pours. Leaks shall be repaired immediately to prevent formation of voids. A final check of baseplate, soleplate, or mounting block level and elevation shall be performed before the grout sets. A grout sample shall be taken for each equipment pad that has a baseplate, soleplate, or mounting block set in grout. The sample shall be placed in a cylinder of sufficient size to yield three two-inch cubes as test samples. The samples shall be tagged with project name, date, time, the equipment number and ambient temperature at the time of placement. Once the epoxy grout cylinder has been completely filled, it shall be placed next to the foundation of the equipment being grouted and allowed to cure for 48 hours. After 48 hours, the test cylinder shall be tested in accordance with the grout manufacturer's recommendations by the independent testing laboratory specified in paragraph 11002-1.02 B. The results shall be reported directly to the Engineer. Forms shall be removed only after the grout has cured sufficiently and upon specific permission from the Engineer. E. COMPLETION: Upon acceptance by the Engineer and the equipment manufacturer's representative BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-15 and after the grout has reached sufficient strength, grout forms and block outs at leveling positions shall be removed. Leveling blocks and shims or wedges and support plates shall be removed, leveling nuts and jack screws shall be backed off to allow the grout to fully support the baseplate, mounting block, or soleplate. Take care not to damage the grout during removal of extended shimming material or leveling equipment and tools. The equipment anchor nuts shall be tightened, using calibrated indicating torque wrenches, to develop the full clamping force required by the equipment manufacturer. Equipment anchor nuts shall be tightened in increments of not more than 25 percent of the final torque value in an alternating pattern to avoid stress concentration on the grout surface. After tightening equipment anchor nuts to final values, apply additional wax, grease, or mastic to all exposed portions of the equipment anchor beneath the baseplate, soleplate, or mounting block. After applying additional wax or mastic to exposed portions of equipment anchors, block outs (pockets) for access to leveling nuts, leveling blocks and shims, or wedges shall be filled with the grout material installed under baseplates, soleplates, or mounting blocks and pointed after the equipment anchor nuts have been tightened to final values. Jackscrews shall be removed and holes in the baseplate, soleplate, or mounting blocks filled with a flexible sealant (silicone rubber) or a short cap screw. Check for baseplate, soleplate, or mounting block movement (soft foot) by individually loosening and re-tightening each equipment anchor. Vertical movement at each equipment anchor shall be measured and recorded during loosening and retightening and shall not exceed 20 micrometers (0.001 inch). Vertical movement shall be measured using a magnetic-based dial indicator on the baseplate, soleplate, or mounting block referenced to the epoxy grout surface of the equipment pad or other approved method. Soft foot conditions shall be sufficient cause for removal and reinstallation of grout and baseplates, soleplates, or mounting blocks. Check for grout voids by tapping along the upper surfaces of the baseplate, soleplate, or mounting block. Grout voids shall be sufficient cause for removal and reinstallation of grout and baseplates, soleplates, or mounting blocks. Grout voids shall be marked. At the discretion of the Engineer, grout voids may be repaired as specified in Chapter 5, Section 3.16 of API 686. 3.04 FINAL INSPECTION The Engineer will conduct a final inspection with the Contractor for conformance to requirements of the contract documents. **END OF SECTION** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RIGID EQUIPMENT MOUNTS AUGUST 2010 11002-16 SECTION 11346 SUBMERSIBLE SUMP PUMPS PARTI-GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies submersible sump pumps complete with motor, motor disconnects, float switches, discharge flange, stainless steel mounting hardware, cable, lifting chain and all necessary apputenances for a full and functioning system. B. TYPE: Pumps shall be of the submersible, centrifugal nonclog type for use in pumping non potable water from the sump of flow meter vaults. C. OPERATING REQUIREMENTS: Equipment provided under this section shall conform to the following: Equipment number N/A Rated capacity, gpmat BEPa 80 Design head, feet 50 Max. speed, rpm 1800 Voltage and phase 115/lph Max. horsepower 0.5 Discharge pipe size, inches 2 Max. sphere passage, size, inches N/A aBccausc the pumps are to operate at constant speed, the pump shall be selected so that the rated condition lies within 5 percent (based upon capacity) of the best efficiency point (BEP) on the pump's head-capacity curve. 1.02 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 SUBMERSIBLE SUMP PUMPS 11346-1 version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference ASTMA48 ASTM A276 UL674 Title Gray Iron Castings Stainless and Heat-Resisting Steel Bars and Shapes Motors and Generators, Electric, for Use in Hazardous Locations, Class I, Groups C and D, Class II, Groups E, F, and G 1.03 ENVIRONMENTAL CONDITIONS The pumps and motors shall be suitable for operation in corrosive conditions. Pumps and motors will be submerged for extended periods of time. The pumped fluid temperature is expected to range from 32 degrees F to 100 degrees F. 1.04 SUBMITTALS The Contractor shall provide the following submittals in accordance with Section 01300: ' i•^^ff 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks (/) shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justifications) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. 2. A copy of the contract document control diagrams and process and instrumentation diagrams relating to the submitted equipment, with addendum updates that apply to the equipment in this section, marked to show specific changes necessary for the equipment proposed in the submittal. If no changes are required, the drawing or drawings shall be marked "no changes required". Failure to include copies of the -""K relevant drawings with the submittal shall be cause for rejection of the entire ._ „ BUENA VISTA LIFT STATION FORCE MAIN (VC4) SUBMERSIBLE SUMP PUMPS AUGUST 2010 11346-2 submittal with no further review. 3. Manufacturer's data including materials of construction and equipment weight. 4. Predicted performance curves developed for the specific application. 5. Motor data on the applicable portions of Form 11060-A specified in Section 01999. PART 2-PRODUCTS 2.01 ACCEPTABLE PRODUCTS Pumps shall be ABS Scavenger EJ 05W, Hydromatic Series W-A1, or equal modified to provide specified features and to meet specified operating conditions. 2.02 MATERIAL Component Pump and motor Casing discharge Impeller All exposed nuts and bolts Shaft Material Cast iron, A48 Cast iron, A48 Cast iron, A48 Stainless steel, ASTM A276, Type 304 Stainless steel, ASTM 276, Type 303 or Type 420 Materials specified are considered the minimum acceptable for the purposes of durability, strength, and resistance to erosion and corrosion. The Contractor may propose alternative materials for the purpose of providing greater strength or to meet required stress limitations. However, alternative materials must provide at least the same qualities as those specified for the purpose. Shop drawings should specifically address any deviations from specified manufacturer or materials with justification for the substitution that it meets the strength, durability and corrosion resistance. 2.03 EQUIPMENT A. IMPELLERS: Impellers shall be statically and dynamically balanced and designed to be nonclog and to pass stringy material. Maximum solids handling capacity shall be as specified in paragraph 11346-1.01 D. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) SUBMERSIBLE SUMP PUMPS AUGUST 2010 11346-3 B. BEARINGS: Bearings shall be heavy-duty permanently lubricated ball type. Bearings for pumps 3-inch diameter discharge and larger shall be designed for an L-10 life of 18,000 hours heavy-duty service without requiring additional lubrication. C. PUMP AND MOTOR CASING: Casings shall be constructed of corrosion resistant cast iron and shall be designed to allow removal of all rotating parts from the motor end of the pumps. All mating surfaces where watertight sealing is required shall be machined and fitted with nitrile O-rings. Unless otherwise specified, pump volute shall have vertical discharge. D. MECHANICAL SEAL: Unless otherwise specified, pumps shall be provided with carbon and ceramic faced mechanical seals. Where specified, pumps 3 inches in diameter and larger shall be provided with double mechanical seals. E. MOTOR: Motors shall have aluminum rotor material and copper stator windings with F-insulation without exceeding the B-temperature rise of 80-degree C at rated load and with Design-B torque / current characteristics rated for continuous operation duty. The motor shall be designed to be nonoverloading over the entire pump curve. The motor housing shall be of submersible construction with the windings operating in a sealed environment. Motors shall be either air or dielectric oil filled with built-in automatic reset overload protection. Explosion-proof motors, where specified, shall be UL listed in accordance with UL 674 for Class I, Group D hazardous atmosphere. F. CABLE: Pump motor and detector cables shall be suitable for submersible pump applications. Power for the motor shall be carried by a heavy-duty, flexible, water-resistant portable cable, sealed at the motor bell and of sufficient length to connect to the junction box or the plug outlet as specified. The cable entry shall prevent water from leaking into the motor due to capillary action even if cable is cut or damaged. G. LIFTING CHAIN: A 12-foot stainless steel (Type 304) lifting chain shall be provided for each pump. BUENA VISTA LIFT STATION FORCE MAIN (VCM) AUGUST 2010 SUBMERSIBLE SUMP PUMPS 11346-4 2.04 CONTROLS Controls shall be integral with the pump. Pumps shall be automatically controlled by means of a tilt sensitive wide angle float switch which is sealed in a non-corrosive enclosure. 2.05 SPARE PARTS Each pump 3 inches and larger shall be provided with the following spare parts: 1 set - all gaskets 1 set - all bearings 1 set - mechanical seals Spare parts shall be packed and boxed as specified in paragraph 11000-2.14. 2.06 PRODUCT DATA Applicable operation and maintenance information shall be provided in accordance with Section 01300 and 01730. PART 3 - EXECUTION 3.01 INSTALLATION Sump pumps shall be installed in accordance with the manufacturer's recommendations. 3.02 TESTING Each pump system shall be tested for control and capacity over a 2-hour period. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 SUBMERSIBLE SUMP PUMPS 11346-5 SECTION 11875 HYDROPNUEMATIC SURGE TANKS PART 1-GENERAL 1.01 DESCRIPTION: A. SCOPE: This section specifies hydropneumatic surge control tanks, complete with air padding controls. B. TYPE: Surge tanks provided under this section shall be pressure padded type with no floating diaphragm or bladder. C. EQUIPMENT LIST: Item Surge Tank 4"SST Stilling Well w Level Element/Transmitter Sight Gauge, isolation ball valves Equipment No. ST-02 LRM-02 N/A D. DESIGN REQUIREMENTS: Equipment No. Tank type Total surge tank volume, minimum, cubic feet Inside diameter, feet, minimum Straight shell length, feet Maximum surge pressure, psig Minimum pressure at design surge event, psig Pressure range during normal operation, psig Design internal pressure, psig Liquid level in tank at design surge event, percent of internal volume Horizontal, cylindrical 1300 9.92 11 87 -7 0-70 150 50 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 HYDROPNEUMATIC SURGE TANKS 11875-1 Equipment No. Design liquid temperature range, degrees F Design ambient temperature range, degrees F 60-80 35 to 110 E. OPERATING AND PERFORMANCE REQUIREMENTS: Equipment furnished under this section shall be suitable for use in the control of changes in piping system pressure resulting from hydraulic transients generated in wastewater force mains and water transmission mains. The liquid level in the tank shall be maintained within ± 3 inches of the level representing the indicated percentage of tank volume by an air padding system using compressed air from the station's existing air system. Accordingly, the air padding system shall include all pressure regulating and rate of flow control devices to control head space pressure as necessary to maintain the required liquid level, taking into account the variations in liquid and ambient temperatures and variation in head space temperatures as affected by solar gain and loss. The surge tank furnished under this section will be used to protect two parallel 24-inch-diameter wastewater force mains for the Buena Vista Lift Station system. Both force mains, each more than 4,000 feet in length, are required to convey the peak flow during wet weather episodes. Only one force main will be in service during dry weather flow conditions. The active force main will be alternated and placed in service when required to accommodate wet weather flows. During dry weather flow conditions, a 4 - 6 hour cycle is anticipated. To accommodate this operational routine, the surge tanks are connected to a common manifold and the manifold itself will be either alternated or connected to both pipelines depending upon operating system requirements. The equipment to be furnished under this section shall be suitable for installation in a weather exposed location at the site. All tank mounted panels, gages, connections and instruments subject to heat damage shall be equipped protective features, including heat tracing, internal heaters, insulation and heat shields to protect against damage due to prolonged exposure under the specified ambient conditions. Equipment furnished under this section will be installed in a seismically active location where severe horizontal ground motion may be expected. Accordingly, the tank supports shall be designed in accordance with CBC for Zone 4 seismic loading. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST 2010 11875-2 1.02 QUALITY ASSURANCE A. REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. Where a conflict between the requirements of this section and those of the listed documents may occur, the requirements of this section shall prevail. Included with this specification are fabrication drawings for the existing surge tank at the Buena Vista Lift Station, ST-01. It is the wish of the City of Carlsbad to match in dimensions, size and appearance the existing surge tank with the new surge tank, ST-02. The design requirements of this specification govern in the design of the new surge tank. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, whether or not the document has been superseded by a version with a later date, discontinued or replaced. Reference ASME Pressure Vessel Code CBC Title Boiler and Pressure Vessel Code for Unfired Pressure Vessels, Section VIII, Division I California Building Code B. UNIT RESPONSIBILITY: The Contractor shall assign unit responsibility as specified in paragraph 11000-1.02 C. to the surge tank manufacturer, who shall be responsible for all equipment specified under this section as well as the appurtenances to the surge tank including stilling well, level sensor, isolation valves, sight gage and level transmitter. A certificate of unit responsibility shall be provided. The tank manufacturer, in turn, shall retain the services of a structural engineer registered in the State of California with not less than ten years' experience in the design, and inspection of fabrication and installation of pressure vessels. The tank manufacturer shall cause the engineer, hereinafter referred to as the 'design professional' to be responsible for the final design of the tank's supports and connections to the foundation system shown. The design professional shall supervise the fabrication, factory testing and field installation and testing of the supports and connections. All calculations, memoranda, and reports produced by the design professional shall bear the professional's original signature and registration seal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST 2010 11875-3 The above provisions, however, shall not be construed as relieving either the tank manufacturer of responsibility for the equipment furnished under this section or the Contractor of responsibility for this portion of the work. C. SOURCE QUALITY CONTROL: 1. Shop Hydrostatic Test: a. Test with level gauge/probe chamber and associated valves installed. b. Tank and pressure components shall be pressure tested at 1.5 times tank design pressure. Test pressure shall be maintained for at least 24 hours. 2. Inspection of Tank Interior Lining a. Monitor and verify the quality of surface preparation, coating application, coating thickness, coating integrity, materials, and conformance to all applicable portions of these specifications. b. Provide full access to all related materials records and materials storage facilities, including equipment and media used for surface preparation. Provide full access during all related surface preparation coating application operations, as requested by Engineer. c. Submit documentation of all surface preparation and application quality control tests. Include, as a minimum, lining thickness testing and holiday test results. 3. Manufacturer's Qualifications a. Manufacturer shall be certified to use the code stamp in accordance with provisions of the ASME Pressure Vessel Code, Section VIII, Division 1. b. All inspections shall be carried out by authorized inspectors regularly employed by an ASME accredited Authorized Agency. Manufacturer shall provide all inspectors and the qualifications of inspector(s) shall be in accordance with Subsection A, Part UG, ASME Pressure Vessel Code, Section VIII, Division 1. 4. Examination of Weld Joints a. Radiographic Examination of Weld Joints BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST 2010 11875-4 b. All weld joints shall be 100 percent radiographed in accordance with the requirements of Subsection B, Part UW and UCS, ASME Pressure Vessel Code, Section VIII, Division 1 . c. Personnel performing and evaluating radiographic examinations shall be qualified in accordance with the requirements of Subsection B, Part UW and UCS, ASME Pressure Vessel Code, Section VIII, Division 1 . d. Acceptance standards and repair requirements of radiographic welds shall be in accordance with the requirements of Subsection B, Part UW and UCS, ASME Pressure Vessel Code, Section VIII, Division 1. e. Magnetic particle examination, liquid penetration examination and ultrasonic examination of welded joints shall be in accordance with ASME Pressure Vessel Code, Section VIII, Division 1, Subsection B, Appendix 6, 8, and 12, f. Examination procedures, acceptance standards, repair requirements and competence of examiners shall be qualified in accordance with ASME Pressure Vessel Code, Section VIII, Division 1. 1.03 SUBMITTALS A. The following submittals shall be provided as specified in Section 01300: 1 . A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks (*0 shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST 2010 11875-5 2. Certificate of Unit Responsibility attesting that the Contractor has assigned, and that the manufacturer accepts, unit responsibility in accordance with the requirements of this Section and paragraph 11000-1.02 C. No other submittal material will be reviewed until the certificate has been received and found to be in conformance with these requirements. 3 Manufacturer's catalog, descriptive data and details confirming conformance to specified design, material and equipment requirements. 4. Shop Drawings: Detailed dimensional fabrication drawings for surge tank including, the following: detailed erection drawings showing complete layout of tank, equipment location and orientation, field assembly joints, support configuration, anchorage details, and assembled level control valve enclosure. 5. Design Calculations: Submit complete design calculation for the tank demonstrating conformance to specifications, codes, and commercial standards listed herein, including ASME code calculations, seismic calculations, and anchoring calculations. 6. Shell and Ends: Thickness and material. 7. Product Data: Specifications for system components, accessories, and protective coatings. Complete data on exterior and interior of tank painting systems in accordance with Section 09900. 8. Supports and Anchorage: Material thickness, connection details, attachment details to shell, and anchor bolt details. 9. Fittings and Attachments: Locations, orientation, sizes, thickness, material of construction. 10. Level and control valve enclosure and level gauge/probe chamber in accordance with Section 17212. 11. Operation and Maintenance Manuals: Provide with delivery of the system. 12. Shop Testing: Tank ASME Form U-1A. Provide with O & M manuals. 13. Installation requirements, showing clearance required for maintenance purposes. Include Manufacturer's written instructions for installation. 14. Certification of Material: Manufacturer shall certify that all material and construction of tanks is in accordance with the requirement of Parts UW and UCS of the ASME Pressure Vessel Code, and these specifications. Submit certified mill test results from the steel manufacturer for each heat of steel BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST 2010 11875-6 used in fabricating the tank. 15. Welding Information: a. For all welds, indicate location, type, size and extent with referenced welding procedure specifications numbers. Distinguish between shop welds and field welds. Indicate by welding symbols or sketches details of all welded joints and preparation of parent metal. b. Written welding procedures for shop and field welds, including welding procedure specifications and procedure qualification records. c. Written nondestructive testing procedure specifications, and nondestructive testing personnel qualifications. d. Current welder performance qualifications for each welder used prior to his performing any work either in the shop or field. e. Credentials of manufacturer's certified welding inspectors and quality control specialist for review prior to starting any welding in the shop or field. f. All nondestructive testing results for each shop-welded and field- welded joint. The results shall include all testing on each weld joint, including re-examination of repaired welds, using radiographic, magnetic particle, liquid penetration examination, or ultrasonic examination methods. Test results shall be reviewed and signed by the welding inspector(s). g. Welder log for field and shop welding. Log shall list all welders to be used for the work and the types of welds each welder is qualified to perform. h. Submit a welding map showing the sequence of welds for all field weld proposed. i. Written weld repair procedure for each type of shop and field weld proposed. j. Written rod control procedure for shop and field operations demonstrating how manufacturer intends to maintain rods in good condition throughout construction and ensure that the proper rods are used for each weld. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST 2010 11875-7 PART 2-PRODUCTS 2.01 SURGE TANK A. MANUFACTURERS: The City of Carlsbad and Engineer believe the following candidate manufacturers are capable of producing equipment and/or products that will satisfy the requirements of the Section. This statement, however, shall not be construed as an endorsement of a particular manufacturer's products, nor shall it be construed that a named manufacture's standard equipment or products will comply with the requirement of this Section. The candidate manufacturers include the following, or approved equal: 1, Benicia Fabrication & Machine, Inc 2, Hanson Tank 3, Pulsco 4, South Gate Engineering B.MATERIALS: Component Shell and Heads Flanges Interior Coating Systems (shop) Exterior Coating System (field, color to match existing surge tank) Material Carbon Steel, ASME SA516 Grade 70 Flat Faced, ASME SA350 Grade LF 2m unless other E-2 (Section 09900) EU-1 (Section 09900) 2.02 MISCELLANEOUS COMPONENTS A. Pressure Gage B. ASME Pressure Relief Valve (PRV) C. Gas Charging Nozzle D. Level and Pressure Sensors E. 16" connection to force main manifold F. 4" drain connection BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 HYDROPNEUMATIC SURGE TANKS 11875-8 G. 4" SST stilling well for level probe w isolation valves BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST 2010 . 11875-9 2.03 ACCESS HATCHES Each surge tank shall be fitted with 30-inch diameter access hatches on each end bell. All hatch covers shall be davited to allow access to the tank interior without the need for hoisting equipment. Davit bearings shall be non corrosive, permanently lubricated. Hatch closure bolts shall be captive, swing away bolts with butterfly nuts. 2.04 EQUIPMENT IDENTIFICATION PLATE The tank shall bear a 16-gauge Type 316 stainless steel nameplate securely mounted on tank in a readily visible location. Plate lettering shall be block type, 3/8-inch high, engraved or die-stamped, black enamel filled. Nameplate shall contain design and fabrication information required by the reference standards, including: Equipment Number, design data, manufacturer, manufacturer's job or invoice number and the applicable code symbol and ASME inspector's stamp. 2.05 PRODUCT DATA A. The following product data shall be submitted in accordance with Section 01300: 1. Applicable operating and maintenance information as specified in Section 01730. American Society of Mechanical Engineers (ASME) form U-A1, Manufacturer's Data Report for Pressure Vessels, affirming that the tank is certified and stamped in accordance with the ASME Pressure Vessel Code. 2. All items stated in paragraph 1.03 of this Section. 2.06 FABRICATION A. The following requirements shall apply to the equipment specified in this section: 1. The manufacturer shall certify that all materials used in the construction of the tank meet the requirements of the ASME Pressure Vessel Code and all requirements of this Specification have been complied with. 2. Material for pressure components shall be laid out during fabrication so that when the tank is completed, the complete set of the original markings required in the specifications for the material will be plainly visible. 3. Inspection of Materials shall be in accordance with the requirements of the ASME Pressure Vessel Code. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 HYDROPNEUMATIC SURGE TANKS 11875-10 2.07 LEVEL CONTROL SYSTEM The tank shall be supplied with level detection probes and control logic devices to maintain the specified liquid level in the tank. Probes, control devices and panel enclosure construction shall conform to the requirements of Divisions 16 and 17 in this project manual. The control system enclosure shall be located as indicated. The, tank manufacturer shall provide conduit and conductor routing drawings for use by the electrical subconsultant. PART 3--EXECUTION 3.01 INSTALLATION AND TESTING A. The Contractor shall cause the equipment manufacturer to inspect the site to verify field dimensions, the locations of equipment, and to determine and verify the installation procedure to be used. B. The supplier shall provide all components and assembly instructions to the Contractor for installation. Contractor shall install tank in accordance with manufacturer's written instructions. C. Construction of the tank foundation piers and grouting of tank mounting plates shall conform to the requirements of Section 03300 and the requirements for equipment bases set forth in Section 11002. D. Assemble Accessories: Make process, control and electrical connections. Make piping connections such that misalignment stresses are not included in tank nozzles. E. Testing shall be performed by the Contractor in the presence of the Engineer and a representative of the tank manufacturer. Testing shall consist of functional test of the simulated power failure when pumps are running at maximum operating flow conditions. Testing shall also include Source Quality Control Tests, as specified in Paragraph 2.06 of this Section. F. System supplier shall provide start-up support (one trip, one day) to test and instruct project personnel. G. The additional provisions listed below are required for ASME SA 516 Grade 70, the material selected for the manufacturing of the tank. 1. Charpy V-notch impact test requirements for ASME SA 516 Grade 70, and ASME SA 350 Grade LF 2 shall be in accordance with ASME Section VIII, except that in no case shall it be less than 30 foot-pounds for the transverse direction at 0 degrees F regardless of thickness and design stress. Charpy V-notch testing is required on all shell steel. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST2010 11875-11 2. Certification of impact tests of material shall be by the material manufacturer, in accordance with the requirements of ASME Pressure Vessel Code, Section VIII, Division 1. 3. Charpy V-Notch impact test shall be performed on all the welded areas of the tank subjected to operating pressure. Charpy testing of welds shall be in accordance with the requirements of ASME Pressure Vessel Code. Weld metal shall be tested for each heat and lot number combination used for each weld procedure. A weld test plate shall be proposed, using a representative actual heat of base material used in the vessel manufacture for testing of weld metal and heat affected zone. The weld metal and heat affected zone shall be tested at a temperature not greater than that for the corresponding base material and shall meet the Charpy minimum requirements for the base material. 4. Normalized heat treatment to enhance the material toughness for the tank construction shall be in accordance with the requirements of ASME SA 516 Grade 70. 5. Toughness requirements for bolting material ASME SA-193, Grade B16 shall be in accordance with ASME Pressure Vessel Code, 3.02 FIELD QUALITY CONTROL A. Field Hydrostatic Test: Hydrostatically test at 1.3 times the tank design pressure following installation and before any dynamic testing. Test period shall be 4 hours minimum, and all leaks shall be immediately repaired. B. Functional Test: 1. Coordinate test schedule with Engineer prior to commencement. 2. Test level control system for all functions. 3. Provide a dynamic test of the surge control system in response to flow startup and stoppage, increasing the number of pumps in service pumps, one at a time, and record pressures for dynamic operation for each pump combination. This latter procedure shall be used for startup and shutdown of flow. 4. Provide suitable test equipment to electronically log surge tank pressure in 0.5 second increments (maximum) for the duration of the dynamic testing. Pressure transducers shall be calibrated and accurate to within 0.5 percent. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HYDROPNEUMATIC SURGE TANKS AUGUST 2010 11875-12 5. Functional Test Report: Contractor shall submit complete written report and electronic data file on all tests performed within 10 days after test completion. Reports shall include: a. Date and time of all testing b. Description of method of testing, including pumping combinations, pressure records, etc. c. Description of any failure or repairs. d. Signature of Contractor and test equipment operator. e. Electronic file on compact disc media containing pressure versus time data for all tests. Data file shall be in Microsoft Excel format, or approved equivalent. **END OF SECTION** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 HYDROPNEUMATIC SURGE TANKS 11875-13 ITEM MW DESCRIPTION 24"-150# FFSO MANWAY WORK ORDER HO. 6956 DETAIL DWG. N24150R-MW NOTE: REFER TO SPECIFICATION SECTION 11875 FOR SPECIFIC DESIGN REQUIREMENTS. THE FABRICATION DRAWINGS ARE PROVIDED FOR REFERENCE ONLY. IT IS THE OWNER'S DESIRE TO MATCH THE NEW SURGE TANK IN BOTH SIZE AND APPEARANCE WITH THE EXISTING SURGE TANK. P1,P1G\ REPAD/ P1,P1G\ "MW"/ 3/8" _J\ /P1,P1G 3/8" FLANGE £1/2" RECESS 1/2" 3. REPAD TO HAVE 1/8"-NPT WEEP HOLES. AIR TEST <3> 5 PSI MAX. 2. ALL FLANGES TO STRADDLE CENTERLINES. 1. DEBURR ALL SHARP EDGES. SOUTH GATEJENGINEERING 11001 VULCAN STREET P.O. BOX 1986 SOUTH GATE, CA. 90280 PH.(562)861-0757 FAX.(562)861-0451 REV 12/12 11/21 DATE SHOP RELEASE SUBMITTA1 DESCRIPTION APP'D Specification Section 11875 ITEM N1 DESCRIPTION 16"-150# FFSO NOZZLE WORK ORDER NO. 6956 DETAIL DWG. N16150R-N1 NOTE: REFER TO SPECIFICATION SECTION 11875 FOR SPECIFIC DESIGN REQUIREMENTS. THE FABRICATION DRAWINGS ARE PROVIDED FOR REFERENCE ONLY. IT IS THE OWNER'S DESIRE TO MATCH THE NEW SURGE TANK IN BOTH SIZE AND APPEARANCE WITH THE EXISTING SURGE TANK. P1,P1G\ REPAD/ P1.P1G 1/2" RECESS 3/8"FLANGE 3. REPAD TO HAVE 1/8"-NPT WEEP HOLES. AIR TEST @ 5 PSi MAX. 2. ALL FLANGES TO STRADDLE CENTERLINES. 1. DEBURR ALL SHARP EDGES. SOUTH GATEENGINEERING 11001 VULCAN-STREET P.O. BOX 1986 SOUTH GATE, CA. 90280 PH. (562)861-0757 FAX.(562)861-0451 REV 12/18 12/12 11/21 DATE REVISION SHOP RELEASE SUBM1TTAL DESCRIPTION APP'D Specification Section 11875 ITEM N2 DESCRIPTION 4"-150# FFSO NOZZLE WORK ORDER NO. 6956 DETAIL DWG. N04150R-N2 NOTE: REFER TO SPECIFICATION SECTION 11875 FOR SPECIFIC DESIGN REQUIREMENTS. THE FABRICATION DRAWINGS ARE PROVIDED FOR REFERENCE ONLY. IT IS THE OWNER'S DESIRE TO MATCH THE NEW SURGE TANK IN BOTH SIZE AND APPEARANCE WITH THE EXISTING SURGE TANK. P1,P1G\i- FLUSH W/ I.D. REPAD/V 3/8 V8" RECESS 5/16" 3. REPAD TO HAVE 1/8"-NPT WEEP HOLES. AIR TEST © 5 PSI MAX. 2. ALL FLANGES TO STRADDLE CENTERLINES. 1. DEBURR ALL SHARP EDGES. SOUTH GATE [ENGINEERING 11001 VULCAN STREET P.O. BOX 1986 SOUTH GATE, CA. 90280 PH.(562)861-0757 FAX,(562)861-0451 REV 12/12 H/21 DATE SHOP RELEASE SUBMITTAL DESCRIPTION APP'D Specification Section 11875 .,...1 h F C / DETAIL DWG. N1S150R-N1 N04150R-N2 N24150R-MW WORK ORDER NO. 6956 NOZZLE SCHEDULE ITEM N1 N2 MW HD A1.2 81 C1.2 DESCRIPTION INLET NOZZLE FIANCE ROLLED PLATE REPAD DRAIN NOZZLE FLANGE PIPE REPAD 24" MANWAY FIANCE PIPE REPAD BUND HANDLE HALF COUPLINGS HALF COUPLING FULL COUPLINGS FIT-UP 1 OF 1 OF 2 OF 1 OF 1 OF 1 OF DWG 4 / 4 4 4 4 4 SIZE ..^tSMSQjK^CL,, 1/2'x 9A5/8"x16"00 } -1/2\l£25te3-'lCfK 4"-150| FFSO 4"-SCH.80 x 9" 1/2"x4.75lDx9"OD 24"-150| FFSO 24"-STD x 9 1/4" 1/4*x24.25*IDx34"OD 24*-15^jl FF 3/4"«x3*x6" 3/4"-3000if T-3000f 2"-3000| MATERIAL SA-105 SA-516.70 SA-516.70 SA-105 SA-106.B SA-516.70 SA-105 SA-1063 SA-516.70 SA-105 SA-36 SA-182- SA-182- SA-182- -304 -304 -304 QTY, 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 4 /«b.r ^ W.-J HEAT #*S yM DETAIL DWG. 3 OF 4 3 OF 4 3 OF 4 EXTERNAL ATTACHMENT ITEM SG LL SD BP OG MG IG WP WB *+* *#* *** DESCRIPTION NAMEPLT BKT LIFT LUGS SADDLES BASEPLATE OUTER GUSSET MIDDLE GUSSET INNER GUSSET WEAR PLATE WEB PLATE STUDS NUTS GASKET FIT-UP 2 OF 1 OF 3 OF DWG 4 3 4 ; { JOTE: REFER TO SPECIFICATION SE REQUIREMENTS. THE FABRICATION )NLY. IT IS THE OWNER'S DESIRE TC WD APPEARANCE WITH THE EXISTI . ' ^g==|^^^^^^^^L-S^BSi•3^JS& SOUTH GATEENGINEERING 11001 VULCAN STREET ! P.O. BOX 1986 SOUTH GATE, CA. 90280 PH.(562)861-0757 FAX. (562)661 -0451 SIZE STD TYPE "H"(3/4" THK) ,^^^^^^V^ 1 1/4'x12*x104"v^ 3/4"xl2"x33" L 3/4"x5 1/2M45/16' *• 3/4"x5 1/2"x7 13/16" 3/4"x14"x140"rJ " 1 1/4"-8UNC x 7" 1 1/4"-8UNC 24"-150| F. FACE CTION11875FORSF DRAWINGS ARE PRC 3 MATCH THE NEWS NG SURGE TANK. MATERIAL C/S SA-36 SA-36 SA-36 s SA-36 SA-36 SA-36 SA-36 SA-193 -B7 SA-194-2H 1/8"THK EPDM QTY. 1 2 2 2 4 8 8 2 2 20 40 1 HEAT #'S N« 'ECIFIC DESIGN )VIDED FOR REFERENCE URGE TANK IN BOTH SIZE 4 3 2 1 0 REV 12/18 12/12 11/21 DATE REVISIONS SHOP RaEASE SUBMITTAL DESCRIPTION Specification Section 11875 c\m5 APPV'D r ( '"*' DETAIL DWG. 1 OF 3 WORK ORDER NO. 6956 INTERNAL CLIPS/BARS/STUDS ITEM VB DESCRIPTION VORTEX BREAKER DETAIL DWG. 4 OF 4 FIT-UP 1 OF DWG 4 SIZE 1/4"x9"x24" MATERIAL QTY. HEAT #'S j SA-36 2 ! PROBEWELL ASSEMBLY ITEM *** 01 02 04 05 DESCRIPTION PROBEWEU ASSY PIPE FLANGE HALF COUPLINGS HALF COUPLINGS FIT-UP 4 OF DWG 4 / \ f NOTE: REFER TO SPECIFICATION SECT FOR SPECIFIC DESIGN REQUIREMENTS FABRICATION DRAWINGS ARE PROVIDE REFERENCE ONLY. IT IS THE OWNER'S MATCH THE NEW SURGE TANK IN BOTH APPEARANCE WITH THE EXISTING SUR SOUTH GATEKNOTNFFRTNO 1 1001 VULCAN STREET P.O. BOX 1986SOUTH GATE, CA. 90280 PH. (562)861 -0757 FAX_fSfi?'\Rfi1 — D451 SIZE ^'"^^ "^--V-^-^ ,-vX— S 4"-SCH.10 x 103 3/4" _ 4"-150l RFSO 3/4"-3000# v-\ 2"~3000f ? x MATERIAL QTY. HEAT #'S -^- ^-^-^^^.^ 1 SA-31 2-304 1^^ SA-105 2 ( SA- 182-304 5 <J SA- 182-304 2 j_ ^-^^^,^~**-~s-/ ON 11875 .THE TJFOR DESIRE TO SIZE AND GE TANK. 4 3 2 1 0 REV 12/18 REVISION 12/12 SHOP RELEASE 11/21 SUBMITTAL DATE DESCRIPTION APPV'D Specification Section 11875 WORK ORDER NO. 6956 SHEET 1 OF 4 P1.P1G,2\ GtRTH SEAMS/ /P1.P1G \UR LUGS NX /P1.P1G.2 /\\LONG SEAMS 132" SHELL LENGTH 1/4 P8/1, P8FC/1\ K TYP CPLGS/ SHELL #2 36" LONG SHELL #1 96" LONG 4. REPADS TO HAVE 1/8"-NPT WEEP HOLES AIR TEST © 5 PS! MAX. 3. ALL FLANGES TO STRADDLE CENTERLINES, 2. DIMENSIONAL TOLERANCE: 1/8"± 1. DEBURR ALL SHARP EDGES. NOTE: REFER TO SPECIFICATION SECTION 11875 FOR SPECIFIC DESIGN REQUIREMENTS. THE FABRICATION DRAWINGS ARE PROVIDED FOR REFERENCE ONLY. IT IS THE OWNER'S DESIRE TO MATCH THE NEW SURGE TANK IN BOTH SIZE AND APPEARANCE WITH THE EXISTING SURGE TANK. NOTES:Specification Section 11875 DETAIL "VB CONSTRUCTION AND STAMPING PER A.S.M.E. SECTION VIII. DIVISION 1 SOUTH GATE ENGINEERING 11OO1 VULCAN STREET P.O. BOX 1986 SOUTH GATE, CA. 90280 PH.(562)861-0757 FAX.(562)861-0451 REV 12/18 12/12 11/21 DATE REVISION SHOP RELEASE SUBMITTAL DESCRIPTION APP'D CUSTOMER NAME:72 TECHNOLOGY PROJECT NAME:120" SURGE TANK / BUENA VISTA PUMP STATION SHELL: 1/2THKx132''x374 7/16" SA-516.70 SERIAL NO.:14847 RELEASE DATE: 11/27/00 HEAPS: 12Q-QD SEMI-EUP 3/4"THK SA-516.70 NATIONAL BOARD NO.: WILL ADVISE '• MODEL NO: HST120-132HE DRAWN BY: JEFF WEISER INTERIOR LINING: SP-10. 12 MILS DFT TNEMEC #104 APPVD BY:EXTERIOR COATING: SP-6. 5 MILS DFT TNEMEC #66-1211 DESIGN/M.A.W.P. ISO & FULL VACUUM / 150 PSI j WORKING TEMP. (Mox./Min.) 1SO/-20 RADIOGRAPHY: TEST PRESSURE: 195 PSI RT-4. TYPE 3S/1H VOLUME:8408 GAL.WEIGHT: 18.000 LBS CORROSION ALLOWANCE: NONE 0*0* 270*. 180' 31 1/2"± HD DEPTH 120" O.D. FRONT HEAD LAYOUT 4 REPADS TO HAVE 1/8"-NPT WEEP HOLES. AiR TEST @ 5 PSI MAX. 3. ALL FLANGES TO STRADDLE CENTERLINES. 2. PUNCH MARK ® 0', 90'. 180', 270'. HOTES: 1. DEBUR.R ALL SHARP EDGES, 1 1/2" WORK ORDER NO. 6956 SHEET 2 Or 4 DIM. LINE SEE NOTE 2 REAR HEAD LAYOUT THiS VIEW ROTATED SOUTH GATEENGINEERING 11001 VULCAN STREET P.O. BOX 1986 SOUTH GATE, CA. 90280 PH.(562)861-0757 FAX.(562)861-0451 NOTE: REFER TO SPECIFICATION SECTION 11875 FOR SPECIFIC DESIGN REQUIREMENTS. THE FABRICATION DRAWINGS ARE PROVIDED FOR REFERENCE ONLY. IT IS THE OWNER'S DESIRE TO MATCH THE NEW SURGE TANK IN BOTH SIZE AND APPEARANCE WITH THE EXISTING SURGE TANK. Specification Section 11875 CONSTRUCTION AND STAMPING PER A.S.M.E. SECTION VIII, DIVISION 1 REV 12/12 11/21 DATE SHOP RELEASE SUBMITTAL DESCRIPTION APPV'D WORK ORDER NO 6956 SHEET 3 OF 4 P1.P1GWEAR PLATE)- TO SHELL 5/16 P1,P1G\ (\ (18) 1 3/16'0 HOLES 30 5/8 TYP14 5/8 TYP 60 3/4 R DETAIL "WEB"DETAIL "BASEPLATE v 'VOTES: 1- DEBURR ALL SHARP EDGES. SOUTH GATE ENGINEERING 11001 VULCAN STREET P.O. BOX 1986 SOUTH GATE, CA. 90280 PH.(562)S61-0757 FAX.(562)861~0451 NOTE: REFER TO SPECIFICATION SECTION 11875 FOR SPECIFIC DESIGN REQUIREMENTS. THE FABRICATION DRAWINGS ARE PROVIDED FOR REFERENCE ONLY. IT IS THE OWNER'S DESIRE TO MATCH THE NEW SURGE TANK IN BOTH SIZE AND APPEARANCE WITH THE EXISTING SURGE TANK. Specification Section 11875 CONSTRUCTION AND STAMPING PER A.S.M.E. SECTION VIII, DIVISION 1 REV 12/18 12/12 11/21 DATE REVISION SHOP RELEASE SUBMITTAL DESCRIPTION APPV'D SECTION 13900 MODIFICATION TO EXISTING STRUCTURES, PIPING, AND EQUIPMENT PART 1« GENERAL 1.01 DESCRIPTION A. GENERAL: This Section specifies the modification of existing structures, piping, and equipment. Modifications listed in this Section supplement work that is shown or specified elsewhere, however, the Contractor is cautioned that this is not a comprehensive list of all of the minor modifications and refurbishments required, specified or otherwise indicated in other locations in the Contract Documents. The Contractor shall furnish all labor, material, equipment including any associated electrical equipment and electrical supply, and incidentals required to modify the existing structures, piping, and equipment specified in this Section. Existing piping and equipment shall dismantled and restored in accordance with the Contract Documents as necessary for the performance of the modifications to equipment, structures, and piping specified in this Section. Throughout the execution of this project, the Contractor shall protect those portions of the facilities being operated by plant staff from dust, debris, water, sludge or other damage, permanent or temporary, resulting from construction activities. The Contract Documents reflect knowledge of conditions at the time of design and may not reflect actual conditions to be encountered by the Contractor. The Contract Documents do not show or specify all features of the existing facilities that may impact the modification work. Other conditions may be hidden from view or may be otherwise inaccessible during the bid period. The Contractor shall evaluate the risk of each modification specified and shall incorporate into their bid price this risk such that change orders are not required. Additional funds above those bid will not be provided for the completion of the work specified in this Section except as specifically detailed in this Section. Prior to initiating work, the Contractor shall field verify all pertinent features of existing facilities, including but not limited to the following: structures, including architectural features; piping, including all pipeline appurtenances and supports; mechanical equipment, including appurtenances and supports; electrical conduits, cables, trays, lights, panels, cabinets, circuits, and appurtenances and supports necessary to complete the work. The Contractor is responsible for identifying and resolving conflicts between modification work, existing facilities, and new construction. The proposed conflict resolution is subject to review and approval by the Engineer. The Contractor shall plan its work such that field MODIFICATION TO EXISTING BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STRUCTURES, PIPING AND EQUIPMENT AUGUST 2010 13900-1 verification, conflict identification, conflict resolution, and Engineer approval are accomplished prior to initiating modification work in the field. Existing penetrations of floors, ceilings and walls, or holes resulting from removal of fasteners or other hardware, which are no longer required because of abandonment of piping or equipment, shall be sealed. Pipe penetrations required as part of this work shall be sealed in a professional and workmanlike manner. Locations of all existing equipment, piping and appurtenances shall be field verified by the Contractor, in accordance with Section 01046 and Section 5 of the General Provisions. The Contractor shall dispose of all equipment, piping, conduit, wiring, and appurtenances removed, except items specifically designated in the Contract Documents. PART 2 » PRODUCTS (Not Used) PART 3-EXECUTION 3.01 GENERAL STRUCTURAL MODIFICATIONS The Contractor shall cut, repair, reuse, excavate, demolish, or otherwise remove parts of the existing structures, piping, and appurtenances, as indicated on the Contract Drawings, herein ^^ specified, or necessary to permit completion of the work under this Contract. The above > work shall include drilling of holes into existing concrete for the purpose of setting dowel rods, anchor bolts, or other appurtenances and cutting of holes in concrete and/or masonry for the installation of pipe, conduits, and other appurtenances. The work shall include all necessary cutting and bending of reinforcing steel, structural steel, or miscellaneous metal work found embedded in the existing structures. Anchor bolts for equipment and structural steel removed together with exposed reinforcement steel shall be cut off 1 inch below the concrete surface. When removing materials or portions of existing structures and when making openings in walls and partitions, the Contractor shall take all precautions and use all necessary barriers and other protective devices so as not to damage the structures beyond the limits necessary for the new work, nor to damage the structures or contents by falling or flying debris. All work for altering existing structures shall comply with the approved construction schedule. Holes in existing concrete or masonry resulting from modification work shall be sealed with concrete or cement mortar. The sides of the openings shall be provided with keyed joints and shall be suitably roughened to furnish a good bond and make a watertight joint. All loose or unsound material adjacent to the opening shall be removed and, if necessary, •^^^jF MODIFICATION TO EXISTING BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STRUCTURES, PIPING AND EQUIPMENT AUGUST 2010 13900-2 replaced with new material. The method for placement of the concrete or grout seal shall provide a suitable means of releasing entrapped air. Surfaces of seals visible in the completed work shall be made to match as nearly as possible the adjacent surfaces. 3.02 GENERAL EQUIPMENT AND PIPING MODIFICATIONS The Contractor shall modify or dismantle and remove all existing equipment, piping and other appurtenances required for the completion of the work. Where called for or required, existing pipelines shall be cut for the purpose of making connections thereto or providing both temporary and permanent blind flanges. Removal of equipment shall include all appurtenances and connections, including electrical. Removal of electrical connections shall include all conductors back to source unless otherwise specified, together with unused conduit. Modification and/or relocation of work shall include all process, auxiliary, drainage, supply, structural, electrical, and control connections as specified and as necessary to yield a complete operational installation. Where necessary or required for the purpose of making connections, the Contractor shall cut existing pipelines in a manner to provide an approved joint. Where required, the Contractor shall weld beads, flanges or provide couplings, as required. Pipe ends shall be capped using groove-end fittings, welded flange or cap, standard blind flanges, or other method approved by the Engineer. Coatings, linings and insulation on existing pipelines modified by the work shall be repaired to new condition, or to the maximum extent practical, as directed by the Engineer. All temporary piping used in the construction of the work of this contract shall conform to the requirements of Section 15050, except as otherwise authorized by the Engineer. 3.03 GENERAL MODIFICATIONS The floor slabs, pavement or walls may contain buried and undocumented electrical conduit and mechanical piping systems. Prior to saw cutting or core drilling, locate encased rebar, conduits, piping, etc. in accordance with Section 01046. Floor areas surveyed shall be marked and labeled identifying obstructions found when available. Prior to installation of equipment, the following information shall be provided in accordance to Section 01300A submittal: 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate MODIFICATION TO EXISTING BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STRUCTURES, PIPING AND EQUIPMENT AUGUST 2010 13900-3 requested deviations from specification requirements or those parts which are to be provided by the Contractor or others. Check marks (V) shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements shall be cause for rejection of the entire submittal and no further submittal material will be reviewed. 2. A copy of the contract document control diagrams, process and instrumentation diagrams and mechanical layout drawings relating to the submitted equipment, with addendum updates that apply to the equipment in this section, marked to show specific changes necessary for the equipment proposed in the submittal. If no changes are required, the drawing or drawings shall be marked "no changes required". Failure to include copies of the relevant drawings with the submittal shall be cause for rejection of the entire submittal with no further review. 2. Certificate of Unit Responsibility attesting that the Contractor has assigned unit responsibility in accordance with the requirements of this section and paragraph 11000-1.02. No other submittal material will be reviewed until the certificate has been received and found to be in conformance with these requirements. 3. Applicable operations and maintenance information as specified in specification Section 01730. 4. Equipment control wiring diagram identifying internal and face mounted components and connections to remote equipment. 6. Shop drawings indicating construction and installation details, a complete detailing of the materials construction and equipment number, unit capacity and weights. 7. Factory testing information either as standard from the manufacturer or as specifically required in this section. 8. Dimensioned drawings of all equipment and accessories as a complete system including cross-section views. 9. Warranty information. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 MODIFICATION TO EXISTING STRUCTURES, PIPING AND EQUIPMENT 13900-4 10. Dimensional drawings, showing required access and clearances, including any layout and installation requirements of the equipment. 11. Manufacturer's catalog and/or other data confirming conformance to the specified design, material, and equipment requirements. 12. Predicted performance data confirming conformance to the specified performance requirements. ** END OF SECTION ** MODIFICATION TO EXISTING BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STRUCTURES, PIPING AND EQUIPMENT AUGUST 2010 13900-5 SECTION 15050 PIPING SYSTEMS PART 1 -- GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies systems of process piping and general requirements for piping systems. Detailed specifications for the components listed on the Piping System Specification Sheets are found in other sections of Division 15. This section shall be used in conjunction with those sections. B. DEFINITIONS: Pressure terms used in Section 15050 and elsewhere in Division 15 are defined as follows: 1. Maximum: The greatest continuous pressure at which the piping system operates. 2. Test: The hydrostatic pressure used to determine system acceptance. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. o BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING SYSTEMS 15050-1 Reference AASHTO M36/M36M ANSIA13.1 ANSI B 1.20.1 ANSI B 16.1 ANSI B 16.3 ANSI B 16.5 ANSI B 16.9 ANSIB16.il ANSI B16.12 ANSI B 16.22 ANSI B 16.26 ANSIB31.1 ANSIB31.3 ASME Section IX ASTM A47 ASTM A53 ASTM A74 ASTMA105/A105M ASTM A106 ASTM A126 ASTMA197 ASTM A234/A234M ASTMA312/A312M ASTM A403/A403M ASTM A536 ASTM A570/A570M ASTM B88 Title Metallic (Zinc or Aluminum) Coated Corrugated Steel Culverts and Underdrains Scheme for the Identification of Piping Systems Pipe Threads, General Purpose (Inch) Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800 Malleable Iron Threaded Fittings Class 150 and 300 Pipe Flanges and Flanged Fittings Factory-Made Wrought Steel Buttwelding Fittings Forged Steel Fittings, Socket Welding and Threaded Cast Iron Threaded Drainage Fittings Wrought Copper and Copper Alloy Solder Joint Pressure Fittings Cast Copper Alloy Fittings for Flared Copper Tubes Power Piping Chemical Plant and Petroleum Refinery Piping Boiler and Pressure Vessel Code; Welding and Brazing Qualifications Malleable Iron Castings Pipe, Steel, Black and Hot Dipped, Zinc-Coated Welded and Seamless Cast Iron Soil Pipe and Fittings Forgings, Carbon Steel, for Piping Components Seamless Carbon Steel Pipe for High-Temperature Service Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings Cupola Malleable Iron Pipe Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures Seamless and Welded Austenitic Stainless Steel Pipe Wrought Austenitic Stainless Steel Piping Fittings Ductile Iron Castings Hot-Rolled Carbon Steel Sheet and Strip, Structural Quality Seamless Copper Water Tube BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING SYSTEMS 15050-2 Reference ASTM C76 ASTM C296 ASTM C443-REV A ASTM C564 ASTM D1248 ASTM D1784 ASTMD1785 ASTM D2241 ASTMD2513 ASTM D2665 ASTM D2996 ASTM D3034 ASTMD3261 ASTM D4174 ASTM D4101 ASTMF441 AWWAC105 AWWAC110 AWWAC111 AWWAC115 AWWAC151 AWWA C200 Title Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe Asbestos-Cement Pressure Pipe Standard Specification for Joints for Circular Concrete Sewer and Culvert Pipe, Using Rubber Gaskets Rubber Gaskets for Cast Iron Soil Pipe and Fittings Polyethylene Plastics Molding and Extrusion Materials Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120 Poly (Vinyl Chloride) (PVC) Plastic Pipe (SDR-PR) Thermoplastic Gas Pressure Pipe, Tubing, and Fittings Poly (Vinyl Chloride) (PVC) Plastic Drain, Waste, and Vent Pipe and Fittings Filament- Wound Reinforced Thermosetting Resin Pipe Standard Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings Butt Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing Cleaning, Flushing, and Purification of Petroleum Fluid Hydraulic Systems Propylene Plastic Injection and Extrusion Materials Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80 Polyethylene Encasement for Ductile-iron Piping for Water and Other Liquids Ductile-Iron and Gray-Iron Fittings, 3 Inch Through 48 Inch, for Water and Other Liquids Rubber-Gasket Joints for Ductile-Iron and Gray-Iron Pressure Pipe and Fittings Flanged Ductile-Iron and Gray-Iron Pipe with Threaded Flanges Ductile-Iron Pipe, Centrifugally Cast in Metal Molds or Sand-Lined Molds, for Water or Other Liquids Steel Water Pipe 6 Inches and Larger BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING SYSTEMS 15050-3 Reference AWWA C205 AWWA C206 AWWA C207 AWWA C208 AWWA C209 AWWA C210 AWWA C214 AWWA C301 AWWA C303 AWWA C600 AWWAC651 AWWA C900 AWWA Mil CISPI301 FEDSPEC L-C-530B(1) MIL-H-13528B MIL-STD-810C SAEJ1227 UPC Title Cement-Mortar Protective Lining and Coating for Steel Water Pipe-4 In. and Larger-Shop Applied Field Welding of Steel Water Pipe Steel Pipe Flanges for Waterworks Services—Sizes 4 In. through 144 In. Dimensions for Fabricated Steel Water Pipe Fittings Cold-Applied Tape Coating for Special Sections, Connections, and Fittings for Steel Water Pipelines Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipe Tape Coating Systems for the Exterior of Steel Water Pipelines Prestressed Concrete Pressure Pipe, Steel Cylinder Type, for Water and Other Liquids Reinforced Concrete Pressure Pipe—Steel Cylinder Type, Pretensioned, for Water and Other Liquids Installation of Ductile-Iron Water Mains and Their Appurtenances Disinfecting Water Mains Polyvinyl Chloride (PVC) Pressure Pipe, 4 Inches Through 12 Inches, for Water Steel Pipe—A Guide for Design and Installation Specification Data for Hubless Cast iron Sanitary System with No-Hub Pipe and Fittings Coating, Pipe, Thermoplastic Resin or Thermosetting Epoxy Hydrochloric Acid, Inhibited, Rust Removing Environmental Test Methods Assessing Cleanliness of Hydraulic Fluid Power Components and Systems Uniform Plumbing Code B. FITTINGS AND COUPLING COMPATIBILITY: To assure uniformity and compatibility of piping components, fittings and couplings for grooved end piping systems shall be furnished by the same manufacturers. