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Home My WebLink AboutFalcon General Engineering; 2004-12-10; PWS04-41ENGRecording requested by: CITY OF CARLSBAD When recorded mail to: City Clerk City of Carlsbad 1200 Carlsbad Village Dr. Carlsbad, CA 92008 DGC# 2007-0107553 FEB15, 2007 3:42 PM OFFICIAL RECORDS SAN DIEGO COUNTY RECORDER'S OFFICE GREGORYJ SMITH.COUNTY RECORDER FEES: 2.00 PAGES: 1 Space above this line for Recorder's Use NOTICE OF COMPLETION Notice is hereby given that: 1. The undersigned is owner of the interest or estate stated below in the property hereinafter described. 2. The full name of the undersigned is Carlsbad Municipal Water District (CMWD), a municipal corporation. 3. The full address of the undersigned is 1200 Carlsbad Village Drive, Carlsbad, California 92008. 4. The nature of the title of the undersigned is: In fee. 5. A work of improvement on the property hereinafter described was completed on December 20, 2006. 6. The name of the contractor for such work of improvement is Falcon General Engineering. 7. The property on which the work of improvement was completed is in the City of Carlsbad, County of San Diego, State of California, and is described as the Calavera Recycled Water Pump Station for the Encina Basin Water Reclamation Program, Phase II Project, Project No. 3889-1B. CARLSBAD MUNICIPAL WATER DISTRICT GLENN PRUIM Public Works Director VERIFICATION OF SECRETARY I, the undersigned, say: I am the Secretary of the Carlsbad Water Municipal District, 1200 Carlsbad Village Drive, Carlsbad, California, 92008. The Board of Directors of said District on February 13 2006, accepted the above described work as completed and ordered that a Notice of Completion be filed. I declare under penalty of perjury that the foregoing is true and correct. Executed opw^fr/t*-^ /J . 2007 at Carlsbad, California. CARLSBAD MUNICIPAL WATER DISTSl^Tf/mm. 2^£O1RRAIN ""•''"'V c>Karen R. Kundtz, Assistant Secretary CARLSBAD MUNICIPAL WATER DISTRICT San Diego County California CONTRACT DOCUMENTS AND SPECIAL PROVISIONS FOR ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERARECYCLED WATER PUMP STATION PWSO4-41 ENG CONTRACT NO. 38891 SWRCB PROJECT NO. C-06-3903=240 CARLSBAD MUNICIPAL WATER DISTRICT 5950 EL CAMINO REAL CARLSBAD, CALIFORNIA 92008 (760) 438-3367 June 2004 , Revised: 1 0/08/03 Contract No. 38891 * Page 1 of 98 Pages TABLE OF CONTENTS Paqe Notice Inviting Bids .......................................................................................................................... 8 Contractor’s Proposal .................................................................................................................... 12 EquipmenVMaterial Source Information ........................................................................................ 18 Bid Security Form .......................................................................................................................... 19 Bidder‘s Bond to Accompany Proposal ......................................................................................... 20 Guide for Completing the “Designation of Subcontractors’’ Form ................................................ 24 Designation of Subcontractors and Amount of Subcontractor’s Bid Items .................................. 24 Bidder’s Statement of Financial Responsibility ............................................................................. 25 Bidder’s Statement of Technical Ability And Experience .............................................................. 26 Bidder’s Certificate of Insurance For General Liability. Employers’ Liability. Automotive Liability And Workers’ Compensation ........................................................................................... 27 Bidder‘s Statement of Re-Debarment ........................................................................................... 29 Bidder’s Disclosure of Discipline Record ...................................................................................... 29 Non-Collusion Affidavit To Be Executed By Bidder And Submitted With Bid .............................. 31 Contract Public Works ................................................................................................................... 32 Labor And Materials Bond ............................................................................................................. 38 Faithful PerformanceNVarranty Bond ........................................................................................... 40 Optional Escrow Agreement For Surety Deposits In Lieu of Retention ........................................ 42 SUPPLEMENTAL PROVISIONS Part 1 Section 1 1-1 1-2 1-3 Section 2 2-3 2-4 2-5 2-9 2-1 0 General Provisions Terms Definitions. Abbreviations And Symbols Terms ............................................................................................................................ 45 Definitions ...................................................................................................................... 45 Abbreviations ................................................................................................................. 46 Scope And Control Of The Work Subcontracts ................................................................................................................. 47 Contract Bonds .............................................................................................................. 47 Plans And Specifications., ............................................................................................ -48 Surveying ................................................................ : ...................................................... 49 Authority Of Board And Engineer .................................................................................. 53 GRevised: 10/08/03 Contract No . 38891 Page 2 of 98 Pages TABLE OF CONTENTS Paqe Section 3 3-3 3-4 3-5 Section 4 4- 1 4-2 Section 5 5- 1 5-4 Section 6 6- 1 6-2 6-6 6-7 6-8 6-9 Section 7 7-3 7-4 7-5 7-7 7-8 7-1 0 7-1 3 Section 9 9- 1 9-3 Changes In Work Extra Work ..................................................................................................................... 54 Changed Conditions ...................................................................................................... 54 Disputed Work ............................................................................................................... 55 Control Of Materials Materials And Workmanship ......................................................................................... 57 Materials Transportation. Handling & Storage .............................................................. 59 Utilities Location ......................................................................................................................... 59 Relocation ...................................................................................................................... 59 Prosecution. Progress And Acceptance Of The Work Construction Schedule And Commencement Of Work ................................................ 59 Prosecution Of Work ..................................................................................................... 64 Delays And Extensions Of Time ................................................................................... 65 Time of Completion ....................................................................................................... 65 Completion And Acceptance ......................................................................................... 65 Liquidated Damages ..................................................................................................... 66 Responsibilities Of The Contractor Liability Insurance .......................................................................................................... 66 Workers’ Compensation Insurance ............................................................................... 66 Permits .......................................................................................................................... 66 Cooperation and Collateral Work .................................................................................. 67 Project Site Maintenance .............................................................................................. 68 Public Convenience And Safety .................................................................................... 68 Laws To Be Observed ................................................................................................... 72 Measurement & Payment Measurement Of Quantities For Unit Price Work ......................................................... 72 Payment ......................................................................................................................... 72 SUPPLEMENTAL PROVISIONS Part 2 Section 203 203-6 203-1 1 Section 204 204-1 Section 206 206-7 206-8 Construction Materials Bituminous Materials Asphalt Concrete. .......................................................................................................... 75 Asphalt Pavement And Crack Sealants ........................................................................ 76 Lumber And Treatment With Preservatives Lumber And Plywood .................................................................................................... 77 Miscellaneous Metal Items Light Gage Steel Tubing And Connectors .................................................................... 81 Traffic Signs .................................................................................................................. 77 GRevised: 10/08/03 Contract No . 38891 Page 3 of 98 Pages TABLE OF CONTENTS . Item Paae Part 3 Section 300 300-1 300-3 300-4 300-5 300-9 Section 301 301 -1 Section 302 302-5 302-9 Section 31 0 31 0-5 31 0-7 Section 313 31 3-1 31 3-2 31 3-3 31 3-4 Construction Methods Earthwork Clearing And Grubbing ................................................................................................. 82 Structure Excavation And Backfill ................................................................................. 82 Unclassified Fill ............................................................................................................. 82 Borrow Excavation ........................................................................................................ 83 Geotextiles For Erosion Control And Water Pollution Control ..................................... 83 Treated Soil. Subgrade Preparation and Placement of Base Materials Subgrade Preparation ................................................................................................... 84 Roadway Surfacing Asphalt Pavement Repairs And Remediation .............................................................. 85 Asphalt Concrete Pavement ......................................................................................... 84 Painting Painting Various Surfaces ............................................................................................ 85 Permanent Signing ....................................................................................................... 86 Temporary Traffic Control Devices Temporary Traffic Pavement Markers .......................................................................... 87 Temporary Railing (Type K) and Crash Cushions ........................................................ 88 Measurement and Payment .......................................................................................... 89 Temporary Traffic Signing ............................................................................................ 87 SUPPLEMENTAL PROVISIONS Special Construction Provisions 1 . Work Site ................................................................................................................................... 90 2 . Storage of Materials and Equipment ........................................................................................ 92 3 . Earthwork and Soil Compaction Tests ..................................................................................... 92 4 . Preservation of Existing Improvements, Restoration of Work Site and Disposal of Spoil and Waste Materials ................................................................................................................. 93 5 . Specified Model Numbers ......................................................................................................... 93 6 . Lateral Design ........................................................................................................................... 93 7 . 8 . 9 . Operation and Maintenance Manuals and Training ................................................................. 94 11 . Reference Documents .............................................................................................................. 96 12 . Safety Requirement of Equipment Furnished by Contractor .................................................... 96 13 . Lubrication ................................................................................................................................. 96 14 . Construction Mitigation Measures ............................................................................................ 97 15 . Hydraulic Automatic Control Valves ......................................................................................... 97 16 . Solenoid Valves ........................................................................................................................ 98 17 . Swing Check Valves (3 Inch and Smaller) ............................................................................... 98 18 . Silent Check Valves .................................................................................................................. 98 Location of Equipment and Ambient Environmental Conditions .............................................. 94 Equipment Performance Documentation ................................................................................. 94 10 . Geological Conditions at Work Site .......................................................................................... 96 %Revised: 10/08/03 Contract No . 38891 Page 4 of 98 Pages TABLE OF CONTENTS Item - SUPPLEMENTAL PROVISIONS State Water Resources Control Board Contract Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 23. 24. 25. State Wage Rate Clause Labor Code Section 1776; Complete Payroll Records; Certified and Available Labor Code Section 1777.5; Employment of Properly Registered Apprentices Labor Code Section 181 0; Definition: A Legal Day’s Work Labor Code Section 181 3; Penalty For Overtime On Any Public Work Contract Labor Code Section 181 5; Minimum Overtime Pay Labor Code Section 1860; Contract Provision Labor Code Section 1861 ; Contractor Certification to Labor Code Section 3700 Cultural Resources Protection Compliance Guidelines for SRF Loan Program MBENVBE (Form 4 must be submitted with bid to be responsive) The Subletting and Subcontracting Fair Practices Act Equal Opportunity Clause (40 CFR 60-8.4(b)) Nondiscrimination Clause Construction Contractors - Affirmative Action Requirements (41 CFR 60-4) Elimination of Segregated Facilities Certification of Non-Segregated Facilities Drug-Free Workplace Certification Use of Debarred Contractors Prohibited Responsibility for Removal, Relocation, or Protection of Existing Utilities (Government Code Section 421 5) Submitting of Bids and Agreeing to Assign (Government Code Section 4552) Non-Collusion Affidavit (Public Contract Code Section 71 06) TO BE NOTARIZED AND SUBMllTED WITH THE BID Labor Code 6500 Public Contract Code Section 7105 Public Contract Code Section 9203 Paqe BP -14 BP -14 BP -15 BP -17 BP -17 BP -17 BP -18 BP -18 BP -18 BP -20 BP -34 BP -34 BP -35 BP -39 BP -43 BP -44 BP -45 BP -46 BP -48 BP -48 BP -49 BP-50 BP-50 BP-51 TECHNICAL SPECIFICATIONS Schedule of Values ................................................................................................................. 01026-1 Start-up, Field Testing, and Acceptance of Equipment Technical Specifications ................. 01 500-1 Trenching Earthwork ............................................................................................................... 02223-1 Basic Earthwork Specifications .............................................................................................. 02300-1 Basic Paving Specifications .................................................................................................... 02500-1 Ornamental Steel Fencing and Gates.. .................................................................... 02833-1 Basic Concrete Formwork Specifications ............................................................................... 031 00-1 Basic Concrete Reinforcement Specifications ....................................................................... 03200-1 Basic Concrete Specifications ................................................................................................ 03300-1 Precast Concrete Moldings .................................................................................................... 03482-1 Basic Concrete Masonry Specifications ................................................................................. 04200-1 Basic Structural Steel and Miscellaneous Metal Work Specifications ................................... 051 00-1 Metal Decking ......................................................................................................................... 05300-1 Bituminous Waterproofing ...................................................................................................... 071 12-1 Built-up Roof System .............................................................................................................. 07500-1 Flashing and Sheet Metal ....................................................................................................... 07600-1 10/08/03 Contract No. 38891 Page 5 of 98 Pages Item . TABLE OF CONTENTS Paqe Roof Hatches .......................................................................................................................... 07720-1 Sealants and Caulking ............................................................................................................ 07920-1 Doors. Frames. and Hardware Technical Specifications ....................................................... 081 00-1 Plaster over Concrete Masonry .............................................................................. .0920 2-1 and Wastewater Facilities ............................................................................................... 09900-1 Petrolatum Wax Tape Coating ............................................................................................... 09902-1 Fire Extinguishers and Brackets ............................................................................................. 10520-1 Close Coupled Vertical Turbine Pumping Unit Technical Specifications .............................. 1 131 0-1 Cathodic Protection by Sacrificial Anodes .............................................................................. 131 10-1 Surge Arrestor Technical Specifications ................................................................................ 13221 -1 General Piping System and Appurtenances .......................................................................... 15000-1 Hydrostatic Testing of Pressure Pipelines .............................................................................. 15044-1 Cement-Mortar Lined and Coated Steel Pipe and Specials .................................................. 15061 -1 Miscellaneous Couplings, Pipe and Appurtenances .............................................................. 15092-1 Process Valves, Regulators and Miscellaneous Valves ........................................................ 15099-1 Recycled Water Facilities (Offsite) ......................................................................................... 151 51 -1 Heating and Ventilation Equipment Technical Specifications ................................................ 15800-1 Short CircuitlCoordination Study Technical Specifications .................................................... 16040-1 Basic Electrical Specifications ................................................................................................ 16050-1 Distribution Switchboards and Motor Control Centers Technical Specifications ................... 16400-1 Variable Frequency Drives Technical Specifications ............................................................. 16500-1 Transient Voltage Surge Suppression System ...................................................................... 1661 5-1 General Instrumentation and Control Components Technical Specifications ....................... 17000-1 Magnetic Flow Meter Technical Specifications ...................................................................... 1721 0-1 Security and Smoke Detection ............................................................................................... 1731 0-1 Tape Coating System with Mortar Shield for the Exterior of Steel Water Pipelines .............. 09870-1 Basic Coating and Painting Specifications for Water. Recycled Water. General Mechanical and Equipment Technical Specifications .............................................. 1 1005-1 Disinfection of Piping .............................................................................................................. 15041-1 Copper Tubing, Brass and Bronze Pipe Fittings .................................................................... 15057-1 Resilient Wedge Gate Valves (RWGV's) ............................................................................... 15100-1 Air Release Valve, Air and Vacuum Valve, and Combination Air Valve Assemblies ............ 15108-1 APPENDIX A . RESIDENT NOTIFICATION EXAMPLE APPENDIX B . CARLSBAD CONDITIONAL USE PERMIT APPENDIX C . SDG&E DRAWINGS AND SERVICE ORDER APPENDIX D . MISCELLANEOUS STANDARD DRAWINGS Carlsbad Municipal Water District Standard Drawings Sewer Main Cleanout Sewer Lateral Below Surface 1" & 2" Air Vacuum Valve Assembly & Appurtenance Outlets of D.I. or Steel Main for 1" thru 2" Inch Assemblies Dielectric Connections to Steel Main Valve Box Assembly Concrete Thrust Blocks for Non-Restrained Joints Gate Valve Installation P.V.C., D.I.P., A.C.P. & Steel Pipe S6 s7 w7 w9 w10 W13 W15 W16 4- %#Revised: 10/08/03 Contract No . 38891 Page 6 of 98 Pages TABLE OF CONTENTS Item - Thrust Block Bearing Areas 2 Inch and Under Backflow Installation Extension Stem and Marker Post Protection Post At Grade 2-Wire Test Station with Anodes Exothermic Weld Process 2-Wire Test Station with Anodes Wiring Diagram Magnesium Anode Concrete Test Box Buried Insulating Flange Mechanical Joint Bond San Diego County Regional Standard Drawings Gravity Retaining Walls General Notes and Details for Gravity Retaining Walls Welded Steel Grate Frames Drainage Structure Grate Corrugated Steel Pipe Inlets, Types A and B Corrugated Steel Pipe Inlets, Details Catch Basin - Type I Pipe Bedding and Trench Backfill for Storm Drains Trench Detail PVC and/or Copper Pipe (3" and Smaller) APPENDIX D - MISCELLANEOUS STANDARD DRAWINGS Krieger & Stewart Standard Drawings Pipeline Trench Welded Steel Pipe Cut-to-Fit & Joint Repair Detail Welded Steel Pipe Shear Ring Detail w19 w20 W23 W24 W26 W 27 W28 W29 W 30 W31 W 32 c-9 c-io D-13 D-15 D-16 D-17 D-29 D-60 1-25 WlOl W137 W138 Paqe APPENDIX E - CMWD'S APPROVED MATERIALS LIST FOR USE ON CONSTRUCTION OF POTABLE AND RECYCLED WATER FACILITIES INFORMATION FOR CONTRACTOR A. TO OBTAIN A COPY OF CURRENT PLAN HOLDERS LIST: PHONE (760) 602-2460 B. QUESTIONS PERTAINING TO PLANS AND CONTRACT DOCUMENTS: CHRISTOPHER M MUEHLBACHER ASSOCIATE ENGINEER PHONE (760) 602-2736 QRevised: 10/08/03 Contract No. 38891 Page 7 of 98 Pages CARLSBAD MUNICIPAL WATER DISTRICT NOTICE INVITING BIDS Sealed bids will be deposited in the Bid Box located in the first floor lobby of the Faraday Center located at 1635 Faraday Avenue, Carlsbad, California, 92008-7314, until 4:OO P.M. on the 2”d day of August, 2004, at which time they will be opened and read, for performing the work as follows: furnishing all labor, material, and equipment for construction of the Calavera Recycled Water Pump Station. CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION The work shall be performed in strict conformity with the specifications as approved by the Board of Directors of the Carlsbad Municipal Water District on file with the Engineering Department. The specifications for the work include the Standard Specifications for Public Works Construction (2003 Edition, and any supplements thereto,), all hereinafter designated “SSPWC” as issued by the Southern California Chapter of the American Public Works Association and as amended by the special provisions sections of this contract. Reference is hereby made to the plans and specifications for full particulars and description of the work. The Carlsbad Municipal Water District encourages the participation of minority and women-owned businesses. Prospective bidders are hereby advised that the project is funded in part by Federal and California State loan funds and Minority Business Enterprise (MBE)NVomen Business Enterprise (WBE) Positive Effort Documentation is required. Refer to State Water Resources Control Board (SWRCB) Contract Requirements herein. The Carlsbad Municipal Water District encourages all bidders, suppliers, manufacturers, fabricators and contractors to utilize recycled and recyclable materials when available, appropriate and approved by the Engineer. The Carlsbad Municipal Water District may disqualify a contractor or subcontractor from participating in bidding when a contractor or subcontractor has been debarred by the Carlsbad Municipal Water or another jurisdiction in the State of California as an irresponsible bidder. No bid will be received unless it is made on a proposal form furnished by the Purchasing Department. Each bid must be accompanied by security in a form and amount required by law. The bidder‘s security of the second and third next lowest responsive bidders may be withheld until the Contract has been fully executed. The security submitted by all other unsuccessful bidders shall be returned to them, or deemed void, within ten (IO) days after the Contract is awarded. Pursuant to the provisions of law (Public Contract Code section 10263), appropriate securities may be substituted for any obligation required by this notice or for any monies withheld by the District to ensure performance under this Contract. Section 10263 of the Public Contract Code requires monies or securities to be deposited with the District or a state or federally chartered bank in California as the Escrow Anent. The Escrow Anent shall maintain insurance to cover negligent acts and omissions of the agentin connection with the handling of retentions $1 00,000 per contract. *m %$Revised: 10/08/03 Contract No. 38891 under this section in an amount not less than Page 8 of 98 Pages The documents which comprise the Bidder’s proposal executed, including notarization where indicated are: 1. 2. 3. 4. 5. 6. 7. Contractor’s Proposal Bidder’s Bond Non-Collusion Affidavit Designation of Subcontractors Bidder’s Statement of Financial Responsibility 8. 9. and that must be completed and properly Certificate of Insurance, the riders covering the City, its officials, employees and volunteers may be omitted at the time of bid submittal but shall be provided by the Bidder prior to award of this contract Bidder’ s Statement Re Debarment Bidder’s Statement of Technical Ability and Experience Acknowledgment of Addendum(s) IO. Bidder’s Disclosure Of Discipline Record 11. Escrow Agreement for Security Deposits - (optional, must be completed if the Bidder wishes to use the Escrow Agreement for Security) B) 12. Equipment/Material Source Information 13. State MBENVBE Information (Attachment *Pursuant to California Public Contracts Code section 41 04(a)(2)(A) portions of the information required on documents numbers four and five, above, may be submitted by the Bidder up to twenty- four (24) hours after the deadline for submitting bids contained in this “Notice Inviting to Bid”. All bids will be compared on the basis of the Engineer’s Estimate. The estimated quantities are approximate and serve solely as a basis for the comparison of bids. The Engineer’s Estimate is $920,000.00. Except as provided herein a bid submitted to the City by a Contractor who is not licensed as a contractor pursuant to the Business and Professions Code shall be considered nonresponsive and shall be rejected by the City. In all contracts where federal funds are involved, no bid submitted shall be invalidated by the failure of California law. Where federal funds are involved the contractor shall be properly licensed at the time the contract is awarded. In all other cases, the contractor shall state their license number, expiration date and classification in the proposal, under penalty of perjury. This invitation to bid does involve federal funds. The following classifications are acceptable for this contract: Classification A, General Engineering If the Contractor intends to utilize the escrow agreement included in the contract documents in lieu of the usual 10% retention from each payment, these documents must be completed and submitted with the signed contract. The escrow agreement may not be substituted at a later date. Sets of plans, special provisions, and Contract documents may be obtained at the Cashier’s Counter on the first floor lobby at the Faraday Center located at 1635 Faraday Avenue, Carlsbad, California 92008-7314, for a non-refundable fee of $100.00 per set. If plans and specifications are to be mailed, the cost for postage should be added. Any prospective bidder who is in doubt as to the intended meaning of any part of the drawings, specifications or other contract documents, or finds discrepancies in or omissions from the drawings and specifications may submit to the Engineer a written request for clarification or correction. Any response will be made only by a written addendum duly issued by the Engineer a copy of which will be mailed or delivered to each person receiving a set of the contract documents. No oral response will be made to such inquiry. Prior to award of the contract neither addition to, modification of nor interpretation of any provision in the contract documents will be given by any agent, employee or contractor of the City of Carlsbad nor may any bidder rely on directions given by any agent, employee or contractor of the City of Carlsbad except as hereinbefore specified. ern k#Revised: 10/08/03 Contract No. 38891 Page 9 of 98 Pages The Carlsbad Municipal Water District reserves the right to reject any or all bids and to waive any minor irregularity or informality in such bids. The general prevailing rate of wages for each craft or type of worker needed to execute the Contract shall be those as determined by the Director of Industrial Relations pursuant to the sections 1770, 1773, and 1773.1 of the Labor Code. Pursuant to section 1773.2 of the Labor Code, a current copy of applicable wage rates is on file in the Office of the City Engineer. The Contractor to whom the Contract is awarded shall not pay less than the said specified prevailing rates of wages to all workers employed by him or her in the execution of the Contract. The Prime Contractor shall be responsible for insuring compliance with provisions of section 1777.5 of the Labor Code and section 4100 et seq. of the Public Contracts Code, "Subletting and Subcontracting Fair Practices Act." The District Engineer is the District's "duly authorized officer" for the purposes of section 41 07 and 41 07.5. The provisions of Part 7, Chapter 1, of the Labor Code commencing with section 1720 shall apply to the Contract for work. All bids are to be computed on the basis of the given estimated quantities of work, as indicated in this proposal, times the unit price as submitted by the bidder. In case of a discrepancy between words and figures, the words shall prevail. In case of an error in the extension of a unit price, the corrected extension shall be calculated and the bids will be computed as indicated above and compared on the basis of the corrected totals. All prices must be in ink or typewritten. Changes or corrections may be crossed out and typed or written in with ink and must be initialed in ink by a person authorized to sign for the Contractor. Bidders are advised to verify the issuance of all addenda and receipt thereof one day prior to bidding. Submission of bids without acknowledgment of addenda may be cause of rejection of bid. The Contractor shall provide bonds to secure faithful performance and warranty of the work in an amount equal to one hundred percent (100%) of the Contract price will be required for work on this project. The Contractor shall provide bonds to secure payment of laborers and materials suppliers, in an amount equal to: 1) One hundred percent (100%) of the total amount payable by the terms of the contract when the total amount payable does not exceed five million dollars (5,000,000). 