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING SYSTEMS 15050-4 PART 2 » PRODUCTS 2.01 PIPING MATERIALS Unless otherwise specified, piping materials, including pipe, gaskets, fittings, connection and joint assemblies, linings and coatings, shall be selected from those listed on the piping system specification sheets. Piping materials shall conform to detailed specifications for each type of pipe and piping appurtenance specified in other sections of Division 15. 2.02 PIPING IDENTIFICATION A. PLASTIC CODING MARKERS: Plastic markers for coding pipe shall conform to ANSI A13.1 and shall be as manufactured by W. H. Brady Company, Seton Name Plate Corporation, Marking Services Inc., or equal. Markers shall be the mechanically attached types that are easily removable; they shall not be the adhesive applied type. Markers shall consist of pressure sensitive legends applied to plastic backing which is strapped or otherwise mechanically attached to the pipe. Legend and backing shall be resistant to petroleum based oils and grease and shall meet criteria for humidity, solar radiation, rain, salt, fog and leakage fungus, as specified by MIL-STD-810C. Markers shall withstand a continuous operating temperature range of -40 degrees F to 180 degrees F. Plastic coding markers shall not be the individual letter type but shall be manufactured and applied in one continuous length of plastic. Markers bearing the legends on the background colors specified in the PIPESPEC shall be provided in the following letter heights: Outside pipe diameter,3 inches Less than 1-1/2 1-1/2 through 3 Greater than 3 Letter height, inches 1/2 1-1/8 2-1/4 a Outside pipe diameter shall include insulation and jacketing. hi addition, pipe markers shall include uni- and bi-directional arrows in the same sizes as the legend. Legends and arrows shall be white on blue or red backgrounds and black on other specified backgrounds. B. PLASTIC TRACER TAPE: Tracer tape shall be 6 inches wide, colored the same as the background colors specified in ANSI A13.1, and made of inert plastic material suitable for direct burial. Tape shall be capable of stretching to twice its original length and shall be as manufactured by Allen Systems, W. H. Brady Co., Seton Name Plate Corporation, Marking Services Inc., or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-5 Tracer tape shall be placed in two locations over pipe: 1) Directly over pipe zone 2) Above trench zone beneath granular base and pavement section Two messages shall be printed on the tape. The first message shall read "CAUTION CAUTION CAUTION RAW SEWAGE FORCE MAIN BURIED BELOW-'^fohM^m^ approximately 2 inches high. The second message shall read "CALL CARLSBAD DEPT OF PUBLIC WORKS (760) 438-2722" with letters approximately 3/4 inch high. Both messages shall be printed at maximum intervals of 2 feet. 2.03 VALVES Valves of the same size and service shall be provided by a single valve manufacturer. Packing shall be nonasbestos material. Actual length of valves shall be within 1/16 inch (plus or minus) of the manufacturer's specified length. Flanges shall meet the requirement of ANSI B16.5. Push-on and mechanical joints shall meet the requirements of AWWA Clll. Valve operators are specified in Sections 15100 and 15110. 2.04 PRODUCT DATA Product data on piping materials shall be provided in accordance with Section 01300 where specified. Piping layout drawings shall be transmitted to the Engineer a minimum of 2 weeks prior to construction. Drawings shall be original layouts by the Contractor; photocopies of contract drawings are not acceptable. PART 3 » EXECUTION 3.01 INSTALLATION A. LOCATION: Piping shall be provided as specified except for adjustments to avoid architectural and structural features and shall be coordinated with electrical construction. B. PIPING SIZES: Where the size of piping is not specified, the Contractor shall provide piping of the sizes required by UPC. Unless specified otherwise, small piping (less than 1 inch in diameter) required for services not described by UPC shall be 1/2 inch. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-6 C. PIPE SUPPORT, ANCHORAGE AND SEISMIC BRACING: 1. GENERAL: Piping shall be supported by anchor brackets, guides, saddles or hangers. Acceptable types of supports, guides, saddles, hangers and structure attachments for general pipe support, expansion/ contraction and for seismic bracing, as well as anchorage details, are shown on the drawings. Minimum spacing shall be as specified for supports and for seismic bracing. Where a specific type of support or anchorage is indicated on the drawings, then only that type shall be used there. Piping shall be vertically supported by anchor brackets, guides, saddles or hangers and shall be seismically braced where indicated to resist lateral load. Supports shall be provided on each run at each change of direction. Pipe supports shall be hot-dip or mechanically galvanized. Unless otherwise specified, existing pipes and supports shall not be used to support new piping. 2. PIPING CONNECTIONS TO MACHINES: Piping at machine connections shall be aligned in all planes to permit insertion of bolts at bolted connections or coupling screwed connections without using jacks, come-a-longs or other mechanical means to align field piping with the connections at the machines. Bolts shall not be forced into mating flange bolt holes and shall be capable being withdrawn using finger pressure alone. The use of 'dutchmen* mitered sections or similar specials to achieve the required alignment with machine connections is strictly prohibited. D. ANCHORAGE FOR BURIED PIPING: All plugs, caps, tees and bends in buried pressure piping systems shall be anchored by means of reaction backing or restrained joints as specified. E. BEDDING AND BACKFILL: Bedding and backfill for buried piping shall be as specified. F. EQUIPMENT CONNECTION FITTINGS Where shown, equipment connection fittings as specified in Section 15085 shall be provided between field piping systems and equipment inlet and outlet connections. G. FLEXIBILITY Unless otherwise specified, piping passing from concrete to earth shall be provided with two pipe couplings or flexible joints as specified in Section 15085. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-7 3.02 PIPING IDENTIFICATION A. PIPE CODING: After application of the specified coating and insulation systems, exposed piping, interior and exterior, and piping in ceiling spaces, pipe trenches, pipe chases and valve boxes shall be identified with plastic markers as specified in paragraph 15050-2.02 A. Legend markers and directional arrows shall be located at each side of walls, floors and ceilings, at one side of each piece of equipment, at piping intersections, and at approximately 50-foot centers. B. PLASTIC TRACER TAPE: A single line of tape as specified in paragraph 15050-2.02 B shall be provided 2.5 feet above the centerline of. buried sewer pipe. For sewer pipelines buried 8 feet or greater below finished grade, contractor shall provide a second line of tape 12 inches below finished grade, above and parallel to each buried pipe. Tape shall be spread flat with message side up before backfilling. 3.03 VALVE IDENTIFICATION Stainless steel tags bearing the specified valve number stamped in 1/4-inch high letters shall be installed on valve flanges in a position visible from floor level. Flangeless valves 8 inches in diameter and larger shall have tags attached to the valve body by self-tapping corrosion resistant metal screws. Flangeless valves 6 inches in diameter and smaller shall have tags attached to the valve stem by stainless steel wire. Wire shall be 0.063 inch minimum. 3.04 TESTING A. GENERAL: Upon completion of piping, but prior to application of insulation on exposed piping, the Contractor shall test the piping systems. Pressures, media and test durations shall be as specified in the PEPESPEC. Equipment which may be damaged by the specified test conditions shall be isolated. Testing shall be performed using calibrated test gages and calibrated volumetric measuring equipment to determine leakage rates. Each test gage shall be selected so that the specified test pressure falls within the upper half of the gage's range. Unless otherwise specified, the Contractor shall notify the Engineer 24 hours prior to each test. Unless otherwise specified, testing, as specified herein, shall include existing piping systems which connect with new pipe systems. Existing pipe shall be tested to the nearest existing valve. Any piping which fails the test shall be repaired. Repair of existing piping will be considered and paid for as extra work. Where testing existing chlorine and sulfur dioxide systems to the nearest isolation valve, Contractor shall provide a tee in the line adjacent to the valve. The branch outlet on the tee shall be valved and used for cleaning, pressure testing, draining, and drying the line. Unless BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-8 otherwise indicated, the existing chlorine or sulfur dioxide system shall not be shut down during testing or connecting the tee and valve. Prior to placing the line in service, the valve on the branch outlet shall be plugged or sealed with a blind flange or threaded plug. Contractor shall be responsible for all damage to the existing system as a result of this work. B. GAS, AIR, AND VAPOR SYSTEMS: The Contractor shall test steam lines hydrostatically in accordance with the ASME procedure for testing pressure piping. Testing medium and procedures for chlorine and sulfur dioxide systems are specified in paragraph 15050-3.04 D. Unless otherwise specified, the testing medium for other gas, air and vapor systems shall be as follows: Pipeline size 2 inch and smaller 2 inch and smaller Greater than 2 inch Greater than 2 inch Specified test pressure 75 psi or less Greater than 75 psi 3 psi or less Greater than 3 psi Testing medium Air or water Water Air or water Water _ with water shall be zero at the specified test pressure throughout the specified test period. Hazardous gas systems shall include sulfur dioxide, chlorine, propane, sludge gas and natural gas systems. The allowable leakage rate for other systems tested with air shall be based on a maximum pressure drop of 5 percent of the specified test pressure for the duration of the period. Prior to starting a test interval using air, the air shall be at ambient temperature and specified test pressure. C. LIQUID SYSTEMS: Leakage shall be zero at the specified test pressure throughout the specified duration for the following systems: exposed piping, buried insulated piping, and buried or exposed piping carrying liquid chemicals. Testing procedures for chlorine and sulfur dioxide systems are specified in paragraph 15050-3.04 D. Testing procedures for hydraulic and lube oil systems are specified in paragraph 15050-3.04 E. Unless otherwise specified, leakage from other buried liquid piping systems shall be less than 0.02 gallon per hour per inch diameter per 100 feet of buried piping. D. CHLORINE AND SULFUR DIOXIDE SYSTEMS (Not Used): 1. GENERAL: Chlorine and sulfur dioxide systems comprise chlorine and sulfur dioxide, ^ "^ in gaseous and liquid phase, under positive and negative pressure. After cleaning, as BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-9 specified in paragraph 15050-3.05 E, the system shall be pressure tested. Pressure gages, relief valves, automatic control valves, and other components which may be damaged or exceeded by test pressures shall be removed and openings shall be blocked off prior to testing. The Contractor shall not attempt to repair leaks until all pressure has dissipated from the system. The system shall be repaired and retested as necessary until a successful test (zero leakage) is achieved. For evaporator-supplied systems, Contractor shall disconnect the vent from the discharge side of the pressure relief valve of each evaporator, plug the resultant opening, inspect and secure all joints, close all valves which discharge to atmosphere, and open all in-line valves. Contractor shall open the valve in the bypass line around the pressure reducing valve on the downstream side of each evaporator to provide a through path around this valve. System piping shall then be tested to 150 psig. After testing, Contractor shall replace all equipment previously removed and close all in-line valves. Contractor shall reconnect the vent line to the downstream side of the pressure relief valve of each evaporator and close the valve in the bypass line around the pressure reducing valve on the downstream side of each evaporator. Steel pipelines shall be hydrostatically tested. However, if drying after hydrostatic testing is impractical or cannot be accomplished, the Contractor may test steel lines with nitrogen gas or dry air providing he takes the necessary safety precautions to safeguard personnel and minimize the risk incurred when performing such a test at high pressures. All PVC pipelines shall be hydrostatically tested. Testing PVC lines with nitrogen or air is not permitted. 2. HYDROSTATIC TESTING: Steel piping lines and PVC solution lines hydrostatically tested shall be tested to 150 psig. PVC vacuum lines shall be hydrostatically tested to 50 psig. After testing, all moisture absorbing gaskets and valve packing shall be replaced. 3, DRYING: Chlorine and sulfur dioxide piping systems shall be dried prior to placing in service. Even if water has not been purposely introduced into the system for hydrostatic testing or cleaning, drying is still required because moisture may enter the system from the atmosphere or other sources. For steel pipe, drying shall be accomplished by passing steam through the lines from the high end of the system until the lines are thoroughly heated. While steaming, the Contractor shall allow condensate and foreign matter to drain out. The steam supply shall then be disconnected and all pockets and low spots in the line drained. While the line is still warm, dry oil-free air having a dew point of -40 degrees F, or below, shall be blown through the line until the exiting air dew point is the same as the supply air. Valves shall be fixed in the half-open position during drying. Valves removed temporarily from the system during drying operations must be free of moisture before being recoupled to the system piping. Drying of PVC pipe applies solely to vacuum lines and consists of draining and removing all water and moisture from the system. After draining the line, the Contractor BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-10 shall first pig the pipe to remove excess water. The Contractor shall then air dry the /^S system in accordance with the requirements for steel pipe. PVC pipe shall not be S^ steamed. 4. NITROGEN OR AIR PRESSURE TESTING: The Contractor may use nitrogen gas or oil-free dry air to test steel lines. Testing consists of gradually introducing nitrogen gas or dry air up to 50 psig and maintaining this pressure while testing the line for leaks with soapy water. When the system is free from leaks at this pressure, the test pressure shall then be increased in increments of 50 psig up to a maximum of 150 psig. At each stepped increase in pressure, the Contractor shall check for leaks and take corrective action as necessary. When the system is free from leaks at the final test pressure, the system shall then be depressurized, the test source disconnected, and the system capped to prevent the entrance of water. For testing with nitrogen gas, the Contractor shall use cylinders of dry high purity nitrogen gas, nitrogen handling cylinder mounted pressure regulator 0 to 300 psig, and necessary fittings and adapters to complete connection between the source and system header. Pressure regulator shall be self-relieving type which vents to the atmosphere and include a throttling valve. For testing with air, the Contractor shall provide oil-free air with a relative humidity of zero. All fittings, adapters, and accessories, pressure regulator and throttling valve shall be suitable for pressure testing with air and rated for 300 psig service. ^^ •^^H^r 5. SERVICE GAS TESTING: Immediately after the chlorine or sulfur dioxide system has been dried and pressure tested, the service gas shall be gradually introduced and the entire system tested for leaks. Time shall be allowed for the complete replacement of air from the piping with service gas. The Contractor shall use a liquid ammonia solution or chlorine gas detector to detect for chlorine leaks. The Contractor shall spray the solution at the pipe connections and shall not squirt the liquid on the pipe or fittings. In the event leaks are detected in the piping or the equipment, they shall not be repaired until all gas has been purged from the line. The reaction of the two substances produces a dense white cloud. Upon completion of repairs, the Contractor shall repeat the cleaning and drying process described in paragraphs 15050-3.04 D and 3.05 E and retest the lines with service gas. The Contractor shall use a commercial electromechanical volt-ammetric sensor for detecting sulfur dioxide leaks. Gas detectors manufactured by InterScan Corporation and Enterra are recommended. E. HYDRAULIC AND LUBE OIL SYSTEMS (Not Used): Upon completion of cleaning, all field connections shall be completed and the system tested at the specified pressure. Pressure loss shall be zero for the specified test period. For fluid power 3 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-11 systems, the manufacturer shall supervise the installation and testing of all system components including all field piping. F. DRAINS: Drain systems, other than pumped drain systems, shall be tested in accordance with UPC. 3.05 CLEANING AND FLUSHING A. GENERAL: Piping systems shall be cleaned following completion of testing and prior to connection to operating, control, regulating or instrumentation equipment. The Contractor may, at his option, clean and test sections of buried or exposed piping systems. Use of this procedure, however, will not waive the requirement for a full pressure test of the completed system. Unless specified otherwise, piping 24 inches in diameter and smaller shall first be cleaned by pulling a tightly fitting cleaning ball or swab through the system. Piping larger than 24 inches in diameter may be cleaned manually or with a cleaning ball or swab. B. TEMPORARY SCREENS: Upon completion of the cleaning, the Contractor shall connect the piping systems to related process equipment. Temporary screens, provided with locator tabs which remain visible from the outside when the screens are in place, shall be inserted in pipelines at the suction of pumps and compressors in accordance with the following table: Equipment suction or piping size, inches 0-1 1-1/4-3 3-1/2-6 Over 6 Maximum screen opening, inches 1/16 1/4 1/2 1 The Contractor shall maintain the screens during testing, initial start-up, and initial operating phases of the commissioning process. In special cases, screens may be removed as required for performance tests. The Contractor shall remove the temporary screens and make the final piping connections after the screens have remained clean for at least 24 consecutive hours of operation. Systems handling solids are exempted. C. GAS AND AIR SYSTEMS: Unless otherwise specified, gas and air system piping 6 inches in diameter and smaller shall be blown out, using air or the testing medium specified. Piping larger than 6 inches shall be cleaned by having a swab or "pig" drawn through the separate reaches of pipe. After connection to the equipment, it shall then be blown out using the equipment. Upon completion of cleaning, BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-12 the piping shall be drained and dried with an airstream. Sludge gas, natural gas and propane systems shall be purged with nitrogen and a nitrogen pad maintained at 10 psi until put in service. Chlorine and sulfur dioxide systems shall be cleaned in accordance with paragraph 15050-3.05 E. D. LIQUID SYSTEMS: After completion of cleaning, liquid systems, unless otherwise specified, shall be flushed with clean water. With temporary screens in place, the liquid shall be circulated through the piping system using connected equipment for a minimum period of 15 minutes and until no debris is collected on the screens. Liquid chlorine and sulfur dioxide lines shall be cleaned in accordance with paragraph 15050-3.05 E. E. CHLORINE AND SULFUR DIOXIDE SYSTEMS (Not Used): 1. GENERAL: All portions of the system shall be cleaned free of oil and grease. 2. STEEL PIPE: All pipe threads shall be washed clean and free from cutting oil. The inside of all pipe sections and fittings shall be cleaned of any pipe dope, oil and grease by drawing a cloth wetted with solvent through each assembly. Valves shall be dismantled, thoroughly cleaned with solvents, and repacked, if necessary. Contractor shall cap or plug all open ends at the end of each work day. Contractor shall use trichloroethylene. The Contractor shall at all times exercise caution to minimize solvent exposure and shall be responsible for its proper handling and disposal. Solvents containing hydrocarbons or alcohols are unacceptable. 3. PVC PIPE: All solution lines shall be cleaned using water only. Vacuum lines shall be cleaned with a detergent and water and thoroughly rinsed to remove all vestiges of detergent. All lines shall be further purged of water by passing a cleaning ball or swab through the lines as specified in paragraph 15050-3.05 A. F. STEAM SYSTEMS (Not Used): Before the steam system is put into service, cleaning shall be performed to remove such contaminants as mill scale, weld scale, corrosion products, oil, grease, dust and dirt. Cleaning shall include a water flush performed at a velocity not less than 2 feet per second, steam blowdown, and an alkaline flush boilout of the boiler. After flushing as indicated above, the boiler shall be treated with a caustic compound such as sodium triphosphate, soda ash, sodium tripolyphosphate, or caustic soda. The cleaning process shall be in accordance with steam system cleaning schemes developed by Dowell, the Mogul Division of Dexter Corp., Bentz Entec, or equal. After cleaning and flushing, and prior to continuous operation of the steam system, adequate corrosion protection shall be provided by maintaining the system full of steam or potable water. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-13 If continuous operation does not occur within 60 days after cleaning and flushing, the steam or potable water shall be treated with an acceptable corrosion inhibiting chemical to assure adequate corrosion protection of the steam system. G. HYDRAULIC AND FLUID POWER OIL SYSTEMS (Not Used): Upon completion of all field piping, but before connection to any control components, hydraulic and fluid power oil systems shall be flushed and cleaned by circulating special flushing oil through the system. Flushing oil and procedures shall comply with ASTM D4174. System shall be cleaned such that internal contamination of system, when tested using procedures specified in SAE 31227, Section 2.3, shall not exceed the Allowable Cleanliness Level (ACL). Unless otherwise specified, the ACL value shall be established by the manufacturer of the major hydraulic system components in accordance with SAE J1227, Section 9.1. System supplier shall provide Certificate of Compliance as product data (paragraph 15050-2.04) that the ACL has been met. H. POTABLE WATER SYSTEMS: Potable water piping systems shall be flushed and disinfected in accordance with AWWA C651. 3.06 PIPING SPECIFICATION SHEETS (PIPESPEC) Piping and valves for groupings of similar plant processes or types of service lines are specified on individual piping specification sheets (PIPESPECS). Piping services are grouped according to the chemical and physical properties of the fluid conveyed and/or by the temperature or pressure requirements. Each grouping of services (PIPESPEC) is identified by a piping system number. Piping services specified in the PIPESPECS and on the drawings are alphabetically arranged by designated service symbols as shown in Table A. Table A also indicates the system number and fluid category of each service. Table A, Piping Services Symbol D RS SA PD 2W Service Drain Raw Sewage Compressed Air Pumped Drainage Water System 24 12 2 12 10 Category Drain Raw Sewage Service Air Raw Sewage/Drainage No. 2 Water BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING SYSTEMS 15050-14 3.06 PIPING SPECIFICATION SHEETS--PIPESPEC Piping Symbol/Service:IA--Instrument Air SA—Service Air System--! Test Requirements: Medium: Pressure: Duration: Ref. spec paragraph 15050-3.04 B. 200 psig 120 minutes Gasket Requirements: Flange: Push-on/Mech Cpl: Compressed gasketing consisting of organic fibers (Kevlar) and neoprene binder N/A Exposed Pipe and Valves: (See drawings for pipe size and valve type) (1/2" and smaller) Pipe: (3/4" thru 2") Pipe: (2" and smaller) Valves: (2 1/2" thru 6") Pipe: Valves: Copper tube; ASTM B88, Type L, drawn. Conn: brass compression type. Ftgs: brass compression type, Swagelok, Gyrolok, or equal. Copper tube; ASTM B88, Type L, drawn. Conn: solder type with threaded adapters or valves. Ftgs; wrought copper or bronze, ANSI B 16.22. Ball: Jamesbury Fig. 351, Nibco T-580, or equal. Globe; Crane 7TF or 17TF, Lunkenheimer 123 or 214, or equal. Lift check: Lunkenheimer 1616, Crane 366E, or equal. Steel: ASTM A53, ERW, Grade B, black, no lining. Ref. spec Section 15061. Conn: butt weld, flanged for valves. Ftgs; steel, ASTM A234, ANSI B 16.9; ends to match pipe. Ball: Jamesbury 5150-31-2200TT, Nibco F-510, or equal. Check: Ported plate style designed for use with pulsating flow; Hoerbiger Depend-A-Check or Compact-A-Check, Dienes Type DL-RF, or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING SYSTEMS 15050-15 Buried and Encased Pipe and Valves: (See drawings for pipe size and valve type. Omit coatings on encased pipe.) (2" and smaller) Pipe: Copper tube: ASTM B88, Type K, annealed or drawn. Conn: solder type. Ftgs; wrought copper or bronze, ANSI B16.22. Valves: Ball: same as exposed with extension stem and valve box. (2 1/2" thru 6") Pipe: Steel; same as exposed with polyethylene tape coating. Field application of coating to all couplings. Ref. spec Section 15061. Conn: same as exposed with coating. Ftgs: same as exposed with coating. Valves: Ball: same as exposed with extension stem and valve box. Coating M-l per spec Section 09900. Remarks: Pipe materials for immersed service air piping shall be: (2" and smaller) Pipe: Stainless steel: ASTM A312, Schedule 40S. Conn: threaded, ANSI B1.20.1. Ftgs: ASTM A403, material, ends and wall thickness to match pipe. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-16 3.06 PIPING SPECIFICATION SHEETS-PIPESPEC Piping Symbol/Service: 2W--No. 2 Water System--10 Test Requirements: Medium: Water; ref. spec paragraph 15050-3.04 C. Pressure: 125 psig Duration: 120 minutes Gasket Requirements: Flange: Compressed gasketing consisting of organic fibers (Kevlar) and neoprene binder Push-on/Mech Cpl: Nitrile or Neoprene Exposed Pipe and Valves: (See drawings for pipe size and valve type) (3" and smaller) Pipe: Steel: ASTM A53, galvanized. Ref. spec Section 15061. Conn: taper threaded, ANSI B1.20.1. Ftgs; malleable iron, ASTM A197, ANSI B16.3, Class 150, galvanized. Valves: Ball: Jamesbury Fig. 351, Nibco T-580, or equal. Globe: Crane 7TF or 17TF, Lunkenheimer 123 or 214, or equal. Swing check: Crane 137, Lunkenheimer 230, or equal. Buried and Encased Pipe and Valves: (See drawings for pipe size and valve type. Omit coating on encased pipe.) (3" and smaller) Pipe: PVC: ASTM D1784, Class 12454-B, ASTM D1785, Sch. 80. Ref. spec Section 15064. Provide magnetic tracer tape. Conn: plain end; solvent weld with threaded or flanged adapters for valves. Ftgs: PVC, Sch. 80, socket weld. Valves: Gate: ref. spec Section 15101, with extension stem and valve box. Coating M-l per spec Section 09900. Remarks: 1. Manual air vents shall be provided at the high points and drains provided at the low points of each reach of pipeline as specified in paragraph 15095-3.03. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-17 3.<W> PIPING SPECIFICATION SHEETS-PIPESPEC Piping Symbol/Service: PD-Pumped Drainage System--12 RS~Raw Sewage SEP--Septage TD-Tank Drain Test Requirements: Medium: Water; ref. spec paragraph 15050-3.04 C. Pressure: ISOpsig Duration: 120 minutes Gasket Requirements: Flange: Compressed gasketing consisting of organic fibers (Kevlar) and neoprene binder Push-on/Mech Cpl: Nitrile or Neoprene Exposed Pipe and Valves: (See drawings for pipe size and valve type) (2" through 24") Pipe: Ductile iron AWWA C151. Ref. spec Section 15062 Conn: restrained bell and spigot with O-ring rubber gasket joint. Flanged adapters for valves. Ftgs: Fittings shall conform to AWWA Cl 10 and spec. Section 15062 and shall include 316 stainless steel fasteners and washers. Valves: Eccentric plug; ref. spec Section 15110. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-18 3.06 PIPING SPECIFICATION SHEETS--PIPESPEC Piping System: 12 (continued) Buried and Encased Pipe and Valves: (See drawings for pipe size, material, and valve type.) (Where HDPE or FPVC is called out on drawings) Pipe: HDPE: AWWA C906, SDR 11, DIPS outside diameter basis, Ref. spec Section 15065. Conn: butt-fusion per ASTM D2657. Ftgs: Fittings shall conform to the applicable requirements of AWWA C906 for the joining methods specified in paragraph 15065-3.02 B OR Fusible PVC: AWWA C905, DR 18, DIPS outside diameter basis, Ref. spec. Section 15064. Conn: butt-fusion per Section 15064. Ftgs: restrained ductile iron per spec Section 15062, epoxy coated and lined, polyethylene wrapped and wax taped. Valves: Eccentric plug: ref. spec Section 15110. (Where DIP is called out on drawings) Pipe: Ductile iron: AWWA C151. Ref. spec Section 15062. Conn: ref spec Section 15062 Ftgs: Fittings shall conform to AWWA Cl 10 and spec. Section 15062 and shall include 316 stainless steel fasteners and washers. Valves: Eccentric plug: ref. spec Section 15110. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-19 3.06 PIPING SPECIFICATION SHEETS-PIPESPEC Piping Symbol/Service:D-Drain System--24 RWP--Rainwater Pipe SD-Sanitary Drain STD--Storm Drain V-Vent Test Requirements: Medium: Pressure: Duration: Gasket Requirements: Flange: Push-on/Mech Cpl: Exposed Pipe and Valves: (See drawings for pipe size.) (3" and smaller) Pipe: Valves: (4" thru 12") Pipe: Valves: (14" and larger) Pipe: In accordance with Section 712, Uniform Plumbing Code. In accordance with Section 712, Uniform Plumbing Code. In accordance with Section 712, Uniform Plumbing Code. Compressed gasketing consisting of organic fibers (Kevlar) and neoprene binder Nitrile or neoprene Valves: Steel: ASTM A53, galvanized. Ref. spec Section 15061. Conn: taper threaded, ANSI B1.20.1. Ftgs: cast iron, threaded drainage fittings, ASTM A126, ANSI B16.12, galvanized. None Cast iron soil pipe (CISP); ASTM A74. Conn: service hub and spigot compression type or hubless cast iron sanitary system per CISPI 301. Ftgs: CISP, ASTM A74, joint options to match pipe. None Ductile iron: AWWA C151. Ref. spec Section 15062. Conn: flanged or mechanical. Ftgs: ductile iron, per spec Section 15062; ends to match Pipe- None BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING SYSTEMS 15050-20 3.06 PIPING SPECIFICATION SHEETS-PIPESPEC Piping System: 24 (continued) Buried and Encased Pipe and Valves Under and 5 Feet Outside Building (See drawings for pipe size.) (12" and smaller) Pipe: Cast iron soil pipe (CISP); same as exposed. Valves: None (14" and larger) Pipe: Ductile iron; same as exposed. Valves: None Buried and Encased Pipe and Valves Beyond 5 Feet Outside Building (See drawings for pipe size.) (8" and smaller) Pipe: PVC; ASTM D1784, Class 12454-B, ASTM D2665, Sch. 40. Ref. spec Section 15064. Provide magnetic tracer tape. Conn: plain end, solvent weld. Ftgs: PVC, socket type, DWV, ASTM D2665. Valves: None (10" and 12") Pipe: PVC: ASTM D3034, SDR 35. Provide magnetic tracer tape. Conn; Push-on with nitrile gasket. Ftgs: PVC or IPS cast iron; ends to match pipe. Valves: None BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING SYSTEMS AUGUST 2010 15050-21 SECTION 15061 STEEL PIPE PART 1» GENERAL 1.01 DESCRIPTION This section specifies steel pipe and fittings. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference Title ANSIB16.3 ANSI B 16.9 ANSIB16.il ASTM A36/A36M ASTM A47 ASTM A53 ASTMA105/A105M ASTMA106REVA ASTMA197 Malleable Iron Threaded Fittings, Class 150 and 300 Factory-Made Wrought Steel Buttwelding Fittings Forged Steel Fittings, Socket-Welding and Threaded Structural Steel Ferritic Malleable Iron Castings Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless Forgings, Carbon Steel, for Piping Components Seamless Carbon Steel Pipe for High-Temperature Service Cupola Malleable Iron BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STEEL PIPE AUGUST 2010 15061-1 Reference Title ASTM A234/A234M ASTM A283/A283M REV A ASTM A536 ASTM A570/A570M ASTM A572/A572M REVB AWWA C200 AWWA C205 AWWA C206 AWWA C207 AWWA C208 AWWA C209 AWWA C210 AWWA C214 AWWA C600 AWWA Mil SSPC-SP10 Pipe Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures Low and Intermediate Tensile Strength Carbon Steel Plates, Shapes and Bars Ductile Iron Castings Hot-Rolled Carbon Steel Sheet and Strip, Structural Quality High Strength Low Alloy Columbium- Vanadium Steels of Structural Quality Steel Water Pipe 6 Inches and Larger Cement-Mortar Protective Lining and Coating for Steel Water Pipe-4 In. and Larger— Shop Applied Field Welding of Steel Water Pipe Steel Pipe Flanges for Waterworks Services— Sizes 4 In. Through 144 In. Dimensions for Fabricated Steel Water Pipe Fittings Cold-Applied Tape Coating for Special Sections, Connections, and Fittings for Steel Water Pipelines Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipe Tape Coating Systems for the Exterior of Steel Water Pipelines Installation of Ductile-Iron Water Mains and Their Appurtenances Steel Pipe—A Guide for Design and Installation Near- White Blast Cleaning _ _ B. TESTING: Factory testing shall conform to the requirements of ASTM A53, ASTM A106, or AWWA C200 as applicable. PART 2 -- PRODUCTS 2.01 PIPE MATERIALS Steel pipe and fittings shall be provided in accordance with ASTM A53, ASTM A106, or AWWA C200 as specified in Section 15050, Piping Systems. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 STEEL PIPE 15061-2 Steel for pipe fabricated to meet requirements of AWWA C200 shall conform to the requirements of ASTM A36, ASTM A572, Grade 42, ASTM A570, Grades 33 and 36, or ASTM A283, Grade D. Steel for ASTM A53 and ASTM A106 pipe shall be Grade B. 2.02 PIPE MANUFACTURE Unless otherwise specified, ASTM A53 pipe shall be Type E, electric resistance welded or Type S, seamless pipe as specified in Section 15050. The minimum wall thickness for ASTM A53 or ASTM A106 pipe shall be Schedule 40 for pipe 10 inch diameter and less and 3/8 inch for pipe 12 inch through 24 inch diameter. Increased shell thickness shall be provided where specified. AWWA C200 pipe shall be straight or spiral seam. The minimum wall thickness shall be 7 gage for pipe 6 inch through 24 inch diameter and 1/4 inch for pipe 26 inch diameter and larger. Increased shell thickness shall be provided where specified. 2.03 CONNECTIONS Connections shall be as specified in Section 15050 and shall conform to Section 15085. Coating for buried connections shall be as specified in paragraph 15085-2.06. 2.04 FITTINGS AND APPURTENANCES Malleable iron threaded fittings and appurtenances shall conform to the requirements of ASTM A47 or ASTM A197, ANSI B16.3. Unless otherwise specified, steel fittings and appurtenances shall conform to the requirements of ASTM A234, ASTM A105, or ANSI B16.ll; and fabricated steel fittings and appurtenances shall conform to AWWA C208. Fittings for grooved end piping systems shall be full flow cast fittings, steel fittings, or segmentally welded fittings with grooves or shoulders designed to accept grooved end couplings. Cast fittings shall be cast of ductile iron conforming to ASTM A536 or malleable iron conforming to ASTM A47. Standard steel fittings, including large size elbows, shall be forged steel conforming to ASTM A106. Standard segmentally welded fittings shall be fabricated of Schedule 40 carbon steel pipe. Unless otherwise specified, all fittings shall be rated for pressure and loadings equal to the pipe. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STEEL PIPE AUGUST 2010 15061-3 2.05 PIPELINING A. EPOXY: Unless otherwise specified, pipe and fittings shall be lined with a liquid epoxy as specified in AWWA C210 with the following exceptions: 1. No coal tar products shall be incorporated in the liquid epoxy. 2. The curing agent may be an amidoamine as well as the other curing agents listed in AWWAC210. The lining shall be applied to a minimum thickness of 16 mils in not less than two coats. B. CEMENT MORTAR: Where specified, pipe and fittings shall be lined with cement mortar as specified in AWWA C205. Fittings and specials larger than 24 inches, not fabricated from centrifugally lined straight sections, shall require 2-inch by 4-inch by 13-gage self-furring wire mesh reinforcement for hand-applied lining. C. HIGH TEMPERATURE SERVICE EPOXY: Where specified, steel pipe and fittings shall be epoxy lined with not less than 10 mils of epoxy suitable for temperatures of 225 degrees F. Epoxy lining shall be 3M Scotchkote 306, Porter MCR 65 High Solids Epoxy, or equal. Surfaces shall be prepared in accordance with SSPC-SP 10 Near White Blast Cleaning, and the lining applied as recommended by the manufacturer. D. GLASS LINING: Where specified, pipe and fittings shall be glass lined with a dual layer coating system of vitreous material to a minimum thickness of 10 mils. Glass lining shall provide continuous coverage as tested by a low voltage holiday detector with only isolated voids permitted due to casting anomalies. Voids, other than isolated pinholes, shall be cause for rejection. Pipe and fittings shall have all internal welds ground smooth and any voids or slag holes ground out, rewelded and ground smooth. Glass lining shall be Ferrock MEH-32, Vitco SG-14, or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STEEL PIPE AUGUST 2010 15061-4 2.06 PIPE COATING A. EPOXY: Unless otherwise specified, pipe and fittings shall be coated with a liquid epoxy as specified in AWWA C210 with the following exceptions: 1. No coal tar products shall be incorporated in the liquid epoxy. 2. The curing agent may be an amidoamine as well as the other curing agents listed in AWWA C210. The coating shall be applied to a minimum thickness of 16 mils in not less than two coats. B. POLYETHYLENE TAPE: Where specified, pipe and fittings shall be coated and wrapped with prefabricated multilayer cold applied polyethylene tape coating in accordance with AWWA C214. The coating application shall be a continuous step operation in conformance with AWWA C214, Section 3. The total coating thickness shall be not less than 50 mils for pipe 24 inches and smaller and not less than 80 mils for pipe 26 inches and larger. 2.07 FUSION EPOXY COATING AND LINING Where specified, steel pipe and fittings shall be fusion epoxy coated and lined. The fusion epoxy coating shall be 3M Scotchkote 203, or equal. Surface preparation shall be in accordance with SSPC-SP 10 Near White Blast Cleaning. The application method shall be by the fluidized bed method and shall attain 12 mils minimum dry film thickness. Field welds, connections and otherwise damaged areas shall be coated and patched according to the manufacturer's instructions with 3M Scotchkote 306. 2.08 JOINT GASKETS Joint gaskets shall be as specified in Section 15085. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STEEL PIPE AUGUST 2010 15061-5 2.09 PRODUCT DATA The following information shall be provided in accordance with Section 01300: 1. Affidavits of Compliance with AWWA C200, ASTM A53, or ASTM A106 as applicable. 2. Contractor's layout drawings as specified in paragraph 15050-2.04. PART 3 » EXECUTION 3.01 INSTALLATION A. GENERAL: Pipe shall be installed in accordance with AWWA Mil, Chapter 16. Welded joints shall be in accordance with AWWA C206 and Section 15085. Sleeve-type mechanical pipe couplings shall be provided in accordance with AWWA Mil and paragraph 15085-2.02 A. Pipe lining and coatings at field joints shall be applied as specified in paragraphs 15061-2.05 and 2.06. Unless otherwise specified, buried mechanical couplings and valves shall be field coated as specified in paragraph 15085-2.06. B. ANCHORAGE: Anchorage shall be provided as specified. Calculations and drawings for proposed alternative anchorage shall be submitted in accordance with Section 01300. 3.02 TESTING Hydrostatic testing shall be in accordance with Section 4 of AWWA C600 except that test pressures and allowable leakage shall be as listed in Section 15050. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) STEEL PIPE AUGUST 2010 15061-6 SECTION 15062 DUCTILE IRON PIPE PART 1-GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies ductile iron pipe, ductile fittings and gaskets. B. DEFINITION: Where cast iron pipe is specified, the term and symbol shall mean ductile iron pipe. 1.02 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference Title ANSIA21.14 ANSI A21.52 ANSI B 16.1 ANSI B 16.5 ASTM A716 ASTMC150 Ductile-Iron Fittings 3 In. Through 24 In., for Gas Ductile-Iron Pipe, Centrifugally Cast, in Metal Molds or Sand Lined Molds for Gas Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800 Pipe Flanges and Flanged Fittings Ductile-Iron Culvert Pipe Portland Cement BUENA VISTA LIFT STATION FORCE MAIN (VC-4) DUCTILE IRON PIPE AUGUST 2010 15062-1 Reference Title AWWAC104 (ANSIA21.4) AWWAC110 (ANSIA21.LO) AWWACill (ANSIA21.il) AWWAC115 (ANSIA21.15) AWWAC150 (ANSI A2 1.50) AWWAC151 (ANSIA21.51) AWWAC153 (ANSIA21.53) AWWAC600 AWWA C606 Cement-Mortar Lining for Ductile- Iron and Gray-Iron Pipe and Fittings for Water Ductile-Iron and Gray-Iron Fittings, 3 In. Through 48 In., for Water and Other Liquids Rubber-Gasket Joints for Ductile- Iron and Gray-Iron Pressure Pipe and Fittings Flanged Ductile-Iron and Gray-Iron Pipe With Threaded Flanges Thickness Design of Ductile-Iron Pipe Ductile-Iron Pipe, Centrifugally Cast, in Metal Molds or Sand-Lined Molds, for Water or Other Liquids Ductile-Iron Compact Fittings, 3 In. Through 12 In. for Water and Other Liquids Installation of Ductile-Iron Water Mains and Their Appurtenances Grooved and Shouldered Type Joints _ PART 2 -•- PRODUCTS 2.01 GENERAL Pipe design, materials and manufacture shall comply with the following documents: Item Thickness design Manufacturing requirements Water or other liquid Gas Gravity service pipe Joints Rubber gasket Threaded flange Fittings Water or other liquid Gas Cement mortar lining Document AWWAC150 AWWAC151 ANSIA21.52 ASTMA716 AWWACill AWWA Cl 15 AWWA Cl 10/AWWA C153 ANSIA21.14 AWWA C104 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 DUCTILE IRON PIPE 15062-2 2.02 PIPE Unless otherwise specified, ductile iron pipe shall be Class 50 and have nominal laying lengths of 18 or 20 feet. For grooved-end pipe, wall thickness shall be minimum Class 53 except where the specified pressure requires heavier pipe. 2.03 GASKETS Unless otherwise specified, gasket stock shall be a synthetic rubber compound in which the elastomer is nitrite or neoprene. The compound shall contain not less than 50 percent by volume nitrite or neoprene and shall be free from factice, reclaimed rubber and other deleterious substances. Gaskets shall, in addition, comply with AWWA Clll for push-on and mechanical joints and with AWWA C606 for grooved end joints. 2.04 FITTINGS Unless otherwise specified, fittings shall conform to AWWA Cl 10. Ends shall be flanged, restrained mechanical joint, restrained push-on, or grooved to suit the conditions specified. Fasteners and washers shall be 316 stainless steel. The AWWA C153 compact ductile iron fittings in sizes 3 through 12 inches are an acceptable substitute for standard fittings unless otherwise specified. Long-radius elbows shall be provided where specified. Grooved end fittings shall comply with paragraph 15050-1.02 B. 2.05 JOINTS A. UNRESTRAINED JOINTS: 1. PUSH-ON JOINTS: Unrestrained joints, where specified, shall be the rubber ring compression, push-on type joint suitable for buried service. Unrestrained joints shall be the Fastite Joint as manufactured by American Cast Iron Pipe Company, the Tyton Joint as manufactured by U.S. Pipe, or equal. This joint is not permitted on fittings or specials, unless otherwise specified. Unless otherwise specified, joints shall have an allowable deflection up to 5 degrees at specified pressures. Joint assembly and field cut joints shall be made in strict conformance with AWWA C600 and manufacturer's recommendations. 2. MECHANICAL JOINTS: Where specified, mechanical joints for above or below ground service shall meet the requirements of ANSI/AWWA A21.10/C110 and ANSVAWWA A21.il/Clll. Gaskets and bolts and nuts shall comply with paragraphs 15062-2.03 and 2.05 D, respectively. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) DUCTILE IRON PIPE AUGUST 2010 15062-3 B. RESTRAINED JOINTS: 1. GENERAL: Unless otherwise specified, restrained joints are required for all exposed and buried piping. Unless otherwise specified, restrained joints shall be flanged or grooved end for exposed service and restrained push-on for buried service. 2. PUSH-ON JOINTS: Restrained push-on joints shall be as specified in paragraph 15062-2.05 A.I., modified for restraint. Joints shall be the Flex-Ring or Lok-Ring Joint as manufactured by American Cast Iron Pipe Company, TR Flex Joint as manufactured by US Pipe, or equal. Restrained joints shall be capable of being deflected after full assembly. Joint assembly shall be in strict conformance with AWWA C600 and manufacturer's recommendations. No field cuts of restrained pipe are permitted without prior approval of the Engineer. 3. FLANGE ASSEMBLIES: Unless otherwise specified, flanges shall be ductile iron and shall be threaded-on flanges conforming to ANSI/AWWA A21.15/C115 or cast-on flanges conforming to ANSI/AWWA A21.10/C110. Flanges shall be adequate for 250 psi working pressure. Bolt circle and bolt holes shall match those of ANSI B16.1, Class 125 flanges and ANSI B16.5, Class 150 flanges. Where specified, flanges shall be threaded-on or cast-on flanges conforming to ANSI B 16.1, Class 250. Unless otherwise specified, bolts and nuts for flange assemblies shall conform with paragraph 15085-2.01 C. Gaskets shall be as specified in paragraph 15085-2.01 B. 4. MECHANICAL JOINTS: Where specified, restrained mechanical joints shall be the positive restraint type. Mechanical joints with retainer glands are not acceptable. Locked mechanical hydrant tees, bends and adapters are an acceptable substitute for anchoring fire hydrants and valves to the pipe main. C. BALL AND SOCKET FLEXIBLE JOINT PIPE: Ball and socket flexible joint pipe shall be the boltless type and shall allow a maximum joint deflection of 15 degrees. Each joint shall be provided with a retainer lock to prevent rotation after assembly. Joints shall be the Flex-Lok Joint as manufactured by American Cast Iron Pipe Company, USIflex as manufactured by U.S. Pipe, or equal. D. BOLTS AND NUTS: Corrosion-resistant bolts and nuts for use with ductile iron joints shall be high-strength, low- alloy steel as specified in ANSI/AWWA Cl 11/A21.11. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 DUCTILE IRON PIPE 15062-4 2.06 PIPE COATING Unless otherwise specified, pipe and fittings shall be coated with fusion-bonded epoxy material as specified in Section 09961 and petroleum wax tape as specified in Section 09902. 2.07 PIPE LINING A. FUSTION BONDED EPOXY LINING: Unless otherwise specified, pipe and fittings shall be lined with fusion-bonded epoxy material as specified in Section 09961. B. CEMENT MORTAR LINING: Where specified, interior surfaces of pipe and fittings shall be cement mortar lined in accordance with AWWA C104. Cement shall be ASTM C150, Type II or V, low alkali, containing less than 0.60 percent alkalies. C. GLASS LINING: Where specified, pipe and fittings shall be glass lined with a dual layer coating system of vitreous material to a minimum thickness of 10 mils. Glass lining shall provide continuous coverage as tested by a low voltage holiday detector with only isolated voids permitted due to casting anomalies. Voids, other than isolated pinholes, shall be cause for rejection. Ductile or cast iron pipe shall be bored, machined, or grit blasted to remove any voids, protrusions or surface irregularities to obtain a smooth continuous surface for glass lining. Pipe shall be at least Class 53 on diameters of 6 inches or greater except for pipe to be bored or machined which shall be of a suitable wall thickness to assure boring or machining will not impair minimum wall thickness required for Class 53. Four-inch pipe shall be Class 56. Fittings shall be ground or grit blasted to remove any voids, protrusions or surface irregularities. Glass lining shall be Ferrock MEH-32, Vitco SG-14, or equal. 2.08 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be used for all ferrous metal materials that are not protected with annodes. A. Polyethylene wrap shall be used for the protection of buried valves in conjunction with wax tape. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) DUCTILE IRON PIPE AUGUST 2010 15062-5 B. Polyethylene sleeves shall be used for the protection of buried ductile iron pipe and fittings. Where the use of a sleeve is not practical, the fittings may be wrapped. Additionally, all bolted connections shall be coated with wax tape hi accordance with Section 09902. C. Polyethylene encasement shall be as indicated below. Polyethylene materials shall be kept out of direct sunlight exposure. 1. Polyethylene sleeves shall be a minimum 0,012" thick polyethylene plastic in accordance with AWWA C105. 2. Polyethylene wrap shall be a minimum 0.008" thick polyethylene plastic in accordance with AWWA C105. 3. Polyethylene wrap and sleeves shall be clear for use with potable water and purple for use with recycled water. 4. Polyethylene or vinyl adhesive tape a minimum of 2" wide or plastic tie straps shall be used to secure polyethylene encasement. 2.09 PRODUCT DATA The following information shall be provided in accordance with Section 01300: 1. Shop drawings. 2. Alignment drawings. 