2) Fifty percent (50%) of the total amount payable by the terms of the contract when the total amount payable is not less than five million dollars ($5,000,000) and does not exceed ten million dollars ($10,000,000). 3) Twenty-five percent (25%) of the total amount payable by the terms of the contract if the contract exceeds ten million dollars ($1 0,000,000). These bonds shall be kept in full force and effect during the course of this project, and shall extend in full force and effect and be retained by the District until they are released as stated in the Supplemental Provisions section of this contract. All bonds are to be placed with a surety insurance carrier admitted and authorized to transact the business of insurance in California and whose assets exceed their liabilities in an amount equal to or in excess of the amount of the bond. The bonds are to be accompanied by the following documents: 1) An original, or a certified copy, of the unrevoked appointment, power of attorney, by laws, or other instrument entitling or authorizing the person who executed the bond to do so. 2) A certified copy of the certificate of authority of the insurer issued by the insurance commissioner. em %#Revised: 10/08/03 Contract No. 38891 Page 10 of 98 Pages If the bid is accepted, the District may require copies of the insurer's most recent annual statement and quarterly statement filed with the Department of Insurance pursuant to Article 10 (commencing with section 900) of Chapter 1 of Part 2 of Division 1 of the Insurance Code, within 10 calendar days of the insurer's receipt of a request to submit the statements. Insurance is to be placed with insurers that: 1) Have a rating in the most recent Best's Key Rating Guide of at least A-:V 2) Are admitted and authorized to transact the business of insurance in the State of California by the Insurance Commissioner. Auto policies offered to meet the specification of this contract must: I) Meet the conditions stated above for all insurance companies. 2) Cover any vehicle used in the performance of the contract, used onsite or offsite, whether owned, non-owned or hired, and whether scheduled or non-scheduled. The auto insurance certificate must state the coverage is for "any auto" and cannot be limited in any manner. Workers' compensation insurance required under this contract must be offered by a company meeting the above standards with the exception that the Best's rating condition is waived. The District does accept policies issued by the State Compensation Fund meeting the requirement for workers' compensation insurance. The Contractor shall be required to maintain insurance as specified in the Contract. Any additional cost of said insurance shall be included in the bid price. The award of the contract by the Board of Director's is contingent upon the Contractor submitting the required bonds and insurance, as described in the contract, within twenty days of bid opening. If the Contractor fails to comply with these requirements, the District may award the contract to the second or third lowest bidder and the bid security of the lowest bidder may be forfeited. The prime contractor and all subcontractors are required to have and maintain a valid City of Carlsbad Business License for the duration of the contract. Approved by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, California, by Resolution No. 121 1, adopted on the eighth day of June, 2004. ISABELLE PAULSEN, CMC Deputy Secretary DATED: June 17,2004 em %$Revised: 10/08/03 Contract No. 38891 Page 11 of 98 Pages CARLSBAD MUNICIPAL WATER DISTRICT CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION CONTRACTOR'S PROPOSAL Board of Directors Carlsbad Municipal Water District 5950 El Camino Real Carlsbad, California 92008 The undersigned declares he/she has carefully examined the location of the work, read the Notice Inviting Bids, examined the Plans, Specifications, Special Provisions and addenda thereto, and hereby proposes to furnish all labor, materials, equipment, transportation, and services required to do all the work to complete Contract No. 38891 in accordance with the Plans, Specifications, Supplemental Provisions and addenda thereto and that he/she will take in full payment therefor the following unit prices for each item complete, to wit: SC H ED U LE "A" Item No. A-1 A-2 A-3 Description Mobilization, demobilization, and preparatory work at a stipulated lump sum of Forty Thousand Dollars (Stipulated Amount: Do not change) Construction schedule at a stipulated lump sum of Eighteen Thousand Dollars (Stipulated Amount: Do not change) Provide excavation safety measures for Schedule A for all trenches or open excavations which are 5' or greater in depth, including sheeting, shoring and bracing, or equivalent method for the protection of life or limb in conformance with applicable safety orders at jzdo T?4D05%9 FW@ Hud@@ &OLiq4J Dollars (Lump Sum) Approximate Quantity Unit and Unit Price Total 1 LS $40,000 $40,000 1 LS 1 LS c3Revised: 10/08/03 Contract No. 38891 $1 8,000 $1 8,000 $4500 $d,S00 Page 12 of 98 Pages Item No. A-4 I, +~ A-5 A-6 A-7 I. . A-a A-9 Approximate Quantity Unit Description and Unit Price Total Masonry block building, floor, and roof, 1 LS $ /@[ 500 $f@,S'OO including all appurtenances (Le. doors, ventilators, roof hatches, etc.) and related work at ?Kol/5m9 Dollars (Lump Sum) Vertical turbine pumping units, including 3 EA &P$* $/3f 3-00 pump cans, motors, and all appurtenances and related work at jGdU4fP 5 i'x 7yilk(&i3 .FM&U&%@ LW Ow ~kdd&?3 WHTY mwe maiguo r"/@ ,quhg@g WW Dollars (Each) AI1 piping and appurtenances, including 1 LS $J~QJ~J +2!0,7SO all valves, meters, gauges, supports, connections to existing pipelines, pipe testing, and all related work at 0A.Y HUd0fl2Q $[.cr\c 7 tcro p we ,&d@~p! mk a 4,~oa *L' #f%JOrZeo 2% HdL2mo Dollars (Lump Sum) .S'Q&J /f(qJOfl F/#qwB 0% Surge tank including all appurtenances and related work at 1 LS 7zuc7/1.rY W6WY TH-Ow#qd 0 qL?@J HI!&JJ@@~ Gni/ &tQar D%llars (Lump Sum) / Masonry block retaining walls, non- 1 LS retaining walls, pilasters, reinforced concrete foundations, decorative steel fencing, swing gate, rolling gate, and all related work at Site work, including clearing and 1 LS grubbing,. grading, overexcavation and recompaction, A.C. paving, concrete slabs, turf stone, sidewalk, concrete V- ditch, catch basins, and all related work at SiMTi ml7 T~04SWd HOd'Q#& OOLw Dollars (Lump Sum) Contract No. 38891 $a%; 754 Page 13 of 98 Pages F- c Approximate Item Quantity Unit No. Description and Unit Price Total A-10 Electrical work, including new electrical 1 LS SJ&h.a? $fl$bdtl service, motor control center, variable frequency drives, controls, instrumentation, lighting, conduit, and conductors, coordination with SDG&E, and all appurtenances and related work at onp N&AM4@ &&HTd lw Dollars (Lump Sum) 1- m& sIpk3 c/t//u,.3n& ?-Lu &;p(/ A &Y m- e. # A-11 Remove potable water pipeline 1 LS segments at intersection of Carlsbad Village Drive and College Boulevard, install blind flanges on existing gate valves, and remove portions of precast concrete "Recycled Water Disconnect Vault" and related work at fiKZ@& pf0&5/aJO 9m MhjdW FiF7-77 floL/&3- Dollars (Lump Sum) A-12 Furnish and install one (1) project sign at 1 LS 'rLt'o IHO&JJ/C)~J b Q6@ &GwdA@ QOL/p?;bs! si Dollars (Lump Sum) 63 b Total amount of bid for Schedule "A" in numbers: $ (, 420, Price(s) given above are firm for 120 days after date of bid opening. Addendum(a) No(s). 01 ' hadhave been received and idare included in this proposal. I The Undersigned has carefully checked all of the above figures and understands that the District will not be responsible for any error or omission on the part of the Undersigned in preparing this bid. The Undersigned agrees that in case of default in executing the required Contract with necessary bonds and insurance policies within twenty (20) days from the date of award of Contract by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, the District may administratively authorize award of the contract to the second or third lqwest bidder a security of the lowest bidder may be forfeited, O'*L,,LJ, Pb L F' I &\LSrh 1- 3 &I R&!&DED: cs Revised: 10/08/03 DATE Contract No. 38891 Page 14 of 98 Pages f’ 2 The Undersigned bidder declares, under penalty of perjury, that the undersigned is licensed to do business or act in the capacity of a contractor within the State of California validly licensed under license number 5;”tO-wtt , classification bt which expires on , and that this statement is true and correct and has the legal effect of an affidavit. 3-30 - 04 A bid submitted to the District by a Contractor who is not licensed as a contractor pursuant to the Business and Professions Code shall be considered nonresponsive and shall be rejected by the City 5 7028.15(e). In all contracts where federal funds are involved, no bid submitted shall be invalidated by the failure of the bidder to be licensed in accordance with California law. However, at the time the contract is awarded, the contractor shall be properly licensed. Public Contract Code 5 101 64. The Undersigned bidder hereby represents as follows: 1. That no Board of Directors member, officer, agent, or employee of the Carlsbad Municipal Water District is personally interested, directly or indirectly, in this Contract, or the compensation to be paid hereunder; that no representation, oral or in writing, of the Board of Directors, its officers, agents, or employees has inducted him/her to enter into this Contract, excepting only those contained in this form of Contract and the papers made a part hereof by its terms; and 2. That this bid is made without connection with any person, firm, or corporation making a bid for the same work, and is in all respects fair and without collusion or fraud. Accompanying this proposal is %MD (Cash, Certified Check, Bond or Cashier‘s Check) for ten percent (1 0%) of the amount bid. i The Undersigned is aware of the provisions of section 3700 of the Labor Code which requires every employer to be insured against liability for workers’ compensation or to undertake self-insurance in accordance with the provisions of that code, and agrees to comply with such provisions before commencing the performance of the work of this Contract and continue to comply until the contract is complete. IC*)SRevised: 10/08/03 Contract No. 38891 Page 15 of 98 Pages License Detail Page 1 of 2 -- License Detail CALIFORNIA-CONTRACTORS STATE LICEN Contractor License # 540704 DISCLAIMER A license status check provides information taken from the CSLB license data base. Before on this information, you should be aware of the following limitations: CSLB complaint disclosure is restricted by law (B&P 7124,6). If this entity is subject tc complaint disclosure, a link for complaint disclosure will appear below. Click on the lin button to obtain complaint and/or legal action information. Per B&P 7071.1 7, only construction related civil judgments known to the CSLB are di Arbitrations are not listed unless the contractor fails to comply with the terms of the arbitration. Due to workload, there may be relevant information that has not yet been entered ont Board's license data base. Extract Date: 08/02/2004 * * * Business Information * * * FALCON GENERAL ENGINEERING INC 572 COLLYN STREET VISTA, CA 92083 Business Phone Number: (760) 630-9570 Entity: Corporation Issue Date: 09/07/1988 Expire Date: 09/30/2004 * * * License Status * * * rhis license is current and active. All information below should be reviewed. * * * Classifications * * * ICIass I Description 'ViGENERAL ENGINEERING CONTRACTOR * * * Certifications * * * lcert I Description I IASB !ASBESTOS - (for bidding purposes only) 1 8/2/2004 License Detail Page 2 of 2 LicenseNumber Request Contractor Name Request * * * Bonding Information * * * $1 0,000 with the bonding company AMERICAN CONTRACTORS INDEMNITY COMPANY. Effective Date: 01/01/2004 -- Contractor's ___ ___ Bonding History CONTRACTOR'S BOND: This license filed Contractor's Bond number 82120 in the amc Personnel Name Request BOND OF QUALIFYING INDIVIDUAL(1): The Responsible Managing Officer (RMO) C ERNEST WINTERQUIST certified that he/she owns 10 percent or more of the voting stock, the corporation. A bond of qualifying individual is not required. Effective Date: 09/07/1988 * * * Workers Compensation Information * * * This license has workers compensation insurance with the STATE COMPENSATION INSURANCE FUND Policy Number: 0803895 Effective Date: 08/16/2001 Expire Date: 08/16/2005 Workers Compensation History Personnel listed on this license (current or disassociated) are listed on other licei Salesperso-n-Request Salesperso-n Napre Request 0 2004 State of California. Conditions of Use Privacy Policy 8/2/2004 Personnel List Page 1 of 1 License Number Rxuest Personnel List CALIFORNIA CONTRACTORS STATE LICEN Contractor License # 540704 Contr-actor Name-Request Personnel Name Request Click on the person's name to see a more detailed page of information on that person. Salesperson Request Association Disassociation C,as$ Date Date Name Title Salesperson Name Request C H R ISTO PH E R WILLIAM I POMA OFFICER 09/07/1988 I IJAMES VERNON NESS OFFICER 09/07/1988 07/09/1990 DALE ERNEST W I NTE RQU IST RMO/CEO/PRES 09/07/1988 A 0 2004 State of California. Comons-ot.Use Privacy Policy 8/2/2004 f F: 8 The Undersigned is aware of the provisions of the Labor Code, Part 7, Chapter 1, Article 2, relative to the general prevailing rate of wages for each craft or type of worker needed to execute the Contract and agrees to comply with its provisions. IF A SOLE OWNER OR SOLE CONTRACTOR SIGN HERE: (1) Name under which business is conducted (2) Signature (given and surname) of proprietor (3) Place of Business City and State (4) ZipCode Telephone No. (Street and Number) IF A PARTNERSHIP, SIGN HERE: (1) Name under which business is conducted (2) Signature (given and surname and character of partner) (Note: Signature must be made by a general partner) (3) Place of Business (Street and Number) City and State 2 t- (4) Zip Code Telephone No. IF A CORPORATION, SIGN HERE: (1) Name under which business is cond (2) !?R=\QmF (Title) Impress Corporate Seal here ... ... ... ... ... .. ~... . , 4- %#Revised: 10/08/03 Contract No. 38891 Page 16 of 98 Pages f 6. _. b !- J. (3) (4) Incorporated under the laws of the State of (1.&L\F Place of Business 532 COLLVN SI-* (Street and Number) City and State USA I c!L (5) Zip Code 92oA3 Telephone No. (1 do) 6 30- 953-0 NOTARIAL ACKNOWLEDGMENT OF EXECUTION BY ALL SIGNATORIES MUST BE AlTACHED 5 k .. List below names of president, vice president, secretary and assistant secretary, if a corporation; if a partnership, list names of all general partners, and managing partners: nALg E.u.hNTEQDLI \sr - kdr- c!+R3smeh5L w. bMA- VPjSEZL ern %#Revised: 10/08/03 Contract No. 38891 Page 17 of 98 Pages T’ A<. i: EQUIPMENT/MATERIAL SOURCE INFORMATION TO ACCOMPANY PROPOSAL CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION The bidder shall indicate opposite each item of equipment or material listed below, the name of the one supplier and manufacturer of each item or equipment or material proposed to be furnished under the bid. Awarding of a contract under this bid will not imply approval by District or the manufacturers listed by the Bidder. EquipmenVMaterial Manufacturer AM E~CA 1. Vertical Turbine Pumps 13 !u 4Li3lA-k - 2. Vertical Hollow Shaft Electric Motors 3. Motor Control Center 4. Flow Meter 5. Surge Arrestor Tank 6. Variable Frequency Drives (Manufacturer) Lis, MOT-DrZ, (Manufacturer) (Manufacturer) (Manufacturer) Pdsm (Manufacturer) (Manufacturer) *- tSRevised: 10/08/03 Contract No. 38891 Page 18 of 98 Pages 4 p f BID SECURITY FORM (Check to Accompany Bid) CONTRACT NO. 38891 BIDDER ENCINA BASIN WATER RECLAMATION PROGRHM, PHASE ll CALAVERA RECYCLED WATER PUMP STATION (NOTE: The following form shall be used if check accompanies bid.) Accompanying this proposal is a *Certified *Cashiers check payable to the order of CARLSBAD MUNICIPAL WATER DISTRICT, in the sum of dollars ($ I this amount being ten percent (10%) of the total amount of the bid. The proceeds of this check shall become the property of the District provided this proposal shall be accepted by the District through action of its legally constituted contracting authorities and the undersigned shall fail to execute a contract and furnish the required Performance, Warranty and Payment Bonds and proof of insurance coverage within the stipulated time; otherwise, the check shall be returned to the undersigned. The proceeds of this check shall also become the property of the District if the undersigned shall withdraw his or her bid within the period of fifteen (15) days after the date set for the opening thereof, unless otherwise required by law, and notwithstanding the award of the contract to another bidder. *Delete the inapplicable word. (Note: If the Bidder desires to use a bond instead of check, the Bid Bond form on the following pages shall be executed--the sum of this bond shall be not less than ten percent (10%) of the total amount of the bid.) 4- %#Revised: 10/08/03 Contract No. 38891 Page 19 of 98 Pages BIDDER’S BOND TO ACCOMPANY PROPOSAL CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE I1 CALAVERA RECYCLED WATER PUMP STATION KNOW ALL PERSONS BY THESE PRESENTS: FIDELITY AND DEPOSIT That we, FALCON GENERAL ENGINEERING, INC,.,, Principal, and OF -,~ND I as Surety are held and firmly bound unto the Carlsbad Municipal Water District, Carlsbad, California, iI;IEfqEif&Wt0,pER@k#: (must be at least ten percent (10%) of the bid amount) heirs, executors and administrators, successors or assigns, jointly and severally, firmly by these presents. AMnTTNT RTD (1 OX) for which payment, well and truly made, we bind ourselves, our THE CONDITION OF THE FOREGOING OBLIGATION 15 SUCH that if the proposal of the above- bounden Principal for CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION in the City of Carlsbad, is accepted by the Board of Directors, and if me Principal shall duly enter into and execute a Contract including required bonds and insurance poficies within twenty (20) days from the date of award of Contract by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, being duty notified of said award, then this obligation shall become null and void; otherwise, it shall be and remain in full force and effect, and the amount specified herein shall be forfeited to the said District. ... I .... .... .... .... I In the event Principal executed this bond as an individual, it is agreed that the de not exonerate the Surety from its obligations under this bond. Executed by PRINCIPAL this 30TH day _. of JULY - ,2004. P R I NCI PAL: FALCON GENERAL ENGINEERING. TNC. (name of Principal) DALE E. WINTEROUIST (print name here) @Revised: 10/08/03 Contract No. 38891 Page 20 of 98 Pages ALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT No 5 sss DEBORAH D. DAVIS, NOTARY PUBLIC I NAME, TITLE OF OFFICER - E.G., 'JANE DOE, NOTARY PUBLIC' '" 7/30/2004 before me, DATE personally appeared DALE E. WINTERQUIST, CHRISTOPHER W. POMA I NAME(S) OF SIGNER(S) [a personally known to me - OR - proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) idare subscribed to the within instrument and ac- knowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their signature(s) on the instrument the person@), or the entity upon behalf of which the person@) acted, executed the instrument. WITNESS my hand and official seal. - OPTIONAL SECTION - CAPACITY CLAIMED BY SIGNER Though statute does not require the Notary to fill in the data below, doing so may prove invaluable to persons relying on the document. 0 INDIVIDUAL CORPORATE OFFICER(S) PRESIDENT, SECRETARY TlTLE(S) PARTNER(S) 0 LIMITED 0 GENERAL - 0 ATTORNEY-IN-FACl 0 TRUSTEE(S) 0 GUARDIAN/CONSERVATOR 0 OTHER: SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTITY(IES) SIGNATURE OF NOTARY OPTIONAL SECTION THIS CERTIFICATE MUST BE ATACHED TO THE DOCUMENT DESCRIBED AT RIGHT: TITLE OR NPE OF DOCUMENT NUMBER OF PAGES DATE OF DOCUMENT Though the data requested here is not required by law, iir could prevent fraudulent reattachment of this form. SIGNERW OTHER THAN NAMED ABOVE AI-IFORNIA ALL-PURPOSE ACKNOWLEDGMENT No 51 sss S;tate of CALIFORNIA SAN DIEGO County of DEBORAH D. DAVIS, NOTARY PUBLIC NAME, TITLE OF OFFICER - E.G ,"JANE DOE, NOTARY PUBLIC' before me, 7/30/2004 DATE On personally appeared KAREN JEAN HALL NAME@) OF SIGNER(S) [a personally known to me - OR - 0 proved to me on the basis of satisfactory evidence to be the person(s) whose narne(s) Ware subscribed to the within instrument and ac- knowledged to me that he/she/they executed the same in his/her/their authorized capacityjies), and that by his/her/their signature@) on the instrument the person(s), or the entity upon behalf of which the person(s) acted, executed the instrument. WITNESS my hand and official seal. c i - OPTIONAL SECTION - CAPACITY CLAIMED BY SIGNER Though statute does not require the Notary lo fill in the data below, doing so may prove invaluable to persons relying on the document. 0 INDIVIDUAL CORPORATE OFFICER(S) TITLE(S) PARTNER(S) LIMITED GENERAL ATTORNEY-IN-FACT 0 TRUSTEE(S) 0 GUARD I AN/CO N S E RV AT0 R 0 OTHER: SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTITY(IES) SIGNATURE OF NOTARY OPTIONAL SECTION THIS CERTIFICATE MUST BE ATACHED TO THE DOCUMENT DESCRIBED AT RIGHT, Though the data requested here is not required by law. it could Drevent fraudulent reattachment of this form TITLE OR TYPE OF DOCUMENT NUMBER OF PAGES SIGNER(S) OTHER THAN NAMED ABOVE DATE OF DOCUMENT PRESIDENT {sign he re) CHRISTOPHER W. POMA (print name here) SECRETARY (title and organization of signatory)' Executed by SURETY this ?nm day of JULY ,2004 . SURfiTy: FIDELITY AND-DEPOSIT COMPANY OF MARYLAND (name of Surety) 801 NORTH BRAND BOULEVARD, PENTHOUSE GLENDALE, CA 91203 - - (address of Surety) 800/ 347-5679 (telephone number of Surety) KAREN JEAN HALL, ATTORNEY-€N-FACT (printed name of Attorney-in-Fact) (Attach corporate resolution showing current power of attorney.) (Proper notarial acknowledge of execution by PRINCIPAL and SURETY must be attached.) (President or vice-president and secretary or assistant secretary must sign for corporations. If only one officer signs, the corporation must attach a resolution certified by the secretary or assistant secretary under corporate seal empowering that officer to bind the corporation,) (If signed by an individual partner, the partnership must allach a statement of partnership authorizing the partner to execute this instrument.) APPROVED AS TO FORM; RONALD R. BALL General Counsel Deputy General Counse? @Revised: 10/08/03 Contract No. 38891 Page 21 of 98 Pages Power of Attorney FIDELITY AND DEPOSIT COMPANY OF MARYLAND KNOW ALL MEN BY THESE PRESENTS: That the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, a corporation of the State of Maryland, by M. P. HAMMOND, Vice President, and T. E. SMITH, Assistant Secretary, in appoint John G. MALONEY, Helen MALONEY, Mark D. as surety, and as it had been duly exec D. Iatarola, Karen J The said Assistant Section 2, of the By- IN WITNESS WHEREOF, the said Vice-president and Assistant Secretary have hereunto subscribed their names and affixed the Corporate Seal of the said FIDELITY AND DEPOSIT COMPANY OF MARYLAND, this 12th day of July, A.D. 2004. r, and on its behalf s or undertakings in purposes, as if they ATTEST: FIDELITY AND DEPOSIT COMPANY OF MARYLAND T. E. Smith Assistant Secretaiy M. P. Hammond Vice President State of Maryland ss: On this 12th day of July, A.D. 2004, before the subscriber, a Notary Public of the State of Maryland, duly commissioned and qualified, came M. P. HAMMOND, Vice President, and T. E. SMITH, Assistant Secretary of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, to me personally known to be the individuals and officers described in and who executed the preceding instrument, and they each acknowledged the execution of the same, and being by me duly sworn, severally and each for hmself deposeth and saith, that they are the said officers of the Company aforesaid, and that the seal affixed to the preceding instrument is the Corporate Seal of said Company, and that the said Corporate Seal and their signatures as such officers were duly affixed and subscribed to the said instrument by the authority and direction of the said Corporation. IN TESTIMONY WHEREOF, I have hereunto set my hand and affixed my Official Seal the day and year first above written. City of Baltimore I Dennis R. Hayden Notary Public My Commission Expires: February 1, 2005 POA-F 012-5012 EXTRACT FROM BY-LAWS OF FIDELITY AND DEPOSIT COMPANY OF MARYLAND “Article VI, Section 2. The Chairman of the Board, or the President, or any Executive Vice-president, or any of the Senior Vice-presidents or Vice-presidents specially authorized so to do by the Board of Directors or by the Executive Committee, shall have power, by and with the concurrence of the Secretary or any one of the Assistant Secretaries, to appoint Resident Vice-presidents, Assistant Vice-presidents and Attorneys-in-Fact as the business of the Company may require, or to authorize any person or persons to execute on behalf of the Company any bonds, undertaking, recognizances, stipulations, policies, contracts, agreements, deeds, and releases and assignments of judgements, decrees, mortgages and instruments in the nature of mortgages, ... and to affix the seal of the Company thereto.” CERTIFICATE I, the undersigned, Assistant Secretary of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, do hereby certify that the foregoing Power of Attorney is still in full force and effect on the date of this certificate; and I do firther certify that the Vice-president who executed the said Power of Attorney was one of the additional Vice-presidents specially authorized by the Board of Directors to appoint any Attorney-in-Fact as provided in Article VI, Section 2, of the By-Laws of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND. This Power of Attorney and Certificate may be signed by facsimile under and by authority of the following resolution of the Board of Directors of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND at a meeting duly called and held on the 10th day of May, 1990. RESOLVED: “That the facsimile or mechanically reproduced seal of the company and facsimile or mechanically reproduced signature of any Vice-president, Secretary, or Assistant Secretary of the Company, whether made heretofore or hereafter, wherever appearing upon a certified copy of any power of attorney issued by the Company, shall be valid and binding upon the Company with the same force and effect as though manually affixed.“ IN TESTIMONY WHEREOF, I have hereunto subscribed my name and affixed the corporate seal of the said Company, this 30TH day of JULY , 2004 . Assistant Secretary ZURICH rHIS IMPORTANT DISCLOSURE NOTICE IS PART OF' YOUR BOND We are making the following informational disclosures in compliance with The Terrorism Risk Insurance Act of 2002. No action is required on your part. Disclosure of Terrorism Premium The premium charge for risk of loss resulting from acts of terrorism (as defined in the Act) under this bond is $.