3. Certifications specified in the following documents: ANSI A21.14, paragraph 14-4.2 ANSI A21.52, paragraph 52-4.2 ASTM A716, paragraph 4.2 AWWA Cl 10, paragraph 10-5.3 AWWA Clll, paragraph 11-7.1 AWWA C115, paragraph 15-4.2 AWWA C151, paragraph 51-5.2 AWWA C153, paragraph 53-6.3 AWWA C606, paragraph 4.1.1.1 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) DUCTILE IRON PIPE AUGUST 2010 15062-6 PART 3 « EXECUTION 3.01 INSTALLATION A. GENERAL: Piping runs specified on the drawings shall be followed as closely as possible. Proposed deviations shall be submitted in accordance with Section 01300. Pipe shall be installed in accordance with AWWA C600. Connections to existing structures and manholes shall be made so that the finished work will conform as nearly as practicable to the requirements specified for the new manholes, including necessary concrete work, cutting and shaping. Concrete mortar shaping within any structure and manhole shall be as specified. B. INSULATING SECTIONS: Where a metallic nonferrous pipe or appurtenance is connected to ferrous pipe or appurtenance, an insulating section shall be provided as specified in paragraph 15085-3.05, C. ANCHORAGE: Anchorage shall be provided as specified. Calculations and drawings for proposed alternative anchorage shall be submitted in accordance with Section 01300. D. POLYETHYLENE ENCASEMENT Polyethylene encasement shall completely encase and cover all buried metal surfaces not otherwise protected with a cathodic protection system. All bolted connections shall be coated with wax tape prior to polyethylene encasement. Pipe & Fittings: All ductile-iron pipe and fittings shall be encased with polyethylene sleeves in accordance with Method A described in AWWA C105, except that tees may be encased with polyethylene wrap in accordance with Method C described in AWWA C105. Valves: Buried valves shall have only the stem and operating nut exposed and the wrap shall be attached so that valve operation will not disturb the wrapping or break the seal. Refer to the applicable valve specification to determine other coating requirements. Polyethylene sleeves shall be secured with polyethylene or vinyl adhesive tape or plastic tie straps at the ends and quarter points along the sleeve in a manner that will hold the sleeve securely in place during backfill. Polyethylene wrap shall be secured with polyethylene or vinyl adhesive tape in a manner that will hold the wrap securely in place during backfill. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) DUCTILE IRON PIPE AUGUST 2010 15062-7 3.02 ACCEPTANCE TESTING Hydrostatic pressure tests shall be conducted in accordance with Section 4 of AWWA C600 except that test pressures and allowable leakage shall be as listed in Section 15050. The Contractor shall conduct the tests in the presence of the Engineer. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) DUCTILE IRON PIPE AUGUST 2010 15062-8 SECTION 15064 PLASTIC PIPE PART 1 -- GENERAL 1.01 DESCRIPTION This section specifies polyvinyl chloride (PVC) pipe and fittings. Where designated on the contract drawings, the Contractor shall use fusible polyvinyl chloride (FPVC™) pipe. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids. If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference AWWA C605 AWWA C900 AWWA M23 ANSI/AWWA C110/A21.10 ANSI/AWWA C111/A2U1 Title Standard for Underground Installation of Polyvinyl Chloride (PVC) Pressure Pipe and Fittings for Water Standard for Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4 in. through 12 in. (100mm through 300mm), for Water Distribution AWWA Manual of Supply Practices PVC Pipe — Design and Installation, Second Edition American National Standard for Ductile-Iron and Gray-Iron Fittings, 3- inch through 48-inch, for Water and Other Liquids American National Standard for Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-1 Reference AWWA C605 AWWAC651 ASTM D638 ASTMD1238 ASTMD1248 ASTMD1505 ASTM D1784 ASTMD1785 ASTMD2122 ASTMD2152 ASTM D2241 ASTM D2665 ASTM D3 139 ASTM F477 ASTM F1057 ASTM F1417 UNI-PUB-6 NSF-14 NSF-61 PPITR-2/2006 Title Standard for Underground Installation of Polyvinyl Chloride (PVC) Pressure Pipe and Fittings for Water Standard for Disinfecting Water Mains Tensile Properties of Plastics Flow Rates of Thermoplastics by Extrusion Plastomer Polyethylene Plastics Molding and Extrusion Materials^ Standard Test Method for the Density of Plastics by the Density-Gradient Technique Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120 Determining Dimensions of Thermoplastic Pipe and Fittings Test Method for Degree of Fusion of Extruded Poly(Vinyl Chloride) (PVC) Pipe and Molded Fittings by Acetone Immersion Poly (Vinyl Chloride) (PVC) Plastic Pipe (SDR-PR) Poly (Vinyl Chloride) (PVC) Plastic Drain, Waste, and Vent Pipe and Fittings Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals Elastomeric Seals (Gaskets) for Joining Plastic Pipe Standard Practice for Estimating the Quality of Extruded Poly (Vinyl Chloride) (PVC) Pipe by the Heat Reversion Technique Standard Test Method for Installation Acceptance of Plastic Gravity Sewer Lines Using Low-Pressure Air Recommended Practice for Low-Pressure Air Testing of Installed Sewer Pipe Plastics Piping System Components and Related Materials Drinking Water System Components-Health Effects PVC Range Composition Listing of Qualified Ingredients BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PLASTIC PIPE 15064-2 PART 2-PRODUCTS 2.01 NON-FUSIBLE PVC PIPE A. PRESSURE PIPE, FITTINGS, AND COUPLINGS PVC material for pipe and fittings shall conform to ASTM D1784, Class 12454. Pipe and fittings shall be in accordance with AWWA C900 DR 18. Pressure rating for pipe shall be in excess of test pressure specified in Section 15050. Neoprene gaskets with push-on joints shall conform to ASTM F477. PVC fittings shall conform to ASTM D3139. Connections to flanged pipe or flanged fittings shall be by means of restrained flanged coupling adapters. Restrained flanged coupling adapters shall not utilize teeth or screws that cut into PVC pipe, shall be approved for use with AWWA C905 pipe, and shall be EBAA Inc. Series 2100 MegaFIange or approved equal. Connections to mechanical joint pipe or mechanical joint fittings shall be by means of mechanical joint restraints. Mechanical joint restraints shall be approved for use with AWWA C905 pipe and shall be EBAA Inc. Series 2000 MegaLug or approved equal. High deflection couplings shall be CertainTeed, or approved equal, and conform to AWWA C905. B. NONPRESSURE PIPE PVC material for gravity sewer pipe and fittings shall conform to Class 12454, as defined in ASTM D1784. Pipe and fittings shall meet the construction and performance requirements of ASTM F949 and F794, and shall meet the performance requirements of ASTM D3034 SDR 35. Nitrile gaskets with push-on joints shall conform to ASTM F477. 2.02 FUSIBLE POLYVINYL CHLORIDE PIPE (FPVC™) A. PRESSURE PIPE FPVC™ pipe for potable water shall conform to AWWA C900, AWWA C905, ASTM D2241 or ASTM D1785 as applicable. Testing shall be in accordance with the referenced AWWA standards for all pipe types. FPVC™ pipe for non-potable water or pressurized wastewater shall conform to AWWA C900, AWWA C905, ASTM D2241 or ASTM D1785 for standard dimensionality, as applicable. Testing shall be in accordance with the referenced AWWA standards. FPVC™ pipe for non-pressure storm or wastewater shall conform to ASTM D3034, ASTM F679, AWWA C900, AWWA C905, ASTM D2241, or ASTM D1785 for standard dimensions as applicable. Testing shall be in accordance with the applicable standard used. BUENA VISTA LIFT STATION FORGE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-3 FPVC™ pipe shall be extruded with plain ends. The ends shall be square to the pipe and free of any bevel or chamfer. There shall be no bell or gasket of any kind incorporated into the pipe. FPVC™ pipe shall be manufactured in a standard 40' nominal length or custom lengths as specified. FPVC™ pipe shall be blue in color for potable water use. FPVC™ pipe shall be purple in color for reclaim, reuse, or other non-potable use. FPVC™ pipe shall be green in color for wastewater use. FPVC™ pipe shall be white in color for surface or storm water use. Pipe generally shall be marked per AWWA C900, AWWA C905, ASTM D2241, or ASTM D1785 as applicable, and shall include as a minimum: 1. Nominal pipe size 2. PVC 3. Dimension Ratio, Standard Dimension Ratio or Schedule 4. AWWA pressure class or standard pressure rating for non-AWWA pipe 5. AWWA standard designation number or pipe type for non-AWWA pipe 6. NSF-61 mark verifying suitability for potable water service 7. Extrusion production-record code 8. Trademark or trade name 9. Cell Classification 12454 and/or PVC material code 1120 may also be included Pipe shall be homogeneous throughout and be free of visible cracks, holes, foreign material, blisters, or other visible deleterious faults. FPVC™ pipe shall include a one-year warranty, which shall cover the cost of replacement pipe and freight to project site, should the pipe have any defects in material or workmanship. In addition to the standard pipe warranty, the fusing Contractor shall provide in writing a warranty for a period of one year for all the fusion joints, including formation, installation, and pressure testing. Warranty periods shall begin on the date of installation and product acceptance after all applicable testing. Connections to flanged pipe or flanged fittings shall be by means of restrained flanged coupling adapters. Restrained flanged coupling adapters shall not utilize teeth or screws that cut into PVC pipe, shall be approved for use with PVC pipe of the type and standard used, and shall be Romac RFCA (PVC version), EBAA Inc. Series 2100 MegaFlange, or approved equal. Connections to mechanical joint pipe or mechanical joint fittings shall be by means of mechanical joint restraints. Mechanical joint restraints shall be approved for use with PVC pipe of the type and standard used, and shall be EBAA Inc. Series 2000 MegaLug or approved equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-4 B. NONPRESSUREPIPE FPVC™ pipe material for gravity sewer pipe and fittings shall conform to Class 12454, as defined in ASTM D1784. Pipe and fittings shall meet the construction and performance requirements of ASTM F949 and F794, and shall meet the performance requirements of ASTM D3034 SDR 35. Nitrile gaskets with push-on joints shall conform to ASTM F477. It shall also be acceptable to use PVC made to pressure piping standards as indicated in this specification. C. FUSION JOINTS FPVC™ pipe lengths shall be assembled in the field with butt-fused joints. The Contractor shall follow the pipe supplier's written instructions for this procedure. Joint strength shall be equal to the pipe as demonstrated by testing requirements. All fusion joints shall be completed as described in this specification. 2.03 FUSIBLE POLYVINYL CHLORIDE SWEEPS OR BENDS FPVC™ sweeps or bends shall conform to the same sizing convention, diameter, dimensional tolerances and pressure class of the pipe being joined by the sweep or bend. FPVC™ sweeps or bends shall be manufactured from the same FPVC™ pipe being used for the installation, and shall have at least 2 feet of straight section on either end of the sweep or bend to allow for fusion of the sweep to the pipe installation. There shall be no gasketed connections utilized with a FPVC™ sweep. Standard FPVC™ sweep or bend angles shall not be greater than 22.5 degrees, and shall be used in nominal diameters ranging from 4 inch through 16 inch. 2.04 PRODUCT DATA The following information shall be provided in accordance with Section 01300: 1. Manufacturer's certificates of compliance with the specified standards and Contractor's layout drawings. 2. For FPVC™ pipe only: a. Pipe supplier data, including experience of pipe supplier by years and number of projects; warranty information; and independent laboratory testing certification. b. Fusion joint data and fusion technician data including fusion joint warranty information and recommended fusion joint procedure, including criteria logged and recorded by data logger. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-5 PART 3 "EXECUTION 3.01 DELIVERY AND OFF-LOADING All pipe shall be bundled or packaged in such a manner as to provide adequate protection of the ends during transportation to the site. Any pipe damaged in shipment shall be replaced as directed by the City of Carlsbad or the Engineer. Each pipe shipment should be inspected prior to unloading to see if the load has shifted or otherwise been damaged. Notify the City or the Engineer immediately if more than immaterial damage is found. Each pipe shipment should be checked for quantity and proper pipe size, color, and type. Pipe should be loaded, off-loaded, and otherwise handled in accordance with AWWA M23, and all of the pipe supplier's guidelines shall be followed. Off-loading devices such as chains, wire rope, chokers, or other pipe handling implements that may scratch, nick, cut, or gouge the pipe are strictly prohibited. During removal and handling, be sure that the pipe does not strike anything. Significant impact could cause damage, particularly during cold weather. If appropriate unloading equipment is not available, pipe may be unloaded by removing individual pieces. Care should be taken to insure that pipe is not dropped or damaged. Pipe should be carefully lowered, not dropped, from trucks. 3.02 HANDLING AND STORAGE Any length of pipe showing a crack or which has received a blow that may have caused an incident fracture, even though no such fracture can be seen, shall be marked as rejected and removed at once from the work. Damaged areas, or possible areas of damage may be removed by cutting out and removing the suspected incident fracture area. Limits of the acceptable length of pipe shall be determined by the City or the Engineer. Any scratch or gouge greater than 10% of the wall thickness will be considered significant and can be rejected unless determined acceptable by the City or the Engineer. Pipe lengths should be stored and placed on level ground. Pipe should be stored at the job site in the unit packaging provided by the manufacturer. Caution should be exercised to avoid compression, damage, or deformation to the ends of the pipe. The interior of the pipe, as well as all end surfaces, should be kept free from dirt and foreign matter. Pipe shall be handled and supported with the use of woven fiber pipe slings or approved equal. Care shall be exercised when handling the pipe to not cut, gouge, scratch or otherwise abrade the piping in any way. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-6 If pipe is to be stored for periods of 1 year or longer, the pipe should be shaded or otherwise shielded from direct sunlight. Covering of the pipe which allows for temperature build-up is strictly prohibited. Pipe should be covered with an opaque material while permitting adequate air circulation above and around the pipe as required to prevent excess heat accumulation. Pipe shall be stored and stacked per the pipe supplier's guidelines. 3.03 FUSION PROCESS (ALTERNATIVE METHOD) FPVC™ pipe will be handled in a safe and non-destructive manner before, during, and after the fusion process and in accordance with this specification and pipe supplier's guidelines. FPVC™ pipe will be fused by qualified fusion technicians, as documented by the pipe supplier. Each fusion joint shall be recorded and logged by an electronic monitoring device (data logger) connected to the fusion machine. 1. Only appropriately sized and outfitted fusion machines that have been approved by the pipe supplier shall be used for the fusion process. Fusion machines must incorporate the following elements: a) HEAT PLATE - Heat plates shall be in good condition with no deep gouges or scratches. Plates shall be clean and free of any debris or contamination. Heater controls shall function properly; cord and plug shall be in good condition. The appropriately sized heat plate shall be capable of maintaining a uniform and consistent heat profile and temperature for the size of pipe being fused, per the pipe supplier's guidelines. b) CARRIAGE - Carriage shall travel smoothly with no binding at less than 50 psi. Jaws shall be in good condition with proper inserts for the pipe size being fused. Insert pins shall be installed with no interference to carriage travel. c) GENERAL MACHINE - Overview of machine body shall yield no obvious defects, missing parts, or potential safety issues during fusion. d) DATA LOGGING DEVICE - An approved datalogging device with the current version of the pipe supplier's recommended and compatible software shall be used. Datalogging device operations and maintenance manual shall be with the unit at all times. If fusing for extended periods of time, an independent 110V power source shall be available to extend battery life. 2. Other equipment specifically required for the fusion process shall include the following: a) Pipe rollers shall be used for support of pipe to either side of the machine BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-7 b) A weather protection canopy that allows full machine motion of the heat plate, fusion assembly and carriage shall be provided for fusion in inclement, extreme temperatures, and /or windy weather, per the pipe supplier's recommendations. c) An infrared (IR) pyrometer for checking pipe and heat plate temperatures. d) Fusion machine operations and maintenance manual shall be kept with the fusion machine at all times. e) Facing blades specifically designed for cutting FPVC™ pipe shall be used. A. JOINT RECORDING Each fusion joint shall be recorded and logged by an electronic monitoring device (data logger) connected to the fusion machine. The fusion data logging and joint report shall be generated by software developed specifically for the butt-fusion of FPVC™ pipe. The software shall register and/or record the parameters required by the pipe supplier and these specifications. Data not logged by the data logger shall be logged manually and be included in the Fusion Technician's joint report. Submittals of the Fusion Technician's joint reports are required as requested by the Engineer. Specific requirements of the Fusion Technician's joint report shall include: 1. Pipe Size and Dimensions 2. Machine Size 3. Fusion Technician Identification 4. Job Identification Number 5. Fusion Number 6. Fusion, Heating, and Drag Pressure Settings 7. Heat Plate Temperature 8. Time Stamp 9. Heating and Cool Down Time of Fusion 10. Ambient Temperature 3.04 INSTALLATION A. NON-FUSIBLE PVC INSTALLATION PVC pipe shall be joined by means of gasketed push-on joints. Foreign material shall be removed from the pipe interior prior to assembly at all connections. B. FUSIBLE PVC LAYOUT All fusion of the pipe shall occur at surface level. No fusion will be completed in the excavated area or trench. Pipe lengths shall be fused in their entirety and staged prior to BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-8 installation in the trench. Fused pipe lengths shall be determined by Contractor preference, manufacturer's recommendations and site constraints. The allowable length and width of open trench or excavation shall adhere to all applicable jurisdictional standards and these specifications. C. FUSIBLE PVC PIPE INSTALLATION Fused lengths of pipe shall be installed by lowering into the trench or excavation, using approved strapping per these specifications. The lowering operation, once initiated shall proceed until the entire length of the fused section of pipe is installed. Coordination of lifting equipment shall ensure that the fused pipe does not exceed the bending and buckling limitations of the pipe, per the manufacturer's recommendations. Three pick points shall be utilized at all times and shall be staged per the manufacturer's recommendations. Under no circumstances will the pipe be "dropped" or "rolled" into the trench or excavation. If the length of the fused pipe is longer than what the available equipment can lower into the trench or excavation at one time, equipment shall be staged so that lowering shall begin at one end of the installation, and proceed along the trench or excavation, so that the entire fused length is installed without exceeding the bending limitations of the fused pipe. Pipe may also be installed by dragging it into the end of the trench via a sloped section that is constructed so as not to exceed the bending radius of the pipe. Pipe may be pulled by the use of a pull head and winch or piece of construction machinery as recommended by the pipe supplier. Fused pipe shall be bedded and backfilled per the drawings, these specifications and all applicable jurisdictional standards. Lengths of fused PVC pipe shall be bedded and removed from direct sunlight for a period of at least two minutes per inch-diameter before any connections are made. This period of thermal equalization of the pipe is to assure proper connections may be installed. D. PVC PIPE CARE PVC pipe shall be handled with care to minimize the possibility of it being cut, kinked, gouged, or otherwise damaged. The use of cables or hooks will not be permitted. Sections of PVC pipe damaged, cut, or gouged shall be repaired by cutting out the section of damaged pipe and then rejoining. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-9 3.05 TAPPING FOR POTABLE AND NON-POT ABLE WATER APPLICATIONS A. Tapping shall be performed using standard tapping saddles designed for use on PVC piping in accordance with AWWA C605. Tapping shall be performed only with use of tap saddles or sleeves. NO DIRECT TAPPING WILL BE PERMITTED. Tapping shall be performed hi accordance with the applicable sections for Saddle Tapping per Uni-Pub- 8. B. All connections requiring a larger diameter than that recommended by the pipe supplier, shall be made with a pipe connection as specified and indicated on the drawings. C. Equipment used for tapping shall be made specifically for tapping PVC pipe: 1. Tapping bits shall be slotted "shell" style cutters, specifically made for PVC pipe. 'Hole saws' made for cutting wood, steel, ductile iron, or other materials are strictly prohibited. 2. Manually operated or power operated drilling machines may be used. D. Taps may be performed while the pipeline is filled with water and under pressure ('wet' tap,) or when the pipeline is not filled with water and not under pressure ('dry' tap). 3.06 TESTING Testing of plastic piping shall be as specified in Section 15050. *** END OF SECTION *** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PLASTIC PIPE AUGUST 2010 15064-10 SECTION 15065 HIGH DENSITY POLYETHYLENE PIPE PART 1-GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies high density polyethylene (HDPE) pipe, fittings, and appurtenances for piping 4 inches to 63 inches in nominal diameter. The designation HDPE is used in the Piping System Specification Sheets (PIPESPEC) in Section 15050 and in this section. B. CHARACTERISTICS: The piping system shall conform with the following: Dimension ratio (DR) 11 Pressure Class in accordance with AWWA C906 160 psig Maximum deflection in installed condition, percent of the average inside diameter of the pipe 2.7 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HIGH DENSITY POLYETHYLENE PIPE AUGUST 2010 15065-1 References ANSI/AWWA C906 ASTMD2321 ASTM D2657 ASTM D3350 PPITR31 Title Polyethylene (PE) Pressure Pipe and Fittings, 4-inch through 63-inch, for Water Distribution Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications Heat Joining Polyolefin Pipe and Fittings Polyethylene Plastics Pipe and Fittings Material Underground Installation of Polyolefin Piping B. INSPECTION AND TESTING: All HDPE materials, pipe and fittings shall be inspected and tested in accordance with the requirements of AWWA C906. C. AFFIDAVIT OF COMPLIANCE: The manufacturer shall furnish an affidavit of compliance conforming to the requirements of AWWA C906, Section 1.5, affirming that the piping components comply with the requirements of AWWA C906 and this section. The affidavit shall be signed under penalty of perjury by an officer of the pipe manufacturer's company. 1.03 SUBMITTALS The following submittals shall be provided in accordance with Section 01300: 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check- marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks (V) shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. 2. Detail drawings which show the type and location of all fittings, joints, and connections to structures and manholes. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HIGH DENSITY POLYETHYLENE PIPE AUGUST 20 10 15065-2 PART 2 « PRODUCTS 2.01 GENERAL HDPE materials, pipe and fittings shall be manufactured, inspected, sampled and tested in accordance with the requirements of AWWA C906 and this section. In case of conflict between the requirements of this section and AWWA C906, the requirements of this section shall prevail. 2.02 MATERIALS HDPE piping components shall be manufactured from materials that meet or exceed the requirements of the Plastic Piping Institute designation PE3408 and that conform to the requirements of ASTM D3350 for a cell classification of PE 345434C. Bolts and nuts for buried mechanical joining components such as flanges shall be made of noncorrosive, high-strength, low-alloy steel having the characteristics specified in ANSI/AWWA Cl 11/A21, regardless of any protective coating. 2.03 PIPE Pipe shall have the nominal dimensions shown with a DIPS outside diameter basis and the dimensions and tolerances specified in AWWA C906. DR rating and pressure class shall be as specified in paragraph 15065-1.01 B. 2.04 FITTINGS Fittings shall conform to the applicable requirements of AWWA C906 for the joining methods specified in paragraph 15065-3.02 B. 2.05 PIPE MARKINGS Pipe marking shall conform to the requirements of AWWA C906. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HIGH DENSITY POLYETHYLENE PIPE AUGUST 2010 15065-3 2.06 PRODUCT DATA The following product data shall be provided in accordance with Section 01300: 1. Affidavit of Compliance specified in paragraph 15065-1.02 C. 2. A report containing a copy of all manufacturers' test results for all tests conducted in accordance with paragraph 15065-1.02 B. PART 3 » EXECUTION 3.01 PIPE HANDLING AND STORAGE The Contractor shall use care in handling and storage of the pipe. Pipe shall be stored on clean, level ground to prevent undue scratching or gouging of the pipe. If the pipe must be stacked for storage, such stacking shall be done in accordance with the pipe manufacturer's recommendations. The handling of the pipe shall be done in such a manner that it is not damaged by dragging over sharp objects or cut by chokers or lifting equipment. Sections of pipe with cuts, gouges, or scratches on the outside diameter (OD) surface that exceed 10-percent of the wall thickness of the pipe shall be removed completely and the ends of the pipeline rejoined. The inside diameter (ID) surface shall be free of cuts, gouges, and/or scratches. 3.02 INSTALLATION A. GENERAL: Unless otherwise specified, the piping system shall be installed in accordance with ASTM D2321, AWWA C906 and the manufacturer's recommendations. B. JOINING: Pipe and fittings shall be joined into continuous lengths on the job site above ground. Unless otherwise specified, joining shall by the butt-fusion method performed in accordance with the pipe manufacturer's recommendations and ASTM D2657. Socket fusion, extrusion welding and hot gas welding shall not be used. The pipe supplier shall be consulted to obtain machinery and expertise for the joining by butt- fusion of HOPE pipe and fittings. No pipe or fittings shall be joined by fusion by any of the Contractor's personnel unless they are adequately trained and qualified in the techniques involved. Butt fusion joining shall yield a joint strength equal to or greater than the tensile strength of the pipe. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 20 10 HIGH DENSITY POLYETHYLENE PIPE 15065-4 Flanged joining, or other mechanical joining methods specified, may be used to make connections to differing piping materials, to equipment, valves and other appurtenances, and where specified. C. TRENCH EXCAVATION: Trenches shall be excavated to ensure that sides will be stable under all working conditions. Trench walls or supports shall comply with all local and national standards for safety. D. LOCATION AND ALIGNMENT: Pipe and fittings shall be placed in the trench with the invert conforming to the elevations, slopes, and alignments shown. E. BEDDING AND BACKFILL: Materials used for bedding and backfill shall be as specified in Section 02200 and as shown. Place materials by methods that will not disturb or damage the pipe. All HOPE pipe shall be at the temperature of the surrounding soil at the time it is backfilled and compacted. Work in and tamp the bedding material in the area under the pipe and up to the spring line before placing and compacting the remainder of the embedment. Blocking under the pipe shall not be permitted. Use compaction equipment and techniques that are compatible with materials specified and location in the trench. Before using heavy compaction or construction equipment directly over the pipe, place sufficient backfill to prevent damage, excessive deflections, or other disturbances of the pipe. 3.03 TESTING A. GENERAL: Testing of piping shall be as specified in Section 15050 and this section. In case of conflict, the requirements of this section shall prevail. B. HYDROSTATIC PRESSURE TESTING: HDPE piping systems shall be fully pressure tested prior to covering the piping and placing the line into service. Water shall be the test medium for hydrostatically testing the pipe. Test procedures shall be as specified in Section 15050 and the following. In case of conflict, the following procedures shall apply. Cover the pipe at intervals and/or at curves if necessary to hold the pipe in place during testing. Connections shall be left exposed for visual leak inspection. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) HIGH DENSITY POLYETHYLENE PIPE AUGUST 2010 15065-5 After all free air is removed from the test section; the pressure in the pipe shall be raised at a steady rate to the required pressure. The pressure in the section shall be measured at the lowest point of the test section. Test pressure shall be as specified in Section 15050. The initial pressure shall be applied and allowed to stand without makeup pressure for 2-3 hours to allow for diametric expansion or pipe stretching to stabilize. After the equilibrium period, the test section shall be returned to the required test pressure and held for 3 hours. Amounts of makeup water allowable for expansion during the pressure test shall be as listed in the Plastic Pipe Institute Technical Report TR 31-88. No visual leaks or pressure drops shall be observed during the final test period. C. DEFLECTION TESTING: 1. GENERAL: Deflection testing shall be performed on the entire length of installed pipe no sooner than 30 days after completion of work adjacent to and over the pipeline, including leakage tests, backfilling, placement of fill, grading, paving, concreting, and any other superimposed loads. Deflection of pipe and fittings in the installed pipeline under external loads shall not exceed the maximum deflection specified in paragraph 15065-1.01 B. The following procedure may be used to measure deflection. 2. DEFLECTION DEVICE: The Contractor shall determine whether the allowable deflection has been exceeded by use of a deflection measuring device. a. DEFLECTION MEASURING DEVICE: This device shall be sensitive to 1.0 percent of the diameter of the pipe being tested and accurate to 1.0 percent of the indicated dimension. The deflection measuring device shall be approved by the Engineer prior to use. b. DEFLECTION MEASURING DEVICE PROCEDURE: Measure deflections through each run of installed pipe. If deflection readings in excess of the maximum allowable specified in paragraph 15065-1.01 B are obtained, retest pipe by a run from the opposite direction. If retest continues to show a deflection in excess of the allowable, remove pipe which has excessive deflection, replace with new pipe, and completely retest in the same manner and under the same conditions. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 HIGH DENSITY POLYETHYLENE PIPE 15065-6 SECTION 15085 PIPING CONNECTIONS PART 1» GENERAL 1.01 DESCRIPTION This section specifies the following methods of connecting metallic piping: flanges, threading, mechanical couplings, equipment connection fittings, dielectric unions, and welding. This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference ANSIB1.1 ANSIB1.20.1 ANSIB16.1 ANSI B 16.5 ANSIB18.2.1 ANSIS 18.2.2 ANSI B31.1 ANSI B31.3 ASME Section DC ASTM B98 ASTM F37 Title Unified Inch Screw Threads (UN and UNR Thread Form) Pipe Threads, General Purpose (Inch) Cast Iron Pipe Flanges and Flanged Fittings Pipe Flanges and Flanged Fittings Square and Hex Bolts and Screws Inch Series Square and Hex Nuts (Inch Series) Power Piping Chemical Plant and Petroleum Refinery Piping Boiler and Pressure Vessel Code; Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators Qualifications Copper-Silicon Alloy Rod, Bar and Shapes Standard Test Methods for Scalability of Gasket Materials BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING CONNECTIONS 15085-1 Reference ASTM F104 ASTMF152 ASTM F593 AWWAC111 AWWA C206 AWWA C207 AWWA C219 AWWA C550 AWWA C606 AWWA Mil NSF61 Title Standard Classification System for Nonmetallic Gasket Materials Standard Test Methods for Tension Testing of Nonmetallic Gasket Materials Stainless Steel Bolts, Hex Cap Screws, and Studs Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings Field Welding of Steel Water Pipe Steel Pipe Flanges for Waterworks Service-Size 4 in. through 144 in. Bolted, Sleeve-Type Couplings for Plain-End Pipe Protective Epoxy Coatings for Valves and Hydrants Grooved and Shouldered Joints Steel Pipe-A Guide for Design and Installation Drinking Water System Components - Health Effects PART 2 - PRODUCTS 2.01 FLANGE ASSEMBLIES A. FLANGES: 1. GENERAL: Flanges shall either be flat flanges or convoluted ring flanges as specified in the following paragraphs. 2. FLAT FLANGES: Cast iron flanges shall be faced in accordance with ANSI B 16.1. Where companion flanges are used, the flanges on pipe shall be refaced to be flush with the companion flange face. Class 150 and Class 300 forged steel flanges shall be raised face conforming to ANSI B16.5. Lightweight slip-on flanges shall be plain face conforming to AWWA C207, Class B and ANSI B16.5. Unless otherwise specified, steel flanges shall be ANSI B16.5, Class 150 or AWWA C207, Class D. Class E AWWA flanges shall be provided where test pressure exceeds 175 psi. Plain faced flanges shall not be bolted to raised face flanges. 3. CONVOLUTED RING FLANGES: Convoluted ring flanges shall be ductile iron, forged steel or cast stainless steel, designed to bear on hubs welded to the pipe and shall be as manufactured by Improved Piping Products. The Engineer knows of no equal. The flange joints shall be rated for not less than 150 percent of the test pressures listed in Section 15050 and shall conform to the requirements of ANSI B 16.5 and AWWA C207. The flange manufacturer shall be prepared to demonstrate, by certified pressure test that the flanges will meet these requirements. *^r BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 20JO PIPING CONNECTIONS 15085-2 B. GASKETS; Gasket material shall be as specified in paragraph 15085-2.03. Gaskets for plain faced flanges shall be the full face type. Thickness shall be 1/16 inch for pipe 10 inches and less in diameter and 1/8 inch for pipe 12 inches and larger in diameter. Unless otherwise specified, gaskets for raised face flanges shall match the raised face and shall be 1/16 inch thick for pipe 3-1/2 inches and less in diameter and 1/8 inch thick for pipe 4 inches and larger. C. BOLTS: Flange assembly bolts shall be ANSI B18.2.1 standard square or hexagon head bolts with ANSI B 18.2.2 standard hexagon nuts. Threads shall be ANSI Bl.l, standard coarse thread series; bolts shall be Class 2A, nuts shall be Class 2B. Bolt length shall conform to ANSI B 16.5. Unless otherwise specified, bolts shall be carbon steel machined bolts with hot pressed hexagon nuts. Bolts for submerged service shall be made of Type 316 stainless steel in conformance with ASTM F593, marking F593F. Nuts for submerged service shall be made of copper-silicon alloy bronze conforming to ASTM B98, alloy C65100, designation H04 or alloy C65500, designation H04. Bolts and nuts for buried service shall be made of noncorrosive high-strength, low-alloy steel having the characteristics specified in ANSI/AWWA C111/A21, regardless of any other protective coating. Where washers are required, they shall be of the same material as the associated bolts. 2.02 MECHANICAL COUPLINGS A. SLEEVE-TYPE COUPLINGS: Unless otherwise specified, sleeve-type mechanical pipe couplings shall be Smith-Blair Type 411, Dresser Style 38, or equal, with the stop removed from the middle ring. Reducing couplings shall be Smith-Blair Type 415, Dresser Style 62, or equal. Sleeve-type flanged coupling adapters shall be Smith-Blair Type 913, Dresser Style 128, or equal. Insulating couplings shall be Smith-Blair Type 416, Dresser Style 39, or equal. Bolts for submerged service shall be made of Type 316 stainless steel in conformance with ASTM F593, markingF593F. Nuts for submerged service shall be made of copper-silicon alloy bronze conforming to ASTM B98, alloy C65100, designation H04, or alloy C65500, designation H04. Bolts and nuts for buried service shall be made of noncorrosive high- strength, low-alloy steel having the characteristics specified in ANSI/AWWA C111/A21, regardless of any other protective coating. Where washers are required, they shall be of the same material as the associated bolts. Gaskets shall be as specified in paragraph 15085-2.03 and AWWA Cl 11. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING CONNECTIONS AUGUST 2010 15085-3 B. PLAIN END COUPLINGS: Plain end pipe couplings for pipe sizes 6 inches and smaller shall be Gustin-Bacon 200, Victaulic Style 99, or equal for Schedule 80 pipe and Gustin-Bacon 205, Victaulic Style 90, or equal for lighter weight pipe. Plain end couplings for pipe sizes 8 inches and larger shall be Gustin-Bacon 200, Victaulic Style 99, or equal. Unless otherwise specified, bolts and nuts shall comply with AWWA C606. Gaskets shall be as specified in paragraph 15085-2.03 and AWWA C606. C. GROOVED END COUPLINGS: Grooved end flexible-type couplings shall be Gustin-Bacon 100, Victaulic Style 77, or equal. Grooved end rigid-type couplings shall be Gustin-Bacon 120 Rigi-Grip, Victaulic Style 07 Zero-Flex, or equal. Flexible-type couplings shall be used for all piping greater than 12 inches in diameter; for pipe 12 inches in diameter and less in rack-mounted tunnel piping applications; and for grooved joints adjacent to pump or blower suction and discharge where grooved couplings are used for noise and vibration control. All other applications for piping 12 inches in diameter and less shall utilize rigid-type couplings. Grooved end flanged coupling adapters shall be either Gustin-Bacon 154, Victaulic Style 741, or equal. Snap-joint grooved end couplings shall be Gustin-Bacon 115, Victaulic Style 78, or equal. Cut grooves are not permitted on fabricated or lightwall pipe. Unless otherwise specified, bolts and nuts shall comply with AWWA C606. Bolts for submerged service shall be Type 316 stainless steel in conformance with ASTM F593, marking F593F. Nuts for submerged service shall be made of copper-silicon alloy bronze conforming to ASTM B98, alloy C65100, designation H04 or alloy C65500, designation H04. Bolts and nuts for buried service shall be made of noncorrosive high-strength, low-alloy steel having the characteristics specified in ANSI/AWWA Cl 11/A21, regardless of any other protective coating. Where washers are required, they shall be of the same material as the associated bolts. Gaskets shall be as specified in paragraph 15085-2.03 and AWWA C 606. D. EQUIPMENT CONNECTION FITTINGS Equipment connection fittings shall provide both lateral and angular misalignment adjustment between equipment connection flanges and the connection to field piping systems by providing individually adjustable flexible joints at each connection. In addition, equipment connection fittings shall provide full pressure thrust restraint between the field piping connection and equipment connection flanges. Equipment connection fittings shall consist of two flanged coupling adapters, a plain end section of pipe and thrust restraint rods and associated fittings designed to transmit thrust without transmitting shear to the thrust restraint rods and without compromising provisions for accommodating angular and parallel misalignment. Materials and features shall conform to the requirements established in this paragraph. Standard "dismantling joints" incorporate BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING CONNECTIONS AUGUST 2010 15085-4 only one flanged coupling adapter and are not acceptable substitutes. Equipment connection fittings shall be Viking Johnson, Romac, or equal, modified as specified to provide the required features. Equipment connection fittings shall each consist of a single sleeve of plain end piping conforming to the requirements of the specified piping system of sufficient length to span the gap between the connection at the equipment and the connection at the field piping with gasketed flange adapters at each end. Thrust restraint shall be provided by means of all threaded rod spanning between flanges and male rod nuts and female washers that are rounded to provide a ball-joint type self aligning feature. All threaded restraint rod shall project through flange and mating flange coupling adapter bolt holes or through holes in restraint lug plates that extend above the flanges and are secured to the flanges with a minimum of two flange bolts. Where the all threaded rods project through flange bolt holes, ball joint type nut and washer combinations and lock washers shall be provided at each face, each end. Where restraint lug plates are employed, ball joint type nuts and washers shall be provided only on the outside faces of the plates and the nuts shall have a self locking feature that prevents nut movement due to vibration or other operational or environmental causes. Double nutting with non-locking nuts shall not be an acceptable method of providing the self locking feature. Thrust rod diameter and material shall be selected to provide sufficient freedom of movement through all bolt holes to allow unrestricted maximum adjustment of equipment connection fittings to accommodate piping misalignment without transmitting any shear to the thrust rods and also to permit full development of thrust restraint at all thrust rod tension take-ups. Design of equipment connection fittings shall conform to AWWA C219. Thrust rods, restraint lug plates, nuts, washers and lock washers shall be Type 316 stainless steel, all selected to develop full rated piping system pressure thrust forces. Dry film molybdenum di-sulfide anti-galling compound shall be factory applied to ends of thrust rods, covering all threads subject to nut travel and tightening. Gaskets shall be as specified in paragraph 15085-2.03. Flange gaskets shall be full face type. Follower gaskets shall be compression wedge type. Sleeves shall be carbon steel or as specified for the specific piping system. Pressure rating of flange adapters shall equal or exceed the pressure rating of mating flanges. All metal portions of equipment connection fittings, with the exception of 316 stainless steel components, shall be coated and lined with fusion bonded epoxy conforming to AWWA C550 and NSF 61. E. BALL JOINTS: Ball joints shall be Hyspan Barco Type N, Style I, 2 W\ 150 Ib flanged, or equal. Ball joints shall be installed per manufacturer's recommendations. The media flow direction can be from either end of the ball joint except for liquids with suspended solids, in which case flow should be from ball end to casing end. In vertical installations, ball joints should be installed with the ball end down to prevent foreign matter from collecting between neck of ball and retainer. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING CONNECTIONS AUGUST 2010 15085-5 2.03 GASKETS Gaskets designated in Section 15050 shall be as follows: 1. EPDM: ethylene-propylene-diene-terpolymer. 2. Neoprene: neoprene. 3. Nitrile: nitrile (Buna N). 4. Compressed gasketing consisting of organic fibers (Kevlar) and neoprene binder; ASTM F104 (F712400), 2500 psi (ASTM F152), 0.2 M17HR LEAKAGE FUEL A (ASTM F37). 5. Compressed gasketing consisting of organic fibers (Kevlar) and SBR binder; ASTM F104 (F712400), 2500 PSI (ASTM F152), 0.1 ml/hr leakage Fuel A (ASTM F37). 6. Gylon gasketing, Garlock Style 3500, 2000 psi (ASTM F152), 0.22 ml/hr Fuel A (ASTMF37). 7. Gylon gasketing, Garlock Style 3510, 2000 psi (ASTM F152), 0.04 ml/hr Fuel A (ASTMF37). 8. Gylon gasketing, Garlock Style 3504, 2000 psi (ASTM F152), 0.12 ml/hr Fuel A (ASTMF37). 9. TFE: noncreeping tetrafluoroethylene (TFE) with insert filler. 10. PTFE bonded EPDM: PTFE bonded to EPDM in full-face gasket having concentric- convex molded rings; Garlock Stress Saver 370 or equal. 2.04 THREAD Pipe thread dimensions and size limits shall conform to ANSI B1.20.1. 2.05 DIELECTRIC UNIONS Dielectric unions shall be EPCO, Capitol Manufacturing, or equal. 2.06 COATINGS Unless otherwise specified, flange assemblies and mechanical type couplings for buried installation shall be field coated with System M-l as specified in Section 09900. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING CONNECTIONS AUGUST 2010 15085-6 2.07 PRODUCT DATA In accordance with Section 01300, the Contractor shall provide for each welder, a welder qualification certificate indicating the welder is certified for pipe welding in accordance with ASME Boiler and Pressure Vessel, Section IX. Each welder's certificate shall be provided to the Engineer prior to that welder working on the job. PART3-EXECUTION 3.01 PIPE CUTTING, THREADING AND JOINTING Pipe cutting, threading and jointing shall conform to the requirements of ANSI B31.1. 3.02 PIPE WELDING Pipe shall be welded by ASME-certified welders using shielded metal arc, gas shielded arc or submerged arc welding methods. Welds shall be made in accordance with the requirements of ANSI B31.1 for piping Systems 8, 26, and 28 specified in Section 15050. Welds shall be made in accordance with the requirements of ANSI B31.3 for piping System 20 specified in Section 15050. Welds for piping systems not specified above shall be made in accordance with AWWA C206. 3.03 TAKEDOWN COUPLINGS Takedown couplings shall be screw unions, flanged or grooved end mechanical coupling type joints and shall be provided as specified. Flanged or grooved end joints shall be employed on pipelines 2-1/2 inches in diameter and larger. Where piping passes through walls, takedown couplings shall be provided within 3 feet of the wall, unless specified otherwise. A union or flanged connection shall be provided within 2 feet of each threaded end valve. 3.04 FLEXIBILITY Unless otherwise specified, piping passing from concrete to earth shall be provided with two pipe couplings or flexible joints as specified on the buried pipe within 2 feet of the structure for 2-inch through 6-inch diameter pipe; within 3 feet of the structure for 8-inch through 24-inch diameter pipe; and within one and one-half pipe diameters of the structure for larger pipe. Where required for resistance to pressure, mechanical couplings shall be restrained in accordance with Chapter 13 of AWWA Mil, including Tables 13-4, 13-5 and 13-5A, and Figure 13-20. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING CONNECTIONS AUGUST 2010 15085-7 3.05 DIELECTRIC CONNECTIONS Where a copper pipe is connected to steel or cast iron pipe, an insulating section of rubber or plastic pipe shall be provided. The insulating section shall have a minimum length of 12 pipe diameters. Dielectric unions as specified in paragraph 15085-2.05 may be used instead of the specified insulating sections. Where copper pipe is supported from hangers, it shall be insulated from the hangers, or copper-plated hangers shall be used. o 3.06 EQUIPMENT CONNECTION FITTINGS Where shown, equipment connection fittings shall be provided between field piping systems and equipment inlet and outlet connections. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPING CONNECTIONS 15085-8 SECTION 15095 PIPING APPURTENANCES PART 1» GENERAL 1.01 DESCRIPTION A. SCOPE This section specifies pipeline thermometers, flow and level gages, pressure gages, strainers, steam traps, vents and drains. B. EXCLUSIONS: Temperature, pressure and flow measuring devices used for instrumentation are specified in Division 17. Instruments specified in Section 17231 are identified in the instrument index in Section 17200. PART 2-PRODUCTS 2.01 PIPELINE THERMOMETERS (Not Used) 2.02 FLOW AND LEVEL GAGES A. ROTAMETERS: Unless otherwise specified, rotameters for purges and other low capacity services shall be Brooks Sho-Rate "50," Wallace & Tiernan 3-inch purge meter, Schutte & Koerting, or equal, with integral needle valve and flow controller. Meter tubes shall be glass, floats shall be stainless steel, and cases shall be aluminum or stainless steel. Unless otherwise specified, meter sizes shall be selected so that the flow rate recommended by the manufacturer of the purged equipment falls within the middle third of the meter scale. Units shall have a 3-inch minimum scale direct reading in the units of flow. Rotameters for high capacity service shall be glass tube-type with a 5-inch scale and stainless steel frame. Flow range shall be as specified and scales shall indicate the units of flow. Rotameters shall be as manufactured by Brooks, Wallace & Tiernan, Schutte & Koerting, or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING APPURTENANCES AUGUST 2010 15095-1 B. SIGHT GAGES: ^% Sight gages shall be 3/4-inch Penberthy 205 Series, Lunkenheimer Fig. 589, or equal, automatic water gage complete with pyrex gage glass and gage glass protector. Overall length of gages, type of mounting, and orientation of set shall be as specified. C. FLOW INDICATORS: Flow indicators shall be provided where specified. Each indicator shall consist of a bronze body with threaded ends and a sight glass with rotary wheel. Pressure ratings for flow indicators shall match pipe pressure ratings. Indicators shall be as manufactured by Jacoby-Tarbox, Schutte & Koerting, Eugene Ernst Products, or equal. 2.03 PRESSURE DEVICES (Not Used) 2.04 STRAINERS (Not Used) 2.05 STEAM TRAPS (Not Used) 2.06 PRODUCT DATA Manufacturer's product data shall be provided in accordance with Section 01300. PART 3 -- EXECUTION 3.01 PIPELINE THERMOMETERS Unless otherwise specified, filled thermometers shall be used on all water based services, and bimetallic thermometers shall be used for high temperature (300 degrees F or above) steam or gaseous services. Filled thermometers shall be installed where vibration or unstable mounting conditions exist. Thermometers shall be provided for all water and process stream inlets and outlets at each heat exchanger, heat extractor, and chiller; where shown, and adjacent to process taps for temperature sensing or transmitting instrumentation. Thermometers for sludge service shall be provided at elbows with the process sensor oriented in the direction of sludge flow. 3.02 GAGE TAPS Gage taps shall be provided on the suction and discharge of pumps, fans, compressors, vacuum pumps and blowers. Gage taps shall consist of a 1/4-inch gage cock attached by a threaded nipple to the pipeline, duct or equipment. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING APPURTENANCES AUGUST 2010 15095-2 3.03 VENTS AND DRAINS Manual air vents shall be provided at the high points of each reach of pipeline where specified. Air vents shall consist of bronze cock and copper tubing return. Air vents shall be taken to the nearest floor with cock mounted 4 feet above the floor. Vents in piping systems for fluids containing solids shall be 1-inch nonlubricated eccentric plug valves fitted with quick couplers. Drains shall be piped to a sump, gutter, floor drain or other collection point with a valve mounted 4 feet above the floor. Drain valves shall be threaded end gate valves of the size specified. When drains cannot be run to collection points, they shall be routed to a point of easy access and shall have hose gate valves of the size specified. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPING APPURTENANCES AUGUST 2010 15095-3 SECTION 15096 PIPE HANGERS AND SUPPORTS PART 1 » GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies hangers and supports for all piping systems specified in Section 15050. This section does not include pipe supports for fire sprinkler systems, pipe anchors, guides or seismic restraints. B. OPERATING CONDITIONS: The hangers and supports specified in this section are provided to resist pipe loads occurring primarily in the downward (gravity) direction. For the purpose of pipe hanger and support selection, this section establishes pipe support classifications based on the operating temperatures of the piping contents. Pipe support classifications are as follows: 1. Hot Systems . A - 1 . 120 degrees F to 450 degrees F A - 2. 451 degrees F to 750 degrees F A -3. Over 750 degrees F 2. Ambient Systems B. 60 degrees F to 1 19 degrees F 3. Cold Systems C - 1. 33 degrees F to 59 degrees F C - 2. -20 degrees F to 32 degrees F C. HANGER AND SUPPORT SELECTION: The Contractor shall select pipe hangers and supports as specified in the project manual. Selections shall be based upon the pipe support classifications specified in this section and any special requirements which may be specified in the project manual. The Contractor shall review the piping layout in relation to the surrounding structure and adjacent piping and equipment before selecting the type of support to be used at each hanger point. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 20 10 15096-1 Hangers and supports shall withstand all static and specified dynamic conditions of loading to which the piping and associated equipment may be subjected. As a minimum, consideration shall be given to the following conditions: 1. Weights of pipe, valves, fittings, insulating materials, suspended hanger components, and normal fluid contents. 2. Weight of hydrostatic test fluid or cleaning fluid if normal operating fluid contents are lighter. 3. Reaction forces due to the operation of safety or relief valves. 4. Wind, snow or ice loadings on outdoor piping. Hangers and supports shall be sized to fit the outside diameter of pipe, tubing, or, where specified, the outside diameter of insulation. Where negligible movement occurs at hanger locations, rod hangers shall be used for suspended lines, wherever practical. For piping supported from below, bases, brackets or structural cross members shall be used. Hangers for the suspension of size 2 1/2 inches and larger pipe and tubing shall be capable of vertical hanger component adjustment under load. The supporting systems shall provide for and control the free or intended movement of the piping including its movement in relation to that of connected equipment. Where there is horizontal movement at a suspended type hanger location, hanger components shall be selected to allow for swing. The vertical angle of the hanger rod shall not, at any time, exceed 4 degrees. There shall be no contact between a pipe and hanger or support component of dissimilar metals. Prevent contact between dissimilar metals when supporting copper tubing by use of copper- plated, rubber, plastic or vinyl coated, or stainless steel hanger and support components. Unless otherwise specified, existing pipes and supports shall not be used to support new piping. Unless otherwise specified, pipe support components shall not be attached to pressure vessels. Stock hanger and support components shall be used wherever practical. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-2 1.02 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference AISC Manual of Steel Construction FEDSPEC WW-H-171e-78 MFMA-2-91 MSSSP-69-91 MSS SP-58-93 Title American Institute of Steel Construction, Manual of Steel Construction, Allowable Stress Design - 9th Ed. Hangers and Supports, Pipe Metal Framing Standards Publication Pipe Hangers and Supports - Selection and Application Pipe Hangers and Supports - Materials, Design and Manufacture PART 2-PRODUCTS 2.01 ACCEPTABLE PRODUCTS Standard pipe supports and components shall be manufactured by B-Line, Carpenter & Patterson, Kin-Line, Grinnell, Michigan, Pipe Shields Incorporated, Superstrut, Unistrut, or equal. Pipe support components shall conform to the requirements of MSS SP-69 and FEDSPEC WW-H-171e. Pipe support materials shall conform to the requirements of MSS SP- 58. Metal framing system components shall conform to the metal framing manufacturers' Association Standard MFMA-2. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PIPE HANGERS AND SUPPORTS 15096-3 2.02 MATERIALS A. GENERAL: Unless otherwise specified, pipe hangers and supports, structural attachments, fittings and accessories shall be hot-dip or mechanically galvanized after fabrication. Nuts, bolts and washers may be zinc-plated except for those subject to moisture or corrosive atmosphere, as specified in paragraph 16000-1.05 B, which shall be type 304 stainless steel. B. PIPE HANGERS AND SUPPORTS: 1. TYPE 1 - CLEVIS PIPE HANGER: Clevis hangers shall be carbon steel with configuration and components equivalent to MSS and FEDSPEC Type 1. a. Steel pipe (insulated) - shall be B-Line B3100, Grinnell Fig. 260, or equal, with insulation shield. b. Steel pipe (uninsulated) - shall be B-Line B3100, Grinnell Fig. 260, or equal. c. Cast and ductile iron pipe - shall be B-Line B3102, Grinnell Fig. 590, or equal. d. Copper pipe (uninsulated) - shall be B-Line B3104 CT, Grinnell Fig. CT-65, or equal. e. Copper pipe (insulated) - shall be B-Line B3100, Grinnell Fig. 260, or equal, with insulation shield. f. Plastic pipe - shall be B-Line B3100 C, Carpenter & Patterson Fig. 100PVC, or equal. 2. TYPE 2 - "J" PIPE HANGER: Hangers shall be carbon steel with configuration and components equivalent to MSS Type 5. a. Steel pipe - shall be B-Line B3690, Grinnell Fig. 67, Michigan model 418, or equal. b. Copper and plastic pipe - shall be Michigan model 419, Unistrut J 1205N series, or equal. 3. TYPE 3 - DOUBLE BOLT PIPE CLAMP: Pipe clamp shall be carbon steel, with configuration and components equivalent to MSS and FEDSPEC Type 3. a. Steel pipe (insulated) - shall be B-Line B3144, Grinnell Fig. 295, or equal, with insulation shield. Insulation shield is optional for hot and ambient systems. b. Steel pipe (uninsulated) - shall be B-Line B3144, Grinnell Fig. 295, or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-4 c. Copper pipe (insulated only) - shall be B-Line B3144, Grinnell Fig. 295, or equal, with insulation shield. 4. TYPE 4 - ADJUSTABLE ROLLER HANGER: Rollers shall be cast iron, yoke and cross bolt shall be carbon steel. Configuration and components shall be equivalent to MSS Type 43 and FEDSPEC Type 44. a. Steel pipe (insulated) - shall be B-Line B3110, Grinnell Fig. 181, or equal, with insulation shield. b. Steel pipe (uninsulated) - shall be B-Line B3110, Grinnell Fig. 181, or equal. c. Copper pipe (insulated only) - shall be B-Line B3110, Grinnell Fig. 181, or equal, with insulation shield. d. Plastic pipe - shall be B-Line B3110, Grinnell Fig. 181, or equal. 5. TYPE 5 - SINGLE PIPE ROLL: Rollers and sockets shall be cast iron, cross rod shall be steel. Configuration and components shall be equivalent to MSS Type 41 and FEDSPEC Type 42. a. Steel pipe (insulated) - shall be B-Line B3114, Grinnell Fig. 171, or equal, with insulation shield. b. Steel pipe (uninsulated) - shall be B-Line B3114, Grinnell Fig. 171, or equal. c. Plastic pipe - shall be B-Line B3114, Grinnell Fig. 171, or equal. 6. TYPE 6 - FRAMING CHANNEL PIPE CLAMP: Pipe clamps shall be steel with galvanized finish and material thickness as listed below: a. Steel pipe (uninsulated) - Pipe size 3/8 inch and 1/2 inch shall be 16 gage; 3/4 inch through 1 1/4 inches shall be 14 gage; 1 1/2 inches through 3 inches shall be 12 gage; 3 1/2 inches through 5 inches shall be 11 gage; 6 and 8 inches shall be 10 gage; Michigan model 431, Powerstrut PS 1100, Unistrut P 1109 series, or equal. b. Steel pipe (insulated) - Pipe clamp shall be as described in paragraph 15096- 2.02 B.6.a with insulation shield. c. Copper (uninsulated) and plastic pipe - Pipe size 3/8 inch and 1 inch shall be 16 gage; 1-1/4 inches and 1-1/2 inches shall be 14 gage; 2 inches through 3 inches shall be 12 gage; 4 inches shall be 11 gage; clamp shall be copper-plated, plastic coated or lined with dielectric material; Michigan model 432, Powerstrut PS 1200, Unistrut P 2024C and P 2024PC series, or equal. d. Copper pipe (insulated) - Pipe clamp shall be as described in paragraph 15096- 2.02 B.6.a with insulation shield. BUENA VISTA LEFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-5 7. TYPE 7 - U-BOLT: U-bolts shall be carbon steel with configuration equivalent to MSS and FEDSPEC Type 24. a. Steel pipe (uninsulated) - shall be Grinnell Fig. 137, B-LineB3188, or equal. b. Steel pipe (insulated) - shall be Grinnell Fig. 137, B-Line B3188, or equal, with insulation shield. c. Cast and ductile iron pipe - shall be Grinnell Fig. 137, B-Line B3188, or equal. d. Copper pipe (uninsulated) - shall be Carpenter & Patterson Fig. 222 CT, B-Line B3501 CT, Grinnell Fig. 137C, or equal. e. Copper pipe (insulated) - shall be Grinnell Fig. 137, B-Line B3188, or equal, with insulation shield. f. Plastic pipe - shall be Grinnell Fig. 137C, Michigan model 151, B-Line B3188 C, or equal. 8. TYPE 8 - ADJUSTABLE PIPE ROLL SUPPORT: Rollers and sockets shall be cast iron, cross rod and support rods shall be carbon steel. a. Steel pipe (insulated) - shall be B-Line B3122, Grinnell Fig. 177, or equal, with insulation shield. b. Steel pipe (uninsulated) - shall be B-Line B3122, Grinnell Fig. 177, or equal. c. Copper pipe (insulated only) - shall be B-Line B3122, Grinnell Fig. 177, or equal, with insulation shield. d. Plastic pipe - shall be B-Line B3122, Grinnell Fig. 177, or equal. 9. TYPE 9 - WELDED PIPE STANCHION: Minimum material thickness shall be standard schedule carbon steel pipe, cut to match contour of the pipe elbow. Use of this support shall be limited to ambient systems only. 10. TYPE 10 - PIPE STANCHION SADDLE: Saddles and yokes shall be carbon steel and comply with MSS Type 37 and FEDSPEC Type 38. a. Steel pipe (insulated) - shall be Carpenter & Patterson Fig. 125, B-Line B3090, or equal, with insulation shield. b. Steel pipe (uninsulated) - shall be Carpenter & Patterson Fig. 125, B-Line B3090, or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-6 c. Cast and ductile iron pipe - shall be Carpenter & Patterson Fig. 125, B-Line B3090 NS, or equal. d. Copper pipe (uninsulated) - shall be Carpenter & Patterson Fig. 125, B-Line B3090, or equal, with insulation shield or lined with dielectric material. e. Copper pipe (insulated) - shall be Carpenter & Patterson Fig. 125, B-Line B3090, or equal, with insulation shield. f. Plastic pipe - shall be Carpenter & Patterson Fig. 125, B-Line B3090, or equal. 11. TYPE 11 - OFFSET PIPE CLAMP: Pipe clamp shall be carbon steel with configuration and components as specified and shall be of standard design manufactured by a pipe hanger component manufacturer. a. Steel pipe (insulated) - shall be B-Line B3148, Grinnell Fig. 103, or equal, with insulation shield. b. Steel pipe (uninsulated) - shall be B-Line B3148, Grinnell Fig. 103, or equal. c. Cast and ductile iron pipe - shall be B-Line B3148 NS, Grinnell Fig. 103, or equal. d. Copper pipe (insulated) - shall be B-Line B3148, Grinnell Fig. 103, or equal, with insulation shield. e. Copper pipe (uninsulated) - shall be B-Line B3 148, Grinnell Fig. 103, or equal, lined with dielectric material. f. Plastic pipe - shall be B-Line B3148, Grinnell Fig. 103, or equal. Vertical pipe support applications shall be as specified above except that insulation shields shall not be used for insulated pipe. 12. TYPE 12 - RISER CLAMP: Riser clamp shall be carbon steel with configuration and components equivalent to MSS and FEDSPEC Type 8. a. Steel pipe (insulated) - shall be B-Line B3373, Grinnell Fig. 261, or equal. b. Steel pipe (uninsulated) - shall be B-Line B3373, Grinnell Fig. 261, or equal. c. Cast and ductile iron pipe - shall be B-Line B3373, Grinnell Fig. 261, or equal. d. Copper pipe (insulated) - shall be B-Line B3373 CT, Grinnell Fig. CT-121, Michigan model 5 1 1 , or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 20 10 15096-7 e. Copper pipe (uninsulated) - shall be B-Line B3373 CT, Grinnell Fig. CT-121, Michigan model 511, or equal. f. Plastic pipe - shall be B-Line B3373, Grinnell Fig. 261c, or equal. 13. TYPE 13 - FRAMING CHANNEL PIPE STRAP: Pipe strap shall be carbon steel, with configuration equivalent to MSS Type 26. a. Steel pipe (uninsulated) - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin-Line No. 477, or equal. b. Steel pipe (insulated) - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin- Line No. 477, or equal, with insulation shield, c. Copper pipe (uninsulated) - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin-Line No. 477, or equal, with insulation shield or lined with dielectric material. d. Copper pipe (insulated) - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin-Line No. 477, or equal, with insulation shield. e. Plastic pipe - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin-Line No. 477, or equal. C. RACK AND TRAPEZE SUPPORTS: 1. GENERAL: Unless otherwise specified, trapeze and pipe rack components shall have a minimum steel thickness of 12 gage, with a maximum deflection 1/240 of the span. 2. TYPE 20 - TRAPEZE PIPE SUPPORT: Trapeze pipe support cross members shall be framing channel as specified in paragraph 15096-2.02 E.5. Flat plate fittings shall be 1 5/8-inch square carbon steel of standard design manufactured by framing channel manufacturer, Unistrut P2471, B-Line B202-2, or equal. 3. TYPE 21 - PIPE RACK SUPPORT: Post and cross members shall be framing channel as specified in paragraph 15096-2.02 E.5. Pipe rack fittings shall be carbon steel, of standard design manufactured by framing channel manufacturer. 90-degree fittings shall be gusseted Unistrut P2484, B-Line B844, or equal. Post base fittings shall be as specified in paragraph 15096-2.02 D.5. D. STRUCTURAL ATTACHMENTS: 1. TYPE A - MALLEABLE IRON CONCRETE INSERT: Concrete inserts shall be malleable iron and comply with MSS and FEDSPEC Type 18. Grinnell Fig. 282, Carpenter & Patterson Fig. 108, or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-8 2. TYPE B - SIDE BEAM BRACKET: Bracket shall be malleable iron and comply with MSS Type 34 and FEDSPEC Type 35. Grinnell Fig. 202, B-Line B3062, or equal. 3. TYPE C - MALLEABLE BEAM CLAMP WITH EXTENSION PIECE: Clamp and extension piece shall be malleable iron, tie rod shall be steel. Beam clamp shall comply with MSS and FEDSPEC Type 30. Grinnell Fig. 218 with Fig. 157 extension piece, B- Line B3054, or equal. 4. TYPE D - STEEL BEAM CLAMP WITH EYE NUT: Beam clamp and eye nut shall be forged steel. Configuration and components shall comply with MSS and FEDSPEC Type 28. Grinnell Fig. 292, Carpenter & Patterson Fig. 297, or equal. 5. TYPE E - FRAMING CHANNEL POST BASE: Post bases shall be carbon steel, of standard design manufactured by framing channel manufacturer. Single channel: Unistrut P2072A, B-Line B280, or equal. Double channel: Unistrut P2073A, B-Line B281, or equal. 6. TYPE F - WELDED BEAM ATTACHMENT: Beam attachment shall be carbon steel and comply with MSS and FEDSPEC Type 22. B-Line B3083, Grinnell Fig. 66, or equal. 7. TYPE G - WELDED STEEL BRACKET: Bracket shall be carbon steel and comply with MSS Type 32 and FEDSPEC Type 33 for medium welded bracket. Heavy welded bracket shall comply with MSS Type 33 and FEDSPEC Type 34. 8. TYPE H - CAST IRON BRACKET: Bracket shall be cast iron, Carpenter & Patterson Fig. 340, or equal. 9. TYPE J - ADJUSTABLE BEAM ATTACHMENT: Beam attachment shall be carbon steel, Carpenter & Patterson Fig. 151, B-Line B3082, or equal, 10. TYPE K - DOUBLE CHANNEL BRACKET: Wall channel shall be single channel framing channel as specified in paragraph 15096-2.02 E.5. Cantilever bracket shall be a carbon steel double framing channel assembly, Unistrut P2542 through P2546, B-Line B297-12 through B297-36, or equal. 11. TYPE L - SINGLE CHANNEL BRACKET: Wall channel shall be single channel framing channel as specified in paragraph 15096-2.02 E.5. Cantilever bracket shall be a carbon steel single framing channel assembly, Unistrut P2231 through P2234, B-Line B198-6, B198-12, B196-18 and B196-24, or equal. 12. TYPE M - WALL MOUNTED CHANNEL: Wall channel shall be single channel framing channel as specified in paragraph 15096-2.02 E.5. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-9 13. TYPE N - PIPE STANCHION FLOOR ATTACHMENT: Baseplate shall be carbon steel with 1/2 inch minimum thickness. Anchor bolt holes shall be 1/16 inch larger than the anchor bolt diameter. The space between the baseplate and the floor shall be filled with nonshrink grout. E. ACCESSORIES: 1. HANGER RODS: Rods shall be carbon steel, threaded on both ends or continuous threaded and sized as specified. 2. WELDLESS EYE NUT: Eye nut shall be forged steel and shall comply with MSS and FEDSPEC Type 17. Eye nut shall be Grinnell Fig. 290, B-Line B3200, or equal. 3. WELDED EYE ROD: Eye rod shall be carbon steel with eye welded closed. Inside diameter of eye shall accommodate a bolt diameter 1/8 inch larger than the rod diameter. Eye rod shall be Grinnell Fig. 278, B-Line B3211, or equal. 4. TURNBUCKLE: Turnbuckle shall be forged steel and shall comply with MSS and FEDSPEC Type 13. Turnbuckle shall be Grinnell Fig. 230, B-Line B3202, or equal. 5. FRAMING CHANNEL: Framing channel shall be 1 5/8 inches square, roll formed, 12- gage .carbon steel. Channel shall have a continuous slot along one side with in-turned clamping ridges. Single channel: Unistrut P1000, B-Line B22, or equal. Double channel: Unistrut P1001, B-Line B22A, or equal. Triple channel: Unistrut P1004A,B- Line B22X, or equal. 2.03 THERMAL PIPE HANGER SHIELD Thermal shields shall be provided at hanger, support and guide locations on pipe requiring insulation. The shield shall consist of an insulation layer encircling the entire circumference of the pipe and a steel jacket encircling the insulation layer. The thermal shield shall be the same thickness as the piping system insulation specified. The standard shield shall be used for hot systems and the vapor barrier shield shall be used for cold systems. Stainless steel band clamps shall be used where specified to ensure against slippage between the pipe wall and the thermal shield. A. STANDARD SHIELD: 1. INSULATION: a. Hydrous calcium silicate, high density, waterproof b. Compressive strength: 100 psi average c. Flexural strength: 75 psi average d. K factor: 0.38 at 100 degrees F mean e. Temperature range: 20 degrees F to 500 degrees F BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-10 2. STEEL JACKET; Galvanized steel. Gage shall be the manufacturer's standard supplied for the given pipe size. 3. CONNECTION: Shield shall have butt connection to pipe insulation. Steel jacket and insulation shall be flush with end. B. VAPOR BARRIER SHIELD: 1. INSULATION: a. Hydrous calcium silicate, high density, waterproof b. Compressive strength: 100 psi average c. Flexural strength: 75 psi average d. K factor: 0.38 at 100 degrees F mean e. Temperature range: 20 degrees F to 500 degrees F 2. STEEL JACKET: Galvanized steel. Gage shall be the manufacturer's standard supplied for the given pipe size. 3. CONNECTION: Shield shall have butt connection to pipe insulation. Insulation shall extend 1 inch each side of steel jacket for vaportight connection to pipe insulation vapor barrier. 2.04 PRODUCT DATA Hanger and support locations and components shall be indicated on the piping layout drawings required by paragraph 15050-2.04. PART 3 - EXECUTION 3.01 HANGER AND SUPPORT LOCATIONS The Contractor shall locate hangers and supports as near as possible to concentrated loads such as valves, flanges, etc. Locate hangers, supports and accessories within the maximum span lengths specified in the project manual to support continuous pipeline runs unaffected by concentrated loads. At least one hanger or support shall be located within 2 feet from a pipe change in direction. The Contractor shall locate hangers and supports to ensure that connections to equipment, tanks, etc., are substantially free from loads transmitted by the piping. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-11 Where piping is connected to equipment, a valve, piping assembly, etc., that will require removal for maintenance, the piping shall be supported in such a manner that temporary supports shall not be necessary for this procedure. Pipe shall not have pockets formed in the span due to sagging of the pipe between supports caused by the weight of the pipe, medium in the pipe, insulation, valves and fittings. 3.02 INSTALLATION Welded and bolted attachments to the building structural steel shall be in accordance with the requirements of the AISC Manual of Steel Construction. Unless otherwise specified, there shall be no drilling or burning of holes in the building structural steel. Hanger components shall not be used for purposes other than for which they were designed. They shall not be used for rigging and erection purposes. The Contractor shall install items to be embedded before concrete is poured. Fasten embedded items securely to prevent movement when concrete is poured. Embedded anchor bolts shall be used instead of concrete inserts for support installations in areas below water surface or normally subject to submerging. The Contractor shall install thermal pipe hanger shields on insulated piping at required locations during hanger and support installation. Butt joint connections to pipe insulation shall be made at the time of insulation installation in accordance with the manufacturer's recommendations. Hanger and support components in contact with plastic pipe shall be free of burrs and sharp edges. Rollers shall roll freely without binding. Finished floor beneath Type N structural attachments and framing channel post bases shall be roughed prior to grouting. Grout between base plate and floor shall be free of voids and foreign material. Baseplates shall be cut and drilled to specified dimensions prior to welding stanchions or other attachments and prior to setting anchor bolts. Plastic or rubber end caps shall be provided at the exposed ends of all framing channels that are located up to 7 feet above the floor. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-12 3.03 ADJUSTMENTS The Contractor shall adjust hangers and supports to obtain required pipe slope and elevation. Shims made of material that is compatible with the piping material may be used. Stanchions shall be adjusted prior to grouting their baseplates. ** END OF SECTION ** BUENA VISTA LEFT STATION FORCE MAIN (VC-4) PIPE HANGERS AND SUPPORTS AUGUST 2010 15096-13 SECTION 15100 VALVES, GENERAL PART 1 - GENERAL 1.01 WORK OF THIS SECTION The Work of this Section includes providing general requirements for valves including epoxy coating, installing, adjusting, and testing of valves and where buried valves are indicated, valve boxes to grade, with covers, stem extensions, and position indicators. 1. Section 15110 Eccentric Plug Valves 2. Section 15166 Sewage Air Release and Vacuum Valves 1.02 SPECIFICATIONS AND STANDARDS Except as otherwise indicated, the current editions of the following standards apply to the Work of this Section: 1. ANSIB16.1 2. ANSIB16.5 3. ANSI/ASMEB 1.20.1 4. ANSI/ASMEB3U 5. ASTMA36 6. ASTMA48 7. ASTMA126 8. ASTMA536 9. ASTMB61 10. ASTM B 62 Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250, and 800 Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys General Purpose Pipe Threads (Inch) Power Piping Specification for Structural Steel Specification for Gray Iron Castings Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings Specification for Ductile Iron Castings Specification for Steam or Valve Bronze Castings Specification for Composition Bronze or Ounce Metal Castings BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 VALVES, GENERAL 15100-1 ll.ASTMB 148 12. ASTM B 584 13.ANSI/AWWAC500 14. ANSI/AWWA C502 15.ANSI/AWWAC503 16. ANSI/AWWA C504 17. ANSI/AWWA C506 Specification for Aluminum-Bronze Castings Specification for Copper Alloy Sand Castings for General Applications Gate Valves for Water and Sewerage Systems Dry-Barrel Fire Hydrants Wet-Barrel Fire Hydrants Rubber-Seated Butterfly Valves Backflow Prevention Devices - Reduced Pressure Principle and Double Check Valve Types 18. ANSI/AWWA C507 Ball Valves 6 Inches Through 48 Inches 19. AWWA C508 20. ANSI/AWWA C509 21.AWWAC550 22. SSPC-SP-2 23. SSPC-SP-5 Swing-Check Valves for Waterworks Service, 2 Inches Through 24 Inches NFS Resilient-Seated Gate Valves for Water and Sewage Systems Protective Interior Coatings for Valves and Hydrants Hand Tool Cleaning White Metal Blast Cleaning '*Wi0r 1.03 SHOP DRAWINGS AND SAMPLES The following shall be submitted in compliance with Section 01300: 1. Manufacturer's product data including catalogue cuts. 2. Manufacturer's installation instructions. 3. Shop drawings showing details and dimensions. 4. Manufacturer's certification that products comply with the indicated requirements. 5. Schedule of valves indicating valve identification and location. 6. Manufacturer's certification that epoxy coatings have been factory tested and comply with the indicated requirements. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 VALVES, GENERAL 15100-2 1.05 OWNER'S MANUAL The following shall be included in the Owner's Manual in compliance with Section 01730: 1. Manufacturer's installation and operating instructions. 2. Manufacturer's maintenance procedures. 3. List of special tools. 4. Schedule of valves indicating valve identification and location. 1.06 FACTORY TESTING A. GENERAL: Valves shall be tested in compliance with the AWWA Standards as indicated. Except as otherwise indicated, each valve body shall be tested under a test pressure equal to twice its design water-working pressure. B. PROOF-OF-DESIGN TESTS: The Contractor shall furnish the Engineer three (3) certified copies of a report from an independent testing laboratory certifying successful completion of proof-of-design testing for all valves of sizes 10-inch and larger unless indicated otherwise in the specific valve Section. In lieu of testing the valves at an independent testing laboratory, proof-of-design testing may be performed at the valve manufacturer's laboratory, but must be witnessed by a representative of a qualified independent testing laboratory representative. Proof-of-design testing shall have been performed on not less than three valves, with all three units demonstrating full compliance with the test standards. Failure to satisfactorily complete the test shall be deemed sufficient evidence to reject all valves of the proposed make or manufacturer's model number. 1.07 FIELD TESTING Valves shall be field-tested for compliance with the indicated requirements. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) VALVES, GENERAL AUGUST 2010 15100-3 PART 2 - PRODUCTS 2.01 VALVES A. GENERAL: Shut-off valves, 6-inch and larger, shall have operators with position indicators. Where buried, these valves shall be provided with valve boxes and covers containing position indicators, and valve extensions. Valve covers shall be marked "SEWER" in accordance with City of Carlsbad standards. Valves mounted higher than 7 feet above working level shall be provided with chain operators. B. GATE VALVE STEMS: Where dezincification is indicated, gate valve stems shall be fabricated with bronze conforming to ASTM B 62, containing not more than 5 percent of zinc nor more than 2 percent of aluminum. Gate valve stems shall be designed for minimum tensile strength of 60,000 psi, minimum yield strength of 40,000 psi, and an elongation of at least 10 percent in 2 inches, as determined by a test coupon poured from the same ladle from which the valve stems are poured. Where dezincification is not indicated, bronze conforming to ASTM B 584 may be used. C. PROTECTIVE COATING: Except where otherwise indicated, ferrous surfaces, exclusive of stainless steel surfaces, in the water passages of all valves 4-inch and larger, and exterior surfaces of submerged valves, shall be epoxy coated. Flange faces of valves shall not be epoxy coated. D. VALVE OPERATORS: Where indicated, valves shall include electric operators recommended by the manufacturer. Operators of the same type shall be furnished by the same manufacturer. Valve operators, regardless of type, shall be installed, adjusted, and tested by the valve manufacturer at the manufacturing plant. E. NUTS AND BOLTS: Nuts and bolts on valve flanges, bodies and supports shall comply with Section 05501. F. SOLENOID VALVES: Solenoid valves shall be ASCO 8210G026, 2-way solenoid valves, 34" NPT threaded, 120/60 VAC, normally closed, 0 to 300 psi rated or equal. Valves shall be installed with bronze isolation valves on each side with unions for disassembly and maintenance. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) VALVES, GENERAL AUGUST 2010 15100-4 2.02 NAMEPLATES, TOOLS AND SPARE PARTS A. NAMEPLATES: Except as otherwise indicated, a label shall be provided on all valves exclusive of hose bibbs and chlorine cylinder valves. The label shall be 1/16-inch plastic or stainless steel, minimum 2 inches by 4 inches in size, and shall be permanently attached to the valve. B. SPARE PARTS: Two sets of packings, O-rings, gaskets, discs, seats, and bushings shall be furnished with each valve, as applicable. PART 3 » EXECUTION 3.01 VALVE INSTALLATION A. GENERAL: Valves, operating units, stem extensions, valve boxes, and accessories shall be installed in accordance with the manufacturer's installation instructions. Valves shall be independently supported to prevent stresses on the pipe. B. ACCESS: Valves shall be installed to provide easy access for operation, removal, and maintenance and to prevent interferences between valve operators and structural members or handrails. C. VALVE ACCESSORIES: Where combinations of valves, sensors, switches, and controls are indicated, the combinations shall be properly assembled and installed to ensure that systems are compatible and operating properly. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) VALVES, GENERAL AUGUST 2010 15100-5 SECTION 15101 GATE VALVES PART 1« GENERAL 1.01 DESCRIPTION This section specifies bronze and iron-body, solid-wedge gate valves. Iron body valves shall be bronze mounted. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference ANSIS 16.1 ASTM A126 AWWA C500 Title Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250 and 800 Gray Iron Castings for Valves, Flanges, and Pipe Fittings Gate Valves for Water and Sewerage Systems B. DESIGN CRITERIA: Gate valves 3 inches through 48 inches in size shall comply with AWWA C500, including applicable hydrostatic testing. Gate valves smaller than 3 inches shall be subject to hydrostatic tests at the test pressure. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) GATE VALVES AUGUST 2010 '15101-1 PART 2 « PRODUCTS 2.01 MATERIALS Materials of construction shall be as follows: Component Body: 3 inches and smaller Larger than 3 inches Wedge: 3 inches and smaller Larger than 3 inches Mounting Stem Seat rings Material Bronze Cast iron, ASTM A126, Class B Bronze Cast iron, ASTM A126, Class B Bronze Bronze, AWWA C500 Bronze, Grade A, AWWA C500 Materials specified are considered the minimum acceptable for the purposes of durability, strength, and resistance to erosion and corrosion. The Contractor may propose alternative materials for the purpose of providing greater strength or to meet required stress limitations. However, alternative materials must provide at least the same qualities as those specified for the purpose. 2.02 MANUFACTURE A. GENERAL: Unless otherwise specified, bronze gate valves shall be provided with integral seats. Iron body valves shall be provided with screwed-on seat rings. Exposed gate valves shall be rising stem type. Buried or submerged gate valves shall be of the nonrising stem type. Rising stem valves and brass nonrising stem valves shall be provided with a Teflon braid packing. Iron body nonrising stem valves shall be provided with 0-ring stem seals. B. END CONNECTIONS: Gate valve end connections shall be flanged or threaded as specified. Threaded ends shall not be provided on gate valves with end connections larger than 4 inches. End flanges shall be integral with the gate valve body and be faced1 and drilled in accordance with ANSI B16.1 for 125-pound flanges. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) GATE VALVES AUGUST 2010 15101-2 C. MANUAL OPERATORS: Unless specified otherwise, valves less than 12 inch size shall be provided with handwheels, and valves 12 inches and larger shall be provided with geared operators. D. BYPASS: Unless otherwise specified, gate valves 16 inches and larger, shall be provided with a bypass valve sized in accordance with AWWA C500. 2.03 PRODUCT DATA The following information shall be provided in accordance with Section 01300: 1. Affidavits of compliance, as required by AWWA C500. 2. Hydrostatic test results. PART 3 - EXECUTION Gate valves shall be installed in the closed position. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) GATE VALVES AUGUST 2010 . 15101-3 SECTION 15110 ECCENTRIC PLUG VALVES PARTI-GENERAL 1.01 DESCRIPTION This section specifies eccentric plug valves. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference ANSI B 16.1 ASTM A126 ASTM A276 ASTM A436 ASTM A536 AWWA C504 Title Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800 Gray Iron Castings for Valves, Flanges, and Pipe Fittings Stainless and Heat-Resisting Steel Bars and Shapes Austenitic Gray Iron Castings Ductile Iron Castings Rubber Seated Butterfly Valves BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 ECCENTRIC PLUG VALVES 15MO-1 B. PROOF OF DESIGN TESTS: The Contractor shall furnish the Engineer three certified copies of a report from an independent testing laboratory certifying successful completion of proof-of-design testing conducted in accordance with AWWA C504, Section 5.2, except that where the word "disc" appears in the standard, it is understood to mean "plug." In lieu of testing the valves at an independent testing laboratory, proof-of-design testing may be performed at the valve manufacturer's laboratory, but must be witnessed by a representative of a qualified independent testing laboratory, and all test reports must be certified by the laboratory representative. Proof-of-design testing shall have been performed on not less than three 6-inch diameter valves, with all three test units demonstrating full compliance with the test standards. Failure to satisfactorily complete the test shall be deemed sufficient evidence to reject all valves of the proposed make or manufacturer's model number. PART 2--PRODUCTS 2.01 MATERIALS Materials of construction shall be as follows: Component Body Plug Plug facing Body seats Less than 3 inches 3 inches and larger Packing Material Cast iron, ASTM A126, Class B Cast iron, ASTM A126, Class By or cast iron ASTM A436 (Ni-resist), or ductile iron, ASTM A536 Neoprene or Buna-N Cast iron, ASTM A126, Class B Stainless steel, ASTM A276, Type 304 or nickel Buna V-flex or TFE Materials specified are considered the minimum acceptable for the purposes of durability, strength, and resistance to erosion and corrosion. The Contractor may propose alternative materials for the purpose of providing greater strength or to meet required stress limitations. However, alternative materials must provide at least the same qualities as those specified for the purpose. •-^—^^jr BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 ECCENTRIC PLUG VALVES 15110-2 2.02 MANUFACTURE A. GENERAL: Valves shall be straight-flow nonlubricated resilient plug type suitable for driptight, bi- directional shutoff at the specified valve design pressure. Port areas for the valve shall be at least 80 percent of the adjacent full pipe area and shall be capable of passing solids 3-Inch of pipe size. Valve body seats consisting of nickel for valves 3 inches and larger shall be constructed of a welded-in overlay of not less than 90 percent pure nickel. Upper and lower journal bearings shall be replaceable, sleeve-type, corrosion resistant, and permanently lubricated. Packing shall be self-adjusting chevron type replaceable without disassembling the valve. Unless otherwise specified, valves shall, as a minimum, conform to the following pressure ratings: Size, inches 12 and smaller 14 through 36 42 through 54 Design pressure, psig 175 150 125 B. END CONNECTIONS: Valves 3 inches and smaller shall have threaded ends. Valve flange drilling for valves larger than 3 inches shall be per ANSI B16.1, Class 125. Grooved-end valves may be provided with grooved-end piping systems. C. MANUAL OPERATORS: Unless otherwise specified, valves 4 inches and smaller shall be provided with a lever type manual operator. Valves larger than 4 inches shall be provided with totally enclosed worm gear operators. Where specified, manual operators shall have an adjustable stop. All operator components shall be sized for the valve design pressure in accordance with AWWA C504, Section 4.5. Operators shall comply with applicable portions of Section 15100. 2.03 PRODUCT DATA The following information shall be provided in accordance with Section 01300: 1. Manufacturer's product data. 2. Proof-of-design test reports specified in paragraph 15110-1.02 B. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) ECCENTRIC PLUG VALVES AUGUST 2010 15110-3 PART 3 - EXECUTION Unless otherwise specified, valves shall be provided with the seat downstream away from flow. Valves at tank connections shall be installed with seat away from tank. Valves on pump discharge lines shall be installed with seat adjacent to the pump. **END OF SECTION** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) ECCENTRIC PLUG VALVES AUGUST 2010 15110-4 SECTION 15166 WASTEWATER AIR RELEASE AND VACUUM VALVES PART 1 -- GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies air release valves, air and vacuum valves, and combination air valves for wastewater service. B. TYPES: 1. GENERAL: Valves furnished under this specification shall be tubular in design with direct acting cylindrical hollow and solid float mechanisms designed to function efficiently in the presence of grease, fibers and paniculate material commonly present in municipal and domestic wastewaters and wastewater effluents. The design shall incorporate materials and geometry that provides self flushing of the valve internals on emptying. Valve designs which employ float guide rods or guide brackets, levers, springs and ball type floats are specifically prohibited. Valves furnished under this section shall be fitted with direct vents of flanged for connection to piping connections as indicated. Main venting orifices and outlet connections shall be equal in diameter to the specified pipeline connection. 2. AIR RELEASE VALVES: Wastewater air release valves (ARV) shall have a small venting orifice to vent the accumulation of air and other gases with the line or system under pressure. Size and capacity shall be as specified. 3. AIR AND VACUUM VALVES: Wastewater air and vacuum valves (ARVV) shall have a dual float system with a large venting orifice to permit the release of air as the line is filling or relieve the vacuum as the line is draining or is under negative pressure. As the pipeline reaches approaches the full condition on filling, the large orifices shall be sealed by the primary float and the secondary float shall allow the remaining air to vent at a reduced rate to prevent development of hydraulic transients. Size and capacity shall be as specified. 4. COMBINATION AIR VALVES: Wastewater combination air valves (CARV) shall have operating features of both the air and vacuum valve and the air release valve. Size and capacity shall be as specified. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 WASTEWATER AIR RELEASE AND VACUUM VALVES 15166-1 1.02 REFERENCES A. This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. B. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference ASTM A126 ASTM A240 Title Gray Iron Castings for Valves, Flanges, and Pipe Fittings Heat-Resisting Chromium and Chromium Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels 1.03 SCHEDULE Forcemain FM"A" FM "A" FM"B" FM"B" Valve size, inches 4 4 4 4 Model RGX RGX RGX RGX Vent connection (a) F F F F System pressure, psig 30-100 30-100 30-100 30-100 Capacity (b) 115 115 115 115 Location (Station) STA5+81 STA 39+28 STA5-78 STA 39+27 (a) F= Flange, S= screened opening (b) Air inlet capacity at 7 psi pressure differential measured in standard cubic feet per second 1.04 SUBMITTALS A. Submittal material, to be provided in accordance with Section 01300, shall include the following: 1. Catalog information for each size to be furnished 2. Certified performance information 3. Materials of construction 4. Installation requirements BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 WASTEWATER AIR RELEASE AND VACUUM VALVES 15166-2 PART 2--PRODUCTS 2.01 ACCEPTABLE PRODUCTS A. Wastewater air release and vacuum valves shall be Vento-O-Mat RGX as provided by International Valve Marketing, Inc. B. Alternative manufacturers' products will be considered, provided the following information has been submitted and accepted as proof the proposed substitution provides equal or improved performance over that of the specified product and materials. Any submittal requesting substitution shall include the information specified under paragraph 15152-1.04 and the following: 1. Detailed construction and functional description of operation with bill of materials and detailed graphics showing construction features and step by step operation demonstrating compliance with the features and operational characteristics specified in this section. 2. Certified performance curves for each size valve to be provided. Performance curves shall be certified and notarized correct by an independent testing laboratory. 3. Not less than four affidavits of performance signed by general managers or executive officers of the owning agency and notarized. The affidavits of performance shall, as a minimum, document the following; a. Side-by-side operation with the specified Vent-O-Mat valves in unscreened wastewater service for periods of not less than 6 months. b. During the side-by-side periods of operation, the proposed valve and the specified valves shall have been inspected for clogging and function on not less than a weekly basis and shall not have required more maintenance effort than the valves specified in this section. c. The affidavits shall contain unreserved acceptance of the proposed valve as a complete equal to the Vent-O-Mat valve. 2.02 MATERIALS Component Body, cover Primary and secondary floats Seats Trim and venting orifices Material Stainless steel, ASTM A240, Type 316L High density polyethylene Nitrile or EPDM Stainless steel, ASTM A240, Type 316L WASTEWATER AIR RELEASE BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AND VACUUM VALVES AUGUST 2010 15166-3 A. Materials specified are considered the minimum acceptable for the purposes of durability, strength, and resistance to erosion and corrosion. The Contractor may propose alternative materials for the purpose of providing greater strength or to meet required stress limitations. However, alternative materials must provide at least the same qualities as those specified for the purpose. 2.03 CONSTRUCTION A. All wastewater air release and vacuum valves shall have tubular elongated bodies and shall be specifically designed for operation on wastewater and wastewater applications. Valve bodies shall be certified for not less than twice the system pressure specified in paragraph 15166-1.03 and shall have over pressure relief features to prevent catastrophic rupture of the valve body. The relief feature shall be incorporated into easily replaced components such as seals or gaskets. 2.04 SPARE VALVES A. One spare valve shall be provided for each type and size of valve specified. 2.05 PRODUCT DATA A. The following information shall be provided in accordance with Section 01300: 1. Manufacturer's product data. 2. Applicable O&M instructions per Section 01730. PART 3 -- EXECUTION 3.01 GENERAL A. Wastewater air release and vacuum valves shall be installed in accordance with the manufacturer's recommendations. Isolation valves shall be provided below each air valve as shown. ** END OF SECTION ** ,^M^h BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 WASTEWATER AIR RELEASE AND VACUUM VALVES 15166-4 SECTION 16000 GENERAL REQUIREMENTS FOR ELECTRICAL WORK PART 1-GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies general requirements for electrical work. Detailed requirements for specific electrical items are specified in other sections but are subject to the general requirements of this section. The electrical drawings and schedules included in this project manual are functional in nature and do not specify exact locations of equipment or equipment terminations. B. DEFINITIONS: 1. ELEMENTARY OR SCHEMATIC DIAGRAM: A schematic (elementary) diagram shows, by means of graphic symbols, the electrical connections and functions of a specific circuit arrangement. The schematic diagram facilitates tracing the circuit and its functions without regard to the actual physical size, shape, or location of the component devices or parts. 2. ONE-LINE DIAGRAM: A one-line diagram shows by means of single lines and graphical symbols the course of an electrical circuit or system of circuits and the components, devices or parts used therein. Physical relationships are usually disregarded. 3. BLOCK DIAGRAM: A block diagram is a diagram of a system, instrument, computer, or program in which selected portions are represented by annotated boxes and interconnecting lines. 4. WIRING DIAGRAM OR CONNECTION SYSTEM: A wiring or connection diagram includes all of the devices in a system and shows their physical relationship to each other including terminals and interconnecting wiring in an assembly. This diagram shall be (a) in a form showing interconnecting wiring only by terminal designation (wireless diagram), or (b) a panel layout diagram showing the physical location of devices plus the elementary diagram. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-1 5. INTERCONNECTION DIAGRAM: Interconnection diagrams shall show all external connections between terminals of equipment and outside points, such as motors and auxiliary devices. References shall be shown to all connection diagrams which interface to the interconnection diagrams. Interconnection diagrams shall be of the continuous line type. Bundled wires shall be shown as a single line with the direction of entry/exit of the individual wires clearly shown. Wireless diagrams and wire lists are not acceptable. Each wire identification as actually installed shall be shown. The wire identification for each end of the same wire shall be identical. All devices and equipment shall be identified. Terminal blocks shall be shown as actually installed and identified in the equipment complete with individual terminal identification. All jumpers, shielding and grounding termination details not shown on the equipment connection diagrams shall be shown on the interconnection diagrams. Wires or jumpers shown on the equipment connection diagrams shall not be shown again on the interconnection diagram. Signal and DC circuit polarities and wire pairs shall be shown. Spare wires and cables shall be shown. 6. ARRANGEMENT, LAYOUT, OR OUTLINE DRAWINGS: An arrangement, layout, or outline drawing is one which shows the physical space and mounting requirements of a piece of equipment. It may also indicate ventilation requirements and space provided for connections or the location to which connections are to be made. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 20 10 GENERAL REQUIREMENTS FOR ELECTRICAL WORK 16000-2 Reference NECA-1 NFPA NFPA-70 NFPA-70E ACI318 Title National Electrical Contractors Association - Standard Practices for Good Workmanship in Electrical Contracting National Fire Protection Association National Electrical Code (NEC) National Electrical Safety Code (NESC) Building Code Requirements for Structural Concrete B. IDENTIFICATION OF LISTED PRODUCTS: Electrical equipment and materials shall be listed for the purpose for which they are to be used, by an independent testing laboratory. Three such organizations are Underwriters Laboratories (UL), Canadian Standards Association (CSA), and Electrical Testing Laboratories (ETL). Independent testing laboratory shall be acceptable to the inspection authority having jurisdiction. When a product is not available with a testing laboratory listing for the purpose for which it is to serve, the product may be required by the inspection authority, to undergo inspection at the manufacturer's place of assembly. All costs and expenses incurred for such inspections shall be included in the original contract price. C. FACTORY TESTS: Where specified in the individual product specification section, factory tests shall be performed at the place of fabrication and performed on completion of manufacture or assembly. The costs of factory tests shall be included in the contract price. 1.03 SUBMITTALS The following submittals shall be provided in accordance with Section 01300: 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check- marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-3 The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justifications) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. 2. Catalog cuts of equipment, devices, and materials requested by the individual specification sections. Catalog information shall include technical specifications and application information, including ratings, range, weight, accuracy, etc. Catalog cuts shall be edited to show only the items, model numbers, and information which apply. a. Catalog cuts shall be assembled in a folder. Each folder shall contain a cover sheet, indexed by item, and cross-referenced to the appropriate specification paragraph. 3. Interconnection diagram: The Contractor shall prepare interconnection diagrams depicting all cable requirements together with their actual terminations as specified in paragraph 16000-1.0 IB. 4. Conduit layout drawings indicating size, location, and support, for all conduits other than single runs of 1-inch diameter or less cast in concrete construction. a. Conduit layout drawings shall illustrate a system which conforms to the requirements of paragraph 16000-3.01-B. b. For layouts that do not conform to 16000-3.01 B, provide engineering design and calculations signed and sealed by a Professional Engineer registered in the state of the project. Engineering design and calculations shall demonstrate that the proposed layout does not impair or significantly reduce the design structural strength. 5. Safety disconnect switch list including legend with equipment tag, equipment description, and power feeder circuit source and location information. 1.04 DRAWINGS Where the Contractor is required to provide information on drawings as part of the specified work, such drawings shall be prepared on 22-inch by 34-inch drafting media complete with borders and title blocks clearly identifying project name, equipment and the scope of the drawing. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-4 Drawing quality and size of presentation shall be such as to permit 50 percent reduction of such drawings for insertion in operation and maintenance manuals. 1.05 PROJECT/SITE CONDITIONS A. GENERAL: Unless otherwise specified, equipment and materials shall be sized and derated for the ambient conditions specified, but not less than an ambient temperature of 40 degrees C at an elevation ranging from sea level to 3000 feet without exceeding the manufacturer's stated tolerances. B. CORROSIVE AREAS: The following areas are designated as corrosive: 1. Metering vaults. C. HAZARDOUS (CLASSIFIED) AREAS: The following areas are designated as hazardous (classified) in accordance with the NEC: Area Metering vaults Hazardous Classification Class 1, Div. 1 D. SEISMIC: Electrical equipment supports, and anchorage shall be designed and installed in accordance with the seismic design requirements specified in the California Building Code, latest edition. 1.06 STORAGE OF MATERIALS AND EQUIPMENT During the interval between the delivery of equipment to the site and installation, all equipment, unless otherwise specified, shall be stored in an enclosed space affording protection from weather, dust and mechanical damage and providing favorable temperature, humidity and ventilation conditions to ensure against equipment deterioration. Manufacturer's recommendations shall be adhered to in addition to these requirements. Equipment and materials to be located outdoors may be stored outdoors if protected against moisture condensation. Equipment shall be stored at least 6 inches above ground. Temporary power shall be provided to energize space heaters or other heat sources for control of moisture condensation. Space heaters or other heat sources shall be energized without disturbing the sealed enclosure. Equipment and materials to be located indoors shall be stored indoors and sealed with plastic film wrap. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-5 1.07 ELECTRICAL NUMBERING SYSTEMS A. RACEWAY NUMBERS: Raceways shall be tagged at all terminations. Contractor shall assign raceway numbers in accordance with the following system where raceway numbers have not been assigned: Raceway Prefix Type of Function C H Control or power - 120V or less Power above 600V N P S X Pneumatic tubing Power 208V to 600V Signal - data communication or instrumentation Spare Prefixes shall be followed by a 4-digit number. Add a letter suffix to distinguish the raceways where more than one raceway is routed to a particular piece of equipment. Example: Raceway number = P3109A where: P = conduit contains power 3109 = unique 4-digit number A = letter to distinguish raceways to same equipment B. CONDUCTOR NUMBERS: Conductors shall be identified with numbers at both ends. Conductor tag numbers shall consist of the equipment number followed by a dash followed by the conductor number specified on the control diagram. Example: Equipment Tag Number = 1900 - LI where: 1900 = cable number LI = conductor number Conductors in parallel or in series between equipment shall have the same conductor number. Neutral conductors shall have the same conductor number. Wherever possible, the conductor number shall be the same as the equipment terminal to which it connects. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-6 Where factory-wired equipment has terminal numbers different than the conductor numbers shown on the control diagrams: 1. Both shall be shown on the interconnection diagram 2. Include a copy of the interconnection diagram inside of the equipment cabinet. PART 2-PRODUCTS 2.01 EQUIPMENT AND MATERIALS A. GENERAL: Equipment and materials shall be new and free from defects. All material and equipment of the same or a similar type shall be of the same manufacturer throughout the work. Standard produc- tion materials shall be used wherever possible. B. EQUIPMENT FINISH: Unless otherwise specified, electrical equipment shall be painted by the manufacturer as specified in Section 09900 - Coating Systems. C. GALVANIZING: Where specified, galvanizing shall be in accordance with Section 05910. 