-waived - . This amount is reflected in the total premium for this bond. Disclosure of Availability of Coverage for Terrorism Losses As required by the Terrorism Risk Insurance Act of 2002, we have made available to you coverage for losses r12sulting from acts of terrorism (as defined in the Act) with terms; amounts, and limitations that do not differ materially as those for losses arising from events other than acts of terrorism. Disclosure of Federal Share of Insurance Company's Terrorism Losses The Terrorism Risk Insurance Act of 2002 establishes a mechanism by which the United States government will share in insurance company losses resulting from acts of terrorism (as defined in the Act) after a insurance company has paid losses in excess of an annual aggregate deductible. For 2002, the insurance company deductible is 1% of direct earned premium in the prior year; for 2003, 7% of direct earned premium in the prior year; for 2004, 10% of xt earned premium in the prior year; and for 2005, 15% of drect earned premium in the prior year. The federal share of an insurance company's losses above its deductible is 90% In the event the United States government participates in losses, the United States goveinment may direct insurance companies to collect a terrorism surcharge G-om policyholders. The Act does not currently provide for insurance industry or United States government participation in terrorism losses that exceed $100 billion in any one calendar year. Definition of Act of Terrorism The Terrorism Risk Insurance Act defines "act of terrorism" as any act that is certified by the Secretary of the Treasury, in concurrence with the Secretary of State and the Attorney General of the United States: 1. to be an act of terrorism; 2. to be a violent act or an act that is dangerous to human life, property or idrastructure; 3. to have resuited in damage within the United States, or outside of the United States in the case of an air camer (as defined in section 40102 of title 49, United 17 States Code) or a United States flag vessel (or a vessel based principally in the United Statesl on which United States income tax is paid and whose insurance coverage is subject to regulation in the United States), or the premises of a United States mission; and 4. to have been committed by an individual or individuals acting on behalf of any foreign person or foreign interest as part of an effort to coerce the civilian population of the United States or to influence the policy or affect the conduct of the United States Government by coercion. But, no act shall be certified by the Secretary as an act of terrorism if the act is committed as part of the course of a war declared by Congress (except for workers' compensation) or property and casualty insurance losses resulting from the act, in the aggregate, do not exceed $5,000,000. hese disclosures are informational only and do not modify your bond or affect your rights under the bond. Copyright Zurich American Insurance Company 2003 -0050749.doc Company Profile Page 1 of 2 Company Profile FIDELITY AND DEPOSIT COMPANY OF MARYLAND 1400 AMERICAN LANE, 19TH FLOOR TOWER 1 SCHUAMBURG, IL 60196-1056 800-382-2 150 Agent for Service of Process ANDREW K. PLATT, C/O ZURICH NORTH AMERICA 801 N. BRAND BLVD., 13TH FLOOR GLENDALE, CA 91203 Unable to Locate theAgent for Service of Process? Reference Information NAIC #: 39306 California Company ID #: 2479-4 Date authorized in California: License Status: UNLIMITED-NORMAL Company Type: Property & Casualty State of Domicile: MARYLAND NAIC Group #: ox January 01, 1982 Lines of Insurance Authorized to Transact The company is authorized to transact business within these lines of insurance. For an explanation of any of these terms, please refer to the glossary. AIRCRAFT AUTOMOBILE BOILER AND MACHINERY BURGLARY CREDIT FIRE LIABILITY MARINE MISCELLANEOUS h ttp: //cdin s w w w . in surance. c a. gov/pl s/wu-co-prof/i db-c o-pro f-ut l .ge t-c o-prof ?p_EID=62 1 7 8/2/2004 Company Profile Page 2 of 2 PLATE GLASS SPRINKLER SURETY TEAM AND VEHICLE WORKERS' COMPENSATION Company Complaint Information Company Enforcement Axtion Documents ~- Company Performance & Comparison Data Composite Complaint Studies Want More? Help Me Find a Company Representative in My Area Financial Rating Organizations Last Revised - April 26,2004 02:22 PM Copyright 0 California Department of Insurance Disclaimer http://cdinswww.insurance.ca.gov/pls/wu~co~prof/idb~co~prof~utl.get~co~prof?p~EID=6217 8/2/2004 h h GUIDE FOR COMPLETING THE "DESIGNATION OF SUBCONTRACTORS" FORM REFERENCES Prior to preparation of the following Subcontractor disclosure form Bidders are urged to review the definitions in section 1-2 of the SSPWC ("Greenbook") and in the Supplemental Provisions to this Contract, especially, "Bid", "Bidder", "Contract", "Contractor", 'Contract Price", "Contract Unit Price", "Engineer", "Subcontractor" and "Work" and the definitions in section 1-2 of the Supplemental Provisions especially "Own Organization." Bidders are further urged to review sections 2-3 SUBCONTRACTS of the Greenbook and section 2-3.1 of these Supplemental Provisions. CAUTIONS This form will be used by the Agency to determine the percentage of work that the Bidder proposes to perform. Bidders are cautioned that failure to provide complete and correct information may result in rejection of the bid as non-responsive. Any bid that proposes performance of more than 50 percent of the work by subcontractors or otherwise to be preformed by forces other than the Bidder's own organization will be rejected as non-responsive. Specialty items of work that may be so designated by the Engineer on the "Contractor's Proposal" are not included in computing the percentage of work proposed to be performed by the Bidder. INSTRUCTIONS The Bidder shall set forth the name and location of business of each and every subcontractor whom the Bidder proposes to perform work or labor or render service in or about the work or improvement, and every subcontractor licensed as a contractor by the State of California whom the Bidder proposes to specially fabricate and install any portion of the work or improvement according to detailed drawings contained in the plans and specifications in excess of one-half of one percent (0.5%) of the Bidder's total bid or, in the case of bids or offers for the construction of streets and highways, including bridges, in excess of one-half of one percent (0.5%) or ten thousand dollars ($1 0,000) whichever is greater. Said name@) and location(s) of business of subcontractor(s) shall be set forth and included as an integral part of the bid offer. The Designation of Subcontractors form must be submitted as a part of the Bidder's sealed bid. Failure to provide complete and correct information may result in reiection of the bid as non- responsive. Suppliers of materials from sources outside the limits of work are not subcontractors. The value of materials and transport of materials from sources outside the limits of work, as shown on the plans, shall be assigned to the Contractor or the Subcontractor as the case may be, that the Bidder proposes as installer of said materials. The value of material incorporated in any Subcontractor- installed bid item that is supplied by the Bidder shall be included as a part of the work that the Bidder proposes to be performed by the Subcontractor installing said item. When a Subcontractor has a Carlsbad business license, the number must be entered on the proper form. If the Subcontractor does not have a valid business license, enter "NONE" in the appropriate space. When the Bidder proposes using a Subcontractor to construct or install less than 100 percent of a bid item, the Bidder shall attach an explanation sheet to the Designation of Subcontractor form. The explanation sheet shall clearly apprise the City of the specific facts that show the Bidder proposes to perform no less than fifty percent (50%) of the work with its own forces. Determination of the subcontract amounts for purposes of award of the contract shall be determined by the Board of Directors in conformance with the provisions of the contract documents and the Supplemental Provisions. The decision of the Board of Directors shall be final. *w tpRevised: 10/08/03 Contract No. 38891 Page 22 of 98 Pages , b: Contractor is prohibited from performing any work on this project with a subcontractor who is ineligible to perform work on a public works project pursuant to Labor Code Sections 1771.1 or 1777.7. Bidders shall make any additional copies of the disclosure forms as may be necessary to provide the required information. The page number and total number of additional form pages shall be entered in the location provided on each type of form so duplicated. 4.- %@Revised: 10/08/03 Contract No. 38891 Page 23 of 98 Pages DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID ITEMS CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE I1 CALAVERA RECYCLED WATER PUMP STATION The Bidder certifies that it has used the sub-bid of the following listed subcontractors in preparing this bid for the Work and that the listed subcontractors will be used to perform the portions of the Work as designated in this list in accordance with applicable provisions of the specifications and section 4100 et seq. of the Public Contract Code, "Subletting and Subcontracting Fair Practices Act." The Bidder further certifies that no additional subcontractor will be allowed to perform any portion of the Work in excess of one-half of one percent (0.5%) of the Bidder's total bid, or in the case of bids or offers for construction of streets and highways, including bridges, in excess of one-hatf of one percent (0.5%) or ten thousand doltars ($10,000), whichever is greater, and that no changes in the subcontractors listed work will be made except upon the prior approval of the Agency. Subcontractor's License No." Page - \ of \ pages of this Subcontractor Designation form " Pumuant to section 4104 (a)(2)(A) California Public Conlraa Code, receipt of the information preceded by an asterisk may be submitted by the Biddei up lo 24 hours after the UeaUIine for submitting bids contained in the "Notice inviting Bids." aRevised: 10/08/03 Contract No. 38891 Page 24 of 98 Pages LI L 1. I I DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID ITEMS CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE I1 CALAVERA RECYCLED WATER PUMP STATION I The Bidder certifies that it has used the sub-bid of the following listed subcontractors in preparing this bid for the Work and that the listed subcontractors will be used to perform the portions of the Work as designated in this list in accordance with applicable provisions of the specifications and section 4100 et seq. of the Public Contract Code, "Subletting and Subcontracting Fair Practices Act." The Bidder further certifies that no additional subcontractor will be allowed to perform any portion of the Work in excess of one-half of one percent (0.5%) of the Bidder's total bid, or in the case of bids or offers for construction of streets and highways, including bridges, in excess of one-half of one percent (0.5%) or ten thousand dollars ($10,000), whichever is greater, and that no changes in the subcontractors listed work will be made except upon the prior approval of the Agency. SUBCONTRACTOR'S BID ITEMS Subcontractor's License No.* Page - 1 of pages of this Subcontractor Designation form " Pursuant to section 4104 (a)(2)(A) California Public Contract Code, receipt of the information preceded by an asteriek may be aubmittfld by the Bidder up to 24 hours after the UeaUline for subrnittlng hlds mlalned In the 'Notlce lnvltlng Bids." @Revised: 10/08/03 Contract No. 38891 Page 24 of 98 Pages dLf6 BIDDER'S STATEMENT OF FINANCIAL RESPONSIBILITY (To Accompany Proposal) CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION Copies of the latest Annual Report, audited financial statements or Balance Sheets may be submitted under separate cover marked CONFIDENTIAL. e- frSRevised: 10/08/03 Contract No. 38891 Page 25 of 98 Pages FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) FINANCIAL STATEMENTS DECEMBER 31,2003 AND 2002 FALCON GENERAL ENGINEERING. INC . (AN S CORPORATION) TABLE OF CONTENTS DECEMBER 31. 2003 AND 2002 Independent Accountant's Review Report ........................................................................... 1 Balance Sheets ........................................................................................................................... 2 Statements of Income ................................................................................................................ 3 Statements of Changes in Stockholders' Equity .................................................................. 4 Statements of Cash Flows .................................................................................................... 5 Notes to Financial Statements ................................................................................................... 6 ey Schedule I . Cost of Revenue ............................................................................................. 14 Schedule I1 . General and Administrative Expenses .......................................................... 15 Schedule III . Earnings from Contracts .............................................................................. 16 Schedule IV . Contracts in Process .................................................................................... 17 Schedule V - Contracts Completed .................................................................................... 18 Schedule VI . Accounts Receivable Aging Summary ....................................................... 19 Schedule VII - Accounts Payable Aging Summary ........................................................... 20 LEON C. COVELL & CO, ' Certified Public Accountant To the Board of Directors Falcon General Engineering, Inc. San Marcos, California Independent Accountant's Review Report We have reviewed the accompanying balance sheets of Falcon General Engineering, Inc. (an S corporation) as of December 31, 2003 and 2002, and the related statements of income, retained earnings and cash flows for the years then ended, in accordance with Statements on Standards for Accounting and Review Services issued by the American Institute of Certified Public Accountants. All information included in these financial statements is the representation of the management of Falcon General Engineering, Inc. A review consists principally of inquiries of company personnel and analytical procedures applied to financial data. It is substantially less in scope than an examination in accordance with generally accepted auditing standards, the objective of which is the expression of an opinion regarding the financial statements taken as a whole. Accordingly, we do not express such an opinion. Based on our review, we are not aware of any material modifications that should be made to the financial statements in order for them to be in conformity with generally accepted accounting principles. Our review was made for the purpose of expressing limited assurance that there are no material modifications that should be made to the financial statements in order for them to be in conformity with generally accepted accounting principles. The information included in the accompanying Schedules I through VII is presented only for supplementary analysis purposes. Such information has been subjected to the inquiry and analytical procedures applied in the review of the basic financial statements, and we are not aware of any material modifications that should be made thereto. March 3,2004 345 West Ninth Avenue, Suite 100 Escondido, CA 92025 (760) 737-0700 FAX (760) 741-2897 E-mail: lcovell @ covellcpa.com Member of American Institute of Certified Public Accountants and California Society 01 Certified Public Accountants CURRENT ASSETS Cash Costs in excess of billings Receivables Prepaid expenses TOTAL CURRENT ASSETS PROPERTY AND EQUIPMENT Less accumulated depreciation PROPERTY AND EQUIPMENT NET FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) BALANCE SHEETS DECEMBER 31,2003 AND 2002 OTHER ASSETS Cash surrender value Investments Other assets TOTAL OTHER ASSETS TOTAL ASSETS ASSETS LIABILITIES AND STOCKHOLDERS' EQUITY CURRENT LIABILITIES Accounts payable Income taxes payable Accrued expenses Current portion long-term debt Billings in excess of costs and estimated earnings TOTAL CURRENT LIABILITIES LONG-TERM DEBT STOCKHOLDERS' EQUITY Treasury stock Common stock Accumulated other comprehensive income Retained earnings TOTAL STOCKHOLDERS' EQUITY TOTAL LIABILITIES AND STOCKHOLDERS' EQUITY 2003 2002 $ 208,745 $ 128,869 62,555 154,522 521,519 35 8,70 1 4,861 792,819 646,953 859,267 743,282 (344,262) (306,118) 515,005 437,164 26,488 23,890 26,428 25,470 6,735 59,651 49,360 $ 1,367,475 $ 1,133,477 $ 110,287 $ 99,404 1,579 4,29 1 2,824 2,64 1 19,151 21,213 179,796 3 1,384 313,637 158,933 240,007 256,250 (36,200) (36,200) 51,000 5 1,000 800,428 705,158 8 1333 1 7 18,294 (1,397) ( 1,664) $ 1,367,475 $ 1,133,477 See accountant's review report and notes to financial statements -L- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) STATEMENTS OF INCOME FOR THE YEARS ENDED DECEMBER 31,2003 AND 2002 2003 YO 2002 Yo CONSTRUCTION REVENUE $ 4,551,896 100.00 $ 4,738,260 100.00 COST OF REVENUE GROSS PROFIT GENERAL, AND ADMINISTRATIVE EXPENSES OPERATING INCOME OTHER INCOME AND (EXPENSES) Interest income Miscellaneous income Interest expense TOTALOTHEREXPENSES 3,639,314 79.95 3,956,429 83.50 912,582 20.05 781,831 16.50 435,294 9.56 395,626 8.35 477,288 10.49 386,205 8.15 1,278 0.03 578 0.01 4,654 0.10 4,156 0.09 (19,751) (0.43) (31,283) (0.66) (13,819) (0.30) (26,549) (0.56) INCOME BEFORE TAXES 463,469 10.18 359,656 7.59 INCOME TAX EXPENSE (6,699) (0.15) (5,089) (0.11) NET INCOME 456,770 10.03 354,567 7.48 OTHER COMPREHENSIVE INCOME Unrealized gain (loss) on marketable securities COMPREHENSIVE INCOME 267 0.01 (479) (0.011 $ 457,037 10.04 $ 354,088 7.47 See accountant's review report and notes to financial statements -3 - FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) STATEMENTS OF CHANGES IN STOCKHOLDER'S EQUITY FOR THE YEARS ENDED DECEMBER 31,2003 AND 2002 ACCUMULATED SHARES OF SHARES OF OTHER TREASURY TREASURY COMMON COMMON RETAINED COMPREHENSIVE STOCK STOCK STOCK STOCK EARNINGS INCOME TOTAL BALANCE, December 3 1,2001 36,200 $ (36,200) 51.000 $ 51,000 $ 386,591 $ (1,185) $ 400,206 COMPREHENSIVE INCOME Net income Dividends paid Other comprehensive income Unrealized holding loss arising during the period 354,567 (3 6,000) 354,567 (36,000) (479) (479) Total comprehensive income 318,088 BALANCE, December 3 1,2002 36,200 (36,200) 51,000 51,000 705,158 (1,664) 718,294 COMPREHENSIVE INCOME Net income 456,770 456,770 Dividends paid (361,500) (361,500) Other comprehensive income Unrealized holding gain arising during the period 267 267 Total comprehensive income 95,537 BALANCE, December 3 I, 2003 36,200 $ (36,200) 51,000 $ 51,000 $ 800,428 $ (1,397) $ 813,831 See accountant's review report and accompanying notes to financial statements -4- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) STATEMENTS OF CASH FLOWS FOR THE YEARS ENDED DECEMBER 31,2003 AND 2002 2003 2002 CASH FLOWS FROM OPERATING ACTIVITIES Net Income PROVIDED BY OPERATING ACTIVITIES ADJUSTMENTS TO RECONCILE NET INCOME TO NET CASH Depreciation and amortization $ 457,037 $ 354,088 38,144 25,075 Unrealized losses on investments (267) 479 (Increase) decrease in costs and estimated earnings in excess of billings (Increase) decrease in contracts receivable (Increase) decrease in prepaid expenses (Increase) decrease in other assets Increase (decrease) in accounts payable 91,967 (72,047) (1 62,s 1 9) 2,692 4,861 9,004 10,883 (25,172) (9,333) (2,735) Increase (decrease) in accrued liabilities 184 6,933 Increase (decrease) in billings in excess of costs and estimated earnings 148,4 12 3 1,384 Increase (decrease) in income taxes payable TOTAL ADJUSTMENTS NET CASH PROVIDED BY OPERATING ACTIVITIES CASH FLOWS FROM INVESTING ACTIVITIES Cash payments for the purchase of property Investment in partnerships Proceeds from investments NET CASH USED BY INVESTING ACTMTIES CASH FLOWS FROM FINANCING ACTIVITIES Net borrowings on line of credit Principal payments on long-term debt Dividends paid NET CASH USED BY FINANCING ACTIVITIES NET INCREASE IN CASH CASH AND EQUIVALENTS, BEGINNING CASH AND EQUIVALENTS, END SUPPLEMENTAL DISCLOSURES OF CASH FLOW INFORMATION CASH PAID DURING THE YEAR FOR Interest expense Income tax (2,712) 119,320 (24,387) 576,357 329,701 (1 15,985) (26,296) (1,572) 881 (1 16,676) (26,296) (18,305) (214,789) (361,500) (36,000) (379,805) (250,789) 79,876 52,616 128,869 76,253 $ 208,745 $ 128,869 $ 19,751 $ 31,283 $ 5,120 $ 800 See accountant's review report and notes to financial statements -5- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) NOTES TO FINANCIAL STATEMENTS DECEMBER 31,2003 AND 2002 A. SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES Business Activity The Company is engaged as a general contractor concentrating on obtaining government fbnded construction projects. The Company operates primarily in the Southern California region. The Company recognizes revenues fiom fixed price and modified fixed price construction contracts on the percentage-of-completion method, measured by the percentage of cost incurred to date to estimated total cost for each contract. That method is used because management considers total cost to be the best available measure of progress on the contracts. Contract costs include all direct material and labor costs and those indirect costs related to contract performance, such as equipment rental, insurance, repairs and depreciation. General and administrative costs are charged to expense as incurred. Provisions for estimated losses on uncompleted contracts are made in the period in which such losses are determined. Changes in job performance, job conditions, and estimated profitability, including those arising from contract penalty provisions, and final contract settlements may result in revisions to costs and income and are recognized in the period in which the revisions are determined. The asset, 'kosts and estimated earnings in excess of billings" represents revenues recognized in excess of amounts billed on uncompleted contracts. The liability, "billings in excess of costs and estimated earnings", represents billings in excess of revenues recognized. Operating Cycle The length of the Company's contracts varies, but is typically one to two years. Accordingly, assets and liabilities are classified as current if they will be liquidated within one to two years from the date of the balance sheet. Assets and liabilities that will not be liquidated within one to two years fi-om the date of the balance sheet are classified as nom current. Comprehensive Income The Company recognizes comprehensive income equal to the change in stockholder's equity from non-owner sources. Comprehensive income is presented as the sum of net income plus other comprehensive income. Other comprehensive income includes revenues, expenses, gains and losses that are excluded from the calculation of net income. -6- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) NOTES TO FINANCIAL STATEMENTS DECEMBER 31,2003 AND 2002 A. SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES (CONTINUED) Contracts Receivable Contracts receivable from performing construction of industrial and commercial buildings are based on contracted prices. Normal contracts receivable are due 30 days after the issuance of the invoice. Contract retentions are due 30 days after completion of the project and acceptance by the owner. Receivable past due more than 120 days are considered delinquent. Delinquent receivables are written off based on individual credit evaluation and specific circumstances of the customer. Income Taxes The corporation's shareholders have elected the corporation to be treated as an S- Corporation in which all income, losses and credits pass through to the shareholders for them to report on their personal tax returns. The California State tax provision is determined at the corporate level at a rate of 1.5%. Cash and Cash Equivalents The Company considers instruments purchased with a fixed maturity date of three months or less to be cash equivalents. Investments The Company accounts for its investments in accordance with the recommendation of the Financial Accounting Standards Board (FASB) in its Statement of Financial Accounting Standards (SFAS) No. 115, Accounting for Certain Investments in Debt and Equity Securities. Under SFAS No. 115 the Company reports its investments in equity securities that have readily determinable value, and all investments in debt securities, at fair value. The fair values of investments are based on quoted market prices. Investment income, (including interest, dividends, and realized and unrealized gains and losses on investments) are included in income from operations. Use of Estimates The preparation of financial statements in conformity with generally accepted accounting principles, requires management to make estimates and assumptions that affect certain reported amounts and disclosures. Accordingly, actual results could differ from those estimates. -7- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) NOTES TO FINANCIAL STATEMENTS DECEMBER 31,2003 AND 2002 A. SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES (CONTINUED) Advertising Advertising costs are charged to operations when incurred. Advertising expense charged to operations was $0 and $0 for the years ended December 31, 2003 and 2002, respectively. B. INVESTMENTS The Company’s investment portfolio consisted of the following at December 3 1 ,: Available for sale Equity securities 2002 - Amortized cost $ 470 $ 949 Gross unrealized gains (losses) 267 (479) Fair value 737 470 25,000 25,000 Investment in partnerships - See Note C Total investments $25,737 $ 25,470 C. INVESTMENT IN PARTNERSHIP The Company invested $25,000 in Majestic Films. D. RECEIVABLES Receivables consist of the following: - 2003 - 2002 Completed Contracts Contracts in Progress Total contract receivables State income tax receivable Employee advances Total receivables $ - $ 500 521 5 19 358,201 5213 19 358,701 $521.519 $358,701 No allowance for uncollectible accounts receivable has been reflected in the financial statements, as management believes all accounts to be collectible. -8- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) NOTES TO FINANCIAL STATEMENTS DECEMBER 31,2003 AND 2002 E. COSTS AND ESTIMATED EARNINGS ON UNCOMPLETED CONTRACTS 2002 - - 2003 Costs incurred on uncompleted contracts $ 5,742,252 $4,726019 Estimated earnings 1,290,677 866,539 7,032,929 5,592,558 Less: Billings to date 7,150,167 5,469,420 $ (117.238) $ 123,138 Included in accompanying balance sheet under the following captions: Costs and estimated earnings in excess of billings $ 62,557 $ 154,222 Billings in excess of costs and estimated earnings 179,795 3 1,384 $ (117,238) S 123.138 F. PROPERTY AND EQUIPMENT The following is a summary of property and equipment at December 3 1 , 2002 and 2001 : - 2003 - 2002 Building Land Vehicles Furniture Equipment Equipment held under a capital lease Building improvements Total property and equipment Less accumulated depreciation Net property and equipment $ 210,000 120,250 299,276 63,388 68,410 48,3 14 49,629 859,267 344,262 S 515.005 $ 210,000 120,250 183,291 63,388 68,410 48,3 14 49,629 743,282 306.1 18 $ 437.164 Depreciation expense for the years ended December 31, 2003 and 2002 is $38,144 and $25,075, respectively. The Company is the lessee of equipment held under a capital leases expiring through 2003. The asset and liability under the capital leases are recorded at the present value of the minimum lease payments. The assets are amortized over their estimated productive lives. Amortization of equipment held under capital leases is included in depreciation and amortization expense. Accumulated depreciation and amortization above includes $203 87 and $15,097 of accumulated amortization on equipment held under a capital lease at December 3 1 , 2003 and 2002, respectively. -9- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) NOTES TO FINANCIAL, STATEMENTS DECEMBER 31,2003 AND 2002 F. PROPERTY AND EQUIPMENT (CONTINUED) Property and equipment are stated at cost and depreciation is provided by the 200% declining balance method based on the estimated useful lives of the related assets as follows: Asset Equipment Vehicles Furniture Land Life 5 - 7 Years 5 Years 5 - 7 Years Not Depreciated G. LINE OF CREDIT The Company has a revolving line of credit with California Federal Bank in the amount of $250,000. The line of credit is secured by accounts receivable. Interest is calculated on outstanding balances at 1.00% over the Wall Street Journal’s published prime interest rate. At December 31, 2003, the prime interest rate is 5.00%, giving the line of credit an interest rate of 6%. The line of credit matures on June 15,2004. At December 31,2003 and 2002, the Company has a balance due of $0 and $0, respectively. H. LONG-TERM DEBT Long-term debt consists of the following notes and lease: Mortgage payable, collateralized by building (office space, 2,000 square feet, warehouse space, 4,000 square feet), payable in monthly installments of $2,105 plus interest of 8.75%, final payment due in May 2009. 2003 - $239,957 Note payable, collateralized by equipment, payable in monthly installments of $916 plus interest of 7.9%, final payment due in October 2004. 8,837 Capital lease obligation, collateralized by leased equipment payable in monthly installments of $596 including interest at 16.42%, maturing August 2005. 10,364 Capital lease obligation, collateralized by leased equipment payable in monthly installments of $762 including interest at 0%, maturing March 2003. - 259,158 Less current portion 19,151 Non-current portion $240,007 - 2002 $ 241,116 18,704 15,356 2,287 277,463 21,213 $ 256.250 - 10- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) NOTES TO FINANCIAL STATEMENTS DECEMBER 31,2003 AND 2002 H. LONG-TERM DEBT (CONTINUED) Annual maturities of long-term debt outstanding at December 3 1, are as follows: Years Ending December 3 1 ,: 2004 2005 2006 2007 2008 Thereafter Total annual maturities $ 19,151 9,326 5,282 5,763 6,288 213,347 $259,157 I. INCOME TAX EXPENSE The provisions for income taxes consist of the following at December 3 1 : - 2003 - 2002 Current Taxes Less: Estimated Tax Payments Accrued (Prepaid) Income Tax $ 6,699 $ 5,089 (5,120) (800) $ (1.579) $ 4,289 J. DEFERRED INCOME TAXES In 1993, the Company adopted FASB Statement No. 109, Accounting for Income Taxes, which requires an asset and liability approach to financial accounting and reporting for income taxes. Deferred income tax assets and liabilities are computed annually for differences between the financial statement and tax bases of assets and liabilities that will result in taxable or deductible amounts in the future based on enacted tax laws and rates applicable to the periods in which the differences are expected to affect taxable income. Valuation allowances are established when necessary to reduce deferred tax assets to the amount expected to be realized. Income tax expense is the tax payable or refimdable for the period plus or minus the change during the period in deferred tax assets and liabilities For the years ended December 3 1,2003 and 2002, management has elected to not recognize deferred taxes for state income due to their immaterial impact on the financial statements. K. BACKLOG (COMPILED) The Company’s backlog of work represents the amount of revenue the Company expects to realize from work to be performed on uncompleted contracts in progress at year-end and from contractual agreements on which work has not begun. The Company’s backlog totaled $7,681,871 and $4,196,534 at December 3 1,2003 and 2002, respectively. - 11 - FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) NOTES TO FINANCIAL STATEMENTS DECEMBER 31,2003 AND 2002 L. CASH FLOW INFORMATION The Company did not have any non-cash financing transactions in 2003 and 2002 respectively. M. COMMON STOCK The Company has 500,000 authorized shares of par value stock. There are currently 51,000 shares issued and 34,000 outstanding. N. TREASURY STOCK Treasury stock consists of 17,000 shares repurchased by the company for $36,200 on August 16,1989. 