2.02 WIRE MARKERS Each power and control conductor shall be identified at each terminal to which it is connected. Conductors size No. 10 AWG or smaller shall have identification sleeves. Conductors No. 8 AWG and larger shall use cable markers of the locking tab type. Tabs shall be white plastic with conductor identification number permanently embossed. Conductors shall be identified in accordance with paragraph 16000-1.07 B. Adhesive strips are not acceptable. The letters and numbers that identify each wire shall be machine printed on sleeves with permanent black ink with figures 1/8 inch high. Sleeves shall be yellow or white tubing and sized to fit the conductor insulation. Shrink the sleeves with hot air after installation to fit the conductor. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-7 Conductor and Wire Marker Manufacture: 1. TMS Thermofit Marker System by Raychem Co 2. Sleeve style wire marking system by W. H. Brady Co. 3. or equal. 2.03 RACEWAY MARKERS Raceway markers tags shall be: 1. Solid brass with 0.036-inch minimum thickness. 2. Raceway number stamped in 3/16-inch minimum height characters 3. Attached to the raceway with 316 stainless steel wire. 2.04 NAMEPLATES Nameplates shall be made from laminated phenolic plastic. 1. Nominal size: 3/4 inch high by 2 inches long. 2. Black backgrounds with 3/16-inch white letters. 3. Fastened using self-tapping stainless steel screws. Abbreviations shall be submitted to the Engineer prior to manufacture because of space limitations. Nameplate adhesives will not be permitted on the outside of enclosures. 2.05 TERMINAL BLOCKS Unless otherwise specified, terminal blocks shall be panhead strap screw type. Terminals shall be provided with integral marking strips that permanently identify with the connecting wire numbers as shown on the drawings: 1. Terminal blocks for P-circuits (power 208-600 volts) a. Rated not less than the conductor current rating b. Rated less than 600 volts AC. 2. Terminal blocks for C-circuits and S-circuits: a. Rated not less than 20 amperes b. Rated less than 600 volts AC. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-8 3. Terminals shall be tin-plated. 4. Insulating material shall be nylon. 2.06 PRODUCT DATA The following information and product data specified under individual specification sections shall be provided in accordance with Section 01300. 1. Applicable operation and maintenance information on an item-by-item basis in accordance with Section 01730. Operation and maintenance information shall be provided at the time of equipment, device, or material site delivery, or at a certain stage of project completion as required by Section 01730, whichever is the earlier. Full-size drawings shall be reduced to 11 x 17 inches. 2. Test results for motors and electrical systems on the forms specified in Section 16030. A file of the original test results shall be maintained by the Contractor. Prior to acceptance of work, the resulting file shall be provided to the Engineer. 3. Description of functional checkout procedures specified under paragraph 16000- 3.02 C shall be provided 14 days prior to performing functional checkout tests. 4. Record documents specified in Section 2 of the General Provisions and Section 16000-3.03. PART 3-EXECUTION 3.01 GENERAL A. CONSTRUCTION: The work under Division 16 shall be performed in accordance with these specifications. Refer to the National Electrical Contractors Association's (NECA) National Electrical Installation Standards (NEIS) for Standard Practices for Good Workmanship in Electrical Contracting (NECA-1) as a minimum baseline of quality and workmanship for installing electrical products and systems that defines what is meant by "neat and workmanlike" as required by the National Electrical Code Section 110-12. Specified requirements supersede NECA practices. Electrical layout drawings are diagrammatic, unless otherwise detailed or dimensioned. The Contractor shall coordinate the location of electrical material or equipment with the work. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-9 Major electrical openings may compromise the structural integrity of the slab and wall elements. Major electrical openings are defined as openings or penetrations greater than two times the wall thickness in any dimension, and include duct bank transitions into a building through structural elements. Major electrical openings shall be constructed according to standard details on the drawings, up to an opening dimension of three feet. For opening dimensions greater than three feet, construct walls and slabs as specifically detailed on the drawings for that case. Major electrical openings proposed by the Contractor shall be submitted to the Structural Engineer of Record for the project for review. Minor changes in location of electrical material or equipment made prior to installation shall be made at no cost to the City of Carlsbad. B. CONDUITS IN CONCRETE CONSTRUCTION: Conduits for power, control and instrumentation may be embedded in and pass through concrete construction subject to the limitations in this paragraph. Where concrete strength or serviceability requirements prevent the direct embedment of conduit, provide adequate support, bracing, and serviceability details: 1. Concrete strength shall not be impaired significantly by the embedment of conduits in or through structural sections. 2. Conduit layout shall conform to the requirements of ACI 318, Sections 3.3 - Aggregates and 6.3 - Conduits and Pipes Embedded in Concrete. 3. Conduits shall be treated similarly to reinforcing steel for purposes of clearance. In general, code sections require conduit spacing the greater of: a. 1.33 times the maximum concrete aggregate size, clear b. Three diameters center to center c. Alternate spacing and layout shall be as reviewed and accepted by the Engineer. 4. Conduit and raceway penetrations through walls and slabs where: a. One side is a conditioned or an occupied space and the other side not; or b. One side has liquid or groundwater contact and the other not; and c. Shall be detailed and constructed to prevent liquid and moisture penetration through the wall or slab section for each conduit. C. HOUSEKEEPING: Electrical equipment shall be protected from dust, water and damage. Motor control centers, switchgear, and buses shall be wiped free of dust and dirt, kept dry, and shall be vacuumed on the inside within 30 days of acceptance of the work. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-10 Before final acceptance, the Contractor shall touch up any scratches on equipment as specified in paragraph 09900-3.03 H. D. ELECTRICAL EQUIPMENT LABELING Electrical equipment shall have field marked signs and labeling to warn qualified persons of the potential electric arc flash hazards per NEC Article 110.16 Flash Protection. Electrical distribution equipment and utilization equipment shall be field labels to identify the power source and the load as specified. Refer to NEC Article 110.22 for Identification of Disconnecting Means installation criteria. Specific information is required such as the equipment tag number and equipment description of both the power source and the load equipment. E. SAFETY DISCONNECT SWITCHES: Heavy duty fused and non-fused disconnect switches with current range of 30 to 600 amperes shall be provided as shown on the drawings with the enclosure type matching the area rating. Provide lock-off provision for a hasp padlock. Provide visible knife blades through a cover viewing window. Provide shielded or insulated line terminals with quick-make / quick-break switch operator. Provide internal barrier kit for additional personnel barrier from accidental contacts with live parts. Provide a legend plate with equipment tag, equipment description, and power feeder circuit source and location identification. Disconnects shall include one auxiliary contact that operates with the power switch blades. The auxiliary contact shall be wired as shown on the drawings for remote status monitoring of the disconnect position where shown or for disconnecting motor space heater where shown. Fuse clips shall be Class R rejection type and sized for UL Class R, one-time, time-delay fuses. Fuse assembly shall have a minimum short circuit capacity of 100,000 amps symmetrical. Provide fuses as shown and one set of spare fuses with each switch. F. MOTOR CONNECTIONS Verify that the motors are purchased with the correct size motor termination boxes for the circuit content specified as shown on the power single line diagrams or submit custom fabrication drawing indicating proposed motor termination box material, size, gasket, termination kit, grounding terminal, motor lead connection method, and motor terminal box connection/support system. Verify the motor termination box location prior to raceway rough- in. G. CONDUCTOR INSTALLATION An enclosure containing disconnecting means, overcurrent devices, or electrical equipment shall not be used as a wireway or raceway for conductors not terminating within the GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 ' 16000-11 enclosure. Provide wireways, raceways, termination boxes, or junction boxes external to the enclosure for the other conductors. 3.02 TESTING A. GENERAL: Prior to energizing the electrical circuits, insulation resistance measurements tests shall be performed using a 1000-volt megohmmeter to verify the conductor is acceptable for use on the project. The test measurements shall be recorded on the specified forms and provided in accordance with paragraph 16000-1.03. B. INSULATION RESISTANCE MEASUREMENTS: 1. GENERAL: Insulation resistance measurements shall be made on conductors and energized parts of electrical equipment. Minimum acceptable values of insulation resistance shall be in accordance with the applicable ICEA, NEMA or ANSI standards for the equipment or material being tested, unless otherwise specified. The ambient temperature at which insulation resistance is measured shall be recorded on the test form. Insulation resistance measurements shall be recorded in a format similar to Form 16000- A, contained in Section 01999. Insulation with resistance of less than 10 megohms is not acceptable. 2. . CONDUCTOR AND CABLE TESTS: The phase-to-ground insulation resistance shall be measured for all circuits rated 120 volts and above except lighting circuits. Measurements may be made with motors and other equipment connected. Solid state equipment shall be disconnected, unless the equipment is normally tested by the manufacturer at voltages in excess of 1000 volts DC. 3. MOTOR TESTS: The Installed Motor Test Form, 16000-B, specified in Section 01999, shall be completed for each motor after installation. Motors shall have their insulation resistance measured before they are connected. Motors 50 HP and larger shall have their insulation resistance measured at the time of delivery as well as when they are connected. Insulation resistance values less than 10 megohms are not acceptable. C. PRE-FUNCTIONAL TEST CHECKOUT: Functional testing shall be performed in accordance with the requirements of Section 16030. Prior to functional testing, all protective devices shall be adjusted and made operative. 1. Submit a description of the proposed functional test procedures prior to the performance of functional checkout. GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-12 2. Prior to energization of equipment, perform a functional checkout of the control circuit. Checkout: a. Energizing each control circuit. b. Operating each control device, alarm device, or monitoring device. c. Operate each interlock to verify that the specified action occurs. Verify motors are connected to rotate in the correct direction. Verification may be accomplished by momentarily energizing the motor, provided the Contractor confirms that neither the motor nor the driven equipment will be damaged by reverse operation or momentary energization. 3.03 RECORD DOCUMENTS Contract documents shall be maintained and annotated by the Contractor during construction, including the record drawings specified in Section 2 of the General Provisions. ** END OF SECTION ** GENERAL REQUIREMENTS BUENA VISTA LIFT STATION FORCE MAIN (VC-4) FOR ELECTRICAL WORK AUGUST 2010 16000-13 SECTION 16030 ELECTRICAL ACCEPTANCE TESTING PART 1-GENERAL 1.01 DESCRIPTION This section specifies the acceptance testing of electrical materials, power distribution and utilization equipment and circuits. Contractor shall provide all labor, tools, material, power, and other services necessary to provide the specified tests. 1.02 REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference NETA ATS NFPA-70 Title Acceptance Testing Specifications for Electric Power Distribution Systems National Electrical Code (NEC) 1.03 SUBMITTALS Functional testing and checkout procedures and schedule shall be provided in accordance with Section 01300. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) ELECTRICAL ACCEPTANCE TESTING AUGUST 2010 16030-1 PART 2-PRODUCTS 2.01 TEST EQUIPMENT AND MATERIALS Test instruments shall be calibrated to references traceable to the National Institute of Standards and Technology and shall have a current sticker showing date of calibration, deviation from standard, name of calibration laboratory and technician, and date recalibration is required. 2.02 PRODUCT DATA In accordance with Section 01300, the Contractor shall submit the completed test report forms 16000-A as specified in Part 3 herein. PART 3-EXECUTION 3.01 TESTING A. GENERAL: The following specified tests, including correction of defects where found and the subsequent re-testing, shall be completed prior to energization of the equipment or systems. Submit all completed test report forms in a 3-ring binder type notebook at the project Substantial Completion date. A megohmmeter shall be used for insulation resistance measurements. B. INSULATION RESISTANCE MEASUREMENTS: 1. GENERAL: Insulation resistance measurements shall be made on conductors and electrical equipment that will carry current. Minimum acceptable values of insulation resistance shall be in accordance with the applicable NETA-ATS, ICEA, NEMA, or ANSI standards for the equipment or material being tested. The ambient temperature at which insulation resistance is measured shall be recorded on the test form. 2. CONDUCTOR AND CABLE TESTS: The phase-to-ground insulation resistance shall be measured for all circuits 120 volts and above except lighting circuits. Measurements may be made with motors and other load equipment connected. Insulation resistance measurements shall be recorded in a format similar to Form 16000-A contained in Section 01999, and submitted for acceptance. Insulation with resistance of less than 10 megohms is not acceptable. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 ELECTRICAL ACCEPTANCE TESTING 16030-2 C. FUNCTIONAL TESTING: Contractor shall submit a description of proposed functional test and checkout procedures conforming to the following requirements, including a schedule for conducting these procedures, not less than 30 days prior to the performance of functional testing. Prior to functional testing, all protective devices shall be adjusted and made operative. Prior to energization of associated equipment, perform a functional checkout of all electrical and instrumentation control circuits as specified in the following and in Division 17. Checkout shall consist of energizing each control circuit and operating each control, alarm, safety device, and each interlock, in turn, to verify that the specified action occurs. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 ELECTRICAL ACCEPTANCE TESTING 16030-3 SECTION 16110 RACEWAYS, BOXES, AND SUPPORTS PART 1-GENERAL 1.01 SCOPE This section covers the furnishing and installation of electrical conduits, wireways, pull boxes, manholes, handholes, cable trays, fittings and supports. Raceways shall be provided for lighting, receptacles, power, control, instrumentation, signaling and grounding systems. 1.02 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference Title ANSIC80.1 ANSI C80.3 ASTMF512 FEDSPECWW-C-581E FEDSPECW-C-1094A JICEMP-1 NEMA ICS 6 NEMA TC2 Rigid Steel Conduit-Zinc Coated Electrical Metallic Tubing-Zinc Coated Smooth-Wall Polyvinylchloride Conduit and Fittings for Underground Installation Conduit, Metal, Rigid and Intermediate; and Coupling, Elbow, and Nipple, Electrical Conduit; Zinc Coated Conduit and Conduit Fittings, Plastic, Rigid Electrical Standards for Mass Production Equipment Industrial Control and Systems Enclosures Electrical Plastic Tubing (EPT) and Conduit (EPC 40 and EPC 80) BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-1 Reference NEMA TC6 NEMAVE1 NEMA 250 NFPA 70 NFPA 79 UBC UL1 UL6 UL360 UL514 UL651 UL797 UL870 UL884 UL886 Title PVC and ABS Plastic Utilities Duct for Underground Installation Cable Tray Systems Enclosures for Electrical Equipment (1000 volts maximum) National Electrical Code (NEC) Electrical Standards for Industrial Machinery Uniform Building Code Flexible Metal Electrical Conduit Rigid Metal Electrical Conduit Liquid Tight Flexible Electrical Conduit Nonmetallic Outlet Boxes, Flush-Device Boxes and Covers Rigid Nonmetal Electrical Conduit Electrical Metallic Tubing Wireways, Auxiliary Gutters, and Associated Fittings Underfloor Raceways and Fittings Outlet Boxes and Fittings for Hazardous (Classified) Locations o 1.03 SUBMITTALS The following information shall be provided in accordance with Section 01300: 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. A check mark (S) shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification^) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. 2. Manufacturer's descriptive literature for materials. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-2 PART 2-PRODUCTS 2.01 RACEWAYS AND FITTINGS General requirements for raceway materials specified in this section are listed in the RACESPECS sheets at the end of this section. The type of raceways and raceway fittings to be used for any given area and application shall conform to the requirements in this section. 2.02 BOXES, GUTTERS, TERMINAL CABINETS, MANHOLES, AND HANDHOLES Provide Type 316L (low carbon), 317, or Type 316 stainless products where specified. Enclosure constructed of mild sheet steel shall be hot-dipped galvanized after fabrication. Hinges shall be continuous type and for NEMA-4X cabinets hinges shall be stainless steel. Table A specifies the electrical enclosure material and rating for the location and application. Table A Location Electrical Enclosure Material and NEMA Rating Indoor: Architecturally Finished Area Indoor: Electrical Room Indoor: Process Areas Indoor: Corrosive Area Outdoor: Corrosive Area Outdoor: Non-Corrosive Areas Corrosive Area (Hypochlorite) Corrosive Area (Polymer) Hazardous Area: Class I Division 2 Hazardous Area: Class I Division 1 NEMA 1: mild steel NEMA 1: mild steel NEMA 4X: Stainless Steel NEMA 4X: Stainless Steel NEMA 4X: Stainless Steel NEMA 4X: Stainless Steel NEMA 4X: Fiberglass NEMA 4X: Stainless Steel NEMA 4X: Stainless Steel NEMA 7: Galvanized Malleable Iron or Aluminum A. PULL BOXES AND WIRING GUTTERS: Indoor boxes and enclosures larger than FD boxes shall be constructed of sheet steel and galvanized after fabrication. Outdoor boxes and enclosures shall be provided with neoprene gaskets on the hinged doors or removable covers. Box and gutter sizes, metal thickness, and grounding shall comply with the National Electrical Code. Bolt-on junction box covers 3 feet square or larger, or heavier than 25 pounds, shall have a rigid handle. Covers larger than 3 x 4 feet shall be split. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-3 B. TERMINAL CABINETS: Terminal cabinets shall be provided with adjustable terminal strip mounting, back-panels for equipment mounting, print pockets in the doors, continuous door hinges, and three-point lockable latches. Terminal cabinets located indoors shall be NEMA 12. Terminal cabinets located outdoors and in corrosive areas shall be modified NEMA 4X with stainless steel door hinge, three-point latch, and filtered ventilation, if required. Terminal block shall conform to Section 16000. C. HANDHOLES: Handholes shall be precast concrete with checker plate, galvanized, traffic covers designed for H 20 loading. Handholes shall be provided with precast solid concrete slab bottoms with sumps. Handholes shall be constructed of 3000 psi reinforced concrete. Handhole cover shall be engraved "ELECTRICAL" or "SIGNAL" as applicable. Dimensions shall be as specified on the drawings. Handhole walls shall be provided with boxouts, as specified for manholes. D. HANDHOLE CABLE SUPPORTS: Provide heavy-duty, non-metal cable racks for support of conductors. Racks shall be UL listed glass-reinforced nylon consisting of slotted wall brackets for support arms designed for a minimum of a 400-pound load. Each support bracket shall from the top to the bottom and the arms shall be adjustable and installed on 24-inch centers. Use '/2-inch stainless steel bolts, hardware, inserts, and fasteners. Cables supports, clamps or racks shall be provided to support the cable at minimum 2 foot intervals. Concrete inserts shall be embedded on 24-inch centers in walls and ceiling. Cable Support Products or equal: 1. Underground Devices Incorporated Type RA arms with CR36 support brackets. 2. Unistrut Power-Rack F20N-STA33 Stanchions with F20N-ARM14 Arms. E. GROUND BUS: Provide a ground bus in concrete handholes and electrical pullboxes with dimension of 3-foot width x 3-foot length x 3-foot depth and larger. Provide a NEMA threaded 4-hoIe grounding plate for connecting two to four-1-hole ground connectors that enter the enclosure from two to four duct banks. Products: Burndy, T&B, or equal. •^jf BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-4 2.03 RACEWAY SUPPORTS A. CONDUIT SUPPORTS: Framing channel with end caps and straps shall be provided to support groups of conduit. Individual conduit supports shall be one-hole pipe straps used with clamp backs and nesting backs where required. Material as specified herein. Conduit supports for PVC coated rigid steel and PVC conduit systems shall be one-hole PVC coated rigid steel clamps or oversized stainless steel clamps. B. CEILING HANGERS: Ceiling hangers shall be adjustable steel rod hangers and fittings. Provide J-Type conduit support for single conduit. Straps or hangers of plumber's perforated tape are not acceptable. Unless otherwise shown, hanger rods shall meet ASTM A193 and be sized as 3/8-inch up to 2-inch conduit and shall be 1/2 inch all-thread rod over 2-inch conduit. Material as specified herein. C. SUSPENDED RACEWAY SUPPORTS AND RACKS: Suspended raceway supports shall consist of concrete inserts, steel rod hangers, and jamb nuts supporting framing channel or lay-in pipe hangers as required. Framing channel shall be a minimum of 12-gauge. Material as specified herein. Hanger rods shall be 1/2-inch diameter all-thread rod and shall meet ASTM A193. Suspended raceway supports and racks shall be braced for seismic forces as specified in Section 16000. D. MATERIALS: Table B specifies the type of raceway supports required for each location and application. Table B Location Indoor, Architecturally finished Area Indoor, Electrical Room Indoor, Process Areas Indoor, Corrosive Area (general) Outdoor, Corrosive Area (general) Outdoor Areas, Non-corrosive Framing Channel HDG HDG Stainless Steel PVC PVC HDG Threaded Rod, Hardware, & Fittings HDG HDG Stainless Steel PVC PVC HDG HDG = Hot Dip Galvanized Finish PVC = PVC COATED BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-5 2.04 CONCRETE ENCASED DUCT BANKS Concrete used for duct banks shall be Class E with red color added and a minimum 28-day compressive strength of 2,000 psi as specified in the Cast-in-Place Concrete Section 03300. 2.05 UNDERGROUND MARKING TAPE Underground detectable marking tape shall be for early warning protection of digging around direct buried cables, conduits, and concrete duct banks. Tape shall be OSHA approved. Marking tape example: Low density polyethylene plastic, nominally 6 inches wide and 4 mil thickness with metallic lined tape with red polyethylene film on top and clear polyethylene film on the bottom. Tape shall be imprinted with a warning continuously along the length similar to: "CAUTION - STOP DIGGING - BURIED ELECTRIC LINE BELOW." Tape Products: Brady "Identoline"; Services and Materials "Buried Underground Tape"; Somerset (Thomas & Berts) "Protect-A-Line"; or equal. 2.06 NAMEPLATES Nameplates shall be provided for boxes in accordance with the requirements of Section 16000. Nameplate wording shall be as shown on the drawings. Provide the functional description of the device on the nameplate, where wording is not specified 2.07 FIRESTOPS Firestops and seals shall be Flamemastic 77, Vimasco No. 1-A, or equal, and shall be applied in accordance with manufacturer's recommendations. Products which are affected by water are not acceptable. 2.08 RACEWAY IDENTIFICATION Raceway number tags shall conform to the requirements of raceway markers, Section 16000. 2.09 ELECTRICAL SEALANT Electrical sealant putty shall be non-hardening, non-oxidizing, non-corrosive, non-poisonous, and non-injurious to human skin with service temperature range of 30 to 200 degrees Fahrenheit. Product shall be used to seal against the entrance of water. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RACEWAYS, BOXES AND SUPPORTS AUGUST 2010 16110-6 2.10 HAZARDOUS AREA AND CORROSIVE AREA CONDUIT SEALS Sealing compound shall be non-hardening type for corrosive areas. Seal fittings for conduit systems in hazardous atmosphere locations shall be hot-dip galvanized cast ferrous alloy or aluminum alloy. Seal fittings shall be 40-percent fill type. Sealing compound shall be hard type installed in UL listed for explosion-proof sealing fittings after the conductors are installed, tested, and accepted. Provide PVC-coated seal fittings used for PVC-coated conduit with 40-mil factory coating. Seal fitting and sealing compound manufacture: Appleton, Grouse-Hinds, or equal. 2.11 PULLING LINE Pulling line shall be polyethylene type, mildew and rot resistant with minimum of 200-pound tensile strength and minimum 1/4-inch diameter. Install in all "future" raceways. Manufacture: Greenlee, Ideal, or equal. 2.12 CONDUIT THREAD LUBRICANT Thread lubricant shall be conductive with anti-seize and anti-corrosion properties, compatible with steel and aluminum conduit materials. Manufacture: T&B CP8 KOPR-Shield; Robroy Threadcompound; or equal. PART 3-EXECUTION 3.01 GENERAL Table C specifies the type of raceway required for each location and application by RACESPEC sheet. Unscheduled conduit shall be galvanized, rigid steel, RACESPEC type GRS. Table C Location Indoor noncorrosive Indoor corrosive Outdoor Concealed Application/Condition Exposed Exposed Exposed (WWTP) Exposed (other) Power circuits embedded in concrete structure or beneath slab-on-grade RACESPEC GRS PGRS PGRS GRS PVC4 BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-7 Location Application/Condition RACESPEC Concealed Underground Underground Nonhazardous Hazardous corrosive Hazardous Architecturally finished areas Architecturally finished areas Instrumentation, communications and data signals encased in concrete, duct bank Power circuits encased in concrete, duct bank Instrumentation, communications and data signals directly buried Final connection to equipment and light fixtures Exposed Final connection to equipment Concealed in framed walls and ceiling spaces (lighting and receptacle circuits only) Final connection to light fixtures PVC4 PVC4 PVC4 LFS PGRS XPFS EMT FLEX 3.02 CONDUIT A. GENERAL: The conduit systems, installation, and hazardous location fittings are specified herein. B. INDOOR AND OUTDOOR CONDUIT SYSTEMS: In general, Contractor shall be responsible for determining conduit routing that conforms to the specified installation requirements: 1. Conduits for lighting and outlets: exposed 2. Conduits for process equipment: concealed 3. Conduit inside structures: exposed 4. Conduit concealed inside water chambers slabs and walls Conduit installation shall conform to the requirements of the RACESPEC sheets and the following specified installation requirements: 1. Exposed conduit: Install parallel or perpendicular to structural members and surfaces. Install conduit horizontally and allow minimum headroom of 7 feet. 2. Route two or more exposed conduits in the same general routing parallel with symmetrical bends. 3. Space exposed conduit installed on supports not more than 10 feet apart. Space multiple conduits in parallel and use framing channel. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-8 4. Comply with the requirements of Section 16000 and herein, where conduits are suspended from the ceiling. 5. Secure conduit rack supports to concrete walls and ceilings with cast-in-place anchors or framing channel concrete inserts. 6. Install conduits at least 6 inches from high temperature piping, ducts, and flues with temperatures higher than 90 degree C. 7. Install conduits between the reinforcing steel in walls or slabs that have reinforcing in both faces. 8. Place conduits under the reinforcement in slabs with only a single layer of reinforcing steel. Separation between conduits, conduits and reinforcement, and conduits and surfaces of concrete shall be maintained in accordance with UBC. 9. Route conduit clear of structural openings and indicated future openings. 10. Provide conduits with flashed and watertight seals routed through roofs or metal walls. 11. Grout conduits into openings cut into concrete and masonry structures. 12. Cap conduits or plug flush conduits during construction to prevent entrance of dirt, trash, and water. Cap or plug empty conduits designated as "future", "spare", or "empty" and include a pulling line accessible at both ends. Use anti-seize compound on cap and plug threads prior to installation. 13. Determine concealed conduit stubup locations from the manufacturer's shop drawings. Terminate concealed conduit for future use in specified equipment. 14. Install conduit flush with structural surfaces with galvanized couplings and plugs. Caps and plugs shall match the conduit system. 15. Provide concealed portions of conduits for future equipment where the drawings indicate future equipment. Match the existing installation for duplicate equipment. 16. Terminate conduits that enter enclosures with fittings that match the NEMA rating of the enclosure. 17. Underground metallic or nonmetallic conduit that turn out of concrete, masonry or earth: Install a 90-degree elbow of PVC-coated rigid steel conduit before emergence above ground. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RACEWAYS, BOXES AND SUPPORTS AUGUST 2010 16110-9 18. Provide O-Z Gedney "Type DX" or Crouse-Hinds "Type XD" bonded, weathertight expansion and deflection fitting for the conduit size where conduit across structural joints that allows structural movement. C. UNDERGROUND CONDUIT SYSTEM; Excavation, backfilling, and concrete work shall conform to respective sections of these specifications. Underground conduit shall conform to the following requirements: 1. Underground conduits shall be reinforced concrete encased that are not shown otherwise on the drawings. 2. Concrete encased conduit shall have minimum concrete thicknesses of 2 inches between conduits, 1 inch between conduit and reinforcing, and 3 inches between reinforcing and earth, unless shown otherwise in an electrical detail. 3. Concrete encasement on exposed outdoor conduit risers shall continue to 3 inches above grade, with top crowned and edges chamfered. 4. Underground conduit bend radius shall be not less than 2 feet minimum at vertical risers and shall be not less than 3 feet elsewhere. 5. Where conduit and concrete encasement are terminated underground, the conduit and reinforcing shall both extend at least 2 feet past the concrete. Conduits shall be capped and threads protected. Steel surfaces shall be given two coats of epoxy paint. 6. Underground conduits and conduit banks shall have 2 feet minimum earth cover unless otherwise shown. 7. Underground conduit banks through building walls shall be cast-in-place or installed with concrete into boxouts with waterstops on all sides of the boxout. Water-stops shall be as specified in the Cast-in-Place Concrete section. Extend the horizontal reinforcement from the duct bank into the boxout terminating with J-hook bends. 8. Conduits not encased in concrete and passing through walls with one side in contact with earth shall be sealed watertight with special rubber gasketed sleeve and joint assemblies or with sleeves and modular rubber sealing elements. 9. Thoroughly swab conduits and raceways on the inside, immediately upon completion of pouring concrete. 10. Label raceways in accordance with Section 16000. 11. After the concrete has set and before backfilling, pull a mandrel through each conduit. The mandrel shall have a diameter equal to the nominal conduit inside diameter minus 1/2 inch and shall not be less than 4 inches long. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RACEWAYS, BOXES AND SUPPORTS AUGUST 2010 16110-10 12. If the mandrel showed signs of protrusions on the inside of the conduit, the conduit shall be repaired or replaced. 13. Provide manufactured plastic conduit spacers anchored to prevent movement during the concrete pour. Manufacture: Carlon, PW Pipe, Underground Devices, or equal. 14. Form the concrete pour ten feet from the wall, manhole, or handhole and form to allow for future conduit entry. 15. Backfill duct banks with clean fill compacted to 90-percent in 6-inch lifts after concrete has cured. Refer to Section 03300 for concrete requirements including minimum 7 days of cure time prior to backfill over duct banks. 16. Allow and provide for two offsets per conduit and raceway for each 100- linear feet to account for unexpected field conditions including for excavation and backfill limited to three feet of extra width and/or depth. Include these specified provisions in the bid price. 17. Provide PVC threaded adapter with female threads where PVC conduit is joined to steel conduit. Procedure: a. Before assembly: Double coat steel conduit with Red-Robroy, Green-Permacote, Blue-Ocal or equal product. b. After assembly: Seal with 65-mil thick, 2-inch wide mastic sealing tape to Vi-inch beyond threads. Products: 3M Scotch 2228; Plymouth 02625; or equal. c. Cover with 20-mil corrosion protection tape applied in Vz-lap layers to 2-inch beyond threads. Products: 3M Scotchwrap 51; Plymouth Plywrap 12; or equal. 18. Where reinforced concrete duct banks enter the side of a building, manhole, or handhole and the reinforcement cannot be brought into a window and be terminated, then drill the structure and embed the reinforcement in epoxy to minimum of 3-inches depth. 19. Provide PVC conduit with bell ends where duct banks terminated at walls, manholes, or handholes. Install bell ends flush with finished concrete. 20. Provide PVC conduit with bell ends where conduit rise below grade into a floor mounted electrical panel, electrical cabinet, MCC, switchboard, or switchgear. 21. Separate power conduits from signal conduit within the same ductbank by 12" or greater separation, as shown. Refer to the drawings or schedules for signal to be installed in metal conduits instead of PVC ducts. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RACEWAYS, BOXES AND SUPPORTS AUGUST 2010 16110-11 22. Separate high voltage ductbanks from low voltage ductbanks, as shown. 23. Provide wireways for transition from underslab conduits rising into wall-mounted panels where the number of conduits exceed the NEC allowable panel space in the bottom of the panel. Provide conduit sleeves or fitting for panel transition. Continuous thread or all-thread is prohibited. D. CONDUIT SEAL-OFF FITTINGS: Conduits passing: 1. Between Class I, Division 1 area and Class I, Division 2 area; provided with sealing fittings located at the boundary in accordance with NEC Article-500. 2. From hazardous or corrosive area into a non-hazardous or non-corrosive area. Install the seal-off material in the conduit seal-off fittings after inspection. 3.03 MANHOLES AND HANDHOLES Unless otherwise specified, manhole and handhole installation shall be as follows: 1. Manholes, handholes, and pull boxes shall be set on a minimum of 6 inches of crushed rock on top of undisturbed or compacted earth. 2. Manholes and handholes shall be set plumb so that water shall drain to the sump. 3. Manhole covers shall be 36-inches in diameter and set at 2 inches above finish grade with surrounding pavement sloping away from the manhole cover. 4. Metallic hardware inside manholes and handholes shall be bonded to the ground plate or ground bus using bolted connections, bonding jumpers and grounding bushings. 3.04 RACEWAY NUMBERING Each new and reused conduit shall be provided with a number tag at each end and in each manhole, handhole, or pull box. Cable trays shall be identified by stencils at intervals not exceeding 50 feet, at intersections, and at each end to identify power cable tray voltage, control cable tray, or instrument cable tray. 3.05 RACESPEC SHEETS The following RACESPECS are included in this section: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) RACEWAYS, BOXES AND SUPPORTS AUGUST 2010 16110-12 3.05 RACEWAY SPECIFICATION SHEETS (RACESPEC) Raceway Identification: Description: Application: Compliance: Construction: Minimum size: Fittings: Other: FLEX Flexible Steel Conduit Final connection to equipment subject to vibration or adjustment. UL1 Spirally wound galvanized steel strip with successive convolutions securely interlocked. 1/2 inch Compression type FLEX shall be provided with an internal ground wire. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-13 3.05 RACEWAY SPECIFICATION SHEETS (RACESPEC) Raceway Identification: GRS Description: Galvanized Rigid Steel Conduit (GRS) Compliance: ANSI and UL Finish: Manufacturers: Minimum size: Fittings: Locknuts, Rings, Hubs: Unions: Conduit Bodies: Boxes: Indoor: Outdoor: Hot-dip galvanized after fabrication, inside and outside. Smooth finished surfaces. Allied Tube and Conduit Corp., Wheatland Tube Co., or equal. Unless otherwise specified, 3/4 inch for exposed, 1 inch for embedded, encased, or otherwise inaccessible. Hot-dip galvanized insulated throat with bonding locknut or ring. The hubs shall utilize a neoprene "O" ring and provide a watertight connection. O-Z Gedney, CHM-XXT, or equal Electro-galvanized ferrous alloy type Appleton UNF or UNY, Crouse-Hinds UNF or UNY, or equal. Threadless fittings are not acceptable. Oversized conduit bodies: Ferrous alloy type with screw taps for fastening covers to match the conduit system. Gaskets shall be made of neoprene. Type FD cast ferrous for all device boxes and for junction boxes less than 6 inches square. Type FD cast ferrous for all device boxes and for junction boxes less than 6 inches square. •~ngf^ BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-14 3.05 RACEWAY SPECIFICATION SHEETS (RACESPEC) Raceway Identification: GRS (continued) Corrosive: NEMA 4X stainless steel or nonmetallic, as specified. Hazardous: NEMA Class 7 cast ferrous. Elbows: (3/4" thru 1-1/2") (2" thru 6") Conduit Bodies (Oversized): (3/4" thru 4") (5" and 6") Expansion Fittings: Manufacturers: Installation: Factory fabricated or field bent. Factory fabricated only. Malleable iron, hot-dip galvanized, unless otherwise noted. Neoprene gaskets for all access plates. Tapered threads for conduit entrances. Electro-galvanized iron or cast iron box. Expansion fittings in embedded runs shall be watertight with an internal bonding jumper. The expansion material shall be neoprene allowing for 3/4-inch movement in any direction. Appleton, Crouse-Hinds, Hubbell, O. Z. Gedney, or equal. Rigid steel conduit shall be made up tight and with conductive thread compound. Joints shall be made with standard couplings or threaded unions. Steel conduit shall be supported away from the structures using hot-dip galvanized malleable iron straps with nesting backs or framing channel. Conduit entering boxes shall be terminated with a threaded hub with a grounding bushing. Exposed male threads on rigid steel conduit shall be coated with zinc-rich paint. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-15 3.05 RACEWAY SPECIFICATION SHEETS (RACESPEC) Raceway Identification: Description: Application: Compliance: Construction: Minimum size: Fittings: Installation: LFS Liquidtight Flexible Steel Conduit Final connection to equipment subject to vibration or adjustment. UL 360 Spirally wound galvanized steel strip with successive convolutions securely interlocked and jacketed with liquidtight plastic cover. 3/4 inch Cadmium-plated malleable iron body and gland nut with cast-in lug, brass grounding ferrule threaded to engage conduit spiral. O-ring seals around the conduit and box connection and insulated throat. Provide forty-five and ninety degree fittings where applicable. Provide PVC coated flexible conduit and fittings where the conduit system is PVC coated. Length of flexible liquidtight conduit shall not exceed 15 times the trade diameter of the conduit and not exceed 36 inches in length. Use conductive thread compound. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-16 3.05 RACEWAY SPECIFICATION SHEETS (RACESPEC) Raceway Identification: Description: Compliance: Finish: Minimum size: Fittings: Covers: Hubs: PGRS Rigid Steel Conduit, Corrosion-Resistant, Polyvinyl Chloride (PVC) Coated. Provide factory made and coated elbows. ANSI, ETL and UL. The PVC coated rigid galvanized steel conduit shall be stamped with the ETL Verification Mark "ETL Verified to PVC-OOi". PGRS shall be hot-dip galvanized rigid steel conduit as specified in 16110-3.03 GRS, with a PVC Coating. The PVC coating shall be gray, minimum 40 mils thick, bonded to the outside and continuous over the entire length of the conduit except at the threads, and be free of blisters, bubbles, or pinholes. Thread protectors shall be used on the exposed threads of the PVC coated conduit. A 2-mil coat of urethane enamel coating shall be bonded to the inside. Coating shall be free of pinholes. Bond strength shall exceed the tensile strength of the PVC coat. 3/4 inch Similarly coated to the same thickness as the conduit and provided with Type 316 stainless steel hardware. Conduit and fittings shall be manufactured by the same company Conduit and fittings shall be coated by the same company. Male threads on elbows and nipples, and female threads on fittings or conduit couplings shall be protected by application of urethane coating. PVC coated covers shall have V-groove seal and stainless steel hardware. Hubs for connection of conduit to junction, device, or terminal boxes shall be threaded cast ferrous alloy. Hubs shall have the same PVC coating as the conduit and insulating grounding bushings. Hubs shall utilize a neoprene "O" ring and shall provide a watertight connection. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-17 3.05 RACEWAY SPECIFICATION SHEETS (RACESPEC) Raceway Identification: PGRS (continued) Boxes: Nonhazardous: Hazardous: Manufacturers: Installation: Training: NEMA Class 4X stainless steel or nonmetallic. NEMA Class 7 cast ferrous. PVC coated conduit that bears the ETL Verified PVC-001 label by Robroy Industries, Plasti-Bond, Perma-Cote, KorKap or equal. Plastic coated conduit shall be made up tight, threaded, and installed using tools approved by the PVC-coated conduit manufacturer. Exposed conduit threads shall be covered by a plastic overlap coated and sealed per manufacturer's recommendations. Pipe wrenches and channel locks shall not be used for tightening plastic coated conduits. Damaged areas shall be patched, using manufacturer's recommended material. The area to be patched shall be built up to the full thickness of the coating. Painted fittings are not acceptable. PVC coated conduit shall be supported away from the structure using PVC coated conduit wall hangers or PVC coated conduit mounting hardware. Damaged work shall be replaced Installers shall be trained and certified in the proper installation techniques provided by the PVC-coated conduit system manufacture. Proof of certification shall be provided under paragraph 16110-1.03. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-18 3.05 RACEWAY SPECIFICATION SHEETS (RACESPEC) Raceway Identification: Description: Application: Compliance: Construction: Minimum size: Fittings: Boxes: Indoor: Outdoor and corrosive: Installation: PVC4 Rigid Nonmetallic Conduit. Heavy wall thickness for direct bury, concrete encasement or surface mounting where not subject to physical damage. NEMATC2,UL651 Schedule 40, high-impact, polyvinylchloride (PVC) 3/4 inch exposed; 1 inch embedded or encased PVC solvent weld type NEMA Class 4, nonmetallic NEMA Class 4X, nonmetallic PVC conduit entering fiberglass boxes or cabinets shall be secured by threaded bushings on the interior of the box and shall be terminated with a threaded male terminal adapter having a neoprene O ring. Joints shall be made with standard PVC couplings. PVC conduit shall have bell ends where terminated at walls and boxes. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-19 3.05 RACEWAY SPECIFICATION SHEETS (RACESPEC) Raceway Identification: Description: Application: Size: Length: XPFS Explosion-proof Flexible Steel Conduit XPFS Conduit coupling shall be used for final connections to motors and other equipment subject to vibration or adjustment in Class I Division 1 hazardous areas and shall be watertight. 1/2 inch-4-inch 4-inch - 36-inch ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VCM) AUGUST 2010 RACEWAYS, BOXES AND SUPPORTS 16110-20 SECTION 16120 600 VOLT CONDUCTORS, WIRE, AND CABLE PART 1 - GENERAL 1.01 DESCRIPTION This section specifies stranded copper cables, conductors, and wire rated 600 volts insulation used for power; lighting, analog, digital, or pulse signals and control circuits. 1.02 REFERENCES This section contains references to the following documents. They are a part of this section. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to document shall mean the documents in effect at the time of Advertisement for bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, whether or not the document has been superseded by a version with a later date, discontinued or replaced. Reference ASTM B3 ASTM B8 ASTM B33 ICEAS-68-516 NEMA WC7 NFPA 70 UL44 UL83 Title Soft or Annealed Copper Wire Concentric-Lay-Stranded Copper Conductors, Hard, Medium- Hard, or Soft Tinned Soft or Annealed Copper Wire for Electrical Purposes Ethylene-Propylene-Rubber-Insulated Wire Cross-Linked-Thermosetting Insulated Wire and Cable for the Transmission and Distribution of Electric Energy National Electric Code (NEC) Rubber-Insulated Wires and Cables Thermoplastic-Insulated Wires and Cables BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 600 VOLT CONDUCTORS, WIRE, AND CABLE 16120-1 1.03 SUBM1TTALS The following information shall be provided in accordance with Section 01300. 1. Submittals specified in Section 16000. 2. Complete catalog cuts for all conductors, wire, and cable. PART 2 - PRODUCTS 2.01 GENERAL A. CABLE SPECIFICATION SHEETS (CABLESPEC): General REQUIREMENTS for conductors and cables specified in this Section are listed on CABLESPEC sheets in paragraph 16120-3.06. 2.02 COLOR CODING A. CONTROL CONDUCTORS: Single-conductor control conductors shall have the following colors for the indicated voltage: Control Conductor Power (AC) Control (AC) Neutral Ground Foreign Voltage (DC) Foreign Voltage (AC) Power (DC) Control (DC) 120V Black Red White Green Blue/White Yellow Blue Violet B. POWER CONDUCTORS: Power CONDUCTORS shall have the following colors for the indicated voltage: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) 600 VOLT CONDUCTORS, WIRE, AND CABLE AUGUST 2010 16120-2 Power Conductor Phase A Phase B Phase C Ground Neutral 480V Brown Orange Yellow Green Gray 208/120V Black Red Blue Green White Cables may be BLACK, with colored 3/4-inch vinyl plastic tape applied at each cable termination. Tape shall be wrapped with 25 percent overlay to provide 3 inches minimum coverage. C. SIGNAL CONDUCTORS: Signal CABLE conductors shall be color coded black and white for pairs or black, white, and red for triads. Each conductor and each group of conductors shall be numbered. 2.03 POWER AND CONTROL CONDUCTORS AND CABLE, 600 VOLT A. SINGLE CONDUCTOR: Provide stranded conductors for all cable or wires. Provide minimum conductor size of 12 AWG for POWER and lighting circuits and minimum conductor size of 14 AWG for control circuits. 2.04 SIGNAL CABLES A. GENERAL: Factory CABLE between manufactured instrument system components shall be provided in compliance with the instrument manufacturer's recommendations. Signal cable shall be provided for instrument signal transmission. Single instrument cable (SIC) shall be provided in accordance with the following examples: 1. CABLESPEC "SIC": a. Cable designation: 1PR#16TSP shielded twisted pair (TSP) 2.05 PORTABLE CORD BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 600 VOLT CONDUCTORS, WIRE, AND CABLE 16120-3 Portable cord shall be provided in accordance with CABLESPEC "CORD," unless otherwise specified. Cords shall contain an equipment grounding conductor. 2.06 SPLICING AND TERMINATING MATERIALS Connectors shall be tool applied compression type of correct size and UL listed for the specific application. Connectors shall be tin-plated high conductivity copper. Wire nuts for a splice is prohibited. Signal and control conductors shall be connected to terminal blocks and field devices and instruments shall be terminated with conductor terminals as specified in paragraph 16000- 2.02. Connectors for wire sizes No. 8 AWG and larger shall be compression tool installed one-hole lugs up to size No. 3/0 AWG, and two-hole or four-hole lugs for size No. 4/0 and larger. Mechanical clamp, dimple, screw-type connectors are not acceptable. In-line splices and taps shall be used only by written consent of the Engineer. Power conductor splices shall be compression type, made with a compression tool die approved for the purpose, as made by Thomas and Betts Corp., or equal. Splices shall be covered with electrical products designed for the application, insulated, and covered with a heat-shrinkable sleeve or boot, as specified elsewhere. Motor connection kits shall consist of heat-shrinkable, polymeric insulating material over the connection area and high dielectric strength mastic to seal the ends against ingress of moisture and contamination. Motor connections may use the Tyco Electronics removable boot product line. Motor connection kits shall accommodate a range of cable sizes for both in-line and stub- type configurations. Connection kits shall be independent of cable manufacturer's tolerances. Refer to the electric motor specification Section 11060. 2.07 CORD GRIPS Cord grips shall be provided where indicated on the Drawings to attach flexible cord to equipment enclosures. Cord grips shall consist of a threaded aluminum body and compression nut with a neoprene bushing and stainless steel wire mesh for strain relief. Cord grip shall provide a watertight seal at enclosure interface and sized to accommodate the flexible cord. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) 600 VOLT CONDUCTORS, WIRE, AND CABLE AUGUST 2010 16120-4 PART 3-EXECUTION 3.01 GENERAL Conductors shall be identified at each connection terminal and at splice points. The identification marking system shall comply with Section 16000. Pulling wire and cable into conduit or trays shall be completed without damaging or putting undue stress on the insulation or jacket. Manufacture recommended and UL Listed pulling compounds are acceptable lubricants for pulling wire and cable. Grease is not acceptable. Raceway construction shall be complete, cleaned, and protected from the weather before cable is installed. Where wire or cable exits a raceway, a wire or cable support shall be provided. Provide tin-plated bus bar. Scratch-brush the contact areas and tin plate the connection where flat bus bar connections are made with un-plated bar. Bolts shall be torqued to the bus manufacturer's recommendations. 3.02 600 VOLT CONDUCTOR AND CABLE Conductors in panels and electrical equipment shall be bundled and laced at intervals not greater than 6 inches, spread into trees and connected to their respective terminals. Lacing shall be made up with plastic cable ties. Cable ties shall be tensioned and cut off by using a tool specifically designed for the purpose such as a Panduit GS2B. Other methods of cutting cable ties are unacceptable. Conductors crossing hinges shall be bundled into groups not exceeding 10 to 15 conductors and protected using nylon spiral flexible covers to protect conductors. Provide oversized plastic panel wiring duct within panels and panelboards. Slack shall be provided in junction and pull boxes, handholes and manholes. Slack shall be sufficient to allow cables or conductors to be routed along the walls. Amount of slack shall be equal to largest dimension of the enclosure. Provide dedicated electrical wireways and insulated cable holders mounted on unistrut in manholes and handholes. Raceway fill limitations shall be as defined by NEC and the following: 1. Lighting and receptacle circuits may be in the same conduit in accordance with de-rating requirements of the NEC. Lighting and receptacle circuits shall not be in conduits with power or control conductors. Signal conductors shall be in separate conduits from power conductors. Motor feeder circuits shall be in separate conduits including small fan circuit unless combination fan-light fixture. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) 600 VOLT CONDUCTORS, WIRE, AND CABLE AUGUST 2010 16120-5 2. Power conductors derived from uninterruptible power supply systems shall not be installed in raceways with conductors of other systems. Install in separate raceways. 