0. COMPENSATED ABSENCES The Company does not accrue for compensated absences, as the amount is considered immaterial. P. CONCENTRATIONS OF RISK Financial instruments that potentially subject the Company to concentrations of credit risk consist principally of cash deposits in banks and other financial institutions, investment securities and accounts receivable. The Company maintains cash and cash equivalents and short and long-term investments with major banks and financial institutions. Accounts at banks are insured by the Federal Deposit Insurance Corporation (FDIC) up to $100,000 at each institution. The Company also maintains accounts with a brokerage company. The accounts contain cash and securities. Balances are insured up to $500,000 by the Securities Investor Protection Corporation (SiPC). At December 31, 2003 and 2002 the Company exceeded FDIC coverage by $152,445 and $28,617 respectively. They did not exceed the SiPC coverage. Concentrations of credit risk with respect to accounts receivable are limited because of the number of customers, which make up the Company’s customer base, thus spreading the credit risk. The Company performs on-going credit evaluations of its customers’ financial condition and, if necessary, maintains allowances for potential losses. The Company also retains the right to place liens on property in order to obtain payment. - 12- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) NOTES TO FINANCIAL STATEMENTS DECEMBER 31,2003 AND 2002 Q. SALES TO MAJOR CUSTOMERS For the years ended December 3 1,2003 and 2002 there were sales to major customers that exceeded 10% of total net sales. Sales to these customers and their accounts receivable balances at December 3 1,2003 and 2002 were as follows: 2002 7 2003 - Accounts Accounts Receivable Sales Receivable Sales Customer A $390,540 $3,193,295 $ 170,550 $2,221,041 CustomerB $ - $ $ - $ 1,299,312 -13- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) COST OF REVENUE FOR THE YEARS ENDED DECEMBER 31,2003 AND 2002 SCHEDULE I 2003 YO 2002 % Plumbing Labor Subcontract Equipment rental Electrical Concrete Insurance Equipment-R&M Estimating costs Payroll taxes Miscellaneous Job site utilities Travel Job fuel Telephone Outside services Bonds Fees TOTAL COST OF REVENUE $ 854,691 800,585 753,049 250,663 231,262 196,741 157,257 150,887 67,816 66,363 25,171 19,612 17,789 16,882 13,406 12,174 4,966 - 18.78 17.59 16.54 5.51 5.08 4.32 3.45 3.31 1.49 1.46 0.55 0.43 0.39 0.37 0.29 0.27 0.1 1 - $ 3,639,314 79.95 $ 1,344,319 28.37 584,818 12.34 170,781 3.60 179,206 3.78 1,069,492 22.57 148,605 3.14 118,119 2.49 82,343 1.74 66,360 1.40 49,739 1.05 6,285 0.13 3,672 0.08 37,428 0.79 8,792 0.19 9,196 0.19 66,701 1.41 7,304 0.15 3,269 0.07 $ 3,956,429 83.50 See accountant's review report and notes to financial statements -14- FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) GENERAL AND ADMINISTRATIVE EXPENSES FOR THE YEARS ENDED DECEMBER 31,2003 AND 2002 SCHEDULE I1 2003 % 2002 Yo Officer's salaries Office salaries Depreciation Estimating costs Payroll taxes Auto expense Insurance Telephone Office expenses Repairs and maintenance Accounting Utilities Property tax Outside services Legal Postage Bank charges Dues & subscriptions Miscellaneous Donations TOTAL GENERAL, AND ADMINISTRATIVE $ 195,768 70,739 38,144 23,692 19,324 16,716 11,375 11,032 10,785 9,231 7,730 5,097 4,582 3,187 2,986 1,982 985 920 599 420 4.30 $ 176,280 1.55 56,400 0.84 25,075 0.52 33,497 0.42 19,644 0.37 15,497 0.25 26,052 0.24 11,378 0.24 6,618 0.20 3,068 0.17 8,005 0.1 1 5,092 0.10 3,595 0.07 2,830 0.07 120 0.04 979 0.02 50 0.02 780 0.01 402 0.01 264 3.72 1.19 0.53 0.71 0.41 0.33 0.55 0.24 0.14 0.06 0.17 0.11 0.08 0.06 0.02 0.02 0.01 0.01 $ 435,294 9.56 $ 395,626 8.35 See accountant's review report and notes to financial statements -15- Contracts in process Completed contracts Total earnings from contracts FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) EARNINGS FROM CONTRACTS FOR THE YEAR ENDED DECEMBER 31,2003 SCHEDULE I11 COST OF GROSS REVENUE REVENUE PROFIT $ 4,443,941 $ 3,586,253 $ 857,688 107,955 53,061 54,894 $ 4,551,896 $ 3,639,314 $ 912,582 See accountant's review report and notes to financial statements. - 16- w I wl Job No. 0102-La Salina 0203-Moonlight Beach 0205-Aqua Amonia 0206-Roicc-Sub 0207-Has No. Island TOTALS FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) CONTRACTS COMPLETED FOR THE YEAR ENDED DECEMBER 31,2003 SCHEDULE V Contract Totals Before January 1,2003 Year Ended December31.2003 Gross Gross Gross Revenues cost of profit Revenues cost of profit Revenues cost of profit earned revenues (loss) eamed revenues (loss) earned revenues (loss) $ 2,275,114 $ 2,032,144 S 242,970 5 2,280,178 S 2,018,151 S 262,027 (5,064) 13,993 (19,057) 440,9 IO 342,750 98,160 437,982 340,383 97,599 2,928 2,367 56 I 307,549 195.422 112,127 198,721 159.776 38.945 108,828 35,646 73.182 87,951 51,865 36,086 86,688 5 1,709 34,919 1.263 156 1,107 899 (899) 899 (899) $ 3,111,524 S 2,623,080 $ 488.444 S 3,003,569 $ 2.570.019 S 433,550 $ 107,955 s 53,061 s 54,894 See accountant's review report and notes to financial statements. -18- FALCON GENERAL, ENGINEERING, INC. (AN S CORPORATION) ACCOUNTS RECEIVABLE AGING SUMMARY DECEMBER 31,2003 SCHEDULE VI Current 1 - 30 31 - 60 61 - 90 TOTAL 0104 $ 64,030 $ - $ - $ - $ 64,030 0202 34,749 32,200 - 66,949 0204 390,540 - 390,540 Total Accounts Receivable $489,319 $ 32,200 $ -$ - $521,519 See accountant's review report and notes to financial statements. -19 FALCON GENERAL ENGINEERING, INC. (AN S CORPORATION) ACCOUNTS PAYABLE AGING SUMMARY DECEMBER 31,2003 SCHEDULE VI1 Current 1-30 31-60 61-90 >90 TOTAL ABC Apprenticeship & Training Trust Fund ABC California Health Trust Affordable Drain Services, Inc. Airgas-West Boyd Fastners Construction Bidboard Inc. Contactors & Employes Retirement Trust Crescent Electric Supply Company Diamond Environmental Svc-OCS Exxon Mobil Fleet Free Builders Supply, Inc. Heavy Equipment Rentals LLC Home Depot Services IC1 Delux Painting Centers Imperial Industrial Coating Kennedy Masonry, Inc. McMaho Const. & International Const.SVC. McMahon Construction National Waterworks Ochs Oil Co. Olsen Steel, Inc. Onesource Distributors, Inc. Pel1 Me11 Supply, Inc. R.A. Greene Cop Reliable Pipe Supply Co., Inc. San Diego County Sheriff IN 005 034 San Diego Gas & Electric-SM San Marcos Trophy Texaco Fleet Management US FilterRJ Enviromental $ 178 $ -$ - 1,927 81 122 2,057 47 232 146 27 1 1,332 206 96 9,736 80,264 386 97 1 48 46 820 295 167 1,063 100 $- 1,327 983 $- 3,885 1,000 2,500 $ 178 1,927 1,063 81 122 100 2,057 47 232 146 27 1 1,332 206 96 1,327 3,885 9,736 80,264 386 97 1 1,000 (2) 48 983 46 820 295 4 167 2,500 Total Accounts Payable $ 99.428 $ 2 $ 1.163 $ 2,310 $ 7,385 $ 110,288 See accountant's review report and notes to financial statements. -20- BIDDER’S STATEMENT OF TECHNICAL AB1 LlTY AND EXPERIENCE (To Accompany Proposal) CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION The Bidder is required to state what work of a similar character to that included in the proposed Contract he/she has successfully performed and give references, with telephone numbers, which will enable the District to judge hidher responsibility, experience and skill. An attachment can be used. Name and Phone I e- PISRevised: 10/08/03 Contract No. 38891 Page 26 of 98 Pages WORK IN PROGRESS BLACK MOUNTAIN RANCH SEWER LIFT STATION NO. 90 Completion scheduled February 1 1,2005, $3,960,946 Black Mountain Ranch LLC Hazard Construction Company; Mr. Jason Mordhurst (858) 587-3600 SYCAMOR ESTATES STONEBRIDGE PARKWAY 1135 WATER PUMP STATION Completion scheduled November 30,2004, $1,832.902 McMillin Development Company; Mr. Kent Irland (6 19) 477-4 1 1 7 BLANKET PURCHASE ORDER AGREEMENT VARIOUS NAVAL SITE - Completion scheduled December 30,2004, $ 1,000,000 Department of The Navy, Southwest Division; Christina Graulau (619) 545-8433 PTO XOlO TRIBUTARY IMPROVEMENTS, AREAS 3 & 8 CAMP PENDLETON, CA. CONTRACT N68711-00-D-0218 Completion scheduled December 30,2004; $ 824,327 Pacific General, Inc., Mr. Don Costello (61 9) 234-6220 HISTORY OF COMPLETED PROJECTS APRIL 1994 -JUNE 30,2004 MAR LAD0 SEWER LIFT STATION CITY OF OCEANSIDE, CA., KB HOMES Pump station online 1 1 /05/03 Project 100% March 13,2004; $3,873,246 KB Homes, Mr. Gary Mingo (858) 509-2015 PTO X005 TRIBUTARY IMPROVEMENTS, AREA 13 CAMP PENDLETON, CA. CONTRACT N68711-00-D-0218 Project 100% November 20,2003; $2,004,297 Pacific General, Inc., Mr. Don Costello (619) 234-6220 RETROFIT OF SEWAGE PUMP STATION B-649 NASNI CORONADE, CA. Project 100% October 3 1,2003; $5 16,933 SDGE, Mr. Kevin Ellis (858) 654-1239 1 AQUA AMMONIA FACILITY BID NO. 02-033, CITY OF POWAY Project 100% January 25,2003; $31 1,446 City of Poway, Ca. Mr. Tom Howard (858) 748-6600 MOONLIGHT BEACH URBAN RUNOFF TREATMENT FACILITY PROJECT NUMBER CMSOlB, CITY OF ENCINITAS Project 100% August 30,2002; $432,511 City of Encinintas, Ca. Mr. Kipp Hefner (760) 633-2775 LA SALINA WASTEWATER TREATMENT PLANT SECONDARY EFFLUENT PUMP STATION, PROJECT NUMBER 722-86-7427; CITY OF OCAEANSIDE, CA. Project 100% September 15,2002; $2,355,914 City of Oceanside, Ca. Mr. Greg Blakely (760) 435-5814 FOXES LANDING SEWER LIFT STATION UPGRADES CITY OF CARLSBAD, CA. Project 100% October 13,2001 $1,078,333.00 City of Carlsbad, Ca. Mr. Dale Schuck (760) 602-2780 ext. 73 18 PALA WASTEWATER TREATMENT FACILITY, LIFT STATIONS 1 & 2 PALA DEVELOPMENT % DPR CONSTRUCTION Project 100% March 3 1,200 1 $ 1,250,000 DPR Construction, Mr. Mike King (6 19) 92 1-9473 WRP NO. 10 SEWER FORCE MAIN AND LIFT STATION 80-17, SPEC. 99-13 COACHELLA VALLEY WATER DISTRICT Project 100% March 24,2001, $3,034,114.00 Coachella Valley Water District, Mr. Alberto Delgado (760) 398-265 1 FLAGLER PUMP STATION, JOB NO. 7495 CITY OF REDONDO BEACH, CA. Project 100% November 01,2001 $500,496.00 City of Redondo Beach, Ca. Mr. Mike Shay (3 10) 3 18-0661 ext. 245 WRP No. 10 TERTIARY FILTER SYSTEM IMPROVEMENTS SPEC. NO. 99-3 - COACHELLA VALLEY WATER DISTRICT Project 100% December 13,1999 $490,834 Coachella Valley Water District, Mr. Alberto Delgado (760) 398-265 1 CONSTRUCTION OF DEL CERRO HIGHLANDS PUMP PLANT CITY OF SAN DIEGO, CA. Project 100% December 12, 1999 $963,163.19 O’Brian Kreitzberg, Mr. Bob Sasche (858) 514-7550 2 REDONDO BEACH CITY YARD FUEL STATION, JOB NO 7125 CITY OF REDONDO BEACH, CA. Project 100% November 20,1999 $249,774.00 City of RedondoBeach, Ca. Mr. Mike Shay (3 10) 3 18-0661 ext. 245 REHABILITATION OF CITY SEWER LIFT STATIONS, CITY OF MANHATTAN BEACH, CALIF. Project 100% April 1. 1999. $972,736.00 City of Manhattan Beach, Mr. Glen Kau (310) 545-5621 ext. 390 REPAIRmEPLACE FILTER SYSTEM AT WATER TREATMENT PLANT, MARINE CORPS AIR STATION, YUMA ARIZONA Project 100% December 8,1998; 96-C-4939 $713,874 ROICC MCAS Yuma, Arizona, Larry Miller (520) 341-2565 REPAIRED SPALLED CONCRETE GRAVING DOCK, 32ND ST. NAVAL STATION Project 100% Sept. 19, 1997; 96-C-4596 $ 199,783 ROICC San Diego Naval Station, Saloman Labrador (619) 556-9898 REPLACE OILY WASTE LINESKONTAINMENT, NAVAL SUBMARINE BASE, POINT LOMA, SAN DIEGO Project 100% June 12,1998; 96-C-3199 $2,630,000 Point Loma Field Team, Ken Conboy (619) 553-0794 OILYWASTE SYSTEM MODIFICATION, NAVAL AMPHIBIOUS BASE, CORONADO CALIF. Project completion expected Sept 01 , 1998; 94-C-4545: $1,33 1,235 ROICC Naval Station San Diego, LTJG Rich Hayes (619) 545-2136 UPGRADE POTABLE WATER SYSTEM PART A (P-213) And UPGRADE CALIF. WASTEWATER SYSTEM PART B (P-214) At NAVAL AIR FACILITY EL CENTRO, Project 100% March 12, 1997; 92-C-4802: $3,040,906 ROICC El Centro, MR. Ed Cooney (760) 339-2469 FUEL SYSTEM UPGRADES and SITE IMPROVEMENTS For FY92 & FY93 At THE NAVAL SUPPLY CENTER, POINT LOMA, SAN DIEGO Project 100% February 20,1997; 93-C-1447: $2,645,014 ROICC Naval Station, San Diego; Mr. Gary Sponsel(619) 556-6284 REPAIR SEWER PUMP STATION BUILDING 307, NAVAL AMPHIBIOUS BASE CORONADO, CALIFORNIA Project 100% complete May 30, 1996; 94-C-4704: $179,332 ROICC Naval Station, San Diego; Mr. Tony Billingham (619) 556-9907 3 PIERCE STREET PUMP STATION UPGRADES, CITY OF RIVERSIDE Project 100% September 12, 1995; P.O. # 95 13252: $1,274,685 City of Riverside, Mr. Dave Kush, (909) 35 1-6188 SMITHSON SPRINGS TANK REHABILITATIN, PINION HILLS, CALIF Project 100% November 1 1, 1994; Project # 94-62: $250,000 Office of Special projects, Co. of San Bernardino, Mr. Gary Martin; (909) 387-5964 SITE WORK, STRUCTURAL, REPAIRS, RECOATING, AND REPAINTING CITY OF HEMET WATER STORAGE TANKS 1,2,3,4 Project 100% August 25, 1994; P.0 # 930285: $1,399,510 Cozad & Thomsen, Kevin Cozad; (909) 652-4454 REPLACE COMPRESSED AIR PIPING, J-K PIER AND VICINITY, NAS NO. ISLAND Project 100% July 22, 1994; Cont. 92-C-0606: $82,385 ROICC No. Island, Philip Giesse; (619) 545-2853 OIL SPILL CONTAINMENT UPGRADES, NAF EL CENTRO Project 100% May 25,1994: Cont. 93-C-1304: $700,476 ROICC El Centro, Lt. Washington; (619) 339-2428 50,000 GALLON WATER STORAGE FACILITY, NAVAL HOSPITAL, CAMP PEND. Project 100% April 4, 1994; Cont. 93-C-1415: $127,219 ROICC Camp Pendleton, Harry Ekdahl Jr.: (619) 725-8201 INSTALL RETAINING WALL BEHIND BUILDING 25R1 Project 100% March 14, 1994; Cont. 94-4-0449: $18,650 Facilities Maintenance Dept., Nate Cervantes; (6 19) 725-3923 STRUCTURAL REPAIRS PIER 8, PHASE 11,32ND ST. NAVAL STATION Project 1005 May 24,1993; Cont. 92-C-0979: $777,636 ROICC South Bay, Lt. Weakland; (619) 556-8936 FY92 FIRE FIGHTING SCHOOL OVERHAUL, 32ND ST. NAVAL STATION Project 100% Jan 2 1 , 1993; Cont. 92-C-1032: $92,053 ROICC South Bay, Lt. Weakland; (619) 556-8936 4 BIDDER'S CERTIFICATE OF INSURANCE FOR GENERAL LIABILITY, EMPLOYERS' LIABILITY, AUTOMOTIVE LIABILITY AND WORKERS' COMPENSATION (To Accompany Proposal) CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION As a required part of the Bidder's proposal the Bidder must attach either of the following to this page. 1. Certificates of insurance showing conformance with the requirements herein for: Comprehensive General Liability Workers Compensation f t Automobile Liability Employer's Liability 2. Statement with an insurance carrier's notarized signature stating that the carrier can, and upon payment of fees and/or premiums by the Bidder, will issue to the Bidder Policies of insurance for Comprehensive General Liability, Employer's Liability, Automobile Liability and Workers Compensation in conformance with the requirements herein and Certificates of insurance to the Agency showing conformance with the requirements herein. All certificates of insurance and statements of willingness to issue insurance for auto policies offered to meet the specification of this contract must: (1) Meet the conditions stated in The Notice Inviting Bids, the Standard Specifications for Public Works Construction and the Supplemental Provisions for this project for each insurance company that the Contractor proposes. (2) Cover any vehicle used in the performance of the contract, used onsite or offsite, whether owned, non-owned or hired, and whether scheduled or non-scheduled. The auto insurance certificate must state the coverage is for "any auto" and cannot be limited in any manner. '3Revised: 10/08/03 Contract No. 38891 Page 27 of 98 Pages ;4CohDm CERTIFICATE OF LIABILITY INSURANCE DATE (MMIDDIYYW) 11/05/04 COVE RAGES THE POLICIES OF INSURANCE LISTED BELOW HAVE BEEN ISSUED TO THE INSURED NAMED ABOVE FOR THE POLICY PERIOD INDICATED. NOTWITHSTANDING ANY REQUIREMENT, TERM OR CONDITION OF ANY CONTRACT OR OTHER DOC IMENT WITH RESPECT TO WHICH THIS CERTIFICATE MAY BE ISSUED OR MAY PERTAIN, THE INSURANCE AFFORDED BY THE POLICIES DESCRIBED HEF IN IS SUBJECT TO ALL THE TERMS, EXCLUSIONS AND CONDITIONS OF SUCH POLICIES. AGGREGATE LIMITS SHOWN MAY HAVE BEEN REDUCED BY PAID CL IMS. PROWCER US1 San Diego LicO539016 (1 Diego, CA 92130 RSR .TR - A - B THIS CERTIFICATE IS ISSUED AS A MATTER OF INFORMATION ONLY AND CONFERS NO RIGHTS UPON THE CERTIFICATE HOLDER. THIS CERTIFICATE DOES NOT AMEND, EXTEND OR CLAIMS MADE OCCUR ,d 314-5100 Falcon General Engineering, Inc. 572 Collyn Street Vista, Ca 92083 H BllPD Ded:5,000 INSURERS AFFORDING COVERAGE NAlC # INSURERA: Landmark American Ins Co 99999 INSURER E: Safeco Insurance Company 33138 INSURER c: RSUl Indemnity INSURER D: POLICY EFFECTIVE DATE (MMIDDIYYI r LIMITS POLICY EXPIRATION DATE IMMIDDIYY) H 0811 6104 GARAGE LIABILITY ANY AUTO k 08/16/05 EACH OCCURRENCE $1 ,000,000 a o-ence) $50,000 DAMAGE TO RENTED MED EXP (Any one person) PERSONAL & ADV INJURY $l,ooo,ooo GENERAL AGGREGATE $2,000,000 PRODUCTS - COMP/OP AGG $l,ooo,ooo $ DEDUCTIBLE WORKERS COMPENSATION AND EMPLOYERS LIABILITY x ANY PROPRIETOWPARTNEWEXECUTIVE OFFICEWMEMBER EXCLUDED? If yes, describe under SPECIAL PROVISIONS below OTHER I GENL AGGREGATE LIMIT APPLIES PER 1 rn J'E"~"; n LOC AUTOMOBILE LIABILITY x ANYAUTO - - ALL OWNED AUTOS SCHEDULED AUTOS - POLICY NUMBER I HA1 26707 I lCG075169 0811 6/04 HA212446 $ PROPERTY DAMAGE (Per accident) AUTO ONLY - EAACCIDENT $ OTHERTHAN EAACC AUTO ONLY: AGG $ 0811 6/04 EACHOCCURRENCE $1 ,000,000 AGGREGATE $1,000,000 WC STATU- OTH- TORY LW FR E.L. EACH ACCIDENT E.L. DISEASE - EA EMPLOYEE E.L. DISEASE - POLICY LIMIT $ $ $ $ COMBINED SINGLE LIMIT rl,OOO,OOO (Ea accident) 0811 6104 City of Carlsbad Public Works-Engineering 1635 Faraday Avenue Carlsbad, CA 92008-7314 SHOULD ANY OF THE ABOVE DESCRIBED POLICIES BE CANCELLED BEFORE THE EXPIRATION DATE THEREOF, THE ISSUING INSURER WlLLmRXRWIL 2 DAYS WRITTEN NOTICE TO THE CERTIFICATE HOLDER NAMED TO THE LEFT,SWUW-K ~R1(RXIB~~AD~~~~x~~~~~~~m~~xx RKBl3ESKKEtWX%JM AUTHORIZED REPRESENTATIVE BODILY INJURY (Per person) BODILY INJURY (Per accident) $ I DESCRIPTION OF OPERATIONS I LOCATIONS /VEHICLES I EXCLUSIONS ADDED BY ENDORSEMENT I SPECIAL PROVISIONS Project: Calavera Recycled Water Pump Station for the Encina Basin Water I- .- _. . . - . . . . - - - - I Reclamation Program, Phase ll, Project # 38891 . . . . . . . . . ... I 0 ACORD CORPORATION 1988 &Q 7- Ld4LQeL ACORD 25 (2001/08) 1 of 2 #S261692/M252781 GHR IMPORTANT If the certificate holder is an ADDITIONAL INSURED, the policy(ies) must be endorsed. A statement on this certificate does not confer rights to the certificate holder in lieu of such endorsement(s). If SUBROGATION IS WAIVED, subject to the terms and conditions of the policy, certain policies may require an endorsement. A statement on this certificate does not confer rights to the certificate holder in lieu of such endorsement(s). DISCLAIMER The Certificate of Insurance on the reverse side of this form does not constitute a contract between the issuing insurer(s), authorized representative or producer, and the certificate holder, nor does it affirmatively or negatively amend, extend or alter the coverage afforded by the policies listed thereon. ACQRD 254 (2001/08) 2 of 2 #S261692/M252781 THIS ENDORSEMENT CHANGES THE POLICY. PLEASE READ IT CAREFULLY. ADDITIONAL INSURED BLANKET-PRIMARY THIS ENDORSEMENT MODIFIES INSURANCE PROVIDED UNDER THE FOLLOWING: COMMERCIAL GENERAL LIABILITY COVERAGE FORM SCHEDULE NAME OF PERSON OR ORGANIZATION: CITY OF CARLSBAD 1635 FARADAY AVENUE CARLSBAD, CA 92008-73 14 PROJECT: CALAVERA RECYCLED WATER PUMP STATION FOR THE ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE 11, PROJECT # 38894 And person or organization to whom or to which you are obligated by virtue of a written contract or by the issuance or existence of a permit, to provide insurance such as is afforded by this policy. (If no entry appears above, information required to complete this endorsement will be shown in the Declarations as applicable to this endorsement.) Section I1 - WHO IS AN INSURED is amended to include as an insured the person or organization shown in the Schedule, but only with respect to liability arising out of “your work” for that insured by or for you. If you are required by a written contract to provide primary insurance, this policy shall be primary as respects your negligence and SECTION IV - COMMERCIAL GENERAL LIABILITY CONDITIONS, 4. Other Insurance does not apply, but only with respects to coverage provided by this policy. This endorsement effective OW1 6/04 forms part of Policy Number LHAl26707 issued to by Landmark American Insurance Company Falcon General Engineering, Inc. Endorsement No : RSG 15001 0903 (CG 2010 1185) Included copyrighted material of Insurance Services Office, Inc 1984 with its permission BROKER COPY STATE P.0. BOX 420807, SAN FRANCISCO, CA 94142-0807 FUN D CERTIFICATE OF WORKERS' COMPENSATION INSURANCE COMPENSATION INSURANCE ISSUE DATE: 11-05-2004 CITY OF CARLSBAD 1635 FARADAY AVENUE PUBLIC WORKS-ENGINEERING CARLSBAD CA 92008-7314 000046 GROUP: POLICY NUMBER: 14614 -2 004 CERTIFICATE ID: 39 CERTIFICATE EXPIRES: 08 -16 -2 005 oa-i6-2004/08-i6-2005 JOB: CALAVERA RECYCLED WATER PUMP STATION FOR THE ENCINA BASIN WATE: RECLAMATION PROGRAM PHASE 11, PROJECT # 38891 This is to certify that we have issued a valid Worker's Compensation insurance policy in a form approved by the California Insurance Commissioner to the employer named below for the policy period indicated. This policy is not subject to cancellation by the Fund except upon 30 days advance written notice to the employer. We will also give you 30 days advance notice should this policy be cancelled prior to its normal expiration. This certificate of insurance is not an insurance policy and does not amend, extend or alter the coverage afforded by the policy listed herein. Notwithstanding any requirement, term or condition of any contract or other document with respect to which this certificate of insurance may be issued or to which it may pertain, the insurance afforded by the policy described herein is subject to all the terms, exclusions, and conditions, of such policy. W AUTHORIZED REPRESENTATIVE PRESIDENT EMPLOYER'S LIABILITY LIMIT INCLUDING DEFENSE COSTS: $1,000,000 PER OCCURRENCE. ENDORSEMENT #2065 ENTITLED CERTIFICATE HOLDERS' NOTICE EFFECTIVE 08-16-2004 IS ATTACHED TO AND FORMS A PART OF THIS POLICY. EMPLOYER FALCON GENERAL ENGINEERING, INC. 572 COLLYN ST VISTA CA 92083 BIDDER’S STATEMENT RE DEBARMENT CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION (To Accompany Proposal) 1. Have you or any of your subcontractors ever been debarred as an irresponsible bidder by another jurisdiction in the State of California? Yes 2. If yes, what wadwere the name(s) of the agency(ies) and what wadwere the period(s) of debarment(s)? Attach additional copies of this page to accommodate more than two debarments. party debarred party debarred agency agency period of debarment period of debarment BY CONTRACTOR: (print namekitle) Page of \ pages of the Re Debarment form 4- tg Revised: 10/08/03 Contract No. 38891 Page 28 of 98 Pages BIDDER’S DISCLOSURE OF DISCIPLINE RECORD (To Accompany Proposal) CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION Contractors are required by law to be licensed and regulated by the Contractors’ State License Board which has jurisdiction to investigate complaints against contractors if a complaint regarding a patent act or omission is filed within four years of the date of the alleged violation. A complaint regarding a latent act or omission pertaining to structural defects must be filed within 10 years of the date of the alleged violation. Any questions concerning a contractor may be referred to the Registrar, Contractors’ State License board, P.O. Box 26000, Sacramento, California 95826. 1) Have you ever had your contractor‘s license suspended or revoked by the California Contractors’ State license Board two or more times within an eight year period? 4 2) Has the suspension or revocation of your contractors license ever been stayed? Yes no 3) Have any subcontractors that you propose to perform any portion of the Work ever had their contractor’s license suspended or revoked by the California Contractors’ State license Board two or more times within an eight year period? Yes 4) Has the suspension or revocation of the license of any subcontractor‘s that you propose to perform any portion of the Work ever been stayed? Yes no 5. 5) If the answer to either of 1. or 3. above is yes fully identify, in each and every case, the party disciplined, the date of and violation that the disciplinary action pertain to, describe the nature of the violation and the disciplinary action taken therefor. (If needed attach additional sheets to provide full disclosure.) Page \ of z pages of this Disclosure of Discipline form h 4- %#Revised: 10/08/03 Contract No. 38891 Page 29 of 98 Pages BIDDER’S DISCLOSURE OF DISCIPLINE RECORD (CO NTlN U ED) (To Accompany Proposal) CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION 6) If the answer to either of 2. or 4. above is yes fully identify, in each and every case, the party who’s discipline was stayed, the date of the violation that the disciplinary action pertains to, describe the nature of the violation and the condition (if any) upon which the disciplinary action was stayed. If needed, attach additional sheets to provide full disclosure. i i, I L. P. BY CONTRACTOR: FALCON Gmm AL €&IN (name of Contractor) By: \ (sign her% Page 2 of 2 pages of this Disclosure of Discipline form 4- CpRevised: 10/08/03 Contract No. 38891 Page 30 of 98 Pages CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT NO 5193 -1 SI02 before me, DEBORAH D. DAVIS, NOTARY PUBLIC 1 DATE NAME, TITLE OF OFFICER - E GI "JANE DOE, NOTARY PUBLIC' personally appeared DALE E. WINTERQUIST 9 NAME(S) OF SIGNER(S) personally known to me - OR - 0 proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) idare subscribed to the within instrument and ac- knowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their signature(s) on the instrument the person(s), or the entity upon behalf of which the person@) acted, executed the instrument. WITNESS my hand and official seal. 9 SIGNATURE OF NOTARY - OPTIONAL SECTlQN m CAPACITY CLAIMED BY SIGNER Though statute does not require the Notary to fill in the data below, doing so may prove invaluable to persons relying on the document. INDIVIDUAL CORPORATE OFFICER(S) PRESIDENT TITLE(S) 0 PARTNER(S) 0 LIMITED 0 ATTORNEY-IN-FACT TRUSTEE(S) 0 GUARDIAN/CONSERVATOR 0 OTHER: 0 GENERAL SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTITY(IES) OPTIONAL SECTION miis CERTIFICATE MUST BE ATTACHED TO TITLE OR TYPE OF DOCUMENT 'THE DOCUMENT DESCRIBED AT RIGHT: NUMBER OF PAGES DATE OF DOCUMENT -ough the data requested here is not required by law, rld prevent fraudulent reattachment of this form. SIGNER(S) OTHER THAN NAMED ABOVE I i I 4: 6. La h' i NON-COLLUSION AFFIDAVIT TO BE EXECUTED BY BIDDER AND SUBMITTED WITH BID CONTRACT NO. 38891 ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION PUBLIC CONTRACT CODE SECTION 7106 State of California ) County of 1 ) ss. IrJTmfQU \st- (Name of Bidder) , being first duly sworn, deposes and says that he or she is ?63WOfl (Title) the party making the foregoing bid that the bid is not made in the interest of, or on behalf of, any undisclosed person, partnership, company, association, organization, or corporation; that the bid is genuine and not collusive or sham; that the bidder has not directly or indirectly induced or solicited any other bidder to put in a false or sham bid, and has not directly or indirectly colluded, conspired, connived, or agreed with any bidder or anyone else to put in a sham bid, or that anyone shall refrain from bidding; that the bidder has not in any manner, directly or indirectly, sought by agreement, communication, or conference with anyone to fix the bid price of the bidder or any other bidder, or to fix any overhead, profit, or cost element of the bid price, or of that of any other bidder, or to secure any advantage against the public body awarding the contract of anyone interested in the proposed contract; that all statements contained in the bid are true; and, further, that the bidder has not, directly or indirectly, submitted his or her bid price or any breakdown thereof, or the contents thereof, or divulged information or data relative thereto, or paid, and will not pay, any fee to any corporation, partnership, company association, organization, bid depository, or to any member or agent thereof to effectuate a collusive or sham bid. I declare under penal of erj ry that the for going is true and correct and that this affidavit was executed on the k.pl'l dayof L, ,2oy * . Signaturb of Bidder Subscribed and day of 120-. (NOTARY SEAL) . .. Signature of Notary 4- Revised: 10/08/03 Contract No. 38891 Page 31 of 98 Pages CONTRACT RECIPIENTS NAME bLL E. w "ERaU r5T PROJI3(JT DE-WRPT~ON ck\ MI3 \%R511\1 RTE R Fw.LmRrtorrL PW. P4WE 4 I' ' - CONTRACT NO. OR SPECILlCATlON NO hJD, 3 fgdq PROJECT LOCATION Chdfmh emc-.&b c\l fim PLWQ C3mn 0t4. LMIE~E wb Crprrusn~~a I ca 0 WE a MBE 0 SUBCONTRACIOR CI JOINT VENTURE 1 cl SUPPLEWSERVICE 0 BROKER I MB-E INFORMATION I 1- -1 XMBE a WE 0 SUBCONTRACTOR ~~SUPPLIE WSERVICE 0 JOINT VENTURE 0 BROKER HMBE ~400~- 0 WE SUBCONTRACTOR 0 SUPPLEWSERVICE 0 JOINT VENTURE 0 BROKER AMOUNT OFCONTRACT $ d 0 0 WORK TO BE PERFORMED& 1 0 MBE cl WE - A A CTOR &SWP~SERVICE 0 JOINT VENTURE 0 BROKER ~~ AMOUNTOFCONTRACT S PHONE WORK TO BE PERFORMED TOTAL MBE AMOUNT: $ TOTALWEAM $ 9 pALG E.~!,Id;LTk3LJ\Sf- SIGNATURE OF PERSON COMPLETING FORM: \1 TITLE: -PRS"- PHONE:pCD_ M&-oS70 DATE: q/ u 2/0 L *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. Issue Date: November 7,2003 BP- 31 CONTRACT PUBLIC WORKS This agreement is made this 10% day of DQcmQc , 20&, by and between the Carlsbad Municipal Water District of Carlsbad, California, a municipal corporation, (hereinafter called "District"), and whose principal place of business is FALCON GENERAL ENGINEERING 572 COLLYN STREET, VISTA, CA 92083 (hereinafter called "Contractor"). District and Contractor agree as follows: 1. for: Description of Work. Contractor shall perform all work specified in the Contract documents ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION, CONTRACT NO. 38891 MARCH, 2004 (hereinafter called "project") 2. equipment, and personnel to perform the work specified by the Contract Documents. Provisions of Labor and Materials. Contractor shall provide all labor, materials, tools, 3. Contract Documents. The Contract Documents consist of this Contract, Notice Inviting Bids, Contractor's Proposal, Bidder's Bond, Designation of Subcontractors, Designation of Owner Operator/Lessors, Bidder's Statements of Financial Responsibility, Technical Ability and Experience, Re Debarment, Non-collusion Affidavit, Escrow Agreement, Release Form, the Plans and Specifications, the Supplemental Provisions, addendum(s) to said Plans and Specifications and Supplemental Provisions, and all proper amendments and changes made thereto in accordance with this Contract or the Plans and Specifications, and all bonds for the project; all of which are incorporated herein by this reference. Contractor, her/his subcontractors, and materials suppliers shall provide and install the work as indicated, specified, and implied by the Contract Documents. Any items of work not indicated or specified, but which are essential to the completion of the work, shall be provided at the. Contractor's expense to fulfill the intent of said documents. In all instances through the life of the Contract, the District will be the interpreter of the intent of the Contract Documents, and the District's decision relative to said intent will be final and binding. Failure of the Contractor to apprise subcontractors and materials suppliers of this condition of the Contract will not relieve responsibility of compliance. 4. Payment. For all compensation for Contractor's performance of work under this Contract, District shall make payment to the Contractor per section 9-3 PAYMENT of the Standard Specifications for Public Works Construction (SSPWC) 2003 Edition, and any supplements thereto, hereinafter designated "SSPWC", as issued by the Southern California Chapter of the American Public Works Association, and as amended by the Supplemental Provisions section of this contract. The Engineer will close the estimate of work completed for progress payments on the last working day of each month. em %pRevised: 10/08/03 Contract No. 38891 Page 32 of 98 Pages 5. Independent Investigation. Contractor has made an independent investigation of the jobsite, the soil conditions at the jobsite, and all other conditions that might affect the progress of the work, and is aware of those conditions. The Contract price includes payment for all work that may be done by Contractor, whether anticipated or not, in order to overcome underground conditions. Any information that may have been furnished to Contractor by District about underground conditions or other job conditions is for Contractor’s convenience only, and District does not warrant that the conditions are as thus indicated. Contractor is satisfied with all job conditions, including underground conditions and has not relied on information furnished by District. 6. Hazardous Waste or Other Unusual Conditions. If the contract involves digging trenches or other excavations that extend deeper than four feet below the surface Contractor shall promptly, and before the following conditions are disturbed, notify District, in writing, of any: A. Hazardous Waste. Material that Contractor believes may be material that is hazardous waste, as defined in section 251 17 of the Health and Safety Code, that is required to be removed to a Class I, Class II, or Class Ill disposal site in accordance with provisions of existing law. B. indicated. Differing Conditions. Subsurface or latent physical conditions at the site differing from those C. Unknown Physical Conditions. Unknown physical conditions at the site of any unusual nature, different materially from those ordinarily encountered and generally recognized as inherent in work of the character provided for in the contract. District shall promptly investigate the conditions, and if it finds that the conditions do materially so differ, or do involve hazardous waste, and cause a decrease or increase in contractor’s costs of, or the time required for, performance of any part of the work shall issue a change order under the procedures described in this contract. In the event that a dispute arises between District and Contractor whether the conditions materially differ, or involve hazardous waste, or cause a decrease or increase in the contractor’s cost of, or time required for, performance of any part of the work, contractor shall not be excused from any scheduled completion date provided for by the contract, but shall proceed with all work to be performed under the contract. Contractor shall retain any and all rights provided either by contract or by law which pertain to the resolution of disputes and protests between the contracting parties. 7. Immigration Reform and Control Act. Contractor certifies it is aware of the requirements of the Immigration Reform and Control Act of 1986 (8 USC sections 11 01 -1 525) and has complied and will comply with these requirements, including, but not limited to, verifying the eligibility for employment of all agents, employees, subcontractors, and consultants that are included in this Contract. 8. Prevailing Wage. Pursuant to the California Labor Code, the director of the Department of Industrial Relations has determined the general prevailing rate of per diem wages in accordance with California Labor Code, section 1773 and a copy of a schedule of said general prevailing wage rates is on file in the office of the City Engineer, and is incorporated by reference herein. Pursuant to California Labor Code, section 1775, Contractor shall pay prevailing wages. Contractor shall post copies of all applicable prevailing wages on the job site. 4w $#Revised: 10/08/03 Contract No. 38891 Page 33 of 98 Pages 9. Indemnification. Contractor shall assume the defense of, pay all expenses of defense, and indemnify and hold harmless the District and the City of Carlsbad, and its officers and employees, from all claims, loss, damage, injury and liability of every kind, nature and description, directly or indirectly arising from or in connection with the performance of the Contract or work; or from any failure or alleged failure of Contractor to comply with any applicable law, rules or regulations including those relating to safety and health; and from any and all claims, loss, damages, injury and liability, howsoever the same may be caused, resulting directly or indirectly from the nature of the work covered by the Contract, except for loss or damage caused by the sole or active negligence or willful misconduct of the District or City. The expenses of defense include all costs and expenses including attorneys’ fees for litigation, arbitration, or other dispute resolution method. Contractor shall also defend and indemnify the City and District against any challenges to the award of the contract to Contractor, arising in whole or in part from alleged inaccuracies or misrepresentation by Contractor, whether intentional or otherwise, and Contractor will pay all costs, including defense costs for the City and District. Defense costs include the cost of separate counsel for City and District, if City or District request separate counsel. 10. Insurance. Contractor shall procure and maintain for the duration of the contract insurance against claims for injuries to persons or damage to property which may arise from or in connection with the performance of the work hereunder by the Contractor, his or her agents, representatives, employees or subcontractors. Said insurance shall meet the District’s policy for insurance as stated in Resolution No. 772. (A) Coverages And Limits Contractor shall maintain the types of coverages and minimum limits indicted herein: a. Comprehensive General Liability Insurance: $1,000,000 combined single limit per occurrence for bodily injury and property damage. If the policy has an aggregate limit, a separate aggregate in the amounts specified shall be established for the risks for which the District and City, or its agents, officers or employees are additional insured. b. Automobile Liability Insurance: $1,000,000 combined single limit per accident for bodily injury and property damage. In addition, the auto policy must cover any vehicle used in the performance of the contract, used onsite or offsite, whether owned, non-owned or hired, and whether scheduled or non-scheduled. The auto insurance certificate must state the coverage is for “any auto” and cannot be limited in any manner. c. Workers’ Compensation and Employers’ Liability Insurance: Workers’ compensation limits as required by the Labor Code of the State of California and Employers’ Liability limits of $1,000,000 per incident. Workers’ compensation offered by the State Compensation Insurance Fund is acceptable to the City. (B) Additional Provisions. Contractor shall ensure that the policies of insurance required under this agreement with the exception of Workers’ Compensation and Business Automobile Liability Insurance contain, or are endorsed to contain, the following provisions: a. The District and City, its officials, employees and volunteers are to be covered as additional insured as respects: liability arising out of activities performed by or on behalf of the Contractor; products and completed operations of the contractor; premises owned, leased, hired or borrowed by the contractor. The coverage shall contain no special limitations on the scope of protection afforded to the District or City, its officials, employees or volunteers: All additional insured endorsements must be evidenced using separate documents attached to the certificate of insurance; one for each company affording general liability and employers’ liability. e %#Revised: 10/08/03 Contract No. 38891 Page 34 of 98 Pages b. The Contractor’s insurance coverage shall be primary insurance as respects the District and City, its officials, employees and volunteers. Any insurance or self-insurance maintained by the District or City, its officials, employees or volunteers shall be in excess of the contractor’s insurance and shall not contribute with it. c. to the District and City, its officials, employees or volunteers. Any failure to comply with reporting provisions of the policies shall not affect coverage provided d. Coverage shall state that the contractor’s insurance shall apply separately to each insured against whom claim is made or suit is brought, except with respect to the limits of the insurer’s liability. (C) Notice Of Cancellation. Each insurance policy required by this agreement shall be endorsed to state that coverage shall not be nonrenewed, suspended, voided, canceled, or reduced in coverage or limits except after thirty (30) days’ prior written notice has been given to the District by certified mail, return receipt requested. (D) Deductibles And Self-Insured Retention (S.I.R.) Levels. Any deductibles or self-insured retention levels must be declared to and approved by the City. At the option of the District, either: the insurer shall reduce or eliminate such deductibles or self-insured retention levels as respects the District and City, its officials and employees; or the contractor shall procure a bond guaranteeing payment of losses and related investigation, claim administration and defense expenses. (E) Waiver Of Subrogation. All policies of insurance required under this agreement shall contain a waiver of all rights of subrogation the insurer may have or may acquire against the District or City or any of its officials or employees. (F) Subcontractors. Contractor shall include all subcontractors as insured under its policies or shall furnish separate certificates and endorsements for each subcontractor. Coverages for subcontractors shall be subject to all of the requirements stated herein. (G) Acceptability Of Insurers. Insurance is to be placed with insurers that have a rating in Best’s Key Rating Guide of at least A-:V. Insurers must also be authorized to transact the business of insurance by the State of California Insurance Commissioner as admitted carriers as evidenced by a listing in the official publication of the Department of Insurance of the State of California and/or under the standards specified by the Board of Directors in Resolution No. 772. (H) Verification Of Coverage. Contractor shall furnish the District with certificates of insurance and original endorsements affecting coverage required by this clause. The certificates and endorsements for each insurance policy are to be signed by a person authorized by that insurer to bind coverage on its behalf. The certificates and endorsements are to be in forms approved by the District and are to be received and approved by the District before the Contract is executed by the District. (I) in the Contractor’s bid. Cost Of Insurance. The Cost of all insurance required under this agreement shall be included e- %#Revised: 10/08/03 Contract No. 38891 Page 35 of 98 Pages 11. Claims and Lawsuits. All claims by contractor for $375,000 or less shall be resolved in accordance with the provisions in the Public Contract Code, Division 2, Part 3, Chapter 1, Article 1.5 (commencing with section 201 04) which are incorporated by reference. A copy of Article 1.5 is included in the Supplemental Provisions I section. The contractor shall initially submit all claims over $375,000 to the District using the informal dispute resolution process described in Public Contract Code subsections 201 04.2(a), (c), (d). Notwithstanding the provisions of this section of the contract, all claims shall comply with the Government Tort Claim Act (section 900 et seq., of the California Government Code) for any claim or cause of action for money or damages prior to filing any lawsuit for breach of this agreement. (A) Assertion of Claims. Contractor hereby agrees that any contract claim submitted to the District must be asserted as part of the contract process as set forth in this agreement and not in anticipation of litigation or in conjunction with litigation. (B) False Claims. Contractor acknowledges that if a false claim is submitted to the District, it may be considered fraud and the Contractor may be subject to criminal prosecution. (C) Government Code. Contractor acknowledges that California Government Code sections 12650 et seq., the False Claims Act, provides for civil penalties where a person knowingly submits a false claim to a public entity. These provisions include false claims made with deliberate ignorance of the false information or in reckless disregard of the truth or falsity of the information. (D) Penalty Recovery. If the Carlsbad Municipal Water District seeks to recover penalties pursuant to the False Claims Act, it is entitled to recover its litigation costs, including attorney’s fees. (E) Debarment for False Claims. Contractor hereby acknowledges that the filing of a false claim may subject the Contractor to an administrative debarment proceeding wherein the Contractor may be prevented from further bidding on public contracts for a period of up to five years. (F) Carlsbad Municipal Code. The provisions of Carlsbad Municipal Code sections 3.32.025, 3.32.026, 3.32.027 and 3.32.028 pertaining to false claims are incorporated herein by reference. (G) Debarment from Other Jurisdictions. Contractor hereby acknowledges that debarment by another jurisdiction is grounds for the Carlsbad Municipal Water District to disqualify the Contractor or subcontractor from participating in future contract bidding. (H) Jurisdiction. Contractor agrees and hereby stipulates that the proper venue and jurisdiction for resolution of any disputes between the parties arising out of this agreement is San Diego County, r California. I have read and understand all provisions of Section 11 above. 12. Maintenance of Records. Contractor shall maintain and make available at no cost to the City, upon request, records in accordance with sections 1776 and 1812 of Part 7, Chapter 1, Article 2, of the Labor Code, If the Contractor does not maintain the records at Contractor’s principal place of business as specified above, Contractor shall so inform the District by certified letter accompanying the return of this Contract. Contractor shall notify the District by certified mail of any change of address of such records. 13. Labor Code Provisions. The provisions of Part 7, Chapter 1, commencing with section 1720 of the Labor Code are incorporated herein by reference. em k#Revised: 10/08/03 Contract No. 38891 Page 36 of 98 Pages CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT No 51 State of ____ ~ -_____ ______ - SAN DIEGO County of__--- KAREN JEAN HALL, NOTARY PUBLIC YAME TITLE OF OFFICEY E G JANk DOE NOTARY PUBLIC On -.!!d5?5&4- 13Pi E before me, personally appeared.--.- CHRISTOPHER W. POMA NAMElSi OF SIGNEAtS) lpersonally known to me - OR - 0 proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) isiare subscribed to the within instrument and ac- knowledged to me that heisheithey executed the same in hidheritheir authorized capacity(ies), and that by his/her/their signature(s) on the instrument the person(s1. or the entity upon behalf of which the person(s) acted, executed the instrument. ~ . +.,AF?E:.I .,&W HALL WTaRv POPLtCCALIFORNIA . I . xr 2 .- ~>r.b ~~(JblhIt !~!477005 f 3-1 . li!Ti.Q COUNT" - OPTIONAL SECTION - CAPACITY CLAIMED BY SIGNER Though statute does no! require the Notary tc fill in the data belcv,, doing so fmay prcve inba!uable to persor:; wying the doci,meii!. 0 INDIVIDUAL [lil CORPORATE OFFICERiS) SECRETARY .- __ -T.E\S) 0 PARTNER(S) 0 LIMITED 0 GENERAL 0 ATTORNEY-IN-FACT TRUSTEE(Sj GUARDIANI'CONSERVATOR 0 OTHER. ~~ SIGNER IS REPRESENTING: NAME CF PERSONIS: [OR ENTITYllESj THIS CERTIFICATE MUST BE ATTACHED TO THE DOCUMENT DESCRIBED AT RIGHT TITLE OR TYPE OF DOCUMENT NUMBER OF PAGES DATE OF DOCUMENT -~ SIGNER(S) OTHER iuld prevent fraudulent reattachment of this form NAMED ABOVE CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT No 51 CALIFORNIA SAN DIEGO State of County of DEBORAH D. DAVIS, NOTARY PUBLIC , NAME, TITLE OF OFFICER. E GI *JANE DOE. NOTARY PUBLIC" before me, DATE ' peirsonally appeared DALE E. WINTERQUIST NAME(S) OF SIGNER(S) personally known to me - OR - 0 proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) isiare subscribed to the within instrument and ac- knowledged to me that hekheithey executed the same in hidheritheir authorized capacity(ies), and that by his/her/their or the entity upon behalf of which the DEBORAH D. DAVIS signature(s) on the instrument the person(s), person(s) acted, executed the instrument. v x-7 - WITNESS my hand and official seal. - OPTIONAL SECTION - CAPACITY CLAIMED BY SIGNER Though statute does not require the Notary to fill in the data below, doing so may prove invaluable lo persons relying on the document. 0 INDIVIDUAL CORPORATE OFFICER(S) PRESIDENT TITLE61 PARTNER(S) LIMITED 0 ATTORNEY-IN-FACT 0 TRUSTEE(S) 0 GUARDIAN/CONSERVATOR 0 OTHER: 0 GENERAL SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTITY(IES) SIGNATURE OF NOTARY OPTIONAL SECTION -HIS CERTIFICATE MUST BE ATTACHED TO - NUMBER OF PAGES DATE OF DOCUMENT Thcugh the data requested here is not required by law it could prevent fraudulent reattachment of this form TITLE OR TYPE OF DOCUMENT HE DOCUMENT DESCRIBED AT RIGHT SIGNER(S) OTHER THAN NAMED ABOVE SisE3- 14. Security. Securities in the form of cash, cashier's check, or certified check may be substituted for any monies withheld by the District to secure performance of this contract for any obligation established by this contract. Any other security that is mutually agreed to by the Contractor and the District may be substituted for monies withheld to ensure performance under this Contract. 15. Provisions Required by Law Deemed Inserted. Each and every provision of law and clause required by law to be inserted in this Contract shall be deemed to be inserted herein and included herein, and if, through mistake or otherwise, any such provision is not inserted, or is not correctly inserted, then upon application of either party, the Contract shall forthwith be physically amended to make such insertion or correction. 16. Additional Provisions. Any additional provisions of this agreement are set forth in the "General Provisions" or 'I Supplemental Provisions" attached hereto and made a part hereof. NOTARIAL ACKNOWLEDGMENT OF EXECUTION BY ALL SIGNATORIES MUST BE AlTACHED (CORPORATE SEAL) CONTRACTOR: (si y n he re) Secretary c.(t\zawlcfLrL. Wk RU\. dPISEP (print name and tthe) ' President or vice-president and secretary or assistant secretary must sign for corporations. If only one officer signs, the corporation must attach a resolution certified by the secretary or assistant secretary under the corporate seal empowering that officer to bind the corporation. If signed by an individual partner, the partnership must attach a statement of partnership authorizing the partner to execute this instrument. APPROVED AS TO FORM: RONALD R. BALL General Counsel By: - Deputy General Counhl @Revised: 10/08/03 Contract No. 38891 Page 37 of 98 Pages LABOR AND MATERIALS BOND WHEREAS, the Board of Directors of the Ci No. 1224 ado ted Se pt e%b e r %y!%b (hereinafter designated as the "Principal"), a Contract for: of State of California, by Resolution , has awarded to FALCON GENERAL ENGI NEE& NG, INC . ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION, CONTRACT NO. 38891 in the City of Carlsbad, in strict conformity with the drawings and specifications, and other Contract Documents now on file in the Office of the Secretary of the Board of Directors (City Clerk of the City of Carlsbad) and all of which are incorporated herein by this reference. WHEREAS, Principal has executed or is about to execute said Contract and the terms thereof require the furnishing of a bond, providing that if Principal or any of their subcontractors shall fail to pay for any materials, provisions, provender or other supplies or teams used in, upon or about the performance of the work agreed to be done, or for any work or labor done thereon of any kind, the Surety on this bond will pay the same to the extent hereinafter set forth. Principal, (hereinafter designated as the "Contractor"), and &$#~I!J-$ 'o~~~~f!?8?---- as Surety, are held firm1 bound unto the Carlsbad Munici al Water District in the sum of ONE MILLION TkNTY-TWO THOUSAND FOUR HUNDRED TWhY Dollars ($1,022,420.0~ said sum being an amount equal to: One hundred percent (100%) of the total amount payable under the terms of the contract by the Carlsbad Municipal Water District, and for which payment well and truly to be made we bind ourseives, our heirs, executors and administrators, successors, or assigns, jointly and severally, firmly by these presents. THE CONDITION OF THIS OBLIGATION IS SUCH that if the Contractor or hidher subcontractors fail to pay for any materials, provisions, provender, supplies, or teams used in, upon, for, or about the performance of the work contracted to be done, or for any other work or labor thereon of any kind, consistent with California Civil Code section 3181, or for amounts due under the Unemployment Insurance Code with respect to the work or labor performed under this Contract, or for any amounts required to be deducted, withheld, and paid over to the Employment Development Department from the wages of employees of the contractor and subcontractors pursuant to section 13020 of the Unemployment Insurance Code with respect to the work and labor, that the Surety will pay for the same, and, also, in case suit is brought upon the bond, reasonable attorney's fees, to be fixed by the court consistent with California Civil Code section 324s. NOW, THEREFORE, WE, FALCON GENERAL ENGINEERING, INC. I as This bond shall inure to the benefit of any of the persons named in California Civil Code section 31 81, so as to give a right of action to those persons or their assigns in any suit brought upon the bond. Surety stipulates and agrees that no change, extension of time, alteration or addition to the terms of the Contract, or to the work to be performed thereunder or the specifications accompanying the same shall affect its obligations on this bond, and it does hereby waive notice of any change, extension of time, alterations or addition to the terms of the contract or to the work or to the specifications. In the event that Contractor is an individual, it is agreed that the death of arty such Contractor shall not exonerate the Surety from its obligations under this bond. - .. @Revised: 1 OlO8JOS Contract No. 38891 Page 38 of 98 Pages '- '.IFORNIA ALL-PURPOSE ACKNOWLEDGMENT No 51 ss CALIFORNIA State of CnlJnty of- SAN DIEGO DEBORAH D. DAVIS, NOTARY PUBLIC 9 NAME. TITLE OF OFFICER. E G 'JANE DOE, NOTARY PUBLIC" On 11/8/2004 before me, DATE DALE E. WINTERQUIST, CHRISTOPHER W. POMA personally appeared NAME(S) OF SIGNER(S1 er] personally known to me - OR - proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) is/are subscribed to the within instrument and ac- knowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their signature(s) on the instrument the person(s), or the entity upon behalf of which the person(s) acted, executed the instrument. WITNESS my hand and official seal. SIGNATURE OF NOTARY - OPTIONAL SECTION - CAPACITY CLAIMED BY SIGNER Though Statute does not require the Nofarj to full in the data below, doing so may prove invaluable to persons relying on the document 0 INDIVIDUAL CORPORATE OFFICER(S) RESIDENT , SECRETARY TITLEG) 0 PARTNER(S) LIMITED n GENERAL U [3 ATTORNEY-IN-FACT 0 TRUSTEE(S) 0 GUARDIAN/CONSERVATOR 0 OTHER: SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTIN(IES) t! OPTIONAL SECTION iIS CERTIFICATE MUST BE ATTACHED TO TITLE OR TYPE OF DOCUMENT 1 fHlf DOCUMENT DESCRIBED AT RIGHT: - NUMBER OF PAGES DATE OF DOCUMENT Though the data requested here is not required by law, CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT No 5193 CALIFORNIA State of SAN DIEGO County of 11 /8/2004 DEBORAH D. DAVIS, NOTARY PUBLIC , NAME, TITLE OF OFFICER - E G ,"JANE DOE, NOTARY PUBLIC' before me, DATE On personally appeared KAREN JEAN HALL NAME(S) OF SIGNER(S) a personally known to me - OR - proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) idare subscribed to the within instrument and ac- knowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their signature(s) on the instrument the person(s), or the entity upon behalf of which the Derson(s) acted, executed the instrument. NOrARY PURI.I(,-CALIFORNIA SAP4 DIEGO COUNTY MY Crlrilni Exu At'QIL 21. 2007 WITNESS my hand and official seal. SIGNATURE OF NOTARY - OPTIONAL SECTION - CAPACITY CLAIMED BY SIGNER Though Statute does nd require the Notary to fill in the data below. doing so may prove invaluable to persons relying on the document c] INDIVIDUAL 0 CORPORATE OFFICER(S) TITLE(S) 0 PARTNER(S) 0 LIMITED 0 GENERAL ATTORNEY-IN-FACT 0 TRUSTEE(S) 0 GUARDlANiCONSERVATOR 0 OTHER. SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTITY(IES) OPTIONAL SECTION THIS CERTIFICATE MUST BE ATACHED TO THlf DOCUMENT DESCRIBED AT RIGHT: Though the data requested here is not required by law, it cculd prevent lraudulent reattachmenl of this form. TITLE OR TYPE OF DOCUMENT NUMBER OF PAGES SIGNER(S) OTHER THAN NAMED ABOVE DATE OF DOCUMENT 8TH Executed by CONTRACTOR this 8TH day Executed by SURETY this 04 120-. NOVEMBER of day of NOVEMBER 04 CONTRACTOR: SURETY: 20-. FALCON GENERAL ENGINEE FIDELITY AND DEPOSIT COMPANY OF MARYLAND (name of Contractor) , (name of Surety) 801 NORTH BRAND BOULEVARD - PENTHOUSE By: GLENDALE, CA 91203 (address of Surety) 800/347-5679 (print name here) PRESIDENT : RNEY - 1X- F'ACT (printed name of Attorney-in-Fact) CHRISTOPHER W. POMA ~~ (print name here) (title and organization of signatory) (attach corporate resolution showing current power of attorney) SECRETARY (Proper notarial acknowledge of execution by CONTRACTOR and SURFTY must be attached.) (President or vice-president and secretary or assistant secretary must sign for corporations. If only one officer signs, the corporation must attach a resolution certified by the secretary or assistant secretary under corporate seal empowering that officer to bind the corporation.) APPROVED AS TO FORM: RONALD R. BALL General Counsel By: Revised: 10/08/03 Contract No. 38891 Page 39 of 98 Pages Power of Attorney FIDELITY AND DEPOSIT COMPANY OF MARYLAND KNOW ALL MEN BY THESE PRESENTS: That the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, a corporation of the State of Maryland, by M. P. HAMMOND, Vice President, and T. E. SMITH, Assistant Secretary, in side hereof and are hereby certified to be in full force and e appoint John G. MALONEY, Helen MALONEY, Mark California, EACH its true and lawful agent and A pursuance of these p had been duly exec D. Iatarola, Karen e extract set forth on the reverse side hereof is a true copy of Article VI, Section 2, of the By- IN WITNESS WHEREOF, the said Vice-president and Assistant Secretary have hereunto subscribed their names and affixed the Corporate Seal of the said FIDELITY AND DEPOSIT COMPANY OF MARYLAND, this 12th day of July, A.D. 2004. ompany, and is now in force. ATTEST: FIDELITY AND DEPOSIT COMPANY OF MARYLAND By: T. E. Smith Assistant Secretaly M. P. Hammond Vice President State of Maryland City of Baltimore On this 12th day of July, A.D. 2004, before the subscriber, a Notary Public of the State of Maryland, duly commissioned and qualified, came M. P. HAMMOND, Vice President, and T. E. SMITH, Assistant Secretary of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, to me personally known to be the individuals and officers described in and who executed the preceding instrument, and they each acknowledged the execution of the same, and being by me duly sworn, severally and each for himself deposeth and saith, that they are the said officers of the Company aforesaid, and that the seal affixed to the preceding instrument is the Corporate Seal of said Company, and that the said Corporate Seal and their signatures as such officers were duly affixed and subscribed to the said instrument by the authority and direction of the said Corporation. IN TESTIMONY WHEREOF, I have hereunto set my hand and affixed my Official Seal the day and year first above written. Dennis R. Hayden Notaiy Public My Commission Expires: February 1,2005 POA-F 012-5012 EXTRACT FROM BY-LAWS OF FIDELITY AND DEPOSIT COMPANY OF MARYLAND "Article VI, Section 2. The Chairman of the Board, or the President, or any Executive Vice-president, or any of the Senior Vice-presidents or Vice-presidents specially authorized so to do by the Board of Directors or by the Executive Committee, shall have power, by and with the concurrence of the Secretary or any one of the Assistant Secretaries, to appoint Resident Vice-presidents, Assistant Vice-presidents and Attorneys-in-Fact as the business of the Company may require, or to authorize any person or persons to execute on behalf of the Company any bonds, undertaking, recognizances, stipulations, policies, contracts, agreements, deeds, and releases and assignments of judgements, decrees, mortgages and instruments in the nature of mortgages, ... and to afix the seal of the Company thereto." CERTIFICATE I, the undersigned, Assistant Secretary of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, do hereby certify that the foregoing Power of Attorney is still in full force and effect on the date of this certificate; and I do fbrther certify that the Vice-president who executed the said Power of Attorney was one of the additional Vice-presidents specially authorized by the Board of Directors to appoint any Attomey-in-Fact as provided in Article VI, Section 2, of the By-Laws of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND. This Power of Attorney and Certificate may be signed by facsimile under and by authority of the following resolution of the Board of Directors of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND at a meeting duly called and held on the 10th day of May, 1990. RESOLVED: "That the facsimile or mechanically reproduced seal of the company and facsimile or mechanically reproduced signature of any Vice-president, Secretary, or Assistant Secretary of the Company, whether made heretofore or hereafter, wherever appearing upon a certified copy of any power of attorney issued by the Company, shall be valid and binding upon the Company with the same force and effect as though manually affuted." IN TESTIMONY WHEREOF, I have hereunto subscribed my name and affixed the corporate seal of the said Company, this 8TH dayof NOVEMBER , 2004 . Assistant Secretary -. ZURICH THIS IMPORTAKT DISCLOSURE NOTICE IS PART OF YOUR BOND We are making the following informational disclosures in compliance with The Terrorism Risk Insurance Act of 2002. No action is required on your part. Disclosure of Terrorism Premium The premium charge for risk of loss resulting fiom acts of terrorism (as defined in the Act) under this bond is $waived - . This amount is reflected in the total premium for this bond. Disclosure of Availability of CoveraEe for Terrorism Losses As required by the Terrorism Risk hurance Act of 2002, we have made available to you coverage for losses resulting from acts of terrorism (as defined in the Act) with terms, amounts, and lirnitations that do not differ materially as those for losses arising from events other than acts of terrorism. Disclosure of Federal Share of Insurance Company's Terrorism Losses The Terrorism Risk Insurance Act of 2002 establishes a mechanism by which the United States government will share in insurance company losses resulting from acts of terrorism (as dehed in the Act) after a insurance company has paid losses in excess of an annual aggregate deductible. For 2002, the insurance company deductible is 1% of ldirect earned premium in the prior year; for 2003,7% of direct earned premium in the prior year; for 2001, 10% of direct earned premium in the prior year; and €or 2005,15% of direct earned premium in the prior year. The federal share of an insurance company's losses above its deductible is 90%. In the event the United States government participates in losses, the United States government may dxect insurance companies to collect a terrorism surcharge from policyholders. The Act does not currently provide for insurance industry or United States government participation in terrorism losses that exceed $1.00 billion in any one calendar year. Definition of Act of Terrorism The Terrorism Risk Insurance Act defines "act of terrorism" as any act that is certified by the Secretary of the Treasury, in concurrence with the Secretary of State and the Attorney General of the United States: 1. 2. 3. 