3. Slices and terminations are subject to inspection by the Engineer prior to and after insulating. 4. In-line splices and tees, where approved by the Engineer, shall be made with tubular compression connectors and insulated as specified for motor terminations. Splices and tees in underground handholes or pull boxes shall be insulated using Scotch-cast epoxy resin or Raychem splicing kits. 5. Terminations at solenoid valves, 120 volt motors, and other devices furnished with pigtail leads shall be made using self-insulating tubular compression connectors within the termination box. 3.03 SIGNAL CABLE Provide terminal blocks at instrument cable junctions within dedicated terminal boxes provided by the installer. Signal circuits shall be run without splices between instruments, terminal boxes, or panels. Circuits shall not be made using conductors from different pairs or triads. Triads shall be used wherever 3-wire circuits are required. Shields are not acceptable as a signal path, except for circuits operating at radio frequencies utilizing coaxial cables. Common ground return conductors for two or more circuits are not acceptable. Shields shall be bonded to the signal ground bus at the control panel only and isolated from ground at the field instrument or analyzer and at other locations. Shields or drain wires for spare circuits shall not be grounded at either end of the cable run. Terminals shall be provided for running signal leads and shield drain wires through junction boxes. Spare circuits and the shield drain wire shall be terminated on terminal blocks at both ends of the cable run and be electrically continuous through terminal boxes. Where instrument cable splicing is required, provide an instrument stand with terminal box rated for the area and environment and mounted approximately 3 feet above grade for instrument cable splices with the circuits and individual conductors provided with label as specified in Section 16000. Cable for paging, security, voice communication, and telephone systems shall be installed and terminated in compliance with the manufacturers and the Utilities recommendations. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) 600 VOLT CONDUCTORS, WIRE, AND CABLE AUGUST 2010 16120-6 3.04 PORTABLE CORD Portable power cords feeding permanent equipment, such as pendant cords feeding motors for pumps, cranes, hoists, and portable items shall have a wire mesh cord grip of flexible stainless steel wire to relieve the tension from the cable termination. Connection of portable cords to permanent wiring shall be accomplished with dedicated boxes and terminals blocks. 3.05 TESTING The Contractor shall test conductors, wire, and cable in accordance with Section 16030. 3.06 CABLE SPECIFICATION SHEETS (CABLESPEC) A. GENERAL: Conductor, wire, and cable types for different locations, service conditions and raceway systems are SPECIFIED on individual cable specification sheets. Scheduled and unscheduled conductors, wires, and cables shall be installed in accordance with the CABLESPEC SHEETS. B. CABLESPEC SHEETS: The following CABLESPEC sheets are included in this section: Type SIC XHHW Volt 600 600 Product P-OS: 1-PR#18 or 16SH or 1-TR#18 or 16SH XLP insulated industrial grade conductor Purpose Cable tray rated instrument cable Power, control, lighting, and receptacles BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 600 VOLT CONDUCTORS, WIRE, AND CABLE 16120-7 3.06 CABLE SPECIFICATION SHEET-CABLESPEC Cable System Identification: Description: Voltage: Conductor Material: Insulation: SIC Single twisted, shielded pair or triad, 18 or 16 AWG, instrumentation and signal cable; UL listed; Cable Tray rated 600 volts Bare annealed copper; stranded per ASTM B8 15 mil, Polyvinyl Chloride (PVC) with 4 mil nylon, 90 degree C temperature rated Color Code per ICEA Method-1: Pairs- Black and White with one conductor in each pair printed alpha-numerically for identification Lay: Shield: Jacket: Flame Resistance: Manufacturer(s): Execution: Use: Installation: Testing: Twisted on a 2-inch lay 100 percent, 1.35 mil aluminum-Mylar tape with a 7-strand tinned copper drain wire 45 mil Polyvinyl Chloride (PVC) UL 1277 Okonite, Okoseal-N Type P-OS (Pair(s) Overall Shield) and Type TOS (Triad(s) Overall Shield); or Cooper Industries- Belden equal; or General Cable equal Analog signal cable and RTD device Triad extension cable. Install in accordance with paragraph 16120-3.03. Test in accordance with paragraph 16120-3.05. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 600 VOLT CONDUCTORS, WIRE, AND CABLE 16120-8 3.06 CABLE SPECIFICATION SHEET-CABLESPEC Cable System Identification; Description: Voltage: Conductor Material: Insulation: Jacket: Flame Resistance: Manufacturer(s): Uses Permitted: Execution: Installation: Testing: XHHW Industrial grade single conductor Sizes: 14 AWG through 750 kcmil as shown 600 volts Bare annealed copper; stranded per ASTM B8 NEC Type XHHW-2; 90 degree C dry and C wet; Cross- Linked Polyethylene (XLP) per ICEA S-66-524 and UL-44; Color in sizes 14, 12 and 10 AWG: Black, Green, Yellow, White, Orange, Brown, Red, Blue None UL83 Okonite, X-Olene; Cablec, Durasheath XLP; or equal. Power, control, lighting and outlet circuits. Install in accordance with paragraph 16120-3.02. Test in accordance with paragraph 16000-3.02 and Section 16030. **END OF SECTION** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 600 VOLT CONDUCTORS, WIRE, AND CABLE 16120-9 SECTION 16175 MISCELLANEOUS ELECTRICAL DEVICES PART 1 - GENERAL 1.01 DESCRIPTION The vendor, manufacturer, and custom control panels shall provide enclosures, selector switches, pushbuttons, indicators, terminal strips, surge devices, nameplates, testing procedures, wiring method, wiring color coding, wire labeling, separation between power, controls, and instruments, hardwired logic relays or PLC logic products as specified herein. A. ELECTRICAL CONTROL AND MONITORING DEVICES: This section specifies electrical control and monitoring devices: 1. Control Devices: a. Pushbuttons b. Selector Switches c. Indicating Lights d. Control Station Enclosures 2. Control Relays: a. Load-Switching b. Logic Level Switching c. Timers and Time Switch d. Alternators B. POWER DEVICES: This section specifies power devices: 1. Magnetic Contactors: a. Lighting Contactors b. Motor Contactors 2. Safety Disconnect Switches 3. Manual starters shall comprise a horsepower rated quick-make, quick-break, toggle mechanism together with overloads in all phase conductors. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-1 4. Field Instrument and Field Analyzer: Key-Switch in control station with surge devices 5. Overcurrent Protection: Circuit breakers 6. Elapsed Time Indicators 7. Current transformers and transducers 8. Time Switch 9. Motor Driven Timers - On Delay and Off Delay 10. Intrusion Switches and Override Key Switches 11. Thermostats 12. Static Ground Indicator and Interlock System Request clarification where conflicts occur with this section and other sections in Divisions 11, 15, 16 and 17. 1.02 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid or on the effective date of the Agreement if there were no Bids. If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-2 Reference NEMA 250 NEMAICS-1 NEMA ICS-2 NEMA KS 1 Title Enclosures for Electrical Equipment (1000 volts maximum) General Standards For Industrial Controls and Systems Industrial Control Devices, Controllers, and Assemblies Enclosed Switches 1.03 SUBMJTTALS The following submittals shall be provided in accordance with Section 01300 and Section 16000: 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check- marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. 2. Arrangement drawings of the panel enclosure indicating the front door and panel equipment arrangement and dimensions, and enclosure type. 3. Nameplate legend with engraving and sizes. 4. Internal layout drawings showing all components. 5. List of materials and components with the layout drawings. 6. Elementary / schematic diagrams 7. Internal wiring connection diagrams. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-3 8. External wiring interconnection diagrams including interlocks. 9. Power and control single line diagrams, where motor controllers are included. 10. Manufacturer's catalog data for all material provided under this section shall be assembled in a folder with each page clearly marked with the item model number and reference number to the specification. PART 2-PRODUCTS 2.01 CONTROL DEVICES A. PUSHBUTTONS: Pushbuttons shall be flush head, heavy-duty, with NEMA rating to match enclosure type. Operators shall BE green for start function, red for stop functions, and black for all other functions. The escutcheon legend shall be as specified on the drawings. 1. UL Listed. 2. Dielectric Strength: 1300 Volts for one minute for Logic Reed contacts, 2200 Volts for one minute for other contacts. 3. 30.5mm mounting hole. 4. Temperature operating range -10 degree C. to +55 degree C. 5. Momentary contact type. 6. When switching circuits are monitored by programmable controllers or other solid state circuits, furnish hermetically-sealed, logic-reed type contacts rated not less than 0.15 amperes at 150 Vac and 0.06 amperes at 30 Vdc. 7. When switching circuits are not monitored by programmable controllers or other solid state circuits, furnish contacts with NEMA Utilization Category rating A600 rated not less than 10 amperes continuous and 6 amperes break at 120 Vac. 8. Pushbuttons designated "Lock-Out-Stop" (LOS) shall be provided with a padlock attachment to maintain the device in a depressed (stop) position. 9. Manufacturer: a. Allen-Bradley 800T/800H series or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-4 B. SELECTOR SWITCHES: Selector switches shall be heavy-duty with NEMA rating to match enclosure type. Selector switches shall have maintained position contacts. Switches shall be provided with contact blocks and number of positions as required performing the specified or indicated operations. The escutcheon legend shall be as specified on the drawings. Provide: 1. UL Listed. 2. Dielectric Strength: 1300 Volts for one minute for Logic Reed contacts, 2200 Volts for one minute for other contacts. 3. 30.5mm mounting hole. 4. Temperature operating range -10 degree C. to +55 degree C. 5. Standard knob operator (not lever type nor wing lever type) 6. Number of positions and contact configuration as shown on Drawings. 7. When switching circuits are monitored by programmable controllers or other solid state circuits, furnish hermetically-sealed, logic-reed type contacts rated not less than 0.15 amperes at 150 Vac and 0.06 amperes at 30 Vdc. 8. When switching circuits are not monitored by programmable controllers or other solid state circuits, furnish contacts with NEMA Utilization Category rating A600 rated not less than 10 amperes continuous and 6 amperes break at 120 Vac. 9. Manufacturer: a. Allen-Bradley 800T/800H series or equal. Field instruments and field analyzers specified shall have a lock-out style selector switch for locking on or locking off the 120Vac power source. The selector switch shall use a control station in NEMA-12, 4, 4X, or 7 as required by the area classification. Provide O-Z/Gedney Class 441 with two position key-operated maintained contact switch. Provide surge protection device that matches the enclosure type of the power disconnect type control station, field instrument, or field analyzer: Telematic TP48 transmitter surge protection device or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-5 C. INDICATING LIGHTS: Red, amber, green, and blue indicating lights shall be heavy-duty full voltage 120Vac or 24Vdc push-to-test LED type with NEMA rating to match enclosure type for installation in a 30.5mm hole. Furnish with 28 chip high visibility LED. The escutcheon and lens color shall be as shown on Drawings or scheduled. White indicating lights shall be as above, incandescent type lamp. 1. MANUFACTURER: a. Allen-Bradley 800H-QRTH10 series or equal for 120Vac applications with colors other than white. b. Allen-Bradley 800HQRTH24 series or equal for 24Vdc applications with colors other than white. c. Allen-Bradley 800H-QRT10 series or equal for 120Vac applications with white. d. Allen-Bradley 800H-QRT24 series or equal for 24Vdc applications with white. 2. INDICATING LIGHT LENS COLOR: Lens Color Typical Function Example Red Danger, running Equipment operating, motor running, valve open, power voltage applied, cycle in automatic Amber Fault condition, Equipment failure, status abnormal attention Green Ready condition End of cycle; unit or head returned; motors stopped; motion stopped; contactors open, valve closed White or Normal condition Normal pressure of air, water, lubrication, Clear control power on, status okay Blue Advisory Control mode not in automatic D. CONTROL STATION ENCLOSURES: 1, Enclosures locations and ratings: a. Indoors: NEMA 12 b. Outdoors and Corrosive areas: NEMA 4X stainless steel c. NEC 500 Hazardous Areas: NEMA-7. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-6 E. CONTROL POWER TRANSFORMERS: 1. Sized for the panel devices and products. 2. Dual primary and single secondary fusing. 2.02 CONTROL RELAYS A. LOAD-SWITCHING CONTROL RELAYS: Control relays used for switching loads such as solenoids, actuators, contactors, motor starter coils, remote interlocking, etc. shall be heavy-duty machine tool type. Contacts shall be 4-pole and be field interchangeable to either normally-open or normally- closed. Relay shall be capable of accepting a 4-pole adder. AC relays shall have NEMA A600 contact ratings and electrical clearances for 600 volts. DC relays shall have NEMA P300 contact ratings and electrical clearances for 250 volts. 1. MANUFACTURER: Allen Bradley Bulletin-700, Square D Class 8501, or equal. B. LOGIC LEVEL SWITCHING CONTROL RELAYS: Control relays for signal circuits shall have a minimum of three SPOT, gold-flashed, fine silver contacts rated 3-AMPERE resistive at 120V AC or 28Vdc. Control relays shall be plug-in type with heavy-duty, barrier-protected screw terminal sockets and clear POLYCARBONATE dust cover with clip fastener. AC models SHALL have neon lamp indicator wired in parallel with coil. DC models shall have LED lamp indicator wired in parallel with coil. 1 . MANUFACTURER: Potter Blumfield series KUP; Schrack Series RA; or equal C. TIMERS: 1. Multi- function, micro-controller based, socket mounted timing relay. 2. Single functions: a. Delay on Make b. Delay on Break c. Recycle (on time first, equal recycle delays) d. Single shot e. Interval f. Trailing edge single shot BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-7 g. Inverted single shot h. Inverted delay on break i. Accumulative delay on make j. Re-triggerable single shot 3. Dual functions: a. Delay on make/delay on break b. Delay on make/recycle (on time first, equal recycle delays.) c. Delay on make/interval d. Delay on make/single shot e. Interval/recycle (on time first, equal recycle delays) f. Delay on break/recycle (on time first, equal recycle delays) g. Single shot/recycle (on time first, equal recycle delays) h. Recycle - both times adjustable (on time first) i. Recycle - both times adjustable (off time first) j. Interval/delay on make k. Accumulative delay on make/interval 4. Time delay range, switch selectable: a. Single function 0.1 second to 1,705 hours in 8 ranges. b. Dual function 0.1 second to 3,100 minutes in 8 ranges. c. Setting accuracy +/- 1 percent or 50 milliseconds, whichever is greater. d. Repeat accuracy +/- 0.1 percent or 16 milliseconds, whichever is greater. 5. Output: a. Two Form-C electromechanical isolated contacts rated 10-amperes resistive at 240Vac b. Rated 1/3-horsepower at 120 or 240Vac. c. Double-pole double-throw: DPDT. d. Mechanical life: 10,000,000 operations. e. Electrical life: 1,000,000 operations at full load. 6. Mounting: Magnal Plug 11-pin socket 7. Environment: -20 to +65 degree C. 8. Manufacturer: a. ABB / SSAC's multifunction type TRDU time delay relay with dip-switch function setting with 12Vdc, 24Vac, 120Vac, 240Vac inputs as required or indicated or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-8 D. TIME SWITCH Provide an electronic time switch with full-year control in a NEMA 3R enclosure. The switch shall incorporate a non-volatile memory that maintains programmed switching times for the life of the time SWITCH and provide a factory installed field replaceable lithium or alkaline battery for time keeping and calendar information for a minimum of 8 years. Furnish with one single-pole, double-throw output switch rated 20-ampere at 240Vac. Furnish with manual override control. 1. Manufacturer: a. Intermatic Model ET70115CR or equal. b. Paragon Electric Company, Inc. EC71ST or equal. E. ALTERNATING RELAY 1. Alternate assignment between "Duty" and "Stand-by" at the end of each run cycle. 2. Double-pole, double-throw output relay rated for 7-amps inductive at 120-volts AC. Isolation not less than 1,500-volt RMS input to output. Life of 1,000,000 operations at full electrical load. 3. Switch to select alteration or continuous operation of either load. 4. Mount in Magnal 11-pin socket. 5. Operating temperature range of-20 to +60-degree C. 6. Manufacturer: a. ABB-SSAC type ARP series or Engineer accepted substitute. F. MOTOR DRIVEN TIMERS- ON DELAY AND OFF-DELAY 1. Time Delay Relay - Upon Energization (TDE) or Upon De-Energization (TDDE): a. TDE driven by a 120 Vac synchronous motor that starts timing when initiated by an external signal via closing a dry contact. Turn a knob on the front of the dial for time settings. TDE device will reset upon power failure. TDDE device will not reset upon power failure. Special configuration where specified: will not reset upon power failure. 2. Provide a pilot light visible from the front of the timer to indicate when the timer motor is energized. Provide visual indication by a cycle progress pointer that advances to zero from the setting then back to zero as time progresses. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-9 3. Provide two of'instantaneous" NEMA Form-C output contacts that actuate when the timing is initiated. Provide two "delayed" NEMA Form-C contacts that actuate when the unit has timed out or de-energized. The timer automatically resets, when the timing cycle is completed. Contact ratings: 10-ampere at 120 Vac and 5-ampere at 240 Vac. 4. Permanently mount and setup the timer with the initial settings shown or specified. Timer range with 16 configurations from 5-seconds to 60-hours. Range and timer setpoints shown on drawings. 5. Timer Manufacturer: a. Eagle Cycl-Flex Automatic or Manual Reset Timer: HP5 series or HP5E series; and b. Automatic Timing Controls: Series 305D Motor Driven Analog Reset; or equal. 2.03 MAGNETIC CONTACTORS A. LIGHTING CONTACTOR: Lighting contactors shall be 100 percent rated for ballast and tungsten lighting, resistance and other non-motor loads. Contactor shall be rated 600Vac, 60-Hertz with the ampere rating and number of poles as indicated on the drawings. Provide a minimum of two poles per NEMA ICS2-211B for industrial-duty applications. The following options shall be available and shall be provided as indicated on the drawings: 1. Auxiliary contacts rated 5-amperes at 600Vac. 2. Timer or time clock attachment. 3. Transient suppression module for 120Vac control circuits. 4. Electrically or mechanically held as specified. Contactors shall be provided with disconnecting means and overcurrent protection mounted in the same enclosure. 1. Manufacturers: a. Allen Bradley Bulletin 500L or 500LP; b. Square D Class 8903; c. ASCO 918 Remote Control with control module; d. or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-10 B. MOTOR CONTACTORS: Motor contactors shall be designed for continuous operation of induction motors at 600Vac or less at 60-Hertz and shall comply with NEMA ICS2-210. Unless otherwise specified or indicated, minimum contactor size shall be NEMA Size-1, Motor contactors shall be supplied with a normally open auxiliary contact for use as a hold-in- contact and status contacts with a minimum of two additional Form-C contacts. Provide 120 Vac coil voltage and 60-Hertz frequency with the number of poles and auxiliary contacts as indicated. 1. Manufacturer: a. GE; b. ABB; c. Allen Bradley; d. Square D; e. Eaton-Cutler Hammer; f. or equal. Provide solid-state overloads relays with one alarm contact. Where specified and shown as E- SSOL, provide the electronic SSOL relay: Automatic Timing and Controls (ATC) Motor Guardian for alarming and tripping on under-current, over-current, single-phase, ground-fault, motor-jam conditions. Provide ATC current transformers and voltage connections. 1. Manufacturer: ATC Lancaster, PA 2. Model: Motor Performance Analyzer; or equal. 2.04 SAFETY DISCONNECT SWITCHES Safety disconnect switches shall be heavy-duty, 30-400-ampere ratings as indicated, fused or non-fused as indicated, stainless steel operator, safety type rated 600 volts AC. Provide fusible disconnect switches with ratings as indicated with built-in fuse pullers. Provide LPS, LPN, or LPJ 200KAIC current limiting fuses as appropriate for the circuit type and the circuit voltage. Enclosure locations and ratings: 1. Indoor enclosures: NEMA 12 2. Outdoor or corrosive areas: NEMA 4X stainless steel 3. Hazardous areas: NEMA 7 4. Classified areas: Suitable for the specified classification. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-il The operating handle shall be capable of being padlocked in the "off* position. The operator shall be a positive, quick-make, quick-break mechanism. Provide bolt-on hubs. Provide door lock. Provide nameplates with the equipment tag number, equipment description, and power source as indicated on the drawings. Submit nameplate list. Switches shall be horsepower rated for motors and shall comply with NEMA KS-1. Switches shall be provided with defeatable door interlocks that prevent the door from opening when the operating handle is in the "on" position. Switches shall have line terminal shields. 1. Manufacturer: a. ABB; b. Cutler-Hammer; c. General Electric; d. Square-D; e. or equal. 2.05 OVERCURRENT PROTECTION A. CIRCUIT BREAKERS: Circuit breakers shall be thermal magnetic, molded case type with the ampere rating as specified. Unless otherwise specified or indicated, circuit breaker interrupting rating shall be 65,000 amperes symmetrical. 2.06 ELAPSED TIME INDICATORS Elapsed time indicators shall be panel mounted, non-resettable, 5.5-digit, hour indicator, rated 120Vac, 60-Hertz. 2.07 CURRENT TRANSFORMERS AND TRANSDUCERS Provide monitoring current transformers with 600Vac insulation and primary ampere rating as indicated with 5-ampere output. Provide AC current transducer for any one of the phase conductors of the power circuit to be installed through onboard toroid. Provide a loop-powered transducer with input rated from 0 to 50-ampere with 4-20madc analog output scaled for the primary current of the current transformer. Provide zero and span adjustments. Manufacturer: ABB AC current transducer TCSA Series Loop Powered and mounting accessories, or equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-12 Provide a DIN rail or back plate mounted AC current transducer that is a loop-powered transducer with input rated from 0 to 5-ampere and with 4-20madc analog output scaled for the primary current of the current transformer. Manufacturer: ABB AC current transducer DCSA Series Loop Powered and mounting accessories, or equal. 2.08 TERMINAL STRIPS, BLOCKS, AND DEVICES Power Wiring: Provide back plate mounted terminal strips rated at 600 Vac. Control Wiring: Provide a DIN rail with spring powered contact rated at 300 Vac 24 ampere with pluggable terminals. Terminal identification standard to the product provided. 1. Manufacturer: a. Standard: Allen Bradley or equal. b. Standard: DIN rail: Phoenix Contact or Weidmuller Z-Series. 2.09 THERMOSTATS Thermostats shall be line voltage type with motor current rated contact and 70-degree to 140- degree Fahrenheit setpoint range. Manufacturer: Honeywell T631 A-1022 or equal. 2.10 NAMEPLATES Nameplates for all control stations, relays, timers, motor contactors and disconnect switches shall be provided in accordance with the requirements of Section 16000-2.04. 2.11 PRODUCT DATA Operation and maintenance data as specified in Section 01730 including approved submittal manufacturer's catalog data, as-built drawings, and instructions for all configurable or programmable components. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-13 PART 3-EXECUTION Control stations, contactors and safety disconnect switches shall be mounted 48 inches above the floor, ground, or slab to center of device. Miscellaneous electrical devices shall be tested in accordance with Section 16000 and Section 16030. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) MISCELLANEOUS ELECTRICAL DEVICES AUGUST 2010 16175-14 SECTION 17000 GENERAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL PART 1--GENERAL 1.01 DESCRIPTION A. SCOPE: This section specifies general requirements which are applicable to providing a complete, functional process control, instrumentation, communication, and signal systems for the Buena Vista Lift Station. The requirements of this section are applicable to all work specified in Division 17 of these specifications. Electrical requirements applicable to this work include those specified in Section 16000 for general electrical requirements; Section 16175 for electrical devices B. DESCRIPTION OF WORK: 1. INSTRUMENTATION AND CONTROL SYSTEM: The work consists of A Hydrualic power unit system and two metering vaults. ^J 2. PROGRAMMING: Programming shall be provided by Encina Wastewater Authority. C. DEFINITIONS: 1. GENERAL: Definitions of terminology related to Instrumentation and Industrial Electronic Systems used in the specifications shall be as defined in IEEE 100, ISA S51.1,andNEMAICS 1. 2. TWO-WIRE TRANSMITTER: A transducer which derives operating power supply from the signal transmission circuit and requires no separate power supply connections. A two-wire transmitter produces a 4 to 20 milliampere current regulated signal in a series circuit with a 24 volt direct current driving potential and a maximum circuit resistance of 600 ohms. 3. FOUR-WIRE TRANSMITTER: A transducer which derives operating power from separate power supply connections. A four-wire transmitter produces a 4 to 20 milliampere current regulated signal in a series circuit with a maximum circuit resistance of 600 ohms. Four-wire transmitters typically require 120Vac or 24Vdc input power supply. GENERAL REQUIREMENTS FOR BUENA VISTA LIFT STATION FORCE MAIN (VC-4) INSTRUMENTATION AND CONTROL AUGUST 2010 17000-1 4. GALVANIC ISOLATION: Electrical node having no direct current path to another electrical node. Galvanic isolation refers to a device with electrical inputs and/or outputs which are isolated from ground, the device case, the process fluid, and separate power supply terminals. Inputs and/or outputs may be externally grounded without affecting the characteristics of the devices or providing path for circulation of ground currents. 5. PANEL: An instrument support system which may be a flat surface, a partial enclosure, or a complete enclosure for instruments and other devices used in process control systems including consoles, cabinets and racks. Panels provide mechanical protection, electrical isolation, and protection from dust, dirt, moisture, and chemical contaminants which may be present in the atmosphere. 6. DATASHEETS: Data sheets shall refer to ISA S20 or ISA TR20.00.01. 7. SIGNAL TYPES: Used in systems specified in Division 17: a. LOW-LEVEL ANALOG: Signal with full output level of 100 millivolts or less including thermocouples and resistance temperature detectors. b. HIGH-LEVEL ANALOG: Signals with full output level greater than 100 millivolts but less than 30 volts, including 4 20 mA transmission. c. DIGITAL CODE: Coded information from the output of an analog to digital converter or digital transmission terminal. d. PULSE FREQUENCY: Counting pulses emitted from speed or flow transmitters. e. MODULATED SIGNALS: Signals from modems or low level audio signals. Normal signal level: plus 4 dBm to minus 22 dBm. Frequency range is 300 to 10,000 Hertz. f. DISCRETE CONTROL OR EVENTS: Dry contact closures and signals monitored by solid state equipment, relays, or control circuits. g. LOW VOLTAGE DISCRETE CONTROL OR EVENTS: Dry contact closures and signals monitored by solid state equipment, relays, or control circuits operating at less than 30 volts and 250 milliamperes. h. HIGH-LEVEL AUDIO SIGNALS: Audio signals exceeding plus 4 dBm, including loudspeaker circuits. i. RADIO FREQUENCY SIGNALS: Continuous wave alternating current signals with fundamental frequency greater than 10 kilohertz. BUENA VISTA LEFT STATION FORCE MAIN (VC-4) AUGUST 2010 GENERAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL 17000-2 8. SYSTEMS INTEGRATOR: A firm engaged in the business of detailed control system design and engineering, instrumentation component purchase, system and panel assembly, programming, and implementing the specified process control and industrial automation systems. 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced. Reference IEEE 100 ISA S5.4 ISA S20 ISAS51.1 ISATR20.00.01 NEMA ICS 1 Title Standard Dictionary of Electrical and Electronics Terms Instrument Loop Diagrams Specification Forms For Process Measurement and Control Instrumentation, Primary Elements, and Control Valves Process Instrumentation Terminology Specification Forms for Process Measurement and Control Instruments Part 1: General Considerations General Standards for Industrial Control and Systems BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 GENERAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL 17000-3 B. PROCESS EQUIPMENT COORDINATION: Division 17 specified equipment shall be coordinated for proper operation with equipment related process equipment specified in other Divisions. Equipment shall be integrated, furnished, and installed in conformance with the drawings, specifications, and the recommendations of the equipment manufacturer and the related processes equipment manufacturers. Systems Integrator shall obtain manufacturer's technical information for items of equipment not provided with, but directly connected to, the control system. Provide the necessary coordination and components for correct signal interfaces between specified equipment and the control system. Systems Integrator shall coordinate with project subcontractors and equipment suppliers. Systems Integrator shall provide installation supervision for all equipment which requires controls. Systems integrator shall coordinate all programming and signal inputs and outputs to be compatible with the Encina Wastewater Authority SCADA system. Conflicts between the plans, specifications, manufacturer/vendor drawings and installation instructions, etc., shall be presented to the Engineer for resolution before proceeding. 1.03 ENVIRONMENTAL CONDITIONS A. GENERAL: Specified data communication and process control equipment shall suitable for operation in indoor locations and in outdoor locations. B. CORROSIVE LOCATIONS: Corrosive locations shall be as specified on the contract drawings. C. HAZARDOUS (CLASSIFIED) AREAS: Hazardous areas shall be as specified on the contract drawings. D. SEISMIC: Equipment and supports shall be braced per the California Building Code, latest edition. GENERAL REQUIREMENTS FOR BUENA VISTA LEFT STATION FORCE MAIN (VC-4) INSTRUMENTATION AND CONTROL AUGUST 2010 17000-4 1.04 FUNCTIONAL REQUIREMENTS A. GENERAL: The instrumentation and control system functions are shown on the drawings and specified in subsequent sections of Division 17. The Systems Integrator drawings and integration practices shall be as defined in IEEE 100, ISA S51.1, and NEMA ICS 1. B. SUBMITTAL DRAWINGS: 1. GENERAL: The drawings included in the project manual are functional in nature and do not show exact locations of equipment or interconnections between equipment. Drawings prepared in AutoCAD version 2006 with borders and title blocks identifying the project, system, revisions to the drawing, and type of drawing. Each revision of a drawing shall include the date and description of the revisions. Drawing prints shall be 11" x 17" with a minimum lettering size of 1/8". Drawings shall be generated using City of Carlsbad furnished drawing borders and title blocks, and in adherence to City of Carlsbad's drawing standards. Diagrams shall carry a uniform and coordinated set of wire numbers and terminal block numbers in compliance with panel wiring, Section 16175 , to permit cross- referencing between contract documents and the drawings prepared by the Contractor. 2. CONNECTION DIAGRAMS: Show components of a control panel in an arrangement similar to the actual layout of the panel including internal wiring between devices within the panel. Show terminal blocks used for internal wiring or field wiring, identified as such. Indicate insulation color code, signal polarities, and wire numbers and terminal block numbers. 3. INTERCONNECTION DIAGRAMS: Show panels, panel devices, and field devices with wire numbers, cable numbers, raceway numbers, terminal box numbers, terminal block numbers, panel numbers, and field device tag numbers. 4. ELEMENTARY OR SCHEMATIC DIAGRAM: Shows, by means of graphic symbols, the electrical connections and functions of a specific circuit arrangement. Provide schematics for internal panel power distribution, lighting, and any panel HVAC. 5. ARRANGEMENT, LAYOUT, OR OUTLINE DRAWINGS: Show the dimensioned external and interior control panel views with components and Bill of Material. Provide panel heat load calculations, and indicate cooling or ventilation provisions as required. GENERAL REQUIREMENTS FOR BUENA VISTA LIFT STATION FORCE MAIN (VC-4) INSTRUMENTATION AND CONTROL AUGUST 2010 17000-5 6. NETWORK BLOCK DIAGRAM: A network block diagram is a diagram of the overall SCADA system, with annotated boxes to show the primary network components (controllers, hubs, switches, computers, displays), and annotated interconnecting lines that show the system communication media and communication protocols. 7. LOOP DIAGRAMS: Provide loop diagrams for analog and discrete loops interconnected into the control system circuits: a. Prepare per ISA S5.4 - Loop Diagrams using the Example Loop Diagrams where included. b. Show device element wiring of the system. c. Show circuits for hardwired device interlocks. d. Show circuit cable and wire cable numbers, signal polarities, and terminal block numbers. 1.05 SUBMITTALS The following information shall be provided in accordance with and Section 01300: 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. A check mark shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each requested deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification for requested deviations from the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. GENERAL REQUIREMENTS FOR BUENA VISTA LIFT STATION FORCE MAIN (VC-4) INSTRUMENTATION AND CONTROL AUGUST 2010 17000-6 2. Detailed product literature, showing product specifications and model number breakdown. Mark to denote features and options included. Include only the applicable pages. 3. Manufacturer's installation manual excerpts, as to be used for this project: a. Installation details/drawings. b. Electrical connection diagrams c. Calibration procedures. 4. Drawings and diagrams specified in paragraph 17000-1.04 B. 5. Nameplate list with material, tag number and description as specified herein. 7. Data Sheets in accordance with ISA 20 for each instrument. Identical instruments may be submitted with one common ISA Data Sheet and accompanying tag list. Review the submittal requirements specified in other Division 17 Sections. PART 2-PRODUCTS 2.01 MATERIALS AND QUALITY Equipment material shall be new, free from defects, and industrial-grade, as specified. Each type of instrument, instrument accessory, and device used throughout the work shall be manufactured by one firm, where possible. Electronic equipment shall be of solid-state construction with printed or etched circuit boards of glass epoxy of sufficient thickness to prevent warping. 2.02 NAMEPLATES Nameplates shall be provided for all field mounted instrument, analyzer, or equipment specified in Division 17. Nameplate lettering shall include the equipment or instrument loop title and the instrument or equipment tag number, where nameplate engraving is not specified or shown. Nameplates shall be machine engraved black phenolic with white 5/32-inch high lettering, as minimum, unless otherwise specified or shown. Nameplate wording may be changed without additional cost or time, if changes are made prior to commencement of engraving. Nameplates shall be attached to support hardware with a minimum of two self-tapping type 316 stainless steel screws in a readily visible location so the nameplate will remain to identify the service when the device is removed. Field instrument namplates shall be attached with braided stainless steel straps where not stand mounted. GENERAL REQUIREMENTS FOR BUENA VISTA LIFT STATION FORCE MAIN (VC-4) INSTRUMENTATION AND CONTROL AUGUST 2010 17000-7 2.03 PRODUCT DATA The following Product Data shall be provided in accordance with Section 01300. 1. Record drawings specified by paragraph 17000-1.04 B and the schedules included in Division 17 shall be provided in accordance with Section 2 of the General Provisions in the latest AutoCAD format and PDF format on CD. a. Provide record drawing prints of all drawings following project start-up, but prior to acceptance of the work showing the final constructed state of the instrumentation and control systems. 2. Operating and maintenance information shall be provided in accordance with Section 01730. Include the following in each Operation and Maintenance manual: a. Final reviewed Submittals, including revised as-built record drawings. b. Manufacturer's operation and maintenance instructions, edited for this project. c. Written record of menu configuration, jumpers, switch settings, and other configurable parameters for each instrument. PART 3--EXECUTION 3.01 INSTALLATION A. GENERAL: Equipment shall be installed in locations that are accessible for operation and maintenance services. Equipment not accessible shall be reinstalled at no cost to the City of Carlsbad, Installation, calibration, settings, and testing procedures are specified in Section 17000, and subsequent sections of Division 17 B. FIELD EQUIPMENT: Equipment shall be provided with ports and adjustable items accessible for in-place testing and calibration. Install equipment between 48 inches and 60 inches above the floor or permanent work platform. Equipment shall be mounted to avoid shock or vibration that may impair operation. Equipment shall be mounted for unobstructed access and walkways. Equipment support systems shall not be attached to handrails, process piping or mechanical equipment. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 GENERAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL 17000-8 Instruments and cabinets supported by concrete walls shall be spaced 5/8 inch by framing channel between instrument or cabinet and wall. Block wall shall have additional installation supports, as required, to avoid damage to the wall. Equipment supports shall be hot-dip galvanized after fabrication or shall be 316L stainless steel, as shown or specified. Support systems including panels shall be designed in accordance with the California Building Code, latest edition, to prevent deformation greater than 1/8 inch in any direction under the attached equipment load and under an external load of 200 pounds. In wet or outdoor areas, conduit penetrations into instrument housing shall be made through the bottom (preferred) or side of enclosures to minimize water entry from around or from inside of conduits. Provide conduit hubs for connections and waterproof mastic for moisture sealant. Nameplates shall be provided for all field mounted equipment. Nameplates shall be attached to support hardware with a minimum of two self-tapping Type 316 stainless steel screws in a readily visible location, but such that if the field device is changed out, the nameplate will remain to identify the service. C. ELECTRICAL POWER CONNECTIONS: Equipment electric power wiring shall comply with Division 16. Power disconnect switches shall be provided within sight of equipment and labeled to indicate the specific equipment served and the power source location. "Within sight of is defined as having an unobstructed view from the equipment served and within 50 feet of the equipment served. Equipment power disconnect switches shall be mounted between 36 inches and 72 inches above the floor or permanent work platform. Where equipment location requirements cannot be met by a single disconnect switch, provide two disconnect switches: one at the equipment and one at the work platform. Provide a surge arrestor on each 120 volt AC disconnect switch serving equipment located outdoors. Surge arrestor shall be Telematic, LP Series or equal. D. SIGNAL CONNECTIONS: Equipment electric signal connections shall be made on terminal blocks or by locking plug and receptacle assemblies. Flexible cable, receptacle and plug assemblies shall be used where shown or specified. Jacketed flexible conduit shall be used between equipment and rigid raceway systems. Flexible cable assemblies may be used where plug and receptacle assemblies are provided and the installation is not subject to mechanical damage in normal use. The length of flexible conduit or cord assemblies shall not exceed 2 feet, except where sufficient length is required GENERAL REQUIREMENTS FOR BUENA VISTA LEFT STATION FORCE MAIN (VC-4) INSTRUMENTATION AND CONTROL AUGUST 2010 17000-9 to allow withdrawal of instruments for maintenance or calibration without disconnection of conduit or cord assemblies. 3.02 FIELD TESTS AND INSPECTIONS A. DELIVERY INSPECTION: The Contractor shall notify the City of Carlsbad's Representative upon arrival of any material or equipment to be incorporated into the work. The Contractor shall remove protective covers or otherwise provide access in order that the City of Carlsbad's Representative may inspect such items. B. INSPECTION AND INSTALLED TESTS: Refer to Section 17030 - Process Instrumentation and Control System Testing. ** END OF SECTION ** GENERAL REQUIREMENTS FOR BUENA VISTA LIFT STATION FORCE MAIN (VC-4) INSTRUMENTATION AND CONTROL AUGUST 2010 17000-10 SECTION 17030 PROCESS INSTRUMENTATION AND CONTROL SYSTEM TESTING PART 1 -- GENERAL 1.01 DESCRIPTION This section specifies Contractor and Systems Integrator performance in testing and documentation of process instrumentation and control system materials and equipment (PICS). The term instrumentation covers field and panel instruments, analyzers, primary sensing elements, transmitters, power supplies, and monitoring devices. Provide the labor, tools, material, power, and services necessary to provide the process instrumentation and control system inspection and testing specified herein. Coordinate all testing with Section 01660: A. Pre-Operational Performance Testing Sequence: 1. Wiring Testing 2. Piping Testing 3. Installation Inspection . 4. Instrumentation Calibration 5. Loop Testing B. Functional Testing Sequence: 1. Control System Closed Loop Commissioning 2. Functional Checkout C. Operational Testing: 1. System Acceptance Testing (SAT) 1.02 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents with additional references listed in Section 17000. PROCESS INSTRUMENTATION BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AND CONTROL SYSTEM TESTING AUGUST 2010 17030-1 All references shall be to the current edition of the document unless specifically stated otherwise. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail, Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no bids). If referenced documents have been discontinued by the issuing organization, reference to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, reference to those documents shall mean the specific document version associated with that date, whether or not the document has been superseded by a version with a later date, discontinued or replaced. Reference ISARP7.1 ISAS51.1 Title Pneumatic Control Circuit Pressure Test Process Instrumentation Terminology B. PROJECT LABELING The items specifying project labeling herein shall include the following as a minimum: Owner's name, facility name, project name, and project number. 1.03 SUBMITTALS Submittal material, to be submitted in accordance with Section 01300, shall consist of the following: A. QUALIFICATION SUBMITTAL: Provide the following submittal in accordance with Section 01300-Submittals: 1. Example test forms per paragraph 17030-3.01 D, revised to show Project Labeling per paragraph 17030-1.02 B. B. DEFINITION SUBMITTAL: Provide the following submittal after review of the Qualification Submittal. 1. A control description outlining operation for each process area's system. PROCESS INSTRUMENTATION BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AND CONTROL SYSTEM TESTING AUGUST 2010 17030-2 2. I/O spreadsheets for each process area's system. 3. Testing status spreadsheets. 4. Test procedures per paragraph 17030-3.01 D. 5. Proposed test forms per PART 3 of this Section 17030, detailed for each test for this project. 6. Provide a copy of this specification and the referenced and applicable sections with addenda updates included with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. 7. Provide a copy of all referenced and applicable Instrumentation Drawings with addenda updates included, marked to indicate requested deviations from specified requirements. 8. Provide a copy of all referenced and applicable Electrical Drawing's Control Diagrams with addenda updates included, marked to indicate requested deviations from specified requirements. 9. Failure to include a copy of the specifications and drawings with the submittal shall be cause for rejection of the entire submittal with no further consideration. PART 2 » PRODUCTS 2.01 PRODUCT DATA Provide the following product data submittal after completion of testing. The following information shall be provided in accordance with specification Section 01300: 1. Completed test forms per PART 3. 2. List of factory calibrated items and calibration certificates. 3. Final Test Report assembled in a three-ring binder and submitted at the completion of the inspection and testing activities for a process area. The binder cover and spine shall be labeled to identify the project name and process area. Test report shall include the applicable test procedures for the process area and the completed inspection and test report forms associated with the equipment and systems of that area. PROCESS INSTRUMENTATION BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AND CONTROL SYSTEM TESTING AUGUST 20 !0 17030-3 Test results shall be organized by equipment item or system with individual, labeled tab dividers to identify each. System deficiencies and non-compliant test results identified in the final test report shall be acknowledged by the responsible testing entity as corrected. PART 3 « EXECUTION 3.01 GENERAL A. GENERAL REQUIREMENTS: Materials, equipment, and construction included under this specification shall be inspected in accordance with this section and subsequent sections of this division. Testing shall be performed by the Contractor in accordance with this and subsequent sections of this division. No required test shall be applied without prior notice to the Engineer. Between 60 and 70 days before the commencement of any testing activity, the Contractor shall provide a detailed step-by-step test procedure complete with forms for the recording of test results, testing equipment used, and a place for identification of the individual performing or, if applicable, witnessing the test. Provide detail assistance to the Contractor in generating form 01660-A, customized for this project. Submit detailed form prior to testing per the requirements of Section 01660. B. TECHNICIAN QUALIFICATIONS: Field instruments and analyzers shall be calibrated and set up by a certified instrument technician qualified to calibrate the instrumentation. Technicians shall be qualified by completion and certification from training courses offered by The Instrumentation, Systems, and Automation Society (ISA), the instrumentation and analyzer manufacturer's training courses, or technician training courses at a recognized trade school that specializes in instrumentation calibration. C. TEST EQUIPMENT AND MATERIALS: Provide test equipment to conduct the specified tests that simulate inputs and read outputs with a rated accuracy at the point of measurement at least three times greater than the component under test. Test instruments shall have a current calibration sticker showing date of calibration, deviation from standard, name of calibration laboratory and technician, and date recalibration is required. Certified calibration reports traceable to the National Institute of Standards and Technology shall be included with the final test report. PROCESS INSTRUMENTATION BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AND CONTROL SYSTEM TESTING AUGUST 2010 17030-4 Provide a documenting calibration system to conduct process instrumentation calibration activities that consist of a documenting process calibrator and an instrumentation data management software system that captures the calibration results and electronically document instrument data, date of calibration, calibration procedures, and as-found and as- left instrument calibration data. D. FIELD TEST PROCEDURE DOCUMENTATION: Test procedures submitted for approval within 60 days from the date of Notice to Proceed. Test procedures for each analog and discrete loop in the process control system shall be organized and assembled in separate volumes for each process area. Final test records shall be submitted in electronic form by scanning and converting the records and files to Adobe PDF format, to preserve actual signatures and signoffs. Test procedure documentation shall include a detailed, step-by-step description of the required test procedure, panel and terminal block numbers for points of measurement, input test values, expected resultant values, test equipment required, process setup requirements, and safety precautions. Test report forms for each loop, including forms for wiring, piping, and individual component tests, shall be included with the test procedure documentation. The actual test results shall be recorded on these forms and a final test report assembled as specified in paragraph 17030-3.04. Test report forms shall be preprinted and completed to the extent possible prior to commencing testing. Test report forms that document the field test procedures shall include the following information: 1. Project name 2. Process area associated with the equipment under test. 3. Instrument loop description. 4. Instrument loop identification number. 5. Instrument nameplate data. 6. Instrument setup and configuration parameters. 7. Time and date of test. 8. Inspection checklist and results. 9. Reference to applicable test procedure. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PROCESS INSTRUMENTATION AND CONTROL SYSTEM TESTING 17030-5 10. Expected and actual test results for each test point in the loop including programmable controller data table or register values. 11. Test equipment used. 12. Space for remarks regarding test procedure or results, unusual or noteworthy observations, etc. 13. Name, date, and signature of testing personnel. E. PERFORMANCE DEVIATION TOLERANCES: Tolerances shall be specified in Division 17. Where tolerances are not specified, refer to the manufacturer's published performance specifications. Overall accuracy requirements for loops consisting of two or more components shall be the root-summation-square (RSS) of the component accuracy specifications. Tolerances for each required calibration point shall be calculated and recorded on the associated test report form. F. INSTALLED TESTS: Equipment and System Performance and Operational Testing - Section 01660 specifies testing of the mechanical, electrical, instrumentation and HVAC systems. The Contractor's Quality Assurance Manager shall coordinate, manage, and supervise the quality assurance program that includes: 1. Testing plan with the sequence for the test work. 2. Calibration program for all instruments and analyzers. 3. Documentation program that records tests results. 4. Performance testing program systems. Test forms provided shall conform to the requirements of reference forms 17000-A and 17000-H included in Section 01999. Additional or detailed forms shall be developed as necessary to suit complex instrumentation. Usage of terms used on test forms shall comply with ISA S51.1. G. WITNESSING: The Engineer reserves the right to observe factory and field instrumentation testing and calibration procedures. The Engineer shall be notified prior to testing, as specified herein. 3.02 PRE-OPERATIONAL PERFORMANCE TESTING A. GENERAL REQUIREMENTS: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PROCESS INSTRUMENTATION AND CONTROL SYSTEM TESTING 17030-6 In general, tests shall be performed in the following order: B. WIRING TESTS: Electrical power and signal cable ring-out and resistance testing. Conducted in accordance with Sections 16000 and 16030. Wiring tests shall not be conducted until cables have been properly terminated, tagged and inspected. 1. Power and Control: Per Section 16030. 2. Signal: Test form 17000-A. C. INSTRUMENTATION CALIBRATION: 1. Instruments and final elements shall be field calibrated in accordance with the manufacturer's recommended procedures and tested in accordance with the Contractor's test procedure. 2. Individual Component Calibration and Testing shall not commence until Instruments and Component Inspections are completed and documented to the satisfaction of the Engineer. 3. Analog instrument calibrated at 0, 10, 50, 90, and 100 percent of the specified full scale range. Each signal sensing trip and process sensing switch shall be adjusted to the required setting. Test data recorded on test forms as specified herein 4. Final element alignment tested and adjusted to verify that each final element operates smoothly over the full range in response to the specified process control signals 5. Test data shall be entered on the applicable test forms at the time of testing: Alarm trips, control trips, and switches shall be set to initial values at this time. Final elements shall be checked for range, dead-band, and speed of response. 6. Any component that fails to meet the required tolerances shall be repaired or replaced by the manufacturer. Repeat the specified tests until the component is, within tolerance. 7. Install a calibration sticker on each instrument following successful calibration that indicates the date of calibration, the name of the testing company, and personnel who calibrated the instrument. 8. Test forms 17000-H. 9. CERTIFIED TEST REPORTS: Field test and inspection activities include verification of instrument parameter setup, verification of instrument zero, and performance at three operating points within the instrument range. Instrument which fail to demonstrate proper performance shall be returned for re-calibration or replaced as agreed depending on the impact to the project as determined by the Engineer. PROCESS INSTRUMENTATION BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AND CONTROL SYSTEM TESTING AUGUST 2010 17030-7 Where instrument field calibration is not feasible, certified factory calibration reports may be submitted that includes the name and address of the laboratory that conducts the calibration testing. Certified factory test reports may be submitted for the following instrument types in lieu of field calibration: Table-A. Factory Calibration Instrument List Instrument Identification FM Instrument Section 17212 Description Magnetic flow metering system E. LOOP TESTING: 1. Loop Testing shall not commence until the Individual Component Calibration and Testing has been completed and documented to the satisfaction of the Engineer. 2. Each instrument loop shall be tested as an integrated system. Check operation from field instruments to transmitter to receiving components to the vendor panel or the Plant Control System Operator Interface Station. Test signals shall be injected at the process impulse line connection where the measuring technique permits, and otherwise at the most primary signal access point. 3. Testing of loops with an interface to a programmable logic controller shall include verification of the programmable logic controller input/output assignment and verification of operation of the input/output system and processor. Inspect the data table or register in the programmable logic controller memory to verify proper operation. 4. If the output control or monitoring device fails to indicate properly, corrections to the loop circuitry or device shall be made. The test shall be repeated until devices and instruments operate as required. 5. Correct loop circuitry and repeat the test until the instruments operate properly. 3.03 FUNCTIONAL TESTING A. PROCESS CONTROL STRATEGY/FUNCTIONAL TESTING: 1. Control Strategy Testing shall not commence until the Loop Testing has been completed and documented to the satisfaction of the Engineer. 2. Control Strategy Testing is performed by the Programmer and consist of installing and debugging the PLC control logic program, verifying the interface points between the PLCs and field devices and equipment, and exercising the control strategies. Control Strategy Testing will be performed on one PLC at a time. PROCESS INSTRUMENTATION BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AND CONTROL SYSTEM TESTING AUGUST 2010 17030-8 3. Provide qualified personnel to immediately correct any deficiencies in the Work that may be encountered during Control Strategy Testing. Failure of the Contractor to provide such personnel in a timely manner may prolong the time allotted to complete Control Strategy Testing. B. CONTROL SYSTEM CLOSED LOOP TESTING: 1. Closed-Loop Commissioning shall not commence until the Control Strategy Testing has been successfully completed and documented to the satisfaction of the Engineer 2. Closed-loop commissioning tests, performed as part of the system tests, shall demonstrate stable operation of each loop under operating conditions. Tests shall include adjustment of loop tuning parameters. 3. Tuning parameters: gain (or proportional band), integral time constant, and derivative time constant for each control loop, adjusted to provide 1/4-amplirude damping, unless otherwise specified. 4. The loop response to a step disturbance shall be provided for each loop. Two graphs shall be made for cascaded control loops, one snowing the secondary loop response with its set point in manual, and the second showing overall loop response. 5. Control loops with "batch" features shall be adjusted to provide optimum response ^t^ following start-up from an integral action saturation condition. ...tiuatf} 6. Graph recording shall be provided showing the response and made at sufficient speed and amplitude to show 1/4 amplitude damping. Label to show loop number and title, and settings of parameters and set point. 7. Where a loop is controlled under the direction of a programmable logic controller, the Engineer will perform the necessary adjustment of loop tuning parameters and setpoints; Contractor shall record the loop response, adjusting final elements, and assuring total integrated loop performance as specified. C. FUNCTIONAL CHECKOUT: Conducted to verify the operation of discrete and hardwired control devices, refer to Section 01660. Exercise the operable devices and energizing the control circuit. Operate control element, alarm device, and interlocks to verify the specified action occurs. 3.04 OPERATIONAL TESTING System Acceptance Test (SAT) shall be performed after component and subsystem tests have been completed. The test of the completed system shall be performed in full operation and PROCESS INSTRUMENTATION BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AND CONTROL SYSTEM TESTING AUGUST 2010 17030-9 shall demonstrate that all functional requirements of this specification have been met. SAT shall demonstrate the following: 1. Each component of the system operates correctly with all other components of the system. 2. Analog control loops operate in a stable manner. 3. Hard-wired and software equipment interlocks perform correctly. 4. Process control sequences perform correctly. 5. PLC application program performs monitoring and control functions correctly. 6. Operator interface graphics represent the monitoring and control functions correctly. ** END OF SECTION ** BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 PROCESS INSTRUMENTATION AND CONTROL SYSTEM TESTING 17030-10 SECTION 17212 TRANSMITTERS PART 1» GENERAL 1.01 DESCRIPTION This section specifies requirements for process parameter transmitters, associated indication devices, and accessories. The application requirements are specified in the INSTRUSPEC sheets in paragraph 17212-3.03. 1.02 REFERENCES References shall be as specified in Section 17000. 1.03 SUBMITTALS Submittals shall be provided as specified in Sections 01300 and 17000, including: 1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check- marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Referenced and applicable sections to be marked up and submitted include: a. Section 01730 - OPERATING AND MAINTENANCE INFORMATION b. Section 17000 - GENERAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL A check mark shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justifications) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) TRANSMITTERS AUGUST 2010 17212-1 2. A copy of the contract document Control Diagrams and Process and Instrumentation Diagrams relating to the submitted equipment, with addendum updates that apply to the equipment in this section, marked to show specific changes necessary for the equipment proposed in the submittal. If no changes are required, the drawing or drawings shall be marked "no changes required". Failure to include copies of the relevant drawings with the submittal shall be cause for rejection of the entire submittal with no further review. 3. Marked Contract Document Mechanical and/or Electrical Plan drawings, sections, and details showing sensor installation locations and details. Failure to include copies of the relevant drawings with the submittal shall be cause for rejection of the entire submittal with no further review. 4. Marked product literature of all equipment and features to be provided. 5. Installation drawings for only the transmitters, sensors, and mounting accessories to be provided. 6. Electrical and signal connection drawings for only the transmitters and sensors to be provided. 7. List of miscellaneous items, cables, spare parts, that will be provided in accordance with INSTRUSPEC sheet requirements. 8. Marked product literature for surge protectors. PART 2 -- PRODUCTS 2.01 GENERAL Measuring elements and transmitters shall comply with the following requirements: 1. Measured parameter output indicators complying with paragraph 17212-2.02 shall be provided with any transmitter that does not include an integral indicator. Indicators, whether integral or separate, shall be calibrated in process units, and engraved on the indicator scale plate. 2. The two-wire type transmitters shall have operating power derived from the signal transmission circuit. 3. Transmitters shall meet specified performance requirements with load variations within the range of 0 to 600 with the power supply at a nominal 24 volts DC with the default range of 0 to 100% corresponding to 4 to 20 made. 4. Transmitter output shall increase with increasing measurement. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) TRANSMITTERS AUGUST 2010 17212-2 5. Time constant shall be adjustable from 0.5 to 5.0 seconds for transmitters used for flow, level transmitters used for flow measurement, or pressure measurement. 6. Transmitter output shall be galvanically isolated via electro-mechanical or optical technology. 7. Transmitter enclosures shall be rated NEMA 250, Type 4, unless otherwise specified. 8. Transmitters located outdoors shall be provided with surge protectors: a. Signal: Emerson/Rosemount Model 470 D, Emerson/EDCO SS64-036-2, CCI SPN-42 FS28 Series, or accepted equal. b. AC Power: UL 1449, LED indicator, screw terminal connections, NEMA 4X. EDCO HSP121A or accepted equal. 9. Two-wire transmitter located in a facility area classified as hazardous per the NFPA and the NEC shall be made safe by means of an intrinsic safety barrier as specified in paragraph 17212-2.03. 10. Four-wire transmitters shall be isolated from the process and power or provided with a loop-powered signal current isolator as specified in paragraph 17212-2.05 connected in the output signal circuit. 2.02 PROCESS PARAMETER OUTPUT INDICATOR Provide digital LED or LCD indicators that are integral to the instrument housing where available from the manufacturer. Displays shall be scaled in engineering units, over the calibrated range of the instrument. Calibrate the indicator scale in process units. Analog output indicators shall be 2.5-inch milli-ammeter with 90-degree movement enclosed in a NEMA 7/9 rated meter case. Provide indicators with accuracy within two percent of span. Provide a diode to maintain loop continuity for indicator removal. 2.03 INTRINSIC SAFETY BARRIERS Intrinsic safety barriers for two-wire transmitters shall be of the active, isolating, loop powered type. Barrier shall be Measurement Technology LTD Type MT3042, Stahl Series 9000, Accepted equal. 2.04 INSTRUMENTATION SPECIFICATION SHEETS (INSTRUSPEC) BUENA VISTA LIFT STATION FORCE MAIN (VC-4) TRANSMITTERS AUGUST 2010 17212-3 General requirements for instruments specified in this section are listed on INSTRUSPEC sheets in paragraph 17212-3.03. 2.05 SIGNAL CURRENT ISOLATOR Isolator shall provide galvanic isolation of milliampere transmission signals from transmitters. Isolator shall be housed in a NEMA 250, Type 4/7 conduit body and derive operating power from the signal input circuit. Input and output signals shall be 4 to 20 milliamperes, and error shall not exceed 0.1 percent of span. Input resistance shall not exceed 550 ohms with an output load of 250 ohms. Isolator shall be Moore Industries SCX 4-20madc to 4-20madc / 5.5VPL / -RF [DIN rail mounted with maximum 250 ohm output impedance, or equal. 2.06 PRODUCT DATA The following data provided in accordance with Section 01300: 1. Operating and maintenance information as specified in paragraph 17000-2.03. Include final reviewed submittal and separate record of all final configuration, jumper, and switch settings for each analyzer. 2, Test results as specified in Section 17030-Part 2. PART 3 -- EXECUTION 3.01 INSTALLATION Installation requirements are specified in paragraph 17000-3.01. 3.02 TESTING Testing requirements are specified in Section 17030. 3.03 INSTRUMENT SPECIFICATION (INSTRUSPEC) SHEETS General requirements for instruments specified in this section are listed on INSTRUSPEC sheets herein. Application requirements are specified in the corresponding Specification Sections and/or on the drawings. INSTRUSPEC sheets for the analyzers listed in the following Table A are included in this paragraph: BUENA VISTA LIFT STATION FORCE MAIN (VC-4) TRANSMITTERS AUGUST 2010 17212-4 Table A: Process Monitors and Indicating Transmitters INSTRUSPEC Symbol FM LRM Instrument Description Magnetic Flow Transmitter Radar Level Detector Instrument Function Flow Measurement Level Detector BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 TRANSMITTERS 17212-5 3.03 INSTRUMENT SPECIFICATION SHEET-INSTRUSPEC Instrument Identification: Instrument Function: Instrument Description: Signal Input: Signal Output: Process Connection: Product Requirements: Flow Tube: FM Flow Measurement Magnetic Flow Metering System Process Analog signal as specified in paragraph 17212-2.01 and scaled pulse frequency Flange, ANSI B16.5, Class 150, raised face. Magnetic flow meter provided as a system consisting of a flow tube with separate or integral converter / indicating transmitter, complete with interconnecting cables Remote mounted indicating transmitter for full-scale flow rates from 1.0 to 30 feet per second. System error shall not exceed the greater of 0.5 percent of flowrate or 0.1 foot per second from 3 to 30 feet per second. Flow tubes manufacturer shall provide grounding rings fabricated from the same metal as for the electrodes below. Flow tube sizes below 2 inches may be wafer-style duc- tile-iron or full-body flanged construction. Electrodes: 316L stainless steel. Instrument Identification: Transmitter: FM (continued) Liner: Polyurethane Contain electronics associated with the magnetic flow meter system. Enclosure rating NEMA-4, cast aluminum or metal compartment for power, field connections and calibration adjustments separate from digital circuitry. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 TRANSMITTERS 17212-6 3.03 INSTRUMENT SPECIFICATION SHEET--INSTRUSPEC Instrument Identification:FM (continued) Means to calibrate the metering system without use of external calibration units. Transmitter self-diagnostics. Traceability certificate of actual flow lab certification provided with each flowtube. Integral 4-digit LCD flow indication calibrated in process units. Data retained in non-volatile memory. Internal circuitry to drive flow signal to zero upon flow meter determined empty pipe condition Pulse frequency shall stop at flows below two percent of maximum range, where the pulse frequency feature is specified. Execution: Installation: Cable: Install in accordance with manufacturer's instructions and the specified functional requirements. Signal cable between the flow tube and transmitter provided by the system manufacturer with sufficient length of cable for continuous installation between the flow tube and the transmitter. Manufacturers:ABB Magmaster MFE; Krohne Optiflux 4000; or accepted equal. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 TRANSMITTERS 17212-7 3.03 INSTRUMENT SPECIFICATION SHEET--INSTRUSPEC Instrument Identification: Instrument Function: Instrument Description: Power Supply: Signal Input Signal Output: Signal Converter/Transmitter: LRM Level Measurement Radar Level Transmitter: Pulse Type - Loop Powered 24Vdc - loop powered. Process As specified in paragraph 17212-2.01 Signal type: 6.3 to 26 GHz range with the maximum output power of 100 milliwatt. Enclosure: NEMA 4X integral mount. Operator Interface: LCD display, scaled in engineering units, with soft-keys for scrolling and configuration. Networks: HART standard or Foundation Fieldbus. Measuring range: 0-60 feet. Accuracy: ±0.2 inch Analog Output: One isolated 4-20 mA, minimum of 300Q. Ambient Temperature Range: -20 to +140°F. Process Temperature Range: -40 to +600°F Pressure Range: full vacuum to 600 psig. Sensor: 3 inch process seal type Process Connection: 4 inch 150 pound ANSI flange Wetted Materials: 316 SS, PTFE, PVDF, Viton, or as approved. Accessories: Provide mounting hardware and cable length glands. Provide Hart data communication interface and software for field programming. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 TRANSMITTERS 17212-8 Instrument Identification LRM (continued) Provide Hart handheld infrared programming device and programming software and cable. Acceptable Manufacturer: VEGAPULS 63 Drexelbrook Model DR7000 Accepted equal. o Execution: Installation:Install in accordance with manufacturer's instructions and the Engineer's installation detail. Contractor to verify size and type of specified tank connection with approved tank submittals. BUENA VISTA LIFT STATION FORCE MAIN (VC-4) AUGUST 2010 TRANSMITTERS 17212-9 APPENDIX A Resident Notification Example Brown Caldwell RESIDENT NOTIFICATION EXAMPLE CITY OF CARLSBAD ROAD WORK ABC CONTRACTORS OFFICE # (760)XXX-XXXX FIELD # (760)XXX-XXXX Dear resident: As a part of the City of Carlsbad's ongoing program to maintain its sewer system, your street will be resurfaced with asphalt concrete over the existing roadway surface. This construction will require the closing of your street to through traffic for one day. Your street, from XYZ Sf. to DEF Ave. will be closed to through traffic and resurfaced on: MOM. TUE. WED. THU. FRI. DATE: XX/XX/XX from 7:OOA.M. to 5:00 P.M. If you don't plan to leave your home by 7:00 A.M. on the above date please park your car on an adjacent street in your neighborhood that will not be resurfaced. Streets scheduled for resurfacing can be determined by calling either the Contractor or the City of Carlsbad's Project Inspector. When walking to and from your car, remember not to walk on the newly overlaid street or you will have black residue on the bottom of your shoes. Please do not drive, walk on, walk pets, play, or skate on the newly overlaid asphalt. Also, please refrain from watering your lawns, washing cars, etc., approximately 6-8 hours after'the asphalt is laid as running water will cause damage to the new surface. ABC is the Contractor that will be performing the sewer improvement and resurfacing work for the city and you may call them at the above phone number if you have any questions regarding the project. Resurfacing of your street will not occur on the day your trash is collected. Mail delivery may be delayed if the postman cannot reach the mailbox that day. If you have a moving company scheduled for that day please call and inform the Contractor of the date. If you have any concerns which cannot be addressed by the Contractor, you may call the City's Project Inspector @ (xxx) xxx-xxxx. Thank you for your cooperation as we work to make a better City of Carlsbad. APPENDIX B Encina Wastewater Authority (EWA) Forms Brown Caldwell B Mail completed and signed application to: Encina Wastewater Authority SPECIAL USE DISCHARGE PERMIT APPLICATION Encina Wastewater Authority 6200 Avenida Encinas Carlsbad, CA 92011 Phone:(760)438-3941 Permit No. Reviewer _ Date SECTION A - GENERAL INFORMATION 1. Company/Applicant Name: 2. Facility/Site Address: 3. 4. 5. 6. Corporate/Owner(s) Names: Head Office Address: Street D Corporation ames: City D Partnership Zip D Sole Proprietor Street City Other Address(es): Street City (Circle: Mailing, Billing, Landlord, Property Manager, Property Owner, Pretreatment Equipment Operator, etc.) Persons to contact concerning this application: (Indicate at which address contact may be reached: F - Facility, HO - Head Office, O - Other) Zip Zip (Attach Additional Sheet(s).) Administration Title Phone No.Ext.Address Inspection/Sampling Title Phone No.Ext.Address Other (Attach Additional Sheet(s).)Title Phone No.Ext.Address (Person Who Can Be Served Notice at the Site) Title Phone No. Ext. Address 1 Person with signatory authority to whom legal documents should be directed. See Page 4 of application for signatory requirements and statement. •7. 9. 10. 11. Sewer Agency:D Buena Sanitation District D City of Carlsbad D City of Encinitas G City of Vista D Leucadia Wastewater District G Vallecitos Water District Discharge Alternatives: Provide a detailed description of the alternatives investigated for disposal including reasons why all other alternatives were not chosen. Attach additional sheet(s). Environmental Risk or Health Hazard: Explain why the discharge is necessary to mitigate an environmental risk or health hazard or to protect the beneficial reuse of wastewater byproducts. Attach additional sheet(s). Waste Origin: The source of the proposed discharge is within the Encina Service Area. (Initial)-""•*«*V Using the criteria established by regulations of the EPA and the State, the proposed discharge is not considered to be toxic or hazardous. (Initial) SECTION B - DISCHARGE CHARACTERISTICS WATER QUALITY INFORMATION 1. Describe all present and past business or other activity(s) occurring at the facility/site that may have an effect on the water quality of the proposed discharge. Attach additional sheet(s). Describe the known or suspected pollutant source(s) and history of the wastewater contaminants. Attach additional sheet(s). Give common and technical names of any materials suspected to be present in the discharge. Briefly describe the physical and chemical properties and concentrations of each substance. Attach additional sheet(s) if necessary including all existing laboratory reports. Name Description Concentration FLOW INFORMATION 1. Describe each proposed discharge by Well #, Pump # or Sample Point #. Attach additional sheet(s) if necessary. Well, Pump or Sample # Flow1 Metered Estimated Discharge Type2 Daily Max Flow3 Peak Hydraulic Flow4 Hours of Discharge Days of Discharge Discharge Period (Mo/Yr) Pretreat- ment (YorN) 1 - Average Gallons Per Discharge Day 3 - Maximum Gallons Per Discharge Day 2 - B = Batch; C = Continuous; I = Intermittent 4 - Instantaneous Maximum Gallons FLOW INFORMATION (Cont.) 2. Is the discharge from your system controlled: D Manually D Automatically 3. Describe any engineering controls and/or planned procedures for preventing flows greater than your permitted amount from entering the sewer system. Attach additional sheet(s). 4. Is there any existing or planned discharge to storm drains? D Yes D No If yes, list NPDES Permit Numbers(s) and attach a copy of the Monitoring and Reporting Requirements. 5. Describe your plan for mitigating the need to discharge to the sewer in the future. Attach additional sheet(s). PRIORITY POLLUTANT INFORMATION Place an "x" by each listed chemical which may be present in your discharge. Some compounds are also known by other names. Include the estimated concentration in mg/L, if known. D Asbestos (fibrous) D Cyanide (total) D Antimony (total) Q Arsenic (total) D Beryllium (total) d Cadmium (total) D Chromium (total) D Copper (total) D Lead (total) D Mercury (total) D Nickel (total) D Selenium (totalO D Silver (totalO D Thallium (total) D Zinc(total) D Acenaphthene D Acenaphthylene D Acrolein D Acrylonitrile Q Aldrin D Anthracene D Benzene D Benzidine D Benzo (a) anthracene n Benzo (b) fluoroanthene D Benzo (k) fluoroanthene D Benzo (g,h,i) perylene D Benzo (a) pyrene D a-BHC (alpha) D b-BHC (beta) D d-BHC (delta) D g-BHC (gamma) D Bis (2-chIoroethyl) ether Q Bis (2-chloroethoxy) methane D Bis (2-chloroisopropyl) ether D Bis (chloromethyl) ether G Bis (2-ethylhexyl) phthalate G Bromodichloromethane D Bromoform D Bromomethane D 4-bromophenyl phenyl ether D Butyl benzyl phthalate D Carbon tetrachloride D Chlordane D 4-chloro-3methylphenol G Chlorobenzene D Chloroethane D 2-chloroethyl vinyl ether D Chloroform 0 Chloromethane D 2-chloronaphthalene D 2-chlorophenol D 4-chlorophenyl phenyl ether D Chrysene D 4,4'-DDD D 4,4'-DDE D 4,4'DDT D Dibenzo (a,b) anthracene D Dibromochloromethane D 1,2-dichlorobenzene D 1,3-dichlorobenzene D 1,4-dichlorobenzene D 3,3'-dichlorobenzidine D 1,1-dichloroethane D 1,2-dichloroethane D 1,1-dichloroethylene D 1,2-trans-dichloroethylene D 2,4-dichlorophenol D 1,2-dichloropropane D 1,3-dichloropropylene D Dieldrin D Diethyl phthalate D 2,4-dimethyl phenol (H Dimethyl phthalate D di-n-butyl phthalate D di-n-octyl phthalate D 4,6-dinitro-o-cresol D 2,4-dinitrophenol G 2,4-dinitrotoluene D 2,6-dinitrotoluene D 1,2-diphenyIhydrazine D a-endosulfan (alpha) D b-endosulfan (beta) D Endosulfan sulfate D Endrin D Endrin aldehyde D Ethylbenzene D Fluoranthene n Fluorene D Heptachlor D Heptachlor epoxide G Hexachlorobenzene D Hexacholorobutadiene D Hexachlorocyclopentadiene D Hexachloroethane D Indeno (l,2,3-c,d) pyrene D Isophorone n Methylene chloride D Naphthalene D Nitrobenzene D 2-nitrophenol D 4-nitrophenol Q n-nitrosodimethylamine D n-nitrosodi-n-propylamine D n-nitrosodiphenylamine D PCB-I016 DPCB-1221 Q PCB-1232 0 PCB-1242 D PCB-1248 D PCB-1254 DPCB-1260 D Pentachlorophenol D Phenanthrene D Phenol D Pyrene G2,3,7,8-tetrachlorodibenzo-p-dioxin 0 1,1,2,2-tetrachloroethane D Tetrachloroethylene D Toluene D Toxaphene D 1,2,4-trichlorobenzene D 1,1,1-trichloroethane D 1,1,2-trichloroethane D Trichloroethylene D 2,4,6-trichlorophenoI D Vinyl chloride SECTION C - DRAWING AND INFORMATION SUBMITTAL REQUIREMENTS (Diagrams may be submitted separately or combined as long as the required information is included.) 1. Assessor's Parcel Number(s): Provide the parcel numbers for all properties in the affected drainage area. 2. Facility/Site Diagram(s): Attach a diagram of the facility/site which includes the plume and/or drainage area, directional flow of water, all existing or proposed wells, pumps, sample points, flow meters, sewer drains, sewer laterals, manholes, discharge point(s), and containment structures (berms). 3. Wastewater Treatment Diagram(s): Attach a diagram of the wastewater pretreatment system (if any) and give expected pollutant removal efficiencies. Include engineering calculations supporting the sizing of the proposed pretreatment equipment. 4. Cleanup and Abatement Order: Attach a copy of any Cleanup and Abatement Order issued by any other regulatory agency having jurisdiction over the discharge, including the pretreatment proposed or required by that order. 5. Remediation Plan: Attach a copy of any proposed or approved Remediation Plan prepared for the property. 6. Sampling Schedule: Attach a proposed sampling schedule including sampling points and constituents. 7. Liens: Attach a copy of any liens against the property. 8. General Liability: Attach proof of general liability and environmental impairment liability insurance of at least $5,000,000 naming EWA and the Member Agencies as additional insureds, and covering all liability for damages resulting from the discharge. 9. Indemnity Agreement: Attach the signed Indemnity Agreement provided to you with this application. SECTION D - CERTIFICATION The certification statement below must be signed as required in items 1, 2, 3 or 4 below: 1. By a responsible corporate officer, if the User submitting the reports is a corporation. For the purpose of this section, a responsible corporate officer means: a. a president, secretary, treasurer, or vice-president of the corporation in charge of a principal business function, or any person who performs similar policy or decision-making functions for the corporation; or b. the manager of one or more manufacturing, production or operation facilities employing more than 250 persons or having gross annual sales or expenditures exceeding $25 million (in second-quarter 1980 dollars), if authority to sign documents has been assigned or delegated to the manager in accordance with corporate procedures. 2. By a general partner or proprietor, if the User submitting the reports is a partnership or sole proprietorship, respectively. 3. By the principal executive officer or director having responsibility for the overall operation of the discharging facility, if the User submitting the reports is a Federal, State, or local governmental entity, or their agents. 4. By a duly authorized representative of the individual designated in item 1,2 or 3 of this section if: a. the authorization is made in writing by the individual described in item 1,2, or b. the authorization specifies either an individual or a position having responsibility for the overall operation of the facility from which the Discharge originates, such as the position of plant manager, operator of a well, or a well field superintendent, or a position of equivalent responsibility, or having overall responsibility for environmental matters for the company; and c. the written authorization is submitted to the Encina Wastewater Authority. "I certify under penalty of law that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false information including the possibility of fines and imprisonment for knowing violations. " SIGNATURE TITLE PRINT NAME DATE INDEMNITY AGREEMENT THIS AGREEMENT is made on _ , by and between the MEMBER AGENCY DISTRICT OR CITY AND THE ENCINA WASTEWATER AUTHORITY (hereinafter "Licensors"), and _ (hereinafter "Licensee"); Licensors and Licensee shall sometimes hereinafter be referred to as the "Parties". RECITALS A. Licensors are the owner/operator of the sewer treatment plant located at 6200 Avenida Encinas in Carlsbad, California (the "Property") and the associated collection system; B. Licensee now desires to discharge _ to the sanitary sewer system as described in the Special Use Discharge Application attached hereto and made a part hereof. NOW THEREFORE, in consideration of the granting of the foregoing, the mutual premises, covenants, conditions and agreements hereinafter set forth, and other good and valuable consideration, the receipt and adequacy of which are acknowledged, the Parties agree as follows: 1. Grant of License - Licensors hereby grant to Licensee, and its employees, representatives and contractors a non-exclusive license (hereinafter the "License") to discharge to the sanitary sewer system as described in Recitals Paragraph B above. This License shall commence on _ , and shall end on _ _ , unless the parties agree in writing to extend the term of the License. Prior to the expiration of the License, Licensee shall, at its sole cost and expense, (a) permanently close the connection to the sanitary sewer system and (b) remove all debris resulting from operations. 2. Compliance with Laws - Licensee shall conduct all operations, which are the subject of this License in compliance with all federal, state, and municipal statutes and ordinances, and with all regulations, orders, and directives of appropriate governmental agencies, as such statutes, ordinances, regulations, orders and directives now exist or provide. 3. Permits - Licensee, at no cost or expense to Licensors, shall be responsible for obtaining any and all governmental permits and approvals, which may be necessary for it to conduct any work or activities under this License Agreement. 4. Liens and Claims - Licensee will not permit any mechanics', vendor's, or similar liens or claims to stand against the Licensors for labor or material furnished in connection with any work performed by Licensee under this License Agreement. Upon reasonable and timely notice of any such lien or claim delivered to Licensee, Licensee may bond and contest the validity and the amount of such lien, but Licensee will immediately pay any judgment rendered, will pay all proper costs and charges, and will have the lien or claim released at its sole expense. 5. Cooperation - Licensee agrees to coordinate its activities with Licensors to minimize any impairment of access by customers or business invitees of Licensors to the Property. 6. Indemnification - Licensee agrees that it will indemnify and hold Licensors, their officers, directors, agents and employees, harmless from and against any claims, demands, liens, 1 actions, suits, judgments, losses, damages, attorney's fees, costs or expenses, and civil criminal or administrative penalties based upon or arising out of or claimed to have arisen out of alleged acts, errors or omissions of Licensee or its authorized contractors, employees and agents in conducting the activities under this License Agreement, including the activities authorized under the Wastewater Discharge Permit issued by the Encina Wastewater Authority (EWA). This indemnification is expressly conditioned on the following: (a) In the event Licensors identify any matter to which this indemnification may apply or receive a notice or claim from any third party of such matter, it shall immediately, and in every case within ninety (90) days of said notice or claim, notify Licensee in writing of such matter. (b) Licensors shall cooperate with Licensee by allowing Licensee, its agents, representatives, contractors and consultants, prompt and ready access to the sanitary sewer system for the purpose of investigating any matter to which this indemnity may apply. Licensors shall provide Licensee with copies of all investigative reports, data or other information in any form which Licensors, its consultants, agents or attorneys may have pertaining to any such matter, on request of Licensee. (c) Notwithstanding anything in this agreement to the contrary, in no event shall Licensee be liable for any special, indirect or consequential damages, including but not limited to claims for loss of use, rents, anticipated profit or business opportunity, or business interruption or mental or emotional distress or fear of injury or disease. (d) This indemnification shall survive termination of this Agreement and expiration of the Permit and shall be effective until the expiration of any applicable statutes of limitations. 7. Compliance with Wastewater Discharge Permit - Licensee agrees to comply with the EWA Pretreatment Ordinance and the terms of the Wastewater Discharge Permit issued by the EWA. Licensee shall not add to the sanitary sewer any material not authorized under the Permit. In the event Licensee adds any material to the sewer that causes a violation of EWA's NPDES Permits, as defined in the EWA Pretreatment Ordinance, Licensee shall indemnify Licensors in accordance with paragraph 6 above. 8. Severabilitv - In case any one or more of the provisions contained in this Agreement shall be invalid, illegal or unenforceable in any respect, the validity, legality, and enforceability of the remaining provisions contained herein shall not in any way be affected or impaired thereby. 9. Notices - Any notice provided for herein or otherwise required to be given hereunder shall be deemed received when personally served or three (3) days after mailing by certified or registered United States mail, return receipt requested, postage prepaid, or by facsimile machine, with transmission and receipt confirmed, or by nationally recognized overnight delivery service, addressed as follows: To Licensors: Encina Wastewater Authority District or City 6200 Avenida Encinas Address Carlsbad, California 92011 To Licensee: With Copies to: The person and place to which notices are to be mailed may be changed by either party by providing written notice of same to the other. 10. Assignment Successors and Assigns - This Agreement may be assigned by either party and in and in such event shall be binding upon and inure to the benefit of the Parties' respective representatives, successors and assigns. 11. Entire Agreement - This License Agreement represents the full, complete and entire agreement between the parties with respect to the subject matter hereof, and the rights and remedies of the Parties shall be solely and exclusively those herein contained, and in lieu of any remedies otherwise available at law or in equity. 12. Governing Law - This Agreement shall be construed and interpreted and governed by and in accordance with the local law of the State of California without reference to any choice of law, rules or policies which may refer the resolution of any dispute arising hereunder to the laws of any other jurisdiction. 13. Counterparts - This Agreement may be executed in one or more counterparts, each of which shall be deemed an original, and all of which, taken together, shall constitute one and the same Agreement. IN WITNESS WHEREOF, the Parties have executed this License Agreement by their duly authorized representative on the date first above written. LICENSORS: LICENSEE: DISTRICT OR CITY & ENCINA WASTEWATER AUTHORITY By: By: Name: Name: Title: Title: _ Date: Date: ENCINA WASTEWATER AUTHORITY LOCAL DISCHARGE LIMITS CONSTITUENT: Cadmium Chromium Copper Lead Nickel Silver Zinc BOD TSS Toxic Organics Oil and Grease pH LIMIT: 0.43 mg/L 3.50 mg/L 4.40 mg/L 1.80 mg/L 1.80 mg/L 4.20 mg/L 6.20 mg/L 500 Ibs/day 500 Ibs/day 2.00 mg/L 400 mg/L 5.5 -11.0 units APPENDIX C Miscellaneous Standard Drawings Brown . Caldwell LIMIT OF 2" GRIND (TYP7J SAWCUT LINE TYPICAL ASPHALT CONCRETE FINISH COURSE SEE GS-28 LIMIT OF 2" GRIND EXISTING AC (TYP-) AND BASE ASPHALT CONCRETE BASE COURSE, SEE GS-28 AGGREGATE BASE PIPE BEDDING AND BACKFILL PER PROJECT PLANS, SPECIFICATIONS, AND CITY STANDARDS. NOTES: 1. THE DETAIL SHOWN ABOVE APPLIES TO TRENCH WIDTHS LESS THAN 25 INCHES. 2. EXISTING A.C. SHALL BE CUT AND REMOVED IN SUCH A MANNER SO AS NOT TO TEAR, BULGE OR DISPLACE ADJACENT PAVEMENT. EDGES SHALL BE CLEAN AND VERTICAL ALL CUTS SHALL BE PARALLEL OR PERPENDICULAR TO STREET CENTERLINE, WHEN PRACTICAL 3. BASE MATERIAL SHALL BE REPLACED TO DEPTH OF EXISTING BASE. A.C. MAY BE SUBSTITUTED FOR BASE MATERIAL AT THE CITY ENGINEER'S DISCRETION. 4. WHEN THE EDGE OF THE GRIND AREA IS WITHIN 24 INCHES OF EDGE OF PAVEMENT, ANY STRUCTURE, AN ADJACENT TRENCH PATCH OR OTHER PAVING JOIN LINE, THE GRIND AREA SHALL BE EXTENDED TO THE EXISTING STRUCTURE OR JOIN LINE. 5. WHEN THE EDGE OF THE GRIND LIES WITHIN A WHEEL PATH, THE GRIND AREA SHALL BE EXTENDED TO THE NEAREST LANE LINE OR EDGE OF PAVEMENT. RFV.APPROVED DATE CITY OF CARLSBAD TRENCH RESURFACING ASPHALT CONCRETE PAVEMENT FOR TRENCH WIDTHS LESS THAN 25" /U*^T- WU*xk 2/10 CITY ENGlfe y DATE SUPPLEMENTAL r*O OK STANDARD NO. OO'^O FULL LANE WIDTH 12 FT. WIN. 26" TO 48" Jf /LIMIT OF 2" GRIND (TYP.) SAWCUT LINE TYPICAL ~7_/ / / / -ASPHALT CONCRETE FINISH COURSE 'SEE GS-28 -LIMIT OF 2" GRIND (TYP.) EXISTING AC AND BASE ASPHALT CONCRETE BASE COURSE, SEE GS-28 AGGREGATE BASE PIPE BEDDING AND BACKFILL PER PROJECT PLANS, SPECIFICATIONS, AND CITY STANDARDS. NOTES: 1. THE DETAIL SHOWN ABOVE APPLIES TO TRENCH WIDTHS FROM 26 INCHES TO 48 INCHES. 2. EXISTING A.C. SHALL BE CUT AND REMOVED IN SUCH A MANNER SO AS NOT TO TEAR, BULGE OR DISPLACE ADJACENT PAVEMENT. EDGES SHALL BE CLEAN AND VERTICAL. ALL CUTS SHALL BE PARALLEL OR PERPENDICULAR TO STREET CENTERLINE, WHEN PRACTICAL 3. BASE MATERIAL SHALL BE REPLACED TO DEPTH OF EXISTING BASE. A.C. MAY BE SUBSTITUTED FOR BASE MATERIAL AT THE CITY ENGINEER'S DISCRETION. 4. WHEN THE EDGE OF THE GRIND AREA IS WITHIN 24 INCHES OF EDGE OF PAVEMENT, ANY STRUCTURE, AN ADJACENT TRENCH PATCH, OR OTHER PAVING JOIN LINE, THE GRIND AREA SHALL BE EXTENDED TO THE EXISTING STRUCTURE OR JOIN LINE. 5. WHEN THE EDGE OF- THE GRIND LIES WITHIN A WHEEL PATH, THE GRIND AREA SHALL BE EXTENDED TO THE NEAREST LANE LINE OR EDGE OF PAVEMENT. REV.APPROVED DATE CITY OF CARLSBAD TRENCH RESURFACING ASPHALT CONCRETE PAVEMENT FOR TRENCH WIDTHS FROM 26" TO 48" K.u*^T- WW/vsk 2/10 CITY ENGINEER ^ DATE SUPPLEMENTAL ^O O« STANDARD NO. VJO-^0 o FULL ROAD WIDTH - GUTTER TO GUTTER SAWCUT LINE TYPICAL ASPHALT CONCRETE FINISH COURSE, SEE GS-28 LIMIT OF 2 GRIND (TYP.) -EXISTING AC AND BASE ASPHALT CONCRETE BASE COURSE, SEE GS-28 AGGREGATE BASE PIPE BEDDING AND BACKFILL PER PROJECT PLANS, SPECIFICATIONS, AND CITY STANDARDS. NOTES: 1. THE DETAIL SHOWN ABOVE APPLIES TO TRENCH WIDTHS GREATER THAN 48 INCHES. 2. EXISTING A.C. SHALL BE CUT AND REMOVED IN SUCH A MANNER SO AS NOT TO TEAR, BULGE OR DISPLACE ADJACENT PAVEMENT. EDGES SHALL BE CLEAN AND VERTICAL ALL CUTS SHALL BE PARALLEL OR PERPENDICULAR TO STREET CENTERLINE, WHEN PRACTICAL 3. BASE MATERIAL SHALL BE REPLACED TO DEPTH OF EXISTING BASE. A.C. MAY BE SUBSTITUTED FOR BASE MATERIAL AT THE CITY ENGINEER'S DISCRETION. RFV.APPROVED DATE CITY OF CARLSBAD TRENCH RESURFACING ASPHALT CONCRETE PAVEMENT FOR TRENCH WIDTHS GREATER THAN 48" itu.vr j^fvxk 2/10 CITY ENGINEER M DATE SUPPLEMENTAL /-*o O7 STANDARD NO. OO-£ I NOTES: 1. A TACK COAT OF ASPHALTIC EMULSION OR PAVING ASPHALT SHALL BE APPLIED TO EXISTING A.C. OR P.C.C. CONTACT SURFACES PRIOR TO RESURFACING PER SSPWC SECTION 302-5. 2. ASPHALT CONCRETE RESURFACING - BASE COURSE: a. MINIMUM TOTAL A.C. THICKNESS SHALL BE ONE INCH GREATER THAN EXISTING A.C. b. A.C. SHALL BE B-PG64-10 FOR BASE COURSE. PER SECTION 203-6 OF SSPWC. c. BASE COURSE SHALL BE LAID DOWN WITH SELF PROPELLED PAVING MACHINE AND AND COMPACTED PER SSPWC SECTION 302-5. 3. ASPHALT CONCRETE RESURFACING (FINISH COURSE): a. PROVIDE 2 INCH DEEP GRIND AND A.C. FINISH COURSE C2-PG64-10 PER SECTION 203-6 OF SSPWC. b. FINISH COURSE FOR RESURFACING SHALL BE LAID DOWN USING A SELF-PROPELLED PAVING MACHINE AND COMPACTED. c. SMOOTHNESS AND COMPACTION OF RESURFACING SHALL MEET THE REQUIREMENTS OF SEC 302-5 SSPWC EXCEPT THAT THE SMOOTHNESS SHALL BE DETERMINED OVER THE LENGTH AND WIDTH OF PAVED AREAS DISTURBED BY THE CONTRACTOR'S OPERATIONS. 4. SURFACE TREATMENT TO MATCH EXISTING PAVEMENT SURFACE (SLURRY, CHIP SEAL, ETC.) 5. SLOUGHING OF TRENCH UNDER PAVEMENT SHALL BE CAUSE FOR REQUIRING ADDITIONAL PAVEMENT AND BASE. o REV.APPROVED DATE CITY OF CARLSBAD NOTES FOR ASPHALT CONCRETE TRENCH RESURFACING CITY ENGINEER •Vs. SUPPLEMENTAL STANDARD NO. 2/10 r DATE EXISTING PAVEMENT SURFACE 6" COMPACTED SAND (SE 30} SECTION 190-E-400 CONCRETE, 6"-8" SLUMP SLURRY BACKFILL. ALLOW MINIMUM 72 HOURS TO CURE. D2-PG64-10 ASPHALT CONCRETE TO MATCH EXISTING PAVEMENT ELEVATION AND THICKNESS AFTER COMPACTION (6" MIN. DEPTH).ASPHALT CONCRETE SHALL MEET THE REQUIREMENTS OF SEC 203-6 AND SEC 302-5 SSPWC. EXISTING A.C. PAVEMENT EXISTING BASE MATERIAL UNDISTURBED SOIL TACK COAT SHALL BE APPLIED TO ALL CONTACT SURFACES PER SEC 302-5.4 OF SSPWC (TYP.). SURFACE TREATMENT TO MATCH EXISTING PAVEMENT (E.G. SEAL COAT, CHIP SEAL, SLURRY SEAL). REV.APPROVED DATE CITY OF CARLSBAD EXPLORATORY UTILITY POTHOLE BACKFILL & RESURFACING (DIAM.<8IN.) CITY ENGINEER 2/1Q DATE SUPPLEMENTAL STANDARD NO. TRENCH WIDTH AT TOP OF TRENCH VARIES TOP OF BACKFILL TO BE SAME AS ORIGINAL GROUND AND MATCH ADJACENT UNDISTURBED GROUND TRENCH WIDTH IN PIPE ZONE AXIMUM ALLOWABLE SLOPE OF EXCAVATION PER REQUIREMENTS OF CAL/OSHA (T) BACKFILL TRENCH ZONE WITH NATIVE EARTH BACKFILL OR IMPORTED MATERIAL 90% RELATIVE COMPAT10N* (DBACKFILL PIPE BASE TS AND PIPE ZONE WTH IMPORTED SAND 90% RELATIVE COMPATION 1 HAUNCHING LIMITED A PIPE DIAMETER 1" THROUGH 8" 10" THROUGH 16" 18' THROUGH 24" 27" THROUGH 36 MIN, 6" 8" 10" 12" MAX, 9" 12" 18" 24"*IN PAVED AREA, TRENCH ZONE SHALL BE COMPACTED TO 95% MIN. NO SCALE ITEM DESCRIPTION SPEC/DWG BEDDING AND BACKFILL MATERIAL SECT 02223 REV.APPROVED DATE CARLSBAD MUNICIPAL WATER DISTRICT TYPICAL TRENCH SECTION CITY ENGINEER DATE STANDARD DWG. NO.W-2 FINISH GRADE. PAVEMENT. RISER SHALL NO REST ON BONNET OF VALVE. (2" WIN. CLEARANCE). SECTION A-A DOMESTIC WATER NOTES: 1. IN NON-ROAD AREAS PLACE MARKER POST NEXT TO VALVE BOX ASSEMBLY AS DIRECTED BY THE ENGINEER. ( SEE DRAWING NO. 23 ). 2. ALL BURIED NUTS AND BOLTS SHALL BE WAX TAPE COATED PER SPEC. 09902 SECTION B-B RECLAIMED WATER 4. SEE DRAWING NO. 23 FOR GATE VALVE EXTENSION. UPPER SIDE OF LID TO RECIEVE 2 COATS OF PAINT. SEE SPECIFICATIONS FOR PAINTING REQUIREMENTS, ( PAGE 4 ), ITEM DESCRIPTION SPEC/DWG VAL BOX & COVER WITH NON-SKID C.I. COVER AND LIFT HOLE. MARKED WATER . VAL. BOX & COVER FOR NORMALLY CLOSED VALVE. VAL. BOX & COVER MARKED RECYCLED WATER . 8" C900 PVC OR ASPHALT COATED WELL CASING. CONCRETE COLLAR IDENTIFY CONC. BY CLASS 560-C-3250 POLYETHYLENE ENCASEMENT REV.APPROVED DATE CARLSBAD MUNICIPAL WATER DISTRICT VALVE BOX ASSEMBLY CITY ENGIN DATE STANDARD DWG. NO.W-13 FITTING OR COUPLING.CAP. 39" MAX. REINFORCING STEEL DETAIL (RIGID PIPE) (2 EA. TYP.) END CAP BLOCK, A=111/4',221/2', ^ 45',50',60'. VERTICAL BEND. =111/^221/2*, 45*,50',60'. TEE (TOP VIEW). - -ztr - *f'i i *• 1*1 • <GM TO HORIZONTAL & VERTICAL BEND. NOTES: 1. FITTINGS SHALL BE DUCTILE IRON FOR DIP. & P.V.C.; CAST IRON FOR A.C.P. {CEMENT LINED SHORT BODY). ' LENGTH INTO AND OUT OF AIL FITTINGS. TEE (SIDE VIEW). 3. CONCRETE SHAli BE 6 SACK, (3250 P.S1). HYDROSTATIC TEST. 4. SEE DWG'S. NO. 17 & 18 FOR REDUCER, PLUG, & BUTTERFLY VALVE THRUST BLOCKS. (- 5. ENGINEER TO PROVIDE CALCULATIONS FOR THRUST/ANCHOR BLOCK SIZE. 6- AU- 8URIEO ^^ ANO WAX TARE COATED p BE ITEM DESCRIPTION CONCRETE THRUST BLOCK. (560-C-5250) SPEC/DWG POLYETHYLENE ENCASEMENT. NO. 4 REINFORCING STEEL. VALVE BOX ASSEMBLY. FL X RT OR FL X MJ GATE VALVE. REV.APPROVED DATE CARLSBAD MUNICIPAL WATER DISTRICT CONCRETE THRUST BLOCKS FOR NON-RESTRAINED JOINTS CITY ENGINI ? ?A>/Pfl DATE STANDARD DWG. NO.W-15 WL^ w/x — s i 1 1 ^ 1 irrUiirrMi \) >;'- •**: '. i -•--i .- A : ** a" . » ' •i _• i ' « « 4 /• * i 4 • '• * - -«4 -, -• A ' 12" ni A r"M DF " i CD, o J =HF ^CD 1 V FINISHED GRADE.1 NOTE: PIPE SH/ !KI ffiWFfIN WJNn DISTRICT ITEM DESCRIPTION SPEC/DWG 4^STEEL PIPE. GALVANIZED / PAINTED 470-C-2000 CONCRETE FOOTING. FILL PIPE WITH 470-C-2000 CONCRETE ( ROUND OFF TOP ). REV.APPROVED DATE CARLSBAD MUNICIPAL WATER DISTRICT PROTECTION POST CITY ENGINEI DATE STANDARD DWG. NO.W-24 FINISH GRADE NOTES: 1. NO DIPS OR LOW SPOTS WILL BE ALLOWED IN PIPING INSTALLATION2. LOCATE ENCLOSURE AS SHOWN ON 3. INSTALL WARNING/IDENTIFICATION JAPE .SHOWN ON 4. BREAK-AWAY BOLTS SHALL BE 5/8 x3 WITH 3/8" HOLE DRILLED IN THE SHAFT OF THE BOLT. INSTALL WITH NUTS ON TOP OF THE aANGE. BOLTS SHAFT SHALL BE FILLED WTH SILICONE SEALANT. 5. AIR AND VACUM VALVES INSTALLED FOR THE USE OF RECYCLED WATER SHALL BE IDENTIFIED AS DESCRIBED IN SECTION 15151 OF THE SPECIFICATIONS 6. CONNECTIONS TO STEEL MAINS SHALL BE IN ACCORDANCE WITH SECTION 15061 7. MATERIALS SHALL BE SELECTED FROM THE APPROVED MATERIALS LIST ITEM DESCRIPTION ITEM 4" AUTOMATIC COMBINATION AIR RELEASE & AIR AACUUM VALVE ASSEMBLY CONCRETE THRUST/ANCHOR BLOCK 11 BREAK-AWAY BOLTS. SEE NOTE 5 4" FLO Dl PIPE x REQUIRED LENGTH (MAXIMUM OF 2 SPOOLS) 4"x8" LONG FLtfD 8-BOLT SPOOL WITH BREAK-OFF GROOVES 4" FLG x MJ/PO 90* BEND 13 4" C-900 PVC PIPE 1/2"x3" STAINLESS STEEL DROP-IN ANCHORS (3 EA Q120' APART) 14 8" GATE WELL 15 4" FLG x MJ/PO/FLG RWCV AVA ASSEMBLY ENCLOSURE 16 TRACER WIRE (IF REQUIRED) 4" FLG x MJ/PO 90' ADAPTER (IF REQUIRED) 42"x42"x6" THICK CONCRETE SLAB 17 4 FLANGE 90' BEND 18 4" MJ/PO/FLG x FLG TEE COLD JOINT STRIP 19 WATER MAIN 1" PVC CONDUIT FOR TRACER WIRE INSTALLED 2" ABOVE SLAB 20 POLYETHYLENE ENCASEMENT & WAX TAPE WRAP BURIED NUTS & BOLTS PER SPEC. 09902 REV.APPROVED DATE CARLSBAD MUNICIPAL WATER DISTRICT 4' AUTOMATIC COMBINATION AIR RELEASE & AIR/VACUUM VALVE INSTALLATIONS CITY ENGINEER DATE STANDARD DWG. NO. VV"33 610mm (24") min 13mm (1/2") dio. lift hole J 356mm (14") 51mm (2") min RISER RING A.C. Pavement C.I. Frame P.C.C. Pavement- Grout around box- recqst concretepipe DOX / XXXXXX 152mm (6") thick grout pad ^—Slope surface of grout pad to drain away from cover, and to meet existing grade. PLAN-IN UNPAVED AREA Brick support all around on 51mm (2") sand base. E ,:32kg/Ml-C-22Mpa 560-C-3250)oncrete NOTES 1. Cover and frame to be cast integrally with pipe box. c-cr*rir\ki iu DAWCT\ AnrA2. Monument base may be cast in place or precast. SECTION IN PAVED AREA 3. Form and taper exposed upper 152mm (6") of cost-in-place base to a top diameter of 127mm (5"). (Precast base shall be sand backfilled). 4. Monument marker shall be a domed brass. 76mm (3") in diameter. 5. Monument Location: a) Set on all centerline intersections unless actual location is modified by the Agency and shown in modified location on map. When centerline intersection is impractical, offset 1.5m (5') on centerline of major street, (see detail at right). If neither centerline can be occupied, two monuments will be set in line around the front on the perimeter of a 3m (10') diameter circle, whose center is the point. b) Set on centerline at intervals not exceeding 305m (1000') on straight runs. c) Set on centerline at points of curvature. d) Set on center at center points of cul-de-sacs. e) Set on centerline when center point of cul—de—sac is offset from centerline. f) These standards may be modified at the discretion of the Agency in cases where strict compliance therewith results in more monuments than it considers necessary. The following technique for reducing the number of monuments will be routine. g) Substitution of one monument on the "Point of Intersection" for monuments at the "Beginning of Curve" and the "Ending of Curve" when the "Point of Intersection" falls within the pavement area. h) Deletion of any monument otherwise required by these standards when its position can be determined by turning one angle from a point on a straight line between two other monuments, providing such point is not more than 91.4m (300') from the point on which the deleted monument would have been placed. Alteration location of monument. Tie distances shown on final sub- division map if alternate locationis used. LOCATION OF STREET SURVEY MONUMENT Revision ORIGINAL Add Metric Reviewed By Approved Kercheval 12/75 T. Stanton T. Stonton Date 03/03 04/06 SAN DIEGO REGIONAL STANDARD DRAWING STREET SURVEY MONUMENT RECOMMENDED BY THE SAN DIEGO REGIONAL STANDARDS COMMITTEE 31011S003 T&lrperson R.C.E. 19246 Date DRAWING NUMBER 1-10 August 2009 STREET LOCATIONS l*?<] rl *! 1 n 152mm (6")-] ^Traffic stripe " I1 */• Marker DETAIL FREEWAY LOCATION MARKERS - Shall be blue 2-way stimsonite lifelite 88AB or equal. ADHESIVE - An ample amount of two (A&B) epoxy or equal. SURFACES -Clean and dry prior to installation per manufacturer's recommendations. Install markers with reflective surfaces facing oncoming vehicles and offset 51mm (2") from lane lines toward fire hydrant. NOTES LFire Department will provide location(s) for all markers in PRD's, Commercial Lots and other areas outside of Public Right of Way. 2. Markers must be installed at the new and relocated hydrants and within all resurfacing projects. 3. For streets without lane lines or streets with raised pavement markers and no painted lane lines, install markers 152mm (6") from centerline or existing markers. LEGEND ON PLANS Marker • Fire Hydrant IXJXI o Revision ORIGINAL Add Metric Reviewed By Approved H. Hecht T. Stanton T. Stanton Date flO/82 03/03 04/06 SAN DIEGO REGIONAL STANDARD DRAWING FIRE HYDRANT MARKERS RECOMMENDED BY THE SAN DIEGO REGIONAL STANDARDS COMMITTEE 3IO11SO03 Chairperson R.C.E. 19246 Dote DRAWING NUMBER M-19 August 2009 NOTES 1. Structural steel tubing used for post & sleeves shall be galvanized 12 gauge cold rolled steel, of the nominal dimensions shown hereon and meet the requirements of ASTM A446 Grade A. 2. Galvanizing shall be per ASTM A525. Posts & sleeves shall have 11mm(7/16") dia. holes spaced 25mm(1") o.c. ±3mm(1/8") & shall have no more variation in straightness than 1.6mm(1/16") in 914mm(3'). Posts shall be square within ±.36mm(0.014"), have twist no greater than 0.062" in 3' and have comer radii of 4mm(5/32") ±.4mm(1/64"). 3. The signs shall be mounted on posts in accordance with Section 56, "Signs" of the State Standard Specifications. All fastening hardware is to be provided by the Contractor. 4. Maximum sign size 5.2 sq. ft. O 57mm x 57mm (2 1/4"x 2 1/4") 12 Gauge Post 51mm(2")x 51mm(2")-12 Gauge Post 44mm x 44mm (I 3/4"x 1 3/4") 12 Gauge Post 1.83m (6') ^ ~ — ^ (Unless Otherwise Shown on Plans) i c c '55 H- O V c o o-t-l In CM CO E in | i XD Z C c c « "K Kl c c c c c £ C c c c c c c c c c c c c c I ~\ cI J 51mm (2")± 10mm (3/8") Rivet (typ.) Rivet Specification Dimension: 10mm(3/8") Dia. Shank 22mm(7/8") Dia. Head Grip Range: .200-.356 Finish: Electro-Galvanize ASTM-B-633 Type III SCI /-10mm(3/8") Rivet (typ.) 57mm(2 1/4") Anchor Sleeve °i =• Existing Ground 51mm (2") Anchor Post Revision ORIGINAL Add Metric Reviewed By Approved G.Parkinson T. Stanton T. Stonton Date 2/95 03/03 04/06 SAN DIEGO REGIONAL STANDARD DRAWING BREAK-AWAY SIGN POST RECOMMENDED BY THE SAN DIEGOREGIONAL STANDARDS COMMITTEE 3IOUS003 Chblrperson R.C.E. 19246 Date DRAWING NUMBER August 2009 75mm (3") 75mm (3") NEW WATER MAIN OR UTILITY CALDER COUPUNG (24") MIN SEE NOTE 2 SEE NOTE 3 -—/j_150mm (6") 1 EXIST SEWER MAIN OR XNEW SEWER LATERAL 75mm (3") CONCRETE ENCASEMENT SEE NOTE 3 SEE NOTE 2 PLAN TRENCH WIDTH EXIST STREET SURFACE OR FINISH GRADE CALDER COUPUNG SEE NOTE 3 .-150mm (6") I EXIST SEWER MAIN OR SEWER LATERAJ 75mm (3") CONCRETE ENCASEMENT SEE NOTE 3 ELEVATION |4 BARS 450mm (18") ON CENTER ll\i 3 300mm (12") ON CENTER ENCASEMENT SECTION REFER TO AGENCY SPECIFICATIONS FOR PROTECTION OF EXISTING FACILITIES ENCASEMENT SHALL EXTEND TO FIRST JOINT BEYOND BOTH SIDES OF TRENCH [600mm (24") MIN 1200mm (48") MAX OF SUITABLE NATIVE SUPPORT BEYOND EDGE OF TRENCHJ 3) CONCRETE ENCASEMENT REQUIRED FOR SEWER MAINS ONLY. CALDER COUPLINGS REQUIRED FOR SEWER LATERALS ONLY. SEWER LATERALS TO BE REPLACED WITH SCH. 80 PVC WITH NO INTERMEDIATE JOINTS. 4) FOR PIPE BEDDING AND TRENCH BACKFILL SEE WP-02 OR SP-02. LEGEND ON PLANS Revision ORIGINAL By Approved J. Tomoaulo Date 10/04 SAN DIEGO REGIONAL STANDARD DRAWING PIPE SUPPORT FOR UNDERCUT SEWER MAINS OR SEWER LATERALS RECOMMENDED BY THE SAN DIEGO REGIONAL STANDARDS COMMITTEE Oialrpgrson R.C.E. 19246 Date DRAWING NUMBER August 2009 AGENCY MAINTAINED PRIVATELY DETAIL 'A' SEE NOTE 7 450mm (18") 3m (10')MAX SEE NOTE 6 REQUIREMENTSNOTES: 1) REFER TO AGENCY SPECIFICATIONS WHERE APPLICABLE 2) INSTALL WARNING/IDENTIFICATION TAPE AS SHOWN ON WP-01 3) LOCATE BACKFLOW PREVENTION DEVICE (BPD) IN SUCH A MANNER THAT WILL ALLOW THE DEVICE TO BE READILY ACCESSIBLE FOR INSPECTION AND REPAIR 4) STRAINERS SHALL NOT BE INSTALLED PRIOR TO THE FIRST SHUT-OFF VALVE 5) ALL ABOVE GROUND PIPING, UNIONS. ELBOWS, & NIPPLES SHALL BE SOLDERED OR THREADED BRASS 6) INSTALL A CASING ENCASED IN CONCRETE WHEN THE DISTANCE BETWEEN THE METER BOX AND THE RISER TO THE BPD EXCEEDS 450mm (18") 7) INSTALL AN ANGLE PRESSURE REDUCING VALVE IN LIEU OF THE FIRST 90" ELL WHEN SYSTEM PRESSURE EXCEEDS 1.03 MPo (150 PSI) PER AGENCY SPECIFICATIONS 8) TESTING SHALL BE CONDUCTED IN ACCORDANCE WITH AGENCY SPECIFICATIONS PRIOR TO ACCEPTANCE 9) BPD & APPURTENANCES INSTALLED FOR THE USE OF RECYCLED WATER SHALL BE IDENTIFIED AS DESCRIBED IN AGENCY SPECIFICATIONS 10)MATERIALS SHALL BE SELECTED FROM THE AGENCY'S APPROVED MATERIALS LIST LEGEND ON PLANS ITEM NO SIZE AND DESCRIPTION ITEM NO SIZE AND DESCRIPTION METER BOX & METER ASSEMBLY SEE WS-01 & WS-02 SCH 80 PVC, BRASS OR COPPER PIPE CONCRETE THRUST BLOCK SEE WT-01 90' ELL SEE NOTES 5 & 7 CONCRETE SLAB. MINIMUM 100mm (4") THICK x 450mm (18") WIDE BRASS OR COPPER PIPE SEE NOTE 5 75mm (3") LONG NIPPLE SEE NOTE 5 BALL VALVE "SHUT-OFF" REDUCED PRESSURE BACKFLOW DEVICE ENCLOSURE (OPTIONAL) UNION SEE NOTE 5 ANGLE PRV SEE NOTES 5 & 7 Revision ORIGINAL Add Metric Replaced W-27 By Approved Kercheval T. Stanton J. Tomasulo Date 12/75 03/03 10/04 SAN DIEGO REGIONAL STANDARD DRAWING 19mm THRU 50mm (3/4" THRU 2") REDUCED PRESSURE BACKFLOW PREVENTION DEVICE RECOMMENDED BY THE SAN DIEGO REGIONAL STANDARDS COMMITTEE 10/28/2004 Cholrparson R.C.E. 19246 Date DRAWING NUMBER WR-01 August 2009 APPENDIX D CMWD'S Approved Materials List for use on Construction of Potable and Recycled Water Facilities Brown Caldwell CARLSBAD MUNICIPAL WATER DISTRICT'S APPROVED MATERIALS LIST FOR USE ON CONSTRUCTION OF POTABLE AND RECYCLED WATER FACILITIES Hem Description Manufacturer/Model AIR/VACUUM VALVE 2-INCH AIR/VACUUM VALVE ABOVE GRADE ENCLOSURE ANGLE METER STOPS 1-INCH Compression x Meter Nut ANGLE METER STOPS 1-INCH Flare x Meter Nut ANGLE METER STOPS 2-INCH Compression x Meter Nut ANGLE METER STOPS 2-INCH Flare x Meter Nut BACKFLOW PREVENTER (R.P.) CORPORATION STOP, FLARE X MIP CORPORATION STOP, COMPRESSION X MIP CORPORATION STOP, MIP X MIP BOLTS AND NUTS, 304 S3 BOLTS AND NUTS, 316 SS BOLTS AND NUTS. A307 BONDING AGENT, EPOXY BUSHING, INSULATING CASING END SEAL CASING SPACER CATHODIC TEST STATION BOX CATHOOIC WELDING Air-Vaccum Valve Assembly. See Standard Dwg W7 See "Valve Box" for below grade components 1" Bronze Angle Meter Stop (Ball Valve) with 90 Degree Lock Wing, Compression x Outlet Swivel Meter Nut 1" Bronze Angle Meter Stop (Ball Valve) with 90 Degree Lock Wing, Flare x Outlet Swivel Meter Nut 2" Bronze Angle Meter Stop (Ball Valve) with 90 Degree Lock Wing, Compression x Outlet Meter Range 2' Bronze Angle Meter Stop (Ball Valve) with 90 Degree Lock Wing, Flare x Outlet Meter Flange Reduced Pressure Principal Type Assemblies; Double Check Valve Detector Assemblies for Fire Sprinkler Systems Bronze Flare x MiP Thread Ball Valve (T-Head only) 1"and 2" Full Opening Bronze Compression x MIP Thread Bal Valve (T-Head only) Tand 2" Ful Opening Bronze MIP x MIP Thread Ball Valve (T-Head only), 1" and 2" Full Opening Hex-Head Machine, ASTM A193, Grade B8 Bolts and ASTM A1 94, Grade 8 Nuts Hex-Head Machine, ASTM A193, Grade B8M Bolts and ASTM A194, Grade 8M Nuts Hex-Head Machine, Cadmium/Zinc Plated, ASTM A307, Grade A Bolts and A307 2H Heavy Hex Nuts Epoxy Resin Based Bonding Agent for Bonding New Mortar or Concrete to existing concrete Nyton, 1-1/4" x1", 1-1/2' x 1", 2-1/2" x 2" 1/4" Thick Styrene Butadiene Rubber Sheet End Seal. Use 1" Wide Stainless Steel Bands, Zippered End Seals with Stainless Steel Bands may also be used. Stainless Steel Casing Spacer, Center Restrained, Position Type with PVC Liner and Non-metallic Anti-friction Runners 25.4 Kg (54 Ibs) Concrete Body with 5.4 Kg (12 Ib) Ductile Iron Lid and Lid Ring. "CP TEST" shall be cast into the Lid in 25mm (1") Letters. For Cathodic Protection Test Stations, Anode Ground Beds and Insulated Flange Test Stations. For Welding Cathodic Bond Wires to Steel Pipelines APCO 145C VAL MATIC 202 CRISPIN UL20 Vent-0-Mat Model 050RBX4021 Pipeline Products VCAS 1830 Tan Ford BA43-444WQ ML Jones E-1963WSG Mueller B-24258 N Ford BA23-444WNU Jones E-1964W Mueller B-24255 N Ford BFA43-777WQ NL Jones E-1975WSG Mueller B-24276 N Ford BFA23-777W NL Jones E-1973W Mueller B -2427 7 N List of Approved Backflow Prevention Assemblies by the State of California, Department of Health Services most recent version FordFB700NL, Jones E-1929, Mueler B-25025 N FordFBHOOQ NL, Jones E-1957G. Mueller B-25028 N Ford FB500 NL, Jones E-1943 Mueller B-2969 N (2') Mueller B-20013N(1") Sika Sikadur 32 Hi-Mod Calpico Corrosion Control Products F.H. Ma honey Advanced Products & Sys. Cascade Calpico Pipeline Seal & Insulator Powerseat Raychem Advanced Products & Sys. Cascade Calpico Pipeline Seal & Insulator Powerseal Raychem Christy G5 May 2010 CARLSBAD MUNICIPAL WATER DISTRICT'S APPROVED MATERIALS LIST FOR USE ON CONSTRUCTION OF POTABLE AND RECYCLED WATER FACILITIES Horn Description Manufacturer.'Motlol CHLORINE COATING. MASTIC COATING, WATERPROOF COUPLING, C900 PVC DEFLECTION COUPLING. C900 PVC CLOSURE OR REPAIR COUPLING, C9Q5 PVC CLOSURE, DEFLECTION OR REPAIR COUPLING, GROOVED COUPLING, STRAIGHT FLEXIBLE COUPLING, FRANSmON FLEXIBLE CUSTOMER SIDE SHUT-OFF VALVE CUSTOMER SIDE SHUT-OFF VALVE ELL, BURY, DUCTILE IRON EPOXY ADHESIVE EXPANSION JOINT FIRE HYDRANT SPOOL, DUCTILE OR CAST IRON, FLANGED FIRE HYDRANT FIRE HYDRANT, 200 PSI or Higher FITTING, DUCTILE IRON Jquid (Gas) or Sodium Hypochtorite Solution. See Section 15040 Cold applied Coal Tar or Epoxy based single component, self- priming, heavy-duty protective exterior coating for buried concrete Epoxy Resin Based Cemetous Trowel Grade protective waterproofing for concrete 4" through 12" Solid PVC for obtaining deflection only. 4" through 12" Solid PVC for closure or repair 1 6' through 36" Solid PVC for Closure, Deflection or Repair Use for Above Ground Dl or Steel Pipe 1 00mm (4") or larger 4" and Larger Steel or Ductile Iron Construction, Slip x Slip, Epoxy Coated with 304 or 316 Stainless Steel Bolts and Nuts. For use on AC, PVC, Dl, or Steel Pipe 4" and Larger, Steel or Ductile Iron Construction, Slip x Slip, Epoxy Coated with 304 or 31 6 Stainless Steel Boris and Nuts. For use on AC PVC, Dl or Steel Pipe 3/4" and 1" Bronze Customer Shut-off (Bal Valve), Inlet Swivel Meter Nut x Outlet FIP Thread, Lockabte Tabs, with Lever Handle 2" Bronze Customer Shut-off (Ball Varve), Inlet Meter Flange x Outlet FIP Thread, Lockable Tabs, with Lever Handle 6" Ductile Iron Bury Ells, Long Radius, Fig x MJ/PO (Use of Short Radius Bury Ells with District Engineer Approval Only) High- Modulus, Low Vicosity, Epoxy Resin Based Adhesive suitable for Grouting Bolts or Dowels For Water Pipeline Bridge Crossings Ductile or Cast Iron Spool with Integrally Cast Ranges and Machined or Cast Exterior Grooves. Spools 12" or longer shall have grooves 3" from each Flange. Spools shorter than 2" shall have one groove centered between the Flanges. Grooves shall be 3/16" deep. ±1/16" and 1/4" wide, + 1/16", 6 Holed 6" Standard 150 PSI Wet Barrel Bronze Fire Hydrants with Six- Hole Bolt Pattern. 4" x 2.5" or 4" x 4" x 2.5" Outlets Project Specification Submittal Required Flanged, Mechanical, Joint or Push-on Tees, Bends, Crosses, Recucers, Adapters, etc., for Water Lines 4" and larger. Manufactured per AWWAC100, C111,C153. Double Cement Mortar Lined. (SSB Finings will not be permitted on C905 Pipe.) Carboline Bitumastic 50 Devoe Devtar 5A Polykem 938 Tnemec HB Tnemecol 46-465, HB Tneme-Tar 46H-413 Sika Top Seal 107 STO CR 241 Certainteed Vinyl Iron HD Certainteed Vinyl Iron HD IPEX Nyloiplast America Septer Grinnell #7001 Tyler 500 Vitaulic #44, #77 APAC301 Ford FC1 Powerseal 3501, 3538 Romac 501 Smith-Blair 411 APAC311.313 Baker Ford FC2A Powerseal 3501, 3538 Romac 501 Smith-Blair 41 3 Mueller Maxrfit FordB13-332Ww/HT34 B13-444W W/HT34 Jones J-1908W ' Mueler B-24351 BF13-777WW/HB-67S Jones J-1913W Mueller B-24337 Clow South Bay Foundry Sika Sikadur 31 , Sikadur 35 APAC 703 Dresser 63 Powrseal 3563 Smith-Blair 611. 612 Clow 2050, 2065 Jones J3700, J3775 Bachman Griffin Nappco/Sigma Pipeline Components Star Tyler May 2010 CARLSBAD MUNICIPAL WATER DISTRICT'S APPROVED MATERIALS LIST FOR USE ON CONSTRUCTION OF POTABLE AND RECYCLED WATER FACILITIES Item Description Manufacturer/Model FITTING, GROOVED FITTING, PIPE RESTRAINT GASKET GASKET, JOINT RESTRAINT GASKET. RUBBER GASOLINE RESISTANT GASKET, RUBBER RING GREASE GROUT JOINT SEALING COMPOUND, PLASTIC ROPE LUBRICANT, PIPE GASKET METER METER BOX 1" SERVICE METER BOX 2" SERVICE METER BOX r SERVICE [ Exposed to Traffic .cads) METER BOX 2" SERVICE [Exposed to Traffic Loads & for Combination Air Release, Std Dwg W7) METER FLANGE MORTAR, REPAIR PAINT PAINT PAINT PAINT, PRIME COAT Grooved ductile Iron Fittings for Grooved end Pipes, 4" through 24" May be used with or in lieu of thrust blocks with approval of District Engineer 1/8" Thick Full Face or Ring, Aramid Fiber Bound with Nitrile. No Asbestos Content Rubber Ring Type with Stainless Steel Locking Segments Vulcanized into the Gasket. Fur use on PVC Carrier and Casing Pipes. Gasoline Resistant Pipe Gaskets for Water Mains 3mm (1/8") Thick, Rubber Ring Type, 1.72 Mpa (250 PSI) Maximum. For 100mm (4") through 900mm (36" Pipe Flanges For Bolt Corrosion Protection on Buried Bolts, NO-OX-ID Type Non-Shrink Cement Based Construction Grout for Crack Repair, Flooring Mortar, Dowel Grouting, Crack Sealing and General Binding For use on Pre-cast Vault and Manhole in Grooved Joints between sections Rubber Gasket Pipe Lubricant for use on PVC or ductile Iron Pipe Joints, NSF Listing required. Supplied by CMWD 12" x 20" x 12"Polymer Meter Box and Cover for 1" Water Services with meters 1" or smaBer. Cover color: Gray for Potable Water Use Purple Lids for Recycled Water Use 17" x 30" x 12" Polymer Meter box with 2-Piece Lid for 2" Water Services with meter larger than 1" and Btowoff Assemblies Cover Color: Gray for Potable Water Use Purple Lids for Recycled Water Use Gray for Potable Water Use Purple Lids for Recycled Water Use Gray for Potable Water Use Purple Lids for Recycled Water Use Bronze Meter Flanges for 1-1/2" and 2" Meters with Slotted Hotes Two Component, Low Shrinkage. Cement Based with High Compresslve and Bonding Strength Valve Box Lids Prime Coat required on all above ground metal surfaces Fire Hydrants Prime Coat required on all above ground metal surfaces Backflow Assys & Vent Pipes, Prime Coat required on al above ground metal surfaces Prime Coat, Prime Coat required on all above ground metal surfaces GrlnneU TylerG-B Victaulic Romac-GripRing Star Pipe-PVC Ring Lock Series 3500 UniFlange- 1300-C Eagle LOC 900 Calpico Garlock 3000 Johns-Man vile Klinger 4401 Tripac 5000 US Pipe Field Lok 350 Newby Calpico Johns- Man villa US Pipe Sanchem NO-OX-ID Dearborn Chemical SikaSikagrout212 STO Epoxy Binder CR633 STO Epoxy Gel CR635 STO N-S Grout CR732 Quickset Joint Sealing Compound Whitlam Blue Lube Amorcast A6000485 Cover A6000484 Lid, Drop In A6000487 Amorcast A6001640PC-12 Cover A600 1643 Lid, Drop In A6000482 Brooks Model No. 37 with Traffic Rated Lid Brooks Model No. 66 with Traffic Rated Lid Ford CF Series Jones J129 A.Y.McDonald 61 OF SikaSikaTop122, 123 STO CR 735, CR 740 Frazee Traffic Line and Marking Paint Yellow #5020301 (2 coats) Frazee Aero Plate II, Bright Yellow #6480462 (2 coats) Rust-Oleum No 7671 Dunes Tan (2 coats) Rust-Oleum No 769 Damp Proof Red or Rust-Oleum No 865 Enamel-Dunes Tan May 2010 CARLSBAD MUNICIPAL WATER DISTRICT'S APPROVED MATERIALS LIST FOR USE ON CONSTRUCTION OF POTABLE AND RECYCLED WATER FACILITIES Item Description M.-iniifactuirr 'Model PIPE, COPPER TUBING PIPE. DUCTILE IRON PIPE. PVC C900 PIPE. PVC C905 PIPE. STEEL CEMENT MORTAR LINED AND COATED (CML+C) PLASTIC ENCASEMENT PLASTIC WRAP PRIMER. WAX TAPE PROTECTOR POST. STEEL SEALANT SERVICE SADDLE FOR ACP AND Dl PIPE SERVICE SADDLE FOR PVC C900 PIPE SERVICE SADDLE FOR PVC C905 PIPE TAG. BRASS IDENTIFICATION TAPE. OUTER WRAP TAPE. UTILITY TAPE, WARNING/ IDENTIFICATION 1" Type K Soft Seamless rolled Tubing 2" Type K Soft Seamless Straight Lengths 1" and 2" Type K Rigid Seamless Straight Lengths For Water Lines 100mm (4") and larger manufactured per AWWA C111 C115.C150.C151. Double Cement Mortar Lined For Water Lines 4" through 12" and 8" Gate Wells. AWWA C900 DR18andDR14 For Water Lines 16" and 20" through 36'. AWWA C905 DR21 and DRJ18 Stee) Cylinder (CML/C), Per AWWA M1 1 and Section 15061 . 1/4' Minimum Wai Thickness. Steel Pipes Used for Recycled Water Installation are to be identified per District requirements. Submittal required. 12-mil Thick Polyethylene Encasement Sleeve for Ductile Iron Pipe (DIP) per AWWA C105 and Recycled PVC, CMC/L, or DIP Non-Purple Water Pipe. Clear Sleeve for Potable Water Purple Color for Recycled Water 8-mil Thick Polyethylene Encasement for Buried Fittings and Valves - Double Wrap Clear Sleeve for Potable Water Purple Color for Recycled Water Surface Primer for Underground Application of Petrolatum Wax Tape 4' Diameter. 0.250' Wall Galvanized A-1 20 Steel Pipe. Concrete Filled Chemical Grout for Joint Sealing Cast Brass ASTM B62 Body with Silicons Bronze Double Straps, IP Outlet Sizes 25mm (1") and 50mm (2") Bronze or Brass Saddle with Stainless Steel Four Bott Strap(s), IP Thread Outlet for Sizes 1 " and 2" for Pipe Sizes 4" through 1 2" Bronze or Brass Saddle with Stainless Steel Four Bolt Strap(s), IP Thread Outlet for Sizes 1" and 2" for Pipe Sizes 16" and Larger. 1" Diameter, 18 Gauge Brass with 3/16" Die Stamped Letters and Numbers. Suitable for Attachment to Cathodic Protection Wires by means of a Nylon Zip Tie. Adhesive Plastic Outer Wrap for Wax Petrolatum Tape in Underground Applications 10 to 50 Mil x 2" Wide General Utility Tape for Corrosion Protection of Above and Below Ground Pipes and Fittings 6" Wide, Warning/Identification (Non-Metallic) Marking Tape for Buried Facilities with Continuous Warning "Caution Water Main Buried Below" or 'Caution Recycled Water Main Buried Below* Tape for Recycled Water shall be Purple Cerro Halstead Lee vlueller Phelps-Dodge American Pipe Griffin Pacific States U.S. Pipe Certainteed Diamond Plastics PEX JM Eagle Month American Pipe Pacific Western VinylTech Certainteed Diamond Plastics IPEX JM Eagle North American Pipe Pacific Western Vinyltech Carbdine Denso Paste Trenton Tern-Coat 3M Scotch Seal Ford 202B Jones J-979 Smith-Blair 323 Romac 202B Mueller BR2B Ford202BS Jones J-969 Smith-Blair 393 Romac 202BS Mueller BR2S Ford 202BS Jones J-969 Romac 202B Mueler BR2S Ford 202BS Jones J-969 Romac 202N Polyken 960 Trenton Polyply Calpico Northtown Polyken 900 Scotch wrap 3M 50, 51 Calpico, Type 1 Line-Tec, Type B T.Christy Eng., Type 1 Terra Tape, Standard 250 Thor, Elast Tec Northtown May 2010 CARLSBAD MUNICIPAL WATER DISTRICT'S APPROVED MATERIALS LIST FOR USE ON CONSTRUCTION OF POTABLE AND RECYCLED WATER FACILITIES Item Doscnption Manufacturor/Model TAPE WARNING/ IDENTIFICATION FOR RECYCLED IRRIGATION TAPE, WAX ABOVEGROUND TAPE. WAX UNDERGROUND TAPPING SLEEVE FOR ACP. AND DIP TAPPING SLEEVE FOR PVC (C900 -C905) VALVE STEM . EXTENSION, FIBERGLASS VALVE STEM EXTENSION, STEEL VALVE, BALL WITH LOCKING TABS VALVE, BUTTERFLY 150 PSI VALVE, BUTTERFLY 250 PSI VALVE, GATE, RESILIENT WEDGE (RWGV) VALVE, PRESSURE RELIEF AND SUSTAINING VALVE, HANDLE BALL, 150 PSI VALVE BOX RECYCLED WATER VALVES VALVE BOX VALVE BOX VALVE BOX VALVE BOX VALVE BOX 3' Wide, Warning/Identification (Non-Metallic) Marking Tape for Buried Irrigation Pipelines. Purple Color with Continuous warning 'Caution Reclaimed Water Main Buried Below" Petrolatum Saturated Synthetic Fabric Tape for use on Aboveground Couplings, Flanges, Fittings, etc. Petrolatum Saturated Synthetic Fabric Tape for use on Underground Couplings, Flanges, Fittings, etc. Primer and Outer Wrap Required. Fabricated Steel Tapping Sleeve for 4" through 12" Wet Taps. Epoxy Coated with Stainless Steel Bolts and Nuts Fabricated Steel Tapping Sleeve for 4" through 1 2" Wet Taps. Epoxy Coated with Stainless Steel Bolts and Nuts Three Part Fiberglass Valve Extension Kit. Use when extension 8 foot or shorter. Round or Square 1-1/2" Diameter Steel Rod, Welded Construction, Hot Dipped galvanized with Top Centering Ring and AWWA 2" Operating Nuts Top and bottom. Use when extension longer than 8 foot. 3/4"Bronze, Straight, FIP x Meter Swivel with Locking Tabs and Purple Handle 18" and Larger, AWWA C504, Class B. Thermosetting or Fusion Bonded Epoxy coated and Lined. Class D or E Flange x Flange Ends 18" and Larger, AWWA C504, Class B. Thermosetting or Fusion Bonded Epoxy coated and Lined. Class D or E Flange x Flange Ends 4" through 16", non-rising Low Zinc Bronze or Stainless Steel Stern, Ductile Body and Bonnet, encapsulated Wedge per AWWA C509 or C515 with Epoxy Coated Interior. Manufactured to AWWA C509 or C515, with 250 PSI Rating 'Ductile Iron Bodies and Bonnets are required 3/4" Through 2", Used as part of meter assembly and provided by CMWD Lid to be marked "Recycled Water, See Standard Dwg W13 For Gate Valves & Butterfly Valves, See Standard Dwg W13, Lids shall be marked "Water" Normally Close Valve, Lids shall be marked "Water 1" Blow Off or Manual Air Releases. See Standard Dwg W5, Lids shal be marked "Water 2" Blow Off or Manual Air Release. See Standard Dwg W6 Lids shal be marked "Water 4" Btow Off Assembly. See Standard Dwg W1 1 Calpico. Type 1 I .ine-Tec, Type B T.Christy Eng., Type 1 Terra Tape, Standard 250 Thor, Elast Tec ^orthtown Trenton #1 Wax-Tape Carboline Densyj Tape Trenton #2 Wax-Tape Baker 428 Series Ford FTSC Romac FTS-420 Smith-Blair 622 Ford 'FAST W/S.S. FLANGE Romac SST W/S.S. FLANGE Mueller H304 w/S.S. FLANGE Pipeline Products FPU-210, FPT-200, FPL-220 Pipeline Products SX-900 South Bay Foundry E4160 1" Ford B13-444w 1" Jones J1908 2"FordBF13-777W 2" Jonesd1913 M&H 1450, 4500 Mueller Lineseal III Pratt Groundhog M&H 1450, 4500 (Class 250) Mueller Lineseal XP 250 Pratt Triton HP-250 American FC, Series 2500 AVK25 Clow F6100, F6100 Ductile Kennedy Ken-Seal ii, KRSR Mueller 2361 M&H 4067, 7067, A2361 U.S. Pipe MetrosealS Metroseal 250 Cla-Val Jones 3/4" J-1098 Jones 1" J-1908, 2" J-1913 Ford 3/4" B13-332W Ford 1" B13-444W Ford 2" B13-777W South Bay Foundary SBF 1208-N Brooks Service 4TT J&R 4T Brooks Service 3RT Brooks Service 4TT J&R 4T South Bay Foundary SBF 1243 South Bay Foundary SBF 1 243 (for 4" Pipe Outlet) and Brooks 4TT or J&R 4T (for Valve) May 2010 CARLSBAD MUNICIPAL WATER DISTRICT'S APPROVED MATERIALS LIST FOR USE ON CONSTRUCTION OF POTABLE AND RECYCLED WATER FACILITIES Description VALVE BOX Air-Vaccum Valve Assembly. See Standard Dwg W7 Valve Boxes Located in traffic shaH use approved manufacturer's Traffic Rated Lids Manuf.Tct liter'Model Amorcast A600 1640 PC-12 w/#6Q001643*Service 5 Cover Brooks 66 (2-piece lid) J&R No W6B (2-pice lid) May 2010 APPENDIX E Disadvantaged Business Enterprise Forms Brown Caldwell FORM1 DISADVANTAGED BUSINESS ENTERPRISE (DBE) "GOOD FAITH" EFFORT LIST OF SUBCONTRACTORS SOLICITED Contractor Name Contractor Address How Located Date of Contact Contact Method Task Description Response (Yes/No) Form for information required to be submitted with the AOA packageo o FORM 2 DISADVANTAGED BUSINESS ENTERPRISE (DBE) "GOOD FAITH" EFFORT BIDS RECEIVED LIST Contractor Name Category (DBE) Task Description Bid Amount Selected (Check) Explanation for Not Selecting Form for information required to be submitted with the AOA package. FORM 3 (Attachment A) DISADVANTAGED BUSINESS ENTERPRISE (DBE) CONTRACTOR CERTIFICATION Firm Name: Address: Phone: Principal Service or Product:Bid Amount $ PLEASE INDICATE PERCENTAGE OF OWNERSHIP oDBE _% Ownership o Prime Contractor o Subcontractor o Supplier of Material/Service o Broker o Sole Ownership o Partnership o Corporation o Joint Venture <^^^FCertified by: Title: DBE Sub (ORIGINAL SIGNATURE AND DATE REQUIRED) Name: Date: Additional proof may be required upon written challenge of this certification by any person or agency. Falsification of this certification by a firm selected to perform federally funded work may result in a determination that the firm is non-responsive and ineligible for future contracts. IMPORTANT: CONTRACTORS CAN NO LONGER SELF-CERTIFY. THEY MUST BE CERTIFIED BY EPA, SMALL BUSINESS ADMINISTRATION (SBA). DEPARTMENT OF TRANSPORTATION (DOT) OR BY STATE, LOCAL, TRIBAL OR PRIVATE ENTITIES WHOSE CERTIFICATION CRITERIA MATCH EPA'S. PROOF OF CERTIFICATION MUST BE PROVIDED. A COPY OF THE CONTRACTOR CERTIFICATION MUST BE SUBMITTED WITH THIS FORM. This form must be submitted within 10 working days after the bid opening date. FORM 4 (Attachment B) PRIME CONTRACTOR/RECIPIENT SELECTED DISADVANTAGED BUSINESS ENTERPRISES (QBE) CONTRACT RECIPIENTS NAME CONTRACT NO OR SPECIFICATION NO PROJECT DESCRIPTION PROJECT LOCATION PRIME CONTRACTOR INFORMATION NAME AND ADDRFSS (Include ZIP Code, Federal Employer Tax ID tt) PHONE AMOUNT OF CONTRACTS DBE INFORMATION ONONE* oDBE o SUBCONTRACTOR O JOINT VENTURE AMOUNT OF CONTRACT S NAME AND ADDRESS (Include ZIP Code.) O SUPPLIER/SERVICE O BROKER PHONE WORK TO BE PERFORMED oDBE o SUBCONTRACTOR o JOINT VENTURE AMOUNT OF CONTRACT S NAME AND ADDRESS (Include ZIP Code,) O SUPPLIER/SERVICE o BROKER PHONE WORK TO BE PERFORMED oDBE o SUBCONTRACTOR O JOINT VENTURE AMOUNT OF CONTRACT $ NAME AND ADDRESS (Include ZIP Code,} o SUPPLIER/SERVICE O BROKER PHONE WORK TO BE PERFORMED oDBE O SUBCONTRACTOR o JOINT VENTURE AMOUNT OF CONTRACT S NAME AND ADDRESS (Include ZIP Code.) O SUPPLIER/SERVICE o BROKER PHONE WORK TO BE PERFORMED TOTAL DBE AMOUNT: SIGNATURE OF PERSON COMPLETING FORM: TITLE:PHONE:DATE: ^Negative reports are required. ORIGINAL SIGNATURE AND DATE REQUIRED. Failure to complete and submit this form with the bid will cause the bid to be rejected as non-responsive. FORMS SUMMARY OF BIDS RECEIVED FROM SUBCONTRACTORS, SUPPLIERS, AND BROKERS (DBE & NON-DBE) THIS SUMMARY IS PREPARED BY THE PRIME CONTRACTOR Type of Job Company Name Selected Bid Amount DBE NON-DBE List type of jobs alphabetically, from low to high in each category and selected low bidder. FORM 6 MINORITY BUSINESS ENTERPRISE/WOMEN BUSINESS ENTERPRISE (DBE) "GOOD FAITH" EFFORT CERTIFICATION BY APPLICANT/RECIPIENT 1. The apparent successful low bidder on DFA funded project number C-06- is (name of bidder) 2. Before the State Water Resources Control Board - Division of Financial Assistance can consider requests for an Approval of Award (AOA) to any bidder the applicant/recipient must certify to the following: DISADVANTAGED BUSINESS ENTERPRISE (DBE) The bidder has obtained % of DBE participation for this contract. Also submitted are Forms 3 and 4 that contain a complete list of those DBE firms subcontracted with or with whom other types of agreements were made. The list includes the names of the firm, address, phone number and dollar amount involved. The following affirmative steps as required by 40 CFR 35.3!50 (d) have been taken: (1) The contractor divided total requirements when economically feasible, into small tasks or quantities to permit maximum participation of minority and women's businesses. (2) The contractor established delivery schedules, where the requirements of the work permitted, which encouraged participation by minority and women's business. (3) The contractor included qualified minority and women's businesses on solicitation lists. (4) The contractor assures that minority and women's businesses were solicited, whenever they were potential sources. (5) The contractor used the services and assistance of the Small Business Administration and/or the Office of Minority Business Development Agency of the U.S. Department of Commerce. It must be understood that the applicant/recipient in its role as a public trustee assumes primary responsibility to achieve an acceptable level of DBE utilization. This primary responsibility is a basic condition of the award of any Clean Water State Revolving Fund financial assistance. Where an application/recipient fails to meet its obligations under these requirements the applicant/recipient may be declared non-responsive and may have funding either annulled, suspended or terminated. In accepting these responsibilities, I hereby certify to the above. Name of Applicant/Recipient Signature of Authorized Representative Date Name and Title of Authorized Representative This form must be submitted with the AOA package. Environmental Protection Agency OMB Control No: 2090-0030 Approved: 05/01/2008 Approval Expires: 01/31/2011 Disadvantaged Business Enterprise Program DBE Subcontractor Participation Form NAME OF SUBCONTRACTOR ADDRESS TELEPHONE NO. PROJECT NAME CONTRACT NO. EMAIL ADDRESS PRIME CONTRACTOR NAME Please use the space below to report any concerns regarding the above EPA-funded project (e.g., reason for termination by prime contractor, late payment, etc.). CONTRACT ITEM NO. ITEM OF WORK OR DESCRIPTION OF SERVICES RECEIVED FROM THE PRIME CONTRACTOR AMOUNT SUBCONTRACTOR WAS PAID BY PRIME CONTRACTOR Subcontractor Signature Title/ Date 'Subcontractor is defined as a company, firm, joint venture, or individual who enters into an agreement with a contractor to provide services pursuant to an EPA award of financial assistance. EPA FORM 6100-2 (DBE Subcontractor Participation Form) OMB Control No: 2090-0030 Approved: 05/01/2008 Approval Expires: 01/31/2011 Environmental Protection Agency Disadvantage*! Business Enterprise Program DBE Subcontractor Participation Form The public reporting and recordkeeping burden for this collection of information is estimated to average fifteen (15) minutes. Burden means the total time, effort, or financial resources expended by persons to generate, maintain, retain, or disclose or provide information to or for a Federal agency. This includes the time needed to review instructions; develop, acquire, install, and utilize technology and systems for the purposes of collecting, validating, and verifying information, processing and maintaining information, and disclosing and providing information; adjust the existing ways to comply with any previously applicable instructions and requirements; train personnel to be able to respond to a collection of information; search data sources; complete and review the collection of information; and transmit or otherwise disclose the information. An agency may not conduct or sponsor, and a person is not required to respond to, a collection of information unless it displays a currently valid OMB control number. Send comments on the Agency's need for this information, the accuracy of the provided burden estimates, and any suggested methods for minimizing respondent burden, including the use of automated collection techniques to the Director, Collection Strategies Division, U.S. Environmental Protection Agency (2822), 1200 Pennsylvania Ave., NW, Washington, D.C. 20460. Include the OMB control number in any correspondence. Do not send the completed EPA DBE Subcontractor Participation Form to this address. EPA FORM 6100-2 (DBE Subcontractor Participation Form) Environmental Protection Agency OMB Control No:, Approved: Approval Expires: Disadvantaged Business Enterprise Program DBE Subcontractor Performance Form NAME OF SUBCONTRACTOR1 PROJECT NAME ADDRESS BID/PROPOSAL NO. TELEPHONE NO. E-MAIL ADDRESS PRIME CONTRACTOR NAME CONTRACT ITEM NO. Currently certified ITEM OF WORK OR DESCRIPTION OF SERVICES BID TO PRIME PRICE OF WORK SUBMITTED TO PRIME CONTRACTOR as an MBE or WBE under EPA's DBE Program? Yes No Signature of Prime Contractor Date Print Name Title Signature of Subcontractor Date Print Name Title 'Subcontractor is defined as a company, firm, joint venture, or individual who enters into an agreement with a contractor to provide services pursuant to an EPA award of financial assistance. EPA FORM 6100-3 (DBE Subcontractor Performance Form) OMB Control No: Approved: Approval Expires: Environmental Protection Agency Disadvantage d Business Enterprise Program DBE Subcontractor Performance Form The public reporting and recordkeeping burden for this collection of information is estimated to average fifteen (15) minutes. Burden means the total time, effort, or financial resources expended by persons to generate, maintain, retain, or disclose or provide information to or for a Federal agency. This includes the time needed to review instructions; develop, acquire, install, and utilize technology and systems for the purposes of collecting, validating, and verifying information, processing and maintaining information, and disclosing and providing information; adjust the existing ways to comply with any previously applicable instructions and requirements; train personnel to be able to respond to a collection of information; search data sources; complete and review the collection of information; and transmit or otherwise disclose the information. An agency may not conduct or sponsor, and a person is not required to respond to, a collection of information unless it displays a currently valid OMB control number. Send comments on the Agency's need for this information, the accuracy of the provided burden estimates, and any suggested methods for minimizing respondent burden, including the use of automated collection techniques to the Director, Collection Strategies Division, U.S. Environmental Protection Agency (2822), 1200 Pennsylvania Ave., NW, Washington, D.C. 20460. Include the OMB control number in any correspondence. Do not send the completed EPA DBE Subcontractor Performance Form to this address. EPA FORM 6100-3 (DBE Subcontractor Performance Form) Environmental Protection Agency OMB Control No:. Approved: Approval Expires: Disadvantaged Business Enterprise Program DBE Subcontractor Utilization Form BID/PROPOSAL NO. NAME OF PRIME BIDDER/PROPOSER PROJECT NAME E-MAIL ADDRESS ADDRESS TELEPHONE NO.FAX NO. The following subcontractors1 will be used on this project: COMPANY NAME, ADDRESS, PHONE NUMBER, AND E-MAIL ADDRESS TYPE OF WORK TO BE PERFORMED ESTIMATE D DOLLAR AMOUNT CURRENTLY CERTIFIED ASANMBE ORWBE? I certify under penalty of perjury that the forgoing statements are true and correct. In the event of a replacement of a subcontractor, I will adhere to the replacement requirements set forth in 40 CFR Part 33 Section 33.302(c). Signature Of Prime Contractor Date Print Name Title 'Subcontractor is defined as a company, firm, joint venture, or individual who enters into an agreement with a contractor to provide services pursuant to an EPA award of financial assistance. EPA FORM 6100-4 (DBE Subcontractor Utilization Form) Environmental Protection Agency OMB Control No: Approved: Approval Expires: Disadvantaged Business Enterprise Program DBE Subcontractor Utilization Form The public reporting and recordkeeping burden for this collection of information is estimated to average fifteen (15) minutes. Burden means the total time, effort, or financial resources expended by persons to generate, maintain, retain, or disclose or provide information to or for a Federal agency. This includes the time needed to review instructions; develop, acquire, install, and utilize technology and systems for the purposes of collecting, validating, and verifying information, processing and maintaining information, and disclosing and providing information; adjust the existing ways to comply with any previously applicable instructions and requirements; train personnel to be able to respond to a collection of information; search data sources; complete and review the collection of information; and transmit or otherwise disclose the information. An agency may not conduct or sponsor, and a person is not required to respond to, a collection of information unless it displays a currently valid OMB control number. Send comments on the Agency's need for this information, the accuracy of the provided burden estimates, and any suggested methods for minimizing respondent burden, including the use of automated collection techniques to the Director, Collection Strategies Division, U.S. Environmental Protection Agency (2822), 1200 Pennsylvania Ave., NW, Washington, D.C. 20460. Include the OMB control number in any correspondence. Do not send the completed EPA DBE Subcontractor Utilization Form to this address. EPA FORM 6100-4 (DBE Subcontractor Utilization Form) APPENDIX F Carlsbad Coastal Development Permit and Special Use Permit Brown Catdwell 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 PLANNING COMMISSION RESOLUTION NO. 6645 A RESOLUTION OF THE PLANNING COMMISSION OF THE CITY OF CARLSBAD, CALIFORNIA, APPROVING COASTAL DEVELOPMENT PERMIT CDP 09-03 TO INSTALL A NEW PARALLEL SEGMENT OF UNDERGROUND SEWER FORCE MAIN; INSTALL A NEW RESIN LINER TO AN EXISTING FORCE MAIN; AND ABANDON IN PLACE A SMALL SECTION OF SEWER FORCE MAIN FROM THE BUENA VISTA LIFT STATION (BVLS) TO THE EAST SIDE OF THE BUENA VISTA CREEK BRIDGE AND ALONG THE EASTERN END OF BUENA VISTA LAGOON, LOCATED FROM THE BVLS SOUTHERLY TO THE JEFFERSON STREET/MARRON ROAD INTERSECTION, THEN WESTERLY ALONG JEFFERSON STREET WEST OF THE MARRON ROAD INTERSECTION TO APPROXIMATELY 180 FEET EASTERLY OF 1-5 IN THE MELLO II SEGMENT OF THE LOCAL COASTAL PROGRAM AND WITHIN LOCAL FACILITIES MANAGEMENT ZONE 1, CASE NAME: BUENA VISTA LIFT STATION SEWER FORCE MAIN (VC-4) CASE NO.: CDP 09-03 WHEREAS, the City of Carlsbad, "Developer," has filed a verified application with the City of Carlsbad regarding property owned by the City of Carlsbad, "Owner," described as That portion of Lot 32 of Hosp Eucalyptus Forest Company's Tract No. 1 shown on Map No. 1136, filed in the office of the Recorder of San Diego County June 8,1908, as conveyed to the State of California in Parcel 1 of deed Recorded March 1, 1971, file No. 37628, San Diego County Official Records, and a portion of public right-of-way on Jefferson Street between Highway 78, Highway 5, and Marron Road ("the Property"); and WHEREAS, said verified application constitutes a request for a Coastal Development Permit as shown on Exhibits "A" - "EEM dated November 4,2009, on file in the Planning Department, BUENA VISTA SEWER LIFT STATION FORCE MAIN (VC-4) - CDP 09-03, as provided by Chapter 21.201.040 of the Carlsbad Municipal Code; and WHEREAS, the Planning Commission did, on November 4, 2009, hold a duly 2 noticed public hearing as prescribed by law to consider said request; and 3 WHEREAS, at said public hearing, upon hearing and considering all testimony c and arguments, if any, of all persons desiring to be heard, said Commission considered all factors 6 relating to the CDP. NOW, THEREFORE, BE IT HEREBY RESOLVED by the Planning o Commission of the City of Carlsbad as follows: 9 A) That the foregoing recitations are true and correct. 10 B) That based on the evidence presented at the public hearing, the Commission APPROVES BUENA VISTA SEWER LIFT STATION FORCE MAIN (VC- 12 *) - CDP 09-03 based on the following findings and subject to the following conditions; 13 Findings: 14 I. That the proposed development is in conformance with the Certified Local Coastal Program and all applicable policies in that tbe proposed sewer force main replacement project will not obstruct views of the coastline or Buena Vista Lagoon as seen from public lands or the public right-of-way, nor otherwise damage the visual beauty of the coastal zone. No above-ground structures are proposed as part of the project 17 with the exception of the approximate 125-foot length of pipe which will hang under the Jefferson Street bridge over Buena Vista Creek. Therefore, the visual beauty and coastal resources within the coastal zone will not diminish with the proposed . g sewer force main project. 20 No agricultural uses currently exist on the site or within the area. The proposed project Is not located in an area of known geologic instability. Portions of the project 21 area are located within the 100-year flood hazard area. These areas include much of the segment of sewer tine within Jefferson Street west of the Marron Road intersection. Since the construction of the sewer pipe hung under the Jefferson 23 Street bridge over Buena Vista Creek will take place on scaffolding hanging from the bridge, no impact to the Buena Vista Creek floodplain will result from the 24 project. The project will not place any new above ground structures within the limits of the identified 100-year flood hazard areas. The project will be underground and will thus not utilize any volume area within the 100-year flood zone. _ Construction of the project will not place equipment, structures or other materials in areas which could impede flows of the 100-year flood. Thus no impediment to 27 flood flows will result from implementation of the project. 28 2. The proposal is in conformity with the public access and recreation policies of Chapter 3 of the Coastal Act in that access to the existing pedestrian trail leading from the PCRESONO.6645 -2- 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 parking lot to a viewpoint overlooking the lagoon will not be affected by this project. Currently access to this trail and viewing area is via the Buena Vista Ecological Preserve Parking Lot owned by the State of California and managed by the California Department of Fish and Game (CDFG). Due to inadequate CDFG staff resources to adequately manage the area, the chain link fence around the parking lot is locked. 3. The project is not located in the Coastal Agricultural Overlay Zone, according to Map X of the Land Use Plan, certified September 1990, and therefore, is not subject to the provisions of the Coastal Agriculture Overlay Zone (Chapter 21.202 of the Zoning Ordinance). 4. The project is consistent with the provisions of the Coastal Resource Protection Overlay Zone (Chapter 21.203 of the Zoning Ordinance) in that the project will adhere to the City's Master Drainage Plan, Grading Ordinance, Storm Water Ordinance, Standard Urban Storm Water Mitigation Plan (SUSMP), and Jurisdictional Urban Runoff Management Program (JURMP) to avoid increased urban runoff, pollutants, and soil erosion. No steep slopes or native vegetation is located on the subject property and the site is not located in an area prone to landslides, or susceptible to accelerated erosion, or liquefaction. While the area may be subject to flooding, the proposed project will be underground, with the exception of the approximate 125-foot length of pipe which will hang under the Jefferson Street bridge over Buena Vista Creek. There are no prime agricultural lands near the site. Construction of the proposed project is not expected to directly or indirectly impact local wildlife movement or migratory fish or wildlife movement because the project is underground and will not result in impacts to biological resources, including the movement of any native resident or migratory wildlife species, or wildlife corridors. In addition, temporary . trenching and pipe placement impacts will only occur on the city streets and the BVLS pad during the construction period. However, construction noise could affect the breeding of migratory songbirds and other bird species associated with the adjacent lagoon, therefore, a mitigation measure has been included hi the project's Mitigation Monitoring and Reporting Program (MMRP) to reduce this potentially significant impact to a less than significant level. 5. The project is consistent with the provisions of the Coastal Shoreline Development Overlay Zone (Chapter 21.204 of the Zoning Ordinance) in that no development is proposed in areas of steep slopes (coastal bluff). No native vegetation located in the adjacent Buena Vista Lagoon will be impacted during construction. All impacts will be mitigated according to the project's MMRP, which is consistent with the City's HMP. The site is not located in an area prone to landslides, or susceptible to accelerated erosion or liquefaction. While the area may be subject to flooding, the proposed project will be underground, with the exception of the approximate 125- foot length of pipe which will hang under the Jefferson Street bridge over Buena Vista Creek. 6. The Planning Commission has reviewed each of the exactions imposed on the Developer contained in this resolution, and hereby finds, in this case, that the exactions are imposed PCRESONO.6645 -3- to mitigate impacts caused by or reasonably related to this project, and the extent and the 2 degree of exaction is in rough proportionality to the impact caused by the project. 3 Conditions: 4 Note: Unless otherwise specified herein, all conditions shall be satisfied prior to start of construction. g 1. If any of the following conditions fail to occur, or if they are, by their terms, to be implemented and maintained over time, if any of such conditions fail to be so 7 implemented and maintained according to their terms, the City shall have the right to revoke or modify all approvals herein granted; deny or further, condition issuance of all 8 future building permits; deny, revoke, or further condition all certificates of occupancy Q issued under the authority of approvals herein granted; record a notice of violation on the property title; institute and prosecute litigation to compel their compliance with said 10 conditions or seek damages for their violation. No vested rights are gained by Developer or a successor in interest by the City's approval of this Coastal Development Permit. 11 2. Staff is authorized and directed to make, or require the Developer to make, all corrections and modifications to the Coastal Development Permit documents, as necessary to make 13 them internally consistent and in conformity with the final action on the project Development shall occur substantially as shown on the approved Exhibits. Any proposed 14 development, different from this approval, shall require an amendment to this approval. 15 3. Developer shall comply with all applicable provisions of federal, state, and local laws and j 6 regulations in effect at the time of building permit issuance. 17 4. Developer shall implement, or cause the implementation of, the Buena Vista Lift Station Sewer Force Main (VC-4) Project Mitigation Monitoring and Reporting 18 Program. 19 5. Developer shall submit to the Planning Director a reproducible 24" x 36" mylar copy of 20 the Site Plan reflecting the conditions approved by the final decision-making body. 21 6. Developer shall include, as part of the plans submitted for any permit plancheck, a reduced legible version of all approving resolution(s) in a 24" x 36" blueline drawing format (including any applicable Coastal Commission approvals). 23 7. This approval is granted subject to the approval of the Mitigated Negative Declaration 24 and Mitigation Monitoring and Reporting Program, and approval of SUP 09-01 and is subject to all conditions contained in Planning Commission Resolutions No. 6644 and 25 6646 for those other approvals incorporated herein by reference. 26 8. Machinery necessary to accomplish the trenching and pipe laying work will be 27 located on urbanized pads and streets, and will maintain a minimum 10 feet from Coastal Sage Scrub (CSS) and Freshwater Marsh (FM) vegetation communities. 28 Staging areas for pipes, machinery, materials and tools will be within adjacent traffic lanes which will also be closed to traffic. Backhoe and similar rubber-tire PCRESONO.6645 -4- 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 9. machinery will be primarily utilized for trenching, with the spoils temporarily laid directly adjacent to the trench, a minimum 10 feet from CSS and FM vegetation. Trucks to transport materials to the site and other smaller vehicles will access the area and park on the public streets and on the existing BVLS pad. This approval shall become null and void if the Notice to Proceed is not issued or commencement of construction does not occur for this project within two (2) years of approval or this coastal development permit will expire unless extended per Section 21.201.210 of the Zoning Ordinance. Engineering: 10. Prior to the commencement of construction, the City will approve a Storm Water Pollution and Prevention Plan (SWPPP). The contractor shall comply with the SWPPP and current requirements and provisions established by the San Diego Region of the California Regional Water Quality Control Board and City of Carlsbad Requirements. 11. Prior to the issuance of Notice to Proceed, the contractor shall submit to the Traffic Engineer a Traffic Control Plan, which shall show a detour plan for routing vehicular traffic around the construction site during the construction of the project. Code Reminders: 12. Developer shall exercise special care during the construction phase of this project to prevent offsite siltation. Planting and erosion control shall be provided in accordance with Carlsbad Municipal Code Chapter 15.16 (the Grading Ordinance) to the satisfaction of the City Engineer. 13. Approval of this request shall not excuse compliance with all applicable sections of the Zoning Ordinance and all other applicable City ordinances in effect at time of building permit issuance, except as otherwise specifically provided herein. 14. The project shall comply with the latest nonresidential disabled access requirements pursuant to Title 24 of the California Building Code. PCRESONO.6645 -5- 1 " PASSED, APPROVED, AND ADOPTED at a regular meeting of the Planningti2..Commission of the City of Carlsbad, California, held on November 4, 2009, by the following vote, to wit: 4 " 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 AYES; Commissioners Baker, Dominguez, Douglas, L'Heureux, Nygaard, Schumacher, and Chairperson Montgomery NOES: ABSENT: ABSTAIN: MARTETL B. MQNT^DMERY^&irperson CARLSBAD PLANNING COMWBSION ATTEST: DONNEU Planning Director PCRESONO.6645 -6- 1 I! PLANNING COMMISSION RESOLUTION NO. 6646 2 3 7 EASTERN END OF BUENA VISTA LAGOON, LOCATED 811 FROM THE BVLS SOUTHERLY TO THE JEFFERSON 9II STREET/MARRON ROAD INTERSECTION, THEN WESTERLY ALONG JEFFERSON STREET WEST OF THE 10 II MARRON ROAD INTERSECTION TO APPROXIMATELY 180 FEET EASTERLY OF 1-5 IN THE MELLO II SEGMENT OF 11 I THE LOCAL COASTAL PROGRAM AND WITHIN LOCAL 12 I, FACILITIES MANAGEMENT ZONE 1. CASE NAME: BUENA VISTA LIFT STATION SEWER 13 19 20 21 23 24 A RESOLUTION OF THE PLANNING COMMISSION OF THE CITY OF CARLSBAD, CALIFORNIA, APPROVING A FLOODPLAIN SPECIAL USE PERMIT TO INSTALL A NEW PARALLEL SEGMENT OF UNDERGROUND SEWER FORCE MAIN; INSTALL A NEW RESIN LINER TO AN EXISTING FORCE MAIN; AND ABANDON IN PLACE A SMALL SECTION OF SEWER FORCE MAIN FROM THE BUENA VISTA LIFT STATION (BVLS) TO THE EAST SIDE OF THE BUENA VISTA CREEK BRIDGE AND ALONG THE FORCE MAIN (VC-4) CASE NO.: SUP 09-01 14 ii 15 I, WHEREAS, the City of Carlsbad, "Developer," has filed a verified application 16 17 18 with the City of Carlsbad regarding property owned by the City of Carlsbad, "Owner," described as That portion of Lot 32 of Hosp Eucalyptus Forest Company's Tract No. 1 shown on Map No. 1136, Hied in the office of the Recorder of San Diego County June 8,1908, as conveyed to the State of California in Parcel 1 of deed Recorded March I, 1971, file No. 37628, San Diego County Official Records, and a portion of public right-of-way on Jefferson Street between __ n Highway 78, Highway 5, and Marron Road ("the Property"); and WHEREAS, said verified application constitutes a request for a Floodplain 25 Planning Department, BUENA VISTA LIFT STATION FORCE MAIN (VC-4) - SUP 09-01, 28 Special Use Permit as shown on Exhibits "A" - "EE" dated November 4, 2009, on file in the 26 " 27 u as provided by Chapter 21.110 of the Carlsbad Municipal Code; and 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 WHEREAS, the Planning Commission did on November 4, 2009, hold a duly noticed public hearing as prescribed by law to consider said request; and WHEREAS, at said public hearing, upon hearing and considering all testimony and arguments, if any, of all persons desiring to be heard, said Commission considered all factors relating to the Floodplain Special Use Permit. NOW, THEREFORE, BE IT HEREBY RESOLVED by the Planning Commission of the City of Carlsbad as follows: A) That the foregoing recitations are true and correct. B) That based on the evidence presented at the public hearing, the Commission APPROVES BUENA VISTA LIFT STATION FORCE MAIN (VC-4) - SUP 09-01, based on the following findings and subject to the following conditions: Findings: 1,The site is reasonably safe from flooding in that the proposed project will be underground, with the exception of the approximate 125-foot length of pipe, which will hang under the Jefferson Street bridge over Buena Vista Creek. Since the construction of the sewer pipe hung under the Jefferson Street bridge over Buena Vista Creek will take place on scaffolding hanging from the bridge, no impact to the Buena Vista Creek floodplain will result from the project. The project as proposed has been designed to minimize the flood hazard to the habitable portions of the structure in that the sewer force main project does not include any habitable portions. The proposed project does not create a hazard for adjacent or upstream properties or structures in that the project will not place any new above ground structures within the limits of the identified 100-year flood hazard areas. The project will be underground and will thus not utilize any volume area within the 100-year flood zone. Construction of the project will not place equipment, structures or other materials in areas which would impede water flow in Buena Vista Creek creating a hazard to any structures adjacent or upstream of the project 4.The proposed project does not create any additional hazard or cause adverse impacts to downstream properties or structures in that the project will not place any new above ground structures within the limits of the identified 100-year flood hazard areas. The project will be underground and will thus not utilize any volume area within the 100-year flood zone. Construction of the project will not place equipment, structures or other materials in areas which could impede water flow in Buena Vista Creek or the lagoon which would create a hazard to any properties or structures downstream of the project. PCRESONO.6646 -2- 1 2 3 7 increase in water surface elevation will result from implementation of the project o 9 10 11 12 13 15 5. The proposed project does not reduce the ability of the site to pass or handle a base flood of 100-year frequency in that the proposed project will be underground, with the exception of the approximate 125-foot length of pipe which will hang under the Jefferson Street bridge over Buena Vista Creek and will not place equipment, structures or other materials in areas which could impede flows of the 100-year flood. 6. The proposed project taken together with all the other known, proposed, and anticipated projects will not increase the water surface elevation of the base flood more than one foot at any point in that construction of the project will not place equipment, structures or other materials in areas which could impede flows of the 100-year flood. Thus no 7. No other required state and federal permits are needed. Conditions; 1. Staff is authorized and directed to make, or require Developer to make, all corrections and modifications to the Special Use Permit documents) necessary to make them internally consistent and in conformity with final action on the project. Development shall occur substantially as shown in the approved Exhibits. Any proposed development, different from this approval, shall require an amendment to this approval. 14 2. This approval is granted subject to the approval of the Mitigated Negative Declaration and Mitigation Monitoring and Reporting Program, and approval of CDP 09-03 and ., is subject to all conditions contained in Planning Commission Resolutions No. 6644 and 6645 for those other approvals incorporated herein by reference. 17 3. This approval shall become null and void if the Notice to Proceed is not issued or commencement of construction does not occur for this project within two (2) years of approval or this special use permit will expire. 20 21 22 23 24 25 26 27 28 PCRESONO.6646 -3- 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 PASSED, APPROVED, AND ADOPTED at a regular meeting of the planning Commission of the City of Carlsbad, California, held on November 4, 2009 by the following vote, to wit: AYES:Commissioners Baker, Dominguez, Douglas, L'Heureux, Nygaard, Schumacher, and Chairperson Montgomery NOES: ABSENT: ABSTAIN: M CARLSBAD PLA ATTEST: DONNEU Planning Director PCRESONO.6646 -4-