4. to be an act of terrorism; to be a violent act or an act that is dangerous to human life, property or inhastructure; to have resuited in damage within the United States: or outside of the United States in the case of an air carrier (as defined in section 40102 of title 49, United 17 States Code) or a United States flag vessel (or a vessel based principally in the United States, on m7hich United States income tax is paid and whose insurance coverage is subject to regulation in the United States), or the premises of a United States mission; and to have been committed by an individual or individuals acting on behalf of any foreign person or foreign interest as part of an effort to coerce the civilian population of the United States or to influence the policy or affect the conduct of the United States Government by coercion. But: no act shall be certu5ed by the Secretary as an act of terrorism if the act is committed as part of the course of a war declared by Congress (except €or workers' compensation) orproperty and casualty insurance losses resulting from the act, in the aggregate, do not exceed $5,000,000. These disclosures are informational only and do not modify your bond or affect your rights under the bond. Copyright Zurich American Insurance Company 2003 -0050749.doc FAITHFUL PERFORMANCWARRANTY BOND WHEREAS, the Board of Directors of the Carlsbad Municipal Water District of the City of 'Carlsbad, State of California, by Resolution No. lZz4 , adopted September 28, , has awarded , (hereinafter to FALCON GENERAL ENGINEERINGy INC. designated as the "Principal"), a Contract for: ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II, CALAVERA RECYCLED WATER PUMP STATION, CONTRACT NO. 38891 in the Carlsbad Municipal Water District, in strict conformity with the contract, the drawings and specifications, and other Contract Documents now on file in the Office of the Secretary of the Board of Directors (City Clerk of the City of Carlsbad), all of which are incorporated herein by this reference. WHEREAS, Principal has executed or is about to execute said Contract and the terms thereof require the furnishing of a bond for the faithful performance and warranty of said Contract; NOW, THEREFORE, WE, FALCON GENERAL ENGINEERING, INC. , as Principal, (hereinafter designated as the "Contractor"), and FIDELITY AND DEPOSIT COMPANY OF MARYLAND , as Surety, are held and firmly bound unto the Carlsbad Municipal Water District, in the sum of ONE MILLION TWENTY-TWO THOUSAND FOUR HUNDRED TWENTY Dollars ......................... ($1 ,uzz 3 42" - "U ), said sum being equal to one hundred percent (100%) of the estimated amount of the Contract, to be paid to District or its certain attorney, its successors and assigns; for which payment, weli and truly to be made, we bind ourselves, our heirs, executors and administrators, successors or assigns, jointly and severally, firmly by these presents. THE CONDITION OF THIS OBLIGATION IS SUCH that if the above bounden Contractor, their heirs, executors, administrators, successoTs or assigns, shall in all things stand to and abide by, and well and truly keep and perform the covenants, conditions, and agreements in the Contract and any alteration thereof made as therein provided on their part, to be kept and performed at the time and in the manner therein specified, and in all respects according to their true intent and meaning, and shall indemnify and save harmless the Carlsbad Municipal Water District, its officers, employees and agents, as therein stipulated, then this obligation shall become null and void; otherwise it shall remain in full force and effect. As a part of the obligaiion secured hereby and in addition io the face amount specified therefor, there shall be included costs and reasonable expenses and fees, including reasonable attorney's fees, incurred by the District in successfully enforcing such obligation, all to be taxed as costs and included in any judgment rendered. Surety stipulates and agrees that no change, extension of time, alteration or addition to the terms of the Contract, or to the work to be performed thereunder or the specifications accompanying the same shall affect its obligations on this bond, and it does hereby waive notice of any change, extension of time, alterations or addition to the terms of the contract or to the work or to the specifications, GRevised: 10/08/03 Contract No. 38891 Page 40 of 98 Pages CclLIFORNIA ALL-PURPOSE ACKNOWLEDGMENT NO 5193 CALIFORNIA StaSe of County of SAN DIEGO DEBORAH D. DAVIS, NOTARY PUBLIC NAME. TITLE OF OFFICER. E GI "JANE DOE NOTARY PUBLIC 11/8/2004 On personally appeared before me, DATE DALE E. WINTERQUIST, CHRISTOPHER W. POMA NAMEIS) OF SIGNER(S) personally known to me - OR - 0 proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) is/are subscribed to the within instrument and ac- knowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their signature(s) on the instrument the person(s), or the entity upon behalf of which the person(s) acted, executed the instrument. 'EBgRiFDz[ NOTARY PUHI~IC~CAL,FORNIA ~ SAN OlE'30 COTv - g 'lY C''n'n' tui 'mi *'* *Oo7 COMM. U1412744 7-=-7.. ,- ./'--===7 WITNESS my hand and official seal. SIGNATURE OF NOTARY - OPTIONAL SECTION - CAPACITY CLAIMED BY SIGNER Though statute does not require the Notary to fill in the data below, doing so may prove invaluable to persons relying on the document 0 INDIVIDUAL CORPORATE OFFICER(S) PRESIDENT. SECRETARY TITLEtS) 0 PARTNER(S) LIMITED 0 ATTORNEY-IN-FACT 0 TRUSTEE(S) 0 GUARDIAN/CONSERVATOR 0 OTHER: 0 GENERAL SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTITY(IES) h OPTIONAL SECTION THIS CERTIFICATE MUST BE ATTACHED TO THE DOCUMENT DESCRIBED AT RIGHT: TITLE OR TYPE OF DOCUMENT B- NUMBER OF PAGES DATE OF DOCUMENT SIGNER(S) OTHER THAN NAMED ABOVE CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT No 51' 1 'ounty of SAN DIEGO 11 /8/2004 DEBORAH D. DAVIS, NOTARY PUBLIC I NAME, TITLE OF OFFICER. E GI "JANE DOE NOTARY PUBLIC" before me, DATE On personally appeared 9 personally known to me - OR - 0 proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) idare subscribed to the within instrument and ac- knowledged to me that he/she/they executed KAREN JEAN HALL NAMEIS) OF SIGNER(S) the same in his/her/their authorized capacityjies), and that by his/her/their signature(s) on the instrument the person(s), person(s) acted, executed the instrument. or the entity upon behalf of which the SAN DIEGO COUNTY WITNESS my hand and official seal. I - SIGNATURE OF NOTARY - OPTIONAL SECTION - CAPACITY CLAIMED BY SIGNER Though statute does no( require the Notary to fill in the data below, doing so may prove invaluable to persons relying on the document 0 INDIVIDUAL CORPORATE OFFICER(S) TITLE(S) 0 PARTNER(S) 0 LIMITED Q ATTORNEY-IN-FACT 0 TRUSTEE(S) 0 GUARDIAN/CONSERVATOR 0 OTHER 0 GENERAL SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTITY(IES) OPTIONAL SECTION CERTIFICATE MUST BE ATTACHED TO TITLE OR TYPE OF DOCUMENT NUMBER OF PAGES SIGNER(S) OTHER THAN NAMED ABOVE THE DOCUMENT DESCRIBED AT RIGHT Though the data requested here IS not required by law, could prevent traudulent reattachment of this form DATE OF DOCUMENT In the event that Contractor is an individual, it is agreed that the death of any such Contractor shall not exonerate the Surety from its obligations under this bond. Executed by SURETY this 8TH dayof 8TH Executed by CONTRACTOR this 04 I20-. day of NOVEMBER Byt+jG&--- DALE E. WINT 04 l20-. NOVEMBER SURETY: FIDELITY AND DEPOSIT COMPANY OF MARYLAND (name of Surety) 801 NORTH BRAND BOULEVARD - PENTHOUSE GLENDALE, CA 91203 (address of Surety) 800/347-5679 (print name here) (teleptpne number of Surety) - PRESIDENT By: (Title and Organization of Signatory) n KAREN JEAN HALL, ATTORNEY- IN-FACT --_ (printed name of Attorney-in-Fact) CHRISTOPHER W. POMA (Attach corporate resolution showing current (print name here) (Title and Organization of signatory) power of attorney.) SECRETARY (Proper notarial acknowledge of execution by CONTRACTOR and SURETY must be attached.) (President or vice-president and secretary or assistant secretary must sign for corporations. If only one officer signs, the corporation must attach a resolution certified by the secretary or assistant secretary under corporate seal empowering that officer to bind the corporation.! APPROVED AS TO FORM: RONALD R. BALL General Counsel De6uty General Counskl @Revised: 10/08/O3 Contract No. 38891 Page 41 of 98 Pages Power of Attorney FIDELITY AND DEPOSIT COMPANY OF MARYLAND KNOW ALL MEN BY THESE PRESENTS: That the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, a corporation of the State of Maryland, by M. P. HAMMOND, Vice President, and T. E. SMITH, Assistant Secretary, in pursuance of authority granted by Article V1, Section 2, of the By-Laws of said Co set forth on the reverse California, EACH its true and lawful agent and A pursuance of these p had been duly exec their own proper pe D. Iatarola, Karen J The said Assistan e extract set forth on the reverse side hereof is a true copy of Article VI, Section 2, of the By- IN WITNESS WHEREOF, the said Vice-president and Assistant Secretary have hereunto subscribed their names and affixed the Corporate Seal of the said FIDELITY AND DEPOSIT COMPANY OF MARYLAND, this 12th day of July, A.D. 2004. r, and on its behalf ds or undertakings in intents and purposes, as if they ed on behalf of John G. Maloney, Helen Maloney, Mark ompany, and is now in force. ATTEST: FIDELITY AND DEPOSIT COMPANY OF MARYLAND T. E. Smith Assistant Secretary M. P. Hammond Vice President State of Maryland City of Baltimore On this 12th day of July, A.D. 2004, before the subscriber, a Notary Public of the State of Maryland, duly commissioned and qualified, came M. P. HAMMOND, Vice President, and T. E. SMITH, Assistant Secretary of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, to me personally known to be the individuals and officers described in and who executed the preceding instrument, and they each acknowledged the execution of the same, and being by me duly sworn, severally and each for himself deposeth and saith, that they are the said officers of the Company aforesaid, and that the seal affixed to the preceding instrument is the Corporate Seal of said Company, and that the said Corporate Seal and their signatures as such officers were duly affixed and subscribed to the said instrument by the authority and direction of the said Corporation. IN TESTIMONY WHEREOF, I have hereunto set my hand and affixed my Official Seal the day and year fist above written. Dennis R. Hayden Notary Public My Commission Expires: February 1,2005 POA-F 012-5012 EXTRACT FROM BY-LAWS OF FIDELITY AND DEPOSIT COMPANY OF MARYLAND "Article VI, Section 2. The Chairman of the Board, or the President, or any Executive Vice-president, or any of the Senior Vice-presidents or Vice-presidents specially authorized so to do by the Board of Directors or by the Executive Committee, shall have power, by and with the concurrence of the Secretary or any one of the Assistant Secretaries, to appoint Resident Vice-presidents, Assistant Vice-presidents and Attorneys-in-Fact as the business of the Company may require, or to authorize any person or persons to execute on behalf of the Company any bonds, undertaking, recognizances, stipulations, policies, contracts, agreements, deeds, and releases and assignments of judgements, decrees, mortgages and instruments in the nature of mortgages, ... and to afix the seal of the Company thereto." CERTIFICATE I, the undersigned, Assistant Secretary of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, do hereby certify that the foregoing Power of Attorney is still in full force and effect on the date of this certificate; and I do fbrther certify that the Vice-president who executed the said Power of Attorney was one of the additional Vice-presidents specially authorized by the Board of Directors to appoint any Attomey-in-Fact as provided in Article VI, Section 2, of the By-Laws of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND. This Power of Attorney and Certificate may be signed by facsimile under and by authority of the following resolution of the Board of Directors of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND at a meeting duly called and held on the 10th day of May, 1990. RESOLVED: "That the facsimile or mechanically reproduced seal of the company and facsimile or mechanically reproduced signature of any Vice-president, Secretary, or Assistant Secretary of the Company, whether made heretofore or hereafter, wherever appearing upon a certified copy of any power of attorney issued by the Company, shall be valid and binding upon the Company with the same force and effect as though manually affuted." IN TESTIMONY WHEREOF, I have hereunto subscribed my name and affixed the corporate seal of the said Company, this 8TH dayof NOVEMBER , 2004 . Assistant Secretary -. ZURICH THIS IMPORTANT DISCLOSURE NOTICE IS PART OF YOUR BUND We are making the following informational disclosures in compliance with The Terrorism Risk Insurance Act of 2002. No action is required on your part. Disclosure of Terrorism Premium The premium charge for risk of loss resulting from acts of terrorism (as defined in the Act) under this bond is $- waived - . This amount is reflected in the total premium for this bond. Disclosure of Availability of Coverage for Terrorism Losses As required by the Terrorism Risk hurance Act of 2002, we have made available to you coverage for losses resulting Gom acts of terrorism (as defined in the Act) with terms, amounts, and limitations that do not differ materially as those for losses arising from events other than acts of terrorism. Disclosure of Federal Share of Insurance Company's Terrorism Losses 'fie Terrorism Risk Insurance Act of 2002 establishes a mechanism by which the United States government will share in insurance company losses resulting from acts of terrorism (as defined in the Act) after a insurance company has paid losses in excess of an mud aggregate deductible. For 2002, the insurance company deductible is 1% of direct eamed premium in the prior yes, for 2003,7% of direct earned premium in the prior year; for 2004, 10% of direct eamed premium in the prior year; and for 2005,15% of hect earned premium in the prior year. The federal share of an insurance company's losses above its deductible is 90%. In the event the United States government participates in losses, the United States government may &rect insurance companies to collect a terrorism surcharge from policyholders. The Act does not currently provide for insurance industry or United States government participation in terrorism losses that exceed $100 billion in any one calendar year. Definition of Act of Terrorism The Terrorism Risk Insurance Act defines "act of terrorism" as any act that is certified by the Secretary of the Treasury, in concurrence with the Secretary of State and the Attorney General of the United States: 1. to be an act of terrorism; 2. to be a violent act or an act that is dangerous to human life, property or infrastructure; 3. to have resulted in damage within the United States, or outside of the United States in the case of an air carrier (as defined in section 40102 of title 49, United 17 States Code) or a United States flag vessel (or a vessel based principally in the United States, on which United States income tax is paid and whose insurance coverage is subject to regulation in the United States), or the premises of a United States mission; and 4. to have been committed by an individual or individuals acting on behalf of any foreign person or €oreign interest as part of an effort to coerce the civihan population of the United States or to influence the policy or affect the conduct of the United States Government by coercion. But, no act shall be cedied by the Secretary as an act of terrorism if the act is committed as part of the course of a wa declared by Congress (except for workers' compensation) or property and casualty insurance losses resulting from the act, in the aggregate, do not exceed $5,000,000. These disclosures are informational only and do not modify your bond or affect your rights under the bond. Copyright Zurich American Insurance Company 2003 -00 j0719.doc OPTIONAL ESCROW AGREEMENT FOR SECURITY DEPOSITS IN LIEU OF RETENTION This Escrow Agreement is made and entered into by and between the Carlsbad Municipal Water District whose address is 5950 El Camino Real, Carlsbad, California, 92008, hereinafter called "District" and whose address is hereinafter called "Contractor" and whose address is hereinafter called "Escrow Agent." For the consideration hereinafter set forth, the District, Contractor and Escrow Agent agree as follows: 1. Pursuant to sections 22300 and 10263 of the Public Contract Code of the State of California, the Contractor has the option to deposit securities with the Escrow Agent as a substitute for retention earnings required to be withheld by the District pursuant to the Construction Contract entered into between the District and Contractor for ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II, CALAVERA RECYCLED WATER PUMP STATION, CONTRACT NO. 38891 in the amount of dated (hereinafter referred to as the "Contract"). Alternatively, on written request of the Contractor, the District shall make payments of the retention earnings directly to the Escrow Agent. When the Contractor deposits the securities as a substitute for Contract earnings, the Escrow Agent shall notify the District within 10 days of the deposit. The Escrow Agent shall maintain insurance to cover negligent acts and omissions of the Escrow Agent in connection with the handling of retentions under these sections in an amount not less than $100,000 per contract. The market value of the securities at the time of the substitution shall be a least equal to the cash amount then required to be withheld as retention under the terms of the contract between the District and Contractor. Securities shall be held in the name of the District and shall designate the Contractor as the beneficial owner. 2. The District shall make progress payments to the Contractor for such funds which otherwise would be withheld from progress payments pursuant to the Contract provisions, provided that the Escrow Agent holds securities in the form and amount specified above. 3. When the District makes payment of retentions earned directly to the Escrow Agent, the Escrow Agent shall hold them for the benefit of the Contractor until such time as the escrow created under this contract is terminated. The Contractor may direct the investment of the payments into securities. All terms and conditions of this agreement and the rights and responsibilities of the parties shall be equally applicable and binding when the District pays the Escrow Agent directly. 4. The Contractor shall be responsible for paying all fees for the expenses incurred by the Escrow Agent in administering the Escrow Account and all expenses of the District. These expenses and payment terms shall be determined by the District, Contractor and Escrow Agent. 5. The interest earned on the securities or the money market accounts held in escrow and all interest earned on that interest shall be for the sole account of Contractor and shall be subject to withdrawal by Contractor at any time and from time to time without notice to the District. 6. Contractor shall have the right to withdraw all or any part of the principal in the Escrow Account only by written notice to Escrow Agent accompanied by written authorization from District to the Escrow Agent that District consents to the withdrawal of the amount sought to be withdrawn by Contractor. m '&Revised: 10/08/03 Contract No. 38891 Page 42 of 98 Pages 7. The District shall have a right to draw upon the securities in the event of default by the Contractor. Upon seven days' written notice to the Escrow Agent from the District of the default, the Escrow Agent shall immediately convert the securities to cash and shall distribute the cash as instructed by the District. 8. Upon receipt of written notification from the District certifying that the Contract is final and complete and that the Contractor has complied with all requirements and procedures applicable to the Contract, the Escrow Agent shall release to Contractor all securities and interest on deposit less escrow fees and charges of the Escrow Account. The escrow shall be closed immediately upon disbursement of all moneys and securities on deposit and payments of fees and charges. 9. The Escrow Agent shall rely on the written notifications from the District and the Contractor pursuant to sections (1) to (8), inclusive, of this agreement and the District and Contractor shall hold Escrow Agent harmless from Escrow Agent's release, conversion and disbursement of the securities and interest as set forth above. 10. The names of the persons who are authorized to give written notices or to receive written notice on behalf of the District and on behalf of Contractor in connection with the foregoing, and exemplars of their respective signatures are as follows: For District: Title FINANCE DIRECTOR Name Signature Address For Contractor: For Escrow Agent: e-. 'dRevised: 10/08/03 Title Name Signature Address Title Name Signature Address Contract No. 38891 Page 43 of 98 Pages At the time the Escrow Account is opened, the District and Contractor shall deliver to the Escrow Agent a fully executed counterpart of this Agreement. IN WITNESS WHEREOF, the parties have executed this Agreement by their proper officers on the date first set forth above. For District: For Contractor: For Escrow Agent: Title MAYOR Name Signature Address Title Name Signature Address Title Name Signature Address GRevised: 10/08/03 Contract No. 38891 Page 44 of 98 Pages SUPPLEMENTAL PROVISIONS FOR ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION CONTRACT NO. 38891 SUPPLEMENTAL PROVISIONS TO STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART I, GENERAL PROVISIONS SECTION 1 -- TERMS, DEFINITIONS ABBREVIATIONS AND SYMBOLS 1-1 TERMS Add the following section: 1-1 ,I Reference to Drawings. Where words "shown", "indicated", "detailed", "noted", "scheduled", or words of similar import are used, it shall be understood that reference is made to the plans accompanying these provisions, unless stated otherwise. Add the following section: 1-1.2 Directions. Where words "directed", "designated", "selected", or words of similar import are used, it shall be understood that the direction, designation or selection of the Engineer is intended, unless stated otherwise. The word "required" and words of similar import shall be understood to mean "as required to properly complete the work as required and as approved by the Engineer," unless stated otherwise. Add the following section: 1-1.3 Equals and Approvals. Where the words "equal", "approved equal", "equivalent", and such words of similar import are used, it shall be understood such words are followed by the expression "in the opinion of the Engineer", unless otherwise stated. Where the words "approved", "approval", "acceptance", or words of similar import are used, it shall be understood that the approval, acceptance, or similar import of the Engineer is intended. Add the following section: 1-1.4 Perform. The word "perform" shall be understood to mean that the Contractor, at its expense, shall perform all operations, labor, tools and equipment, and further, including the furnishing and installing of materials that are indicated, specified or required to mean that the Contractor, at its expense, shall furnish and install the work, complete in place and ready to use, including furnishing of necessary labor, materials, tools, equipment, and tansportation. 1-2 DEFINITIONS. Modify as follows: The following words, or groups of words, shall be exclusively defined by the definitions assigned to them herein. Agency or Owner - the Carlsbad Municipal Water District of Carlsbad, California. Board of Directors - the Board of Directors of the Carlsbad Municipal District of the City of Carlsbad. Executive Manager - the Executive Manager of the Carlsbad Municipal Water District or hidher approved representative. em %#Revised: 10/08/03 Contract No. 38891 Page 45 of 98 Pages Dispute Board - persons designated by the Executive Manager to hear and advise the Executive Manager on claims submitted by the Contractor. The Executive Manager is the last appeal level for informal dispute resolution. Engineer - the District Engineer of the Carlsbad Municipal Water District or hidher approved representative. The District Engineer is the third level of appeal for informal dispute resolution. Minor Bid Item - a single contract item constituting less than 10 percent (10%) of the original Contract Price bid. Own Organization - When used in Section 2-3.1 - Employees of the Contractor who are hired, directed, supervised and paid by the Contractor to accomplish the completion of the Work. Further, such employees have their employment taxes, State disability insurance payments, State and Federal income taxes paid and administered, as applicable, by the Contractor. When used in Section 2-3.1 ”own organization” means construction equipment that the Contractor owns or leases and uses to accomplish the Work. Equipment that is owner operated or leased equipment with an operator is not part of the Contractots Own Organization and will not be included for the purpose of compliance with section 2-3.1 of the Standard Specifications and these Supplemental Provisions. Owner Operator/Lessor - Any person who provides equipment or tools with an operator provided who is employed by neither the Contractor nor a subcontractor and is neither an agent or employee of the Agency or a public utility Principal Inspector - The Senior Inspector’s immediate supervisor and second level of appeal for informal dispute resolution. Project inspector - the Engineer’s designated representative for inspection, contract administration and first level for informal dispute resolution. Construction Manager - the Project Inspector‘s immediate supervisor and first level of appeal for informal dispute resolution. Project Manager - the District Engineer of the Carlsbad Municipal Water District or hidher approved representative. Senior Inspector - the Project Inspector’s immediate supervisor and first level of appeal for informal dispute resolution. 1-3 ABBREVIATIONS 1-3.2 Common Usage, add the following: Abbreviation Apts Bldg CMWD CSSD cfs Comm DR E G gal Gar GNV gpm IE LCWD Word or Words Apartment and Apartments Building band Buildings Carlsbad Municipal Water District Carlsbad Supplemental Standard Drawings Cubic Feet per Second Commercia I Dimension Ratio Electric Gas Gallon and Gallons Garage and Garages Ground Not Visible gallons per minute Invert Elevation Leucadia County Water District 4.- %#Revised: 10/08/03 Contract No. 38891 Page 46 of 95 Psaes MSL MTBM NCTD OHE OMWD ROW S SDNR SDRSD SFM SWRCB T UE W WD Mean Sea Level (see Regional Standard Drawing M-12) Microtunneling Boring Machine North County Transit District Overhead Electric Olivenhain Municipal Water District Rig ht-of-Way Sewer or Slope, as applicable San Diego Northern Railway San Diego Regional Standard Drawings Sewer Force Main State Water Resources Control Board Telephone U nde rg round Electric Water, Wider or Width, as applicable Vallecitos Water District SECTION 2 -- SCOPE AND CONTROL OF THE WORK 2-3 SUBCONTRACTS. 2-3.1 General, add the following: Should the Contractor fail to adhere to the provisions requiring the Contractor to complete 50 percent of the contract price with its own organization, the Agency may at its sole discretion elect to cancel the contract or to deduct an amount equal to 10 percent of the value of the work performed in excess of 50 percent of the contract price by other than the Contractor's own organization. The Board of Directors shall be the sole body for determination of a violation of these provisions. In any proceedings under this section, the prime contractor shall be entitled to a public hearing before the Board of Directors and shall be notified ten (IO) days in advance of the time and location of said hearing. The determination of the Board of Directors shall be final. 2-4 CONTRACT BONDS, modify the second sentence of paragraph one as follows: Delete, "who is listed in the latest wsion of U.S. Department of Treasury Circular 570." Modify Paragraphs three and four to read: The Contractor shall provide a faithful performance/warranty bond and payment bond (labor and materials bond) for this contract. The faithful performance/warranty bond shall be in the amount of 100 percent of the contract price . The Contractor shall provide bonds to secure payment of laborers and material suppliers, in an amount equal to: 1) One hundred percent (100%) of the total amount payable bu the terms of the contract when the total amount payable does not exceed five million dollars ($5,000,000. 2) Fifty percent (50%) of the total amount payable, by the terms of the contract when the total amount payable is not less than five million dollars ($5,000,000) and does not exceed ten million dollars ($1 0,000,000). 3) Twenty-five percent (25%) of the total amount payable be the terms of the contract if the contract exceeds ten million dollars ($1 0,000,000). Both bonds shall extend in full force and effect and be retained by the Agency during this project until they are released according to the provisions of this section. The faithful performance/warranty bond will be reduced to 25 percent of the original amount 30 days after recordation of the Notice of Completion and will remain in full force and effect for the one year warranty period and until all warranty repairs are completed to the satisfaction of the Engineer. The bonds to secure payment of laborers and material suppliers shall be released six months plus 30 days after recordation of the Notice of Completion if all claims have been paid. Add the following: All bonds are to be placed with a surety insurance carrier admitted and authorized to transact the business of insurance in California and whose assets exceed their 4w %@Revised: 10/08/03 Contract No. 38891 Page 47 of 98 Pages liabilities in an amount equal to or in excess of the amount of the bond. The bonds are to contain the following documents: I) An original, or a certified copy, of the unrevoked appointment, power of attorney, by laws, or other 2) A certified copy of the certificate of authority of the insurer issued by the insurance commissioner. If the bid is accepted, the Agency may require a financial statement of the assets and liabilities of the insurer at the end of the quarter calendar year prior to 30 days next preceding the date of the execution of the bond. The financial statement shall be made by an officer's certificate as defined in Section 173 of the Corporations Code. In the case of a foreign insurer, the financial statement may be verified by the oath of the principal officer or manager residing within the United States. instrument entitling or authorizing the person who executed the bond to do so. 2-5 PLANS AND SPECIFICATIONS. 2-5.1 General, add the following: The specifications for the work include the Standard Specifications for Public Works Construction, (SSPWC), 2003 Edition, and any supplements thereto, hereinafter designated "SSPWC", as written and promulgated by the Joint Cooperative Committee of the Southern California Chapter American Public Works Association and Southern California Districts Associated General Contractors of California, and as amended by the Supplemental Provisions section of this contract. The construction plans consist of one set. This set is designated as City of Carlsbad Drawing No, 404-7B and consists of 29 sheets. The standard drawings used for this project are the latest edition of the San Diego Area Regional Standard Drawings, hereinafter designated SDRS, as issued by the San Diego County Department of Public Works, together with the most recent edition of the Carlsbad Municipal Water District Supplemental Standard Drawings. Copies of some of the pertinent standard drawings are enclosed as an appendix to these Supplemental Provisions. 2-5.2 Precedence of Contract Documents, modi@ as follows: If there is a conflict between Contract Documents, the document highest in precedence shall control. The precedence shall be the most recent edition of the following documents listed in order of highest to lowest precedence: 1) Permits from other agencies as may be required by law. 2) Addenda issued during the bidding process. 3) Supplemental Provisions. 4) SWRCB Contract Requirements 5) Construction Plans. 6) Technical Specifications. 7) Standard Plans. a) City of Carlsbad Supplemental Standard Drawings. b) Carlsbad Municipal Water District Standard Drawings. c) City of Carlsbad modifications to the San Diego Area Regional Standard Drawings. d) San Diego Area Regional Standard Drawings. e) State of California Department of Transportation Standard Plans. 8) Standard Specifications for Public Works Construction. 9) Reference Specifications. 10) Manufacturer's Installation Recommendations. Change Orders, Supplemental Agreements and approved revisions to Plans and Specifications will take precedence over items 2) through IO) above. Detailed plans and plan views shall have precedence over general plans. 2-5.3.3 Submittals, add the following: Furnish six (6) copies of each submittal. Each submittal shall be consecutively numbered. Resubmittals shall be labeled with the number of the original submittal followed by an ascending alphabetical designation (e.g. The label '4-C' would indicate the third instance that the fourth submittal has been given to the Engineer). Each sheet of each submittal shall be consecutively numbered. Each set of shop drawings and submittals shall be accompanied by a letter of transmittal on the Contractor's letterhead. The Letter of Transmittal shall ollr %PRevised: 10/08/03 Contract No. 38891 Paae 48 nf 198 Pannc contain the following: 1) Project title and Agency contract number. 2) Number of complete sets. 3) Contractor's certification statement. 4) Specification section numbeqs) pertaining to material submitted for review. 5) Submittal number (Submittal numbers shall be consecutive including subsequent submittals 6) Description of the contents of the submittals. 7) Identification of deviations from the contract documents. When submitted for the Engineer's review, Shop Drawings shall bear the Contractor's certification that he has reviewed, checked, and approved the Shop Drawings and that they are in conformance with the requirements of the Contract Documents. The Contractor shall subscribe to and shall place the following certification on all submittals: "I hereby certify that the (equipment, material) shown and marked in this submittal is that proposed to be incorporated into this Project, is in compliance with the Contract Documents, can be installed in the allocated spaces, and is submitted for approval. By: Title: Date: Company Name: Except as may otherwise be provided herein, the Engineer will return prints of each submittal to the Contractor, with his comments noted thereon, within 30 calendar days following their receipt by the Engineer. It is considered reasonable that the Contractor shall make a complete and acceptable submittal to the Engineer by the second submission of a submittal item. The Owner reserves the right to withhold monies due the Contractor to cover additional costs of the Engineer's review beyond the second submission. If 3 copies of a submittal are returned to the Contractor marked "NO EXCEPTIONS TAKEN" formal revision and resubmission of said submittal will not be required. If 3 copies of a submittal are returned to the Contractor marked "MAKE CORRECTIONS NOTED", formal revision and resubmission of said submittal will not be required. If 1 copy of the submittal is returned to the Contractor marked "AMEND AND RESUBMIT", the Contractor shall revise said submittal and shall resubmit required number of copies of said revised submittal to the Engineer. If 1 copy of the submittal is returned to the Contractor marked "REJECTED-RESUBMIT", the Contractor shall revise said submittal and shall resubmit required number of copies of said revised submittal to the Engineer. Add the following: 2-5.4 Record Drawings, The Contractor shall provide and keep up-to-date a complete "as-built" record set of blue-line prints, which shall be corrected in red daily and show every change from the original drawings and specifications and the exact "as-built" locations, sizes and kinds of equipment, underground piping, valves, and all other work not visible at surface grade. Prints for this purpose may be obtained from the Agency at cost. This set of drawings shall be kept on the job and shall be used only as a record set and shall be delivered to the Engineer upon completion of the work. Payment for performing the work required by section 2-5.4 shall be included in various bid items and no additional payment will be made therefor. 2-9 SURVEYING 2-9.1 Permanent Survey Markers, Delete sections 2-9.1 and replace Contractor shall not cover or disturb permanent survey monuments or em %#Revised: 10/08/03 Contract No. 38891 with the following: The benchmarks without the Page 49 of 98 Pages consent of the Engineer. Where the Engineer concurs, in writing, with the Contractor that protecting an existing monument in place is impractical, the Contractor shall employ a licensed land surveyor or a registered civil engineer authorized to practice land surveying within the State of California, hereinafter surveyor, to establish the location of the monument before it is disturbed. The Contractor shall have the monument replaced by the surveyor no later than thirty (30) days after construction at the site of the replacement is completed. The surveyor shall file corner record(s) as required by §§ 8772 and 8773, et seq. of the California Business and Professions Code. When a change is made in the finished elevation of the pavement of any roadway in which a permanent survey monument is located, the Contractor shall adjust the monument frame and cover to the new grade within 7 days of paving unless the Engineer shall approve otherwise. Monument frames and covers shall be protected during street sealing or painting projects or be cleaned to the satisfaction of the Engineer. 2-9.2 Survey Service, Delete sections 2-9.2 and replace with the following: The Contractor shall hire and pay for the services of a surveyor to perform all work necessary for establishing control, construction staking, records research and all other surveying work necessary to construct the work, provide surveying services as required herein and provide surveying, drafting and other professional services required to satisfy the requirements of the Land Surveyors Act. Surveyor shall be resident on the site during all surveying operations and shall personally supervise and certify the surveying work. Add the following section: 2-9.2.1 Submittal of Surveying Data, All surveying data submittals shall conform to the requirements of section 2-5.3.3, “Submittals”, herein. The Contractor shall submit grade sheets to the Engineer before commencing work in the area affected by the grade sheets. The Contractor shall submit field notes for all surveying required herein to the Engineer within ten days of performing the survey. All surveying field notes, grade sheets and survey calculations shall be submitted in bound form on 215mm by 280 mm (8’1; by 11”) paper. The field notes, calculations and data shall be clear and complete with name of the Surveyor, the party chief, field crew members, preparer of the field notes or calculations. They shall be annotated with the date of observation or calculation, be numbered with consecutive page numbers and shall be readable without resort to any electronic aid, computer program or documentation for any computer program. The field notes shall be prepared in conformance with the CALTRANS “Surveys Manual”. The Contractor shall have a Record of Survey prepared by the Surveyor and file it in conformance with 8700 - 8805 of the State of California Business and Professions Code when the surveyor performs any surveying that such map is required under §§ 8762 of the State of California Business and Professions Code and whenever the Surveyor shall establish, set or construct any permanent survey monument. SDRS drawing M-10 type monuments, bolts, spikes, leaded tacks and nails (when set in concrete), iron pipes, reinforcing steel and all monuments and marks that are at, or accessory to, property corners and street centerlines are permanent survey monuments. The Record of Survey shall show all monuments set, control monuments used, the basis of bearings and all other data needed to determine the procedure of survey and the degree of accuracy attained by the field surveying including the unadjusted ratio of closure. The unadjusted ratio of closure shall not exceed 1 part in 40,000. The record of survey shall show the location and justification of location of all permanent monuments set and their relation to the street right-of-way. Record(s) of Survey(s) shall be submitted for the Engineer’s review and approval before submittal to the County Surveyor and before submittal to the County Recorder. Add the following section: 2-9.2.2 Survey Requirements, Stakes shall be set at offsets approved by the Engineer at no greater intervals than specified in TABLE 2-9.2.2(A) as measured along the project stationing. Stakes shall be set to show the location and grade of future curbs adjacent to traffic signal locations where the curb is not being built as a part of this contract. Staking and marking shall be completed by the Surveyor and inspected and approved by the Engineer before the start of construction in the area marked. Centerline monument shall have the disk stamped with the date the monument was set and the registration number of the Surveyor. Habitat mitigation sites and other areas to be preserved that are shown on the plans shall be staked and flagged prior to the start of any other activities within the limits of the work. When curb and gutter does not exist and is not being installed as a part of the project the location of adjacent facilities being constructed as a part of the contract the Contractor e= %#Revised: 10/08/03 Contract No. 38891 Page 50 of 98 Paaes shall place stakes defining the horizontal and vertical location of such adjacent utility vaults, poles or other facilities that are being installed as parts of, or adjunct to, the project either by the Contractor and/or those noted on the plans as to be inshlled by others. TABLE 2-9.2.2(A) Survey Requirements for Construction Staking Feature Staked Street Centerline Clearing Slope Fence Rough Grade Cut! or Fills 2 10 m (33’) Final Grade (includes top of: Basement soil, subbaseand base) Asphalt Paverneni Finish Course Drainage Structures, Pipes & similar Facilities@, 0 Curb Traffic Signal 0 Signal Poles & Controller 0 Junction Box 0 Conduit 0 Minor Structure 0 Abutment Fill Wall 0 Major Structure 0 Stake Description a SDRS M-10 Monument Lath in soil, painted line In PCC & A( surfaces RP + Markei Stake RP + Markei Stake RP + Marker Stake RP + Marker Stake, Blue- op in gradin( area RP, paint on previous course RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake + Line Stake RP + Marker Stake + Line Stake RP + Marker Stake + Line ’oint +Guard Stake Centerline or Parallel to Centerline Spacing@, 63 1300m (1 000’), Street Intersections, Begin and end of curves, only when shown on the plans lath - Intervisible, I 15m (50’) on tangents & I7.5m (25’) on curves, Painted line - continuous lntervisible and I 15m (50’) I 60 m (200’) on tangents, I 15m (50’) on :urves when R2 3001-1-1 (1000’) & 7.5m (25’) 01 curves when R< 300m (1 000’) I 15m (50’) I 15 m (50’) on tangents & curves when R2 300rn (1 000’) & I 7.5m (25’) on curves when R I 300m (1 000’) I 7.5rn (25’) or as per the intersection grid Ioints shown on the plan whichever provides the denser information itervisible & 17.5m (25’), beginning and end BC & EC of facilities, Grade breaks, Nignrnent breaks, Junctions, Inlets & similar facilities, Risers & similar facilities (except plumbing), Skewed cut-off lines I 7.5m (25’), BC & EC, at %A, %A & %A on curb retums & at beginning & end Vertical locations shall be based on the ultimate elevation of curb and sidewalk at each pole & controller location at each junction box location I 15 m (50’) on tangents & curves when R2 300m (1 000’) & 2 7.5m (25’) on curves when R I 300m (1 000’) or where grade I 0.30% or catch basins: at centerline of box, ends of box & wings & at each end of the local depression 0 I 15 m (50’) & along end slopes & conic transitions 2 15 rn (50’) and at beginning & end of: each wall, BC & EC, layout line angle points, :hanges in footing dimensions &/or elevation &wall heioht Lateral Spacing 0, B on street centerline at clearing lint Grade Breaks % g7.6 m (25’; N/A (constant offset) N/A 16.7 m (22’) edge of pavement, paving pass width, crown line & grade breaks IS appropriate (constant offset) IS appropriate IS appropriate IS appropriate IS appropriate IS appropriate IS appropriate Setting Tolerance (With in) 7 mm (0.02’) Horizontal. also see section 2-9 :2.1 herein 0.3 m (1 ’) Horizontal 30 rnrn (0.1’) Vertical & Horizontal 30 mm (0.1’) Horizontal 30 rnrn (0.1’) Vertical & Horizontal 10 mm (’/() Horizontal 8 7 mm ( 14”) Vertical 10 mm (’/() Horizontal & 7 mrn ( /4”) Vertical 10 rnm (’/() Horizontal & 7 mrn ( /$) Vertical IO mm (’/() Horizontal 8 7 mm I /AI’\ Vertical IO rnrn (‘/a”) Horizontal & 7 mm (’/;) Vertical IO mm (”/() Horizontal & 7 mm ( /4”) Vertical IO rnrn (J/8(’) Horizontal & when depth cannot be measured from existina Davement 7 mm (‘/() Vertical IO mm (’/$) Horizontal & 7 mm (’/4”) Vertical (when vertical data needed) 30 mm (0.1’) Vertical & Horizontal 7 mm ( ‘14”) Horizontal & 7 rnrn (’/4”) Vertical 4- %#Revised: 10/08/03 Contract No. 38891 Page 51 of 98 Pages Feature Staked Footings, Bents Abutments & Wingwalls Superstructure: Miscellaneous (9 Contour Gradins Q - Utilities 0, 0 Channels, Dikes & Ditches 0 Signs O Subsurface Drains 0 Overside Drains O Markers 0 Railings & Barriers 8 AC Dikes 0 Box Culverts Pavement MarkersO 0 Staking for feati Stake Description 8 RP + Markei Stake + Line Point +Guar( Stake RP RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake + Line Point +Guarc Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP : may be om and the accuracy requirements Reference points shall be suf installation & inspection of the for the txmoses of this table 0 Centerline or Parallel to Centerline Spacing@, Q 3 m to 10 m (IO’ to 33’) as required by the Engineer, BC & EC, transition points & at seginning & end. Elevation points on footing at bottom of columns 3 m to 10 m (1 0’ to 33’) sufficient to use strin! lines, BC & EC, transition points & at seginning & end. Elevation phnts on footing at bottom of columns I 15 m (50’) I 15 m (50’) on tangents & curves when Rr 300m IIOOO’) & s 7.5m (25’1 on curves when R k30Om (i000’) or &eregrade I 0.30% intervisible & I 30 m (loo’), BC & EC of facilities, Grade breaks, Alignment breaks, Junctions, Inlets & similar facilities At sign location intervisible & s 15m (50’), BC & EC of facilities, Grade breaks, Alignment breaks, Junctions, Inlets & similar facilities, Risers & similar facilities longitudinal location for asphalt street surfacing -C 15 m (50’) on angents & curves when R2 300m (1000’) & 5 7.5m (25’) on curves when R I 300m (1 000’) At beginning & end and s 15 m (50’) on angents & curves when R 2 300m (1 000’) & I 7.5m (25’) on curves when R I 300m (1000’) At beginning & end 3 m to 10 m (10’ to 33’) as required by the Engineer, BC & EC, transition points & at jeginning & end. Elevation points on footing: & at invert 30 m (200’) on tangents, 15m (50’) on curves when R 2 300m (1000’) & 7.5m (25’) on curves when R 2 300m (1 000’) For PCC surfaced streets lane cold joints will suffice ?d when adjacent marker stakes reference t Lateral Spacing 0, G as appropriate as appropriate along contour line as appropriate as appropriate Line point as appropriate 4t beginning 8 end At marker location(s) at railing & barrier location(s) 3s appropriate as appropriate at pavement marker location(s) Setting Tolerance (Within) 10 mm Horizontal & 7 mm ( /4”) Vertical 10 mm (J/q’) Horizontal 8 7 mm ( /4”) Vertical 30 mm (0.1’) Vertical & Horizontal 10 mm (Yq”) Horizontal & 7 mm ( /4”) Vertical 30 mm (0.1’) Horpontal& 7 mm ( /47 Vertical 30 mm (0.17 Vertical & Horizontal 30 mm (0.1’) Horizontal &7 mm (’/4”) Vertical 30 mm (0.1 ’) Hor&ontal & 7 mm ( 14”) Vertical 7 mm (’/4”) Horizontal 10 mm (”/e”) Horizontal & Vertical 30 mm (0.1’) Horizontal 8 Vertical 10 mm (”/\”) Horizontal & 7 mm ( 14”) Vertical 7 mm (‘/4”) Horizontal offset and elevation of those features f the RP meet the requirements for the feature iently durable and set securely enough to survive with accuracy intact throughout the iatures or adjacent facilities for which they provide control. RP means reference point 8 Perpendicular to centerline. @ Some features are not necessarily parallel to centerline but are referenced thereto (D Multi-plane surfaced features shall be staked so as to provide line & grade information for each plane of the feature G) t means greater than, or equal to, the number following the symbol. 5 means less than, or equal to, the number following the symbol. B, The cut datum for storm drainage & sanitary sewer pipes & similar structures shall be their invert. The cut datum for all other utilities shall be the top of their pipe or conduit. All guard stakes, line stakes and lath shall be flagged. Unless otherwise approved by the Engineer flagging, paint and marking cards shall be the color specified in TABLE 2-9.2.2(6) %#Revised: 10/08/03 Contract No. 38891 Paqe 52 of 98 Panes TABLE 2-9.2.2(B) Survey Stake Color Code for Construction Staking I Clearing I Limits of clearing Grading I Slope, intermediate slope, abutment fill, rough grade, contour grading, final Type of Stake I Description I Color” Horizontal Control I Coordinated control points, control lines, control reference points, centerline, I WhitelRed White/Orange Yellow/Black Yellow I alignments, etc. I Vertical Control 1 Bench marks Structure Drainane, Sewer, Curb grade, etc. Bridges, sound and retaining walls, box culverts, etc. Pipe culverts, iunction boxes, drOD inlets. headwalls. sewer lines, storm White Blue - I drains, slope protection, curbs, gutters, etc. I Signs, railings, barriers, lighting, etc. Right-of-way I Fences, R/ W lines, easements, property monuments, etc. Miscellaneous ~~ W hiteh’ellow Orange Add the following section: 2-9.2.3 Payment for Survey, Payment for work performed to satisfy the requirements of Sections 2-9.1 through 2-9.3.2 shall be included in the actual bid items requiring the survey work and no additional payment will be made. Extension of unit prices for extra work shall include full compensation for attendant survey work and no additional payment will be made therefor. Payment for the replacement of disturbed monuments and the filing of corner records shall be incidental to the work necessitating the disturbance of said monuments and no additional payment will be made the ref0 r. 2-10 AUTHORITY OF BOARD AND ENGINEER Add the following section: 2-10.1 Availability of Records, The Contractor shall, at no charge to the agency, provide copies of all records in the Contractor’s or subcontractor’s possession pertaining to the work that the Engineer may request. Add the following section: 2-10.2 Audit And Inspection, Contractor agrees to maintain and/or make available, to the Engineer, within San Diego County, accurate books and accounting records relative to all its activities and to contractually require all subcontractors to this contract to do the same. The Engineer shall have the right to monitor, assess, and evaluate Contractor’s and its subcontractor‘s performance pursuant to this Agreement, said monitoring, assessments, and evaluations to include, but not be limited to, audits, inspection of premises, reports, contracts, subcontracts and interviews of Contractor’s staff and the staff of all subcontractors to the contract. At any time during normal business hours and as often as the Engineer may deem necessary, upon reasonable advance notice, Contractor shall make available to the Engineer for examination, all of its, and all subcontractors to this contract, records with respect to all matters covered by this Contract and will permit the Engineer to audit, examine, copy and make excerpts or transcripts from such data and records, and to make audits of all invoices, materials, payrolls, records of personnel, and other data relating to all matters covered by this Contract. However, any such activities shall be carried out in a manner so as to not unreasonably interfere with Contractor‘s ongoing business operations. Contractor and all of its subcontractors to this contract shall maintain such data and records for as long as may be required by applicable laws and regulations. e* P’SRevised: 10/08/03 Contract No. 38891 Page 53 of 98 Pages SECTION 3 -- CHANGES IN WORK 3-3 EXTRA WORK. 3-2.2.1 Contract Unit prices, add the following: In the case of an increase or decrease in quantity of a minor bid item in excess of 25 percent of the original quantity bid adjustment of contract unit price for such items will be limited to that portion of the change in excess of 25 percent of the original quantity listed in the Contractor‘s bid proposal for this contract. Adjustments in excess of 25 percent may, at the option of the Engineer, be paid pursuant to section 3-3, Extra Work. 3-3.2.2 ( c ) Tool and Equipment Rental, second paragraph, modify as follows: Regardless of ownership, the rates and right-of-way delay factors to be used in determining rental and delay costs shall be the edition of the, “Labor Surcharge & Equipment Rental Rates” published by CALTRANS, current at the time of the actual use of the tool or equipment. The right-of-way delay factors therein shall be used as multipliers of the rental rates for determining the value of costs for delay to the Contractor and subcontractors, if any. The labor rates published therein are not a part of this contract . 3-3.2.3 Markup, replace with the following: (a) and shall constitute the markup for all overhead and profits: Delete section 3-3.2.3 from the 1995 and 1996 Supplements to the SSPWC and Work by Contractor. The following percentages shall be added to the Contractor‘s costs 1) Labor ................................... 20 2) Materials ............................. 15 3) Equipment Rental ................... 15 4) Other Items and Expenditures . . 15 To the sum of the costs and markups provided for in this section, 1 percent shall be added as compensation for bonding. (b) When all or any part of the extra work is performed by a Subcontractor, the markup established in 3-3.2.3(a) shall be applied to the Subcontractor‘s actual cost of such work. A markup of IO percent on the first $5,000 of the subcontracted portion of the extra work and a markup of 5 percent on work added in excess of $5,000 of the subcontracted portion of the extra work may be added by the Contractor. 3-3.3 Daily Reports by Contractor, add the following after the second sentence: Payment for extra work will not be made until such time that the Contractor submits completed daily reports and all supporting documents to the Engineer. Work by Subcontractor. 3-4 CHANGED CONDITIONS. delete the second sentence of paragraph three, delete paragraph five (5), and add the following: The Contractor shall not be entitled to the payment of any additional compensation for any act, or failure to act, by the Engineer, including failure or refusal to issue a change order, or for the happening of any event, thing, occurrence, or other cause, unless the Contractor shall have first given the Engineer due written notice of potential claim as hereinafter specified. Compliance with this section shall not be required as a prerequisite to notice provisions in Section 6-7.3 Contract Time Accounting, nor to any claim that is based on differences in measurement or errors of computation as to contract quantities. The written notice of potential claim for changed conditions shall be submitted by the Contractor to the Engineer upon their discovery and prior to the time that the Contractor performs the work giving rise to the potential claim. The Contractor’s failure to give written notice of potential claim for changed conditions to the agencyupon their discovery and before they are disturbed shall constitute a waiver of all claims in connection therewith . ** %#Revised: 10/08/03 Contract No. 38891 Page 54 of 98 Panes The Contractor shall provide the District with a written document containing a description of the particular circumstances giving rise to the potential claim, the reasons for which the Contractor believes additional compensation may be due and nature of any and all costs involved within 20 working days of the date of service of the written notice of potential claim for changed conditions. Verbal notifications are disallowed. The potential claim shall include the following certification relative to the California False Claims Act, Government Code Sections 12650-1 2655. “The undersigned certifies that the above statements are made in full cognizance of the California False Claims Act, Government Code sections 12650-1 2655. The undersigned further understands and agrees that this potential claim, unless resolved, must be restated as a claim in response to the City‘s proposed final estimate in order for it to be further considered.” By: Title: Date: Company Name: The Contractor’s estimate of costs may be updated when actual costs are known. The Contractor shall submit substantiation of its actual costs to the Engineer within 20 working days after the affected work is completed. Failure to do so shall be sufficient cause for denial of any claim subsequently filed on the basis of said notice of potential claim. It is the intention of this section that differences between the parties arising under and by virtue of the contract be brought to the attention of the Engineer at the earliest possible time in order that such matters be settled, if possible, or other appropriate action promptly taken. 3-5 DISPUTED WORK. Add the following: The Contractor shall give the agency written notice of potential claim prior to commencing any disputed work. Failure to give said notice shall constitute a waiver of all claims in connection therewith. Delete second sentence of paragraph one and add the following: Prior to proceeding with dispute resolution pursuant to Public Contract Code (PCC) provisions specified hereinafter, the contractor shall attempt to resolve all disputes informally through the following dispute resolution chain of command: 1. Project Inspector 2. Senior Inspector 3. Principal Inspector 4. Public Works Director 5. Executive Manager The Contractor shall submit a complete report within 20 working days after completion of the disputed work stating its position on the claim, the contractual basis for the claim, along with all documentation supporting the costs and all other evidentiary materials. At each level of claim or appeal of claim the District will, within 10 working days of receipt of said claim or appeal of claim, review the Contractor’s report and respond with a position, request additional information or request that the Contractor meet and present its report. When additional information or a meeting is requested the District will provide its position within 10 working days of receipt of said additional information or Contractor’s presentation of its report. The Contractor may appeal each level’s position up to the Executive Manager after which Contractor may proceed under the provisions of the Public Contract Code. The authority within the dispute resolution chain of command is limited to recommending a resolution to a claim to the Executive Manager. Actual approval of the claim is subject to the change order provisions in the contract. e= $#Revised: 10/08/03 Contract No. 38891 Page 55 of 98 Pages All claims by the contractor for $375,000 or less shall be resolved in accordance with the procedures in the Public Contract Code, Division 2, Part 3, Chapter 1, Article 1.5 (commencing with Section 20104) which is set forth below: ARTICLE 1.5 RESOLUTION OF CONSTRUCTION CLAIMS 20104. (a)(l) This article applies to all public works claims of three hundred seventy-five thousand dollars ($375,000) or less which arise between a contractor and a local agency (2) This article shall not apply to any claims resulting from a contract between a contractor and a public agency when the public agency has elected to resolve any disputes pursuant to Article 7.1 (commencing with Section 10240) of Chapter 1 of Part 2. (b)(l) "Public work" has the same meaning as in Sections 3100 and 3106 of the Civil Code, except that "public work" does not include any work or improvement contracted for by the state or the Regents of the University of California. (2) "Claim" means a separate demand by the contractor for (A) a time extension, (6) payment of money or damages arising from work done by, or on behalf of, the contractor pursuant to the contract for a public work and payment of which is not othetwise expressly provided for or the claimant is not othetwise entitled to, or (C) an amount the payment of which is disputed by the local agency (c) The provisions of this article or a summary thereof shall be set forth in the plans or specifications for any work which may give rise to a claim under this article. (d) This article applies only to contracts entered into on or after January 1, 1991. 20104.2. For any claim subject to this article, the following requirements apply: (a) The claim shall be in writing and include the documents necessary to substantiate the claim. Claims must be filed on or before the date of final payment. Nothing in this subdivision is intended to extend the time limit or supersede notice requirements otherwise provided by contract for the filing of claims. (b)(l) For claims of less than fifty thousand dollars ($SO,OOO), the local agency shall respond in writing to any written claim within 45 days of receipt of the claim, or may request, in writing, within 30 days of receipt of the claim, any additional documentation supporting the claim or relating to defenses to the claim the local agencymay have against the claimant. (2) If additional information is thereafter required, it shall be requested and provided pursuant to this subdivision, upon mutual agreement of the local agency and the claimant. (3) The local agency's written response to the claim, as further documented, shall be submitted to the claimant within 15 days after receipt of the further documentation or within a period of time no greater than that taken by the claimant in producing the additional information, whichever is greater. (c)(l) For claims of over fifty thousand dollars ($50,000) and less than or equal to three hundred seventy-five thousand dollars ($375,000), the local agency shall respond in writing to all written claims within 60 days of receipt of the claim, or may request, in writing, within 30 days of receipt of the claim, any additional documentation supporting the claim or relating to defenses to the claim the local agency may have against the claimant. (2) If additional information is thereafter required, it shall be requested and provided pursuant to this subdivision, upon mutual agreement of the local agency and the claimant. (3) The local agency's written response to the claim, as further documented, shall be submitted to the claimant within 30 days after receipt of the further documentation, or within a period of time no greater than that taken by the claimant in producing the additional information or requested documentation, whichever is greater. (d) If the claimant disputes the local agency's written response, or the local agency fails to respond within the time prescribed, the claimant may so notify the local agency, in writing, either within 15 days of receipt of the local agency's response or within 15 days of the local agency's failure to respond within the time prescribed, respectively, and demand an informal conference to meet and confer for settlement of the issues in dispute. Upon a demand, the local agency shall schedule a meet and confer conference within 30 days for settlement of the dispute. (e) Following the meet and confer conference, if the claim or any portion remains in dispute, the claimant may file a claim as provided in Chapter 1 (commencing with Section 900) and Chapter 2 (commencing with Section 910) of Part 3 of Division 3.6 of Title 1 of the Government Code. For purposes of those provisions, the running of the period of time within which a claim must be filed shall be tolled from the time the claimant submits his or her written claim pursuant to subdivision (a) until the time that claim is denied as a result of the meet and confer process, including any period of 10/08/03 Contract No. 38891 Page 56 of 98 Panes time utilized by the meet and confer process. (f) This article does not apply to tort claims and nothing in this article is intended nor shall be construed to change the time periods for filing tort claims or actions specified by Chapter 1 (commencing with Section 900) and Chapter 2 (commencing with Section 910) of Part 3 of Division 3.6 of Title 1 of the Government Code. 20104.4. The following procedures are established for all civil actions filed to resolve claims subject to this article: (a) Within 60 days, but no earlier than 30 days, following the filing or responsive pleadings, the court shall submit the matter to nonbinding mediation unless waived by mutual stipulation of both parties. The mediation process shall provide for the selection within 15 days by both parties of a disinterested third person as mediator, shall be commenced within 30 days of the submittal, and shall be concluded within 15 days from the commencement of the mediation unless a time requirement is extended upon a good cause showing to the court or by stipulation of both parties. If the parties fail to select a mediator within the 15day period, any party may petition the court to appoint the mediator: (b)(l) If the matter remains in dispute, the case shall be submitted to judicial arbitration pursuant to Chapter 2.5 (commencing with Section 11 41 .I 0) of Title 3 of Part 3 of the Code of Civil Procedure, notwithstanding Section 1141.11 of that code. The Civil Discovery Act of 1986 (Article 3 (commencing with Section 2016) of Chapter 3 of Title 3 of Part 4 of the Code of Civil procedure) shall apply to any proceeding brought under the subdivision consistent with the rules pertaining to judicial arbitration. (2) Notwithstanding any other provision of law, upon stipulation of the parties, arbitrators appointed for purposes of this article shall be experienced in construction law, and, upon stipulation of the parties, mediators and arbitrators shall be paid necessary and reasonable hourly rates of pay not to exceed their customary rate, and such fees and expenses shall be paid equally by the parties, except in the case of arbitration where the arbitrator, for good cause, determines a different division. In no event shall these fees or expenses be paid by state or county funds. (3) In addition to Chapter 2.5 (commencing with Section 1141 .I 0) Title 3 of Part 3 of the Code of Civil Procedure, any party who after receiving an arbitration award requests a trial de novo but does not obtain a more favorable judgment shall, in addition to payment of costs and fees under that chapter, pay the attorney’s fees of the other party arising out of the trial de novo. (c) The court may, upon request by any party, order any witnesses to participate in the mediation or arbitration process. 20104.6. (a) No local agency shall fail to pay money as to any portion of a claim which is undisputed except as otherwise provided in the contract. (b) In any suit filed under Section 201 04.4, the local agency shall pay interest at the legal rate on any arbitration award or judgment. The interest shall begin to accrue on the date the suit is filed in a court of law. SECTION 4 - CONTROL OF MATERIALS 4-1 MATERIALS AND WORKMANSHIP. 4-1.3.1 General, add the following: The Contractor shall provide the Engineer free and safe access to any and all parts of work at any time. Such free and safe access shall include means of safe access and egress, ventilation, lighting, shoring, dewatering and all elements pertaining to the safety of persons as contained in the State .of California, California Code of Regulations, Title 8, Industrial Relations, Chapter 4, Division of Industrial Safety, Subchapter 4, Construction Safety Orders and such other safety regulations as may apply. Contractor shall furnish Engineer with such information as may be necessary to keep the Engineer fully informed regarding progress and manner of work and character of materials. Inspection or testing of the whole or any portion of the work or materials incorporated in the work shall not relieve Contractor from any obligation to fulfill this Contract. em ESRevised: 10/08/03 Contract No. 38891 Page 57 of 98 Pages 4-1.4 Test of Materials, delete the phrase, “and a reasonable amount of retesting”, from the third sentence of the first paragraph. add the following: Except as specified in these Supplemental Provisions, the Agency will bear the cost of testing of locally produced materials and/or on-site workmanship where the results of such tests meet or exceed the requirements indicated in the Standard Specifications and the Supplemental Provisions. The cost of all other tests shall be borne by the Contractor. At the option of the Engineer, the source of supply of each of the materials shall be approved by him before the delivery is started. All materials proposed for use may be inspected or tested at any time during their preparation and use. If, after incorporating such materials into the Work, it is found that sources of supply that have been approved do not furnish a uniform product, or if the product from any source proves unacceptable at any time, the Contractor shall furnish approved material from other approved sources. If any product proves unacceptable after improper storage, handling or for any other reason it shall be rejected, not incorporated into the work and shall be removed from the project site all at the Contractor’s expense. Compaction tests may be made by the Engineer and all costs for tests that meet or exceed the requirements of the specifications shall be borne by the Agency. Said tests may be made at any place along the work as deemed necessary by the Engineer. The costs of any retests made necessary by noncompliance with the specifications shall be borne by the Contractor. 4-1.6 Trade names or Equals, add the following: The Contractor is responsible for the satisfactory performance of substituted items. If, in the sole opinion of the Engineer, the substitution is determined to be unsatisfactory in performance, appearance, durability, compatibility with associated items, availability of repair parts and suitability of application the Contractor shall remove the substituted item and replace it with the originally specified item at no cost to theAgency. Add the following section: 4-2 MATERIALS TRANSPORTATION, HANDLING & STORAGE. The Contractor shall order, purchase, transport, coordinate delivery, accept delivery, confirm the quality and quality received, prepare storage area(s), store, handle, protect, move relocate, remove and dispose excess of all materials used to accomplish the Work. Materials shall be delivered to the site of the work only during working hours, as defined in section 6-7.2 and shall be accompanied by bills of lading that shall clearly state for each delivery: the name of the Contractor as consignee, the project name and number, address of delivery and name of consignor and a description of the material(s) shipped. Prior to storage of any materials which have been shipped to or by the Contractor to any location within the Agency’s boundaries the Contractor shall provide the Engineer a copy of lease agreements for each property where such materials are stored. The lease agreement shall clearly state the term of the lease, the description of materials allowed to be stored and shall provide for the removal of the materials and restoration of the storage site within the time allowed for the Work. All such storage shall conform to all laws and ordinances that may pertain to the materials stored and to preparation of the storage site and the location of the site on which the materials are stored. Loss, damage or deterioration of all stored materials shall be the Contractor’s responsibility. Conformance to the requirements of this section, both within and outside the limits of work are a part of the Work. The Engineer shall have the right to verify the suitability of materials and their proper storage at any time during the Work. SECTION 5 -- UTILITIES 5-1 LOCATION. Add the following: The Agency and affected utility companies have, by a search of known records, endeavored to locate and indicate on the Plans, all utilities which exist within the limits of the work. However, the accuracy and/or completeness of the nature, size and/or location of utilities indicated on the Plans is not guaranteed. 4-i t4Revised: 10/08/03 Contract No. 38891 Paae 5R nf QR Pancrc 5-4 RELOCATION. Delete the first paragraph and substitute the following: In order to minimize delays to the Contractor caused by the failure of other parties to relocate utilities that interfere with the construction, the Contractor, upon request to the Engineer, may be permitted to temporarily omit the portion of work affected by the utility. Such omission shall be for the Contractor’s convenience and no additional compensation will be allowed therefor. The portion thus omitted shall be constructed by the Contractor immediately following the relocation of the utility involved unless otherwise directed by the Engineer. SECTION 6 -- PROSECUTION, PROGRESS AND ACCEPTANCE OF THE WORK 6-1 CONSTRUCTION SCHEDULE AND COMMENCEMENT OF WORK. Delete subsection 6-1 and substitute the following: Except as otherwise provided herein and unless otherwise prohibited by permits from other agencies as may be required by law the Contractor shall begin work within 15 calendar days after receipt of the “Notice to Proceed“. Add the following section: 6-1 .I Pre-Construction Meeting. After, or upon, notification of contract award, the Engineer will set the time and location for the Preconstruction Meeting. Attendance of the Contractor’s management personnel responsible for the management, administration, and execution of the project is mandatory for the meeting to be convened. Failure of the Contractor to have the Contractor’s responsible project personnel attend the Preconstruction Meeting will be grounds for default by Contractor per section 6-4. No separate payment will be made for the Contractor’s attendance at the meeting. The notice to proceed will only be issued on or after the completion of the preconstruction meeting. Add the following section: 6-1 .I .I Baseline Construction Schedule Submittal. The Contractor shall submit the Baseline Construction Schedule per the submittal requirements of section 2-5.3. The submittal of the Baseline Construction Schedule shall include each item and element of sections 6-1.2 through 6-1.2.9 and shall be on hard (paper) copy and electronic media conforming to section 6-1.3.3 Electronic Media. Add the following section: 6-1.2 Preparation and Review of the Baseline Construction Schedule. The Contractor shall prepare the Baseline Construction Schedule as a Critical Path Method (CPM) Schedule in the precedence diagram method (activity-on-node) format. The Baseline Construction Schedule shall depict a workable plan showing the sequence, duration, and interdependence of all activities required to represent the complete performance of all project work as well as periods where work is precluded. The Baseline Construction Schedule shall begin with the projected date of issuance of the notice to proceed and conclude with the date of final completion per the contract duration. The Baseline Construction Schedule shall include detail of all project phasing, staging, and sequencing, including all milestones necessary to define beginning and ending of each phase or stage. Add the following section: 6-1.2.1 Time-Scaled Network Diagram. As a part of the Baseline Construction Schedule the Contractor shall prepare and submit to the Engineer a complete time-scaled network diagram showing all of the activities, logic relationships, and milestones comprising the schedule. Add the following section: 6-1.2.2 Tabular Listing. As a part of the Baseline Construction Schedule the Contractor shall prepare and submit to the Engineer a tabular listing of all of the activities, showing for each activity the identification number, the description, the duration, the early start, the early finish, the late start, the late finish, the total float, and all predecessor and successor activities for the activity described. e= %#Revised: 10/08/03 Contract No. 38891 Page 59 of 98 Pages Add the following section: 6-1.2.3 Bar Chart. As a part of the Baseline Construction Schedule the Contractor shall prepare and submit to the Engineer a chart showing individual tasks and their durations arranged with the tasks on the vertical axis and duration on the horizontal axis. The bar chart shall use differing texture patterns or distinctive line types to show the critical path. Add the following section: 6-1.2.4 Schedule Software. The Contractor shall use commercially available software equal to the Windows 95 compatible “Suretrak” program by Primavera or “Project” program by Microsoft Corporation to prepare the Baseline Construction Schedule and all updates thereto. The Contractor shall submit to the Agency a 89 mm (3.5”) data disk with all network information contained thereon, in a format readable by a Microsoft Windows 95 system. The Agency will use a “Suretrak”, “Project” or equal software program for review of the Contractor’s schedule. Should the Contractor elect to use a scheduling program other than the “Suretrak program by Primavera or “Project” program by Microsoft Corporation the Contractor shall provide the Engineer three copies of the substituted program that are fully licensed to the Agency and 32 class hours of on-site training by the program publisher for up to eight Agency staff members. The classes shall be presented on Mondays through Thursdays, inclusive, between the hours of 8:OO a.m. and 5:OO p.m. The location dates and times of the on-site training shall be submitted to the Engineer for approval five working days before the start of the on-site training. The training shall be completed prior to the submittal of the first Baseline Construction Schedule. Add the following section: 6-1.2.5 Schedule Activities. Except for submittal activities, activity durations shall not be shorter than 1 working day nor longer than 15 working days, unless specifically and individually allowed by the Engineer. The Baseline Construction Schedule shall include between 100 and 500 activities, including submittals, interfaces between utility companies and other agencies, project milestones and equipment and material deliveries. The number of activities will be sufficient, in the judgment of the Engineer, to communicate the Contractor’s plan for project execution, to accurately describe the project work, and to allow monitoring and evaluation of progress and of time impacts. Each activity’s description shall accurately define the work planned for the activity and each activity shall have recognizable beginning and end points. Add the following section: 6-1.2.6 Float. to whatever party or contingency first exhausts it. Add the following section: 6-1.2.7 Restraints to Activities. Any submittals, utility interfaces, or any furnishing of Agency supplied materials, equipment, or services, which may impact any activity’s construction shall be shown as a restraint to those activities. Time periods to accommodate the review and correction of submittals shall be included in the schedule. Float or slack time within the schedule is available without charge or compensation Add the following section: 6-1.2.8 Late Completion. A Baseline Construction Schedule showing a project duration longer than the specified contract duration will not be acceptable and will be grounds for default by Contractor, per section 64. Add the following section: 6-1.2.9 Early Completion. The Baseline Construction Schedule will show the Contractor’s plan to support and maintain the project for the entire contractual timespan of the project. Should the Contractor propose a project duration shorter than contract duration, a complete Baseline Construction Schedule must be submitted, reflecting the shorter duration, in complete accordance with all schedule requirements of section 6-1. The Engineer may choose to accept the Contractor’s proposal of a project duration shorter than the duration specified; provided the Agency is satisfied the shortened Baseline Construction Schedule is reasonable and the Agency and all other entities, public and private, which interface with the project are able to support the provisions of the shortened Baseline Construction Schedule. The Agency’s acceptance of a shortened duration project will be confirmed through the execution of a contract change order revising the project duration and <$Revised: 10/08/03 Contract No. 38891 Page 60 of 98 Paaes implementing all contractual requirements including liquidated damages in accordance with the revised duration. Add the following section: 6-1.2.10 Engineer’s Review. The Construction Schedule is subject to the review of the Engineer. The Engineer’s determination that the Baseline Construction Schedule proposed by the Contractor complies with the requirements of these special provisions shall be a condition precedent to issuance of the Notice to Proceed by the Engineer. If the Engineer determines that the Construction Schedule does not meet the requirements of these specifications the Contractor shall correct the Construction Schedule to meet these specifications and resubmit it to the Engineer. Failure of the Contractor to obtain the Engineer’s determination that the initial Construction Schedule proposed by the Contractor complies with the requirements of these special provisions within thirty (30) working days after the date of the preconstruction meeting shall be grounds for termination of the contract per section 6-4. Days used by the Engineer to review the initial Construction Schedule will not be included in the 30 working days. The Engineer will review and return to the Contractor, with any comments, the Baseline Construction Schedule within 15 working days of submittal. The Baseline Construction Schedule will be returned marked as per sections 6-1.2.10.1 through 6-1.2.10.3. Add the following section: 6-1.2.10.1 “Accepted.” Notice to Proceed, and will receive payment for the schedule in accordance with section 6-1.8.1. The Contractor may proceed with the project work upon issuance of the Add the following section: 6-1.2.10.2 “Accepted with Comments.” The Contractor may proceed with the project work upon issuance of the Notice to Proceed. The Contractor must resubmit the schedule incorporating the comments prior to receipt of payment per section 6-1.8.1. Add the following section: 6-1.2.10.3 “Not Accepted.” The Contractor must resubmit the schedule incorporating the corrections and changes of the comments prior to receipt of payment per section 6-1.8.1. The Notice to Proceed will not be issued by the Engineer if the changes of the comments are not submitted as required hereinbefore and marked “Accepted” or “Accepted with Comments” by the Engineer. The Contractor, at the sole option of the Engineer, may be considered as having defaulted the contract under the provisions of section 6-4 DEFAULT BY CONTRACTOR if the changes of the comments are not submitted as required hereinbefore and marked “Accepted” by the Engineer. Add the following section: 6-1.3 Preparation of Schedule Updates and Revisions. The Contractor shall meet with the Engineer during the last week of each month to agree upon each activity’s schedule status and shall submit monthly updates of the Baseline Construction Schedule confirming the agreements no later than the fifth working day of the following month. The monthly update will be submitted on hard (paper) copy and electronic media conforming to section 6-1.3.3 Electronic Media per the submittal requirements of section 2-5.3 and will include each item and element of sections 6-1.2 through 6- 1.2.9 and 6-1.3.1 through 6-1.3.7. Add the following section: 6-1.3.1 Actual Activity Dates. The actual dates each activity was started and/or completed during the month. After first reporting an actual date, the Contractor shall not change that actual date in later updates without specific notification to the Engineer with the update. Add the following section: 6-1.3.2 Activity Percent Complete. Contractor shall report the percentage determined by the Engineer as complete for the activity. Add the following section: 6-1.3.3 Electronic Media. The schedule data disk shall be a 3’/; high density diskette, labelled with the project name and number, the Contractor’s name and the date of preparation of the For each activity underway at the end of the month, the *= %#Revised: 10/08/03 Contract No. 38891 Page 61 of 98 Pages schedule data disk. The schedule data disk shall be readable by the software specified in section 6- 1.2.2 Schedule Software and shall be free of file locking, encryption or any other protocol that would impede full access of all data stored on it. Add the following section: 6-1.3.4 List of Changes. A list of all changes made to the activities or to the interconnecting logic, with an explanation for each change. Add the following section: 6-1.3.5 Change Orders, Each monthly update will include the addition of the network revisions reflecting the change orders approved in the previous month. The network revisions will be as agreed upon during the review and acceptance of the Contractor’s change orders. Add the following section: 6-1.3.6 Bar Chart. Each monthly update will include a chart showing individual tasks and their durations arranged with the tasks on the vertical axis and duration on the horizontal axis. The bar chart shall use differing texture patterns or distinctive line types to show the critical path. Add the following section: 6-1.4 Engineer’s Review of Updated Construction Schedule. The Engineer will review and return the Updated Construction Schedule to the Contractor, with any comments, within 5 working days of submittal. The Updated Construction Schedule will be returned marked as per sections 6- 1.4.1 through 6-1.4.3. Any Updated Construction Schedule marked “Accepted with Comments” or “Not Accepted” by the Engineer will be returned to the Contractor for correction. Upon resubmittal the Engineer will review and return the resubmitted Updated Construction Schedule to the Contractor, with any comments, within 5 working days. Failure of the Contractor to submit a monthly updated construction schedule will invoke the same consequences as the Engineer returning a monthly updated construction schedule marked “Not Accepted“. Add the following section: 6-1.4.1 “Accepted.” for the schedule in accordance with section 6-1.8.2. The Contractor may proceed with the project work, and will receive payment Add the following section: 6-1.4.2 “Accepted with Comments.” The Contractor may proceed with the project work. The Contractor must resubmit the Updated Construction Schedule to the Engineer incorporating the corrections and changes noted in the Engineer’s comments prior to receipt of payment per section 6-1 ~3.2. Add the following section: 6-1.4.3 “Not Accepted.” The Contractor must resubmit the Updated Construction Schedule to the Engineer incorporating the corrections and changes noted in the Engineer’s comments prior to receipt of payment per section 6-1.8.2. The Contractor, at the sole option of the Engineer, may be considered as having defaulted the contract under the provisions of section 6-4 DEFAULT BY CONTRACTOR if the changes of the comments are not submitted and marked “Accepted” by the Engineer before the last day of the month in which the Updated Construction Schedule is due. If the Contractor fails to submit the corrected Updated Construction Schedule as required herein the Contractor may elect to proceed with the project at its own risk. Should the Contractor elect not to proceed with the project, any resulting delay, impact, or disruption to the project will be the Contractor’s responsibility. Add the following section: 6-1.5 Late Completion or Milestone Dates. Should the Schedule Update indicate a completion or contractually required milestone date later than the properly adjusted contract or milestone duration, the Agency may withhold Liquidated Damages for the number of days late. Should a subsequent “Accepted” Schedule Update remove all or a portion of the delay, all or the allocated portion of the previously held Liquidated Damages shall be released in the monthly payment to the Contractor immediately following the “Accepted” schedule. 4ii %#Revised: 10/08/03 Contract No. 38891 Paae 62 nf QR Parrac Add the following section: 6-1.6 Interim Revisions. Should the actual or projected progress of the work become substantially different from that depicted in the Project Schedule, independently of and prior to the next monthly update, the Contractor will submit a revised Baseline Construction Schedule, with a list and explanation of each change made to the schedule. The Revised Construction Schedule will be submitted per the submittal requirements of section 2-5.3 and per the schedule review and acceptance requirements of section 6-1, including but not limited to the acceptance and payment provisions. Add the following section: 6-1.7 Final Schedule Update. The Contractor shall prepare and submit a final schedule update when one hundred percent of the construction work is completed. The Contractor’s Final Schedule Update must accurately represent the actual dates for all activities. The final schedule update shall be prepared and reviewed per sections 6-1.3 Preparation of Schedule Updates and Revisions and 6-1. 4 Engineer’s Review of Updated Construction Schedule. Acceptance of the final schedule update is required for completion of the project and release of any and all funds retained per section 9-3.2. Add the following section: 6-1.8 Measurement and Payment. Construction Schedule will be paid for at the stipulated lump sum price of eighteen thousand dollars ($18,000.00). The stipulated lump sum price paid for Construction Schedule shall include full compensation for furnishing all labor, materials including, but not limited to, the computer hardware and software, tools, equipment, and incidentals; and for doing all the work involved in attending meetings, preparing, furnishing, updating, revising the tabular, bar and flow chart Construction Schedules and narrative reports required by these special provisions and as directed by the Engineer. The Engineer’s determination that each and any construction schedule proposed by the Contractor complies with the requirements of these special provisions shall be precedent to each and any payment for the Construction Schedule. Payments for Construction Schedule will be made as per sections 6-1.8.1 through 6-1.8.3. Add the following section: 6-1.8.1 Initial Payment. Five thousand dollars ($5,000.00) of the stipulated lump sum bid for the Construction Schedule will be made when the Engineer has accepted a Construction Schedule for this project Add the following section: 6-1.8.2 Monthly Updated Construction Schedule Payments. Monthly Updated Construction Schedule Payments of one thousand dollars ($1,000.00) will be made subsequent to the initial payment for the Construction Schedule for each monthly Construction Schedule, updated as required herein, that the Engineer has accepted as sufficient within the month that the monthly progress payment pertains. No payment shall be made, nor shall any payment accrue, for any monthly updated construction schedule that is not marked “Accepted” by the Engineer on or before the twentieth working day of the month such monthly updated construction schedule is due per section 6-1.3 Preparation of Schedule Updates and Revisions. The sum of the amounts paid for Construction Schedule during the initial and subsequent payment periods, or extensions to the contract, shall not exceed the stipulated lump sum price for Construction Schedule. Add the following section: 6-1.8.3 Concluding Payment. A Final payment of three thousand dollars ($3,000.00) for the Construction Schedule will be made when both one hundred percent of the contract work is completed and the Engineer has accepted a final construction schedule update prepared and submitted by the Contractor as required herein that shows the actual beginning and ending dates and all other data that is required for baseline and update schedules for each activity shown on the baseline construction schedule and updates thereto that the Engineer accepted for this project. 4- %#Revised: 10/08/03 Contract No. 38891 Page 63 of 98 Pages 6-2 PROSECUTION OF WORK. Add the following section: 6-2.1 General Description. The Contract work to be performed consists of furnishing all labor, equipment, and materials to construct a recycled water pump station as shown on the Construction Drawings (Plans) and specified in the Contract Documents. Major project components include: masonry block retaining walls and decorative steel fencing, suction and discharge piping, connections to existing pipelines, masonry block building housing electrical and mechanical equipment, surge arrestor system, SDG&E electrical service, and site pavement. Add the following section: 6-2.2 Order of Work I) Prior to beginning construction, Contractor shall excavate, expose, and determine ("pothole") the exact location and depth of each and every potential interference including, but not limited to, all facilities shown specifically (depth and location) on the Construction Drawings (Plans), or which have been located and marked by respective non member companies or utilities. Prior to performing connection construction work, Contractor shall verify pipe materials, diameters, and elevations, and provide appropriate materials to complete connection construction, all based on Contractor's field measurements. 2) Construct site retaining walls, equipment building, suction and discharge piping, surge arrestor system, and electrical service. Discharge piping shall be constructed up to, but not including, the connection to the 12" recycled water transmission pipeline. 3) College Boulevard street improvements and 16" and/or 12" recycled water transmission pipelines may be under construction by others during construction of the pump station. Contractor shall coordinate with Agency and street improvement and pipeline contractor(s). Contractor shall consider the 16" and 12" recycled water transmission pipelines to be charged with water. Contractor shall dewater said pipelines prior to constructing specified connections. 4) Upon completion of pump station construction work, Contractor shall install temporary blind flange at the proposed point of connection with the 12" recycled water transmission pipeline and perform pre-startup and control system verification of all pump station equipment systems and facilities by re-circulating water from the station discharge piping to station suction piping. Contractor shall perform pre-startup and control system verification by simulating telemetry signals from the Agency furnished telemetry panel. Once Contractor has successfully demonstrated proper operation of all pump station equipment and facilities, Agency will have the new telemetry panel installed and connected to the MCP telemetry terminal strip. Contractor shall provide Equipment Building access to Agency's telemetry equipment installer for a period of two (2) weeks. Upon completion of telemetry panel installation, Contractor shall schedule full pump station startup and testing of all pump station equipment systems and facilities with the Agency's telemetry system providing automatic control functions. In addition, Contractor shall remove temporary blind flange from 12" discharge piping and construct connection to 12" recycled water transmission pipeline. Upon completion of connection to 12" recycled water transmission pipeline, Contractor shall remove piping segments between potable water and recycled water pipelines at the intersection of Carlsbad Village Drive and College Boulevard (as shown on the Drawings). Contractor shall perform piping removal work within a 6-hour period. Remainder of em %@Revised: 10/08/03 Contract No. 38891 Paae 64 nf 9R Panm work relating to the Recycled Water Disconnect Vault may be performed during pump station startup and testing. Contractor shall commence pump station startup immediately following removal of piping segments between potable water and recycled water pipelines. Contractor shall perform pump station startup and equipment testing in accordance with Contract Document requirements, including fourteen (14) day “live test“ as required by Specification Section 01 500. Add the following section: 6-2.3 Project Meetings. The Engineer will establish the time and location of weekly Project Meetings. Each Project Meeting shall be attended by the Contractor’s Representative. The Project Representative shall be the individual determined under section 7-6, “The Contractor’s Representative”, SSPWC. No separate payment for attendance of the Contractor, the Contractor’s Representative or any other employee or subcontractor or subcontractor’s employee at these meetings will be made. 6-6 DELAYS AND EXTENSIONS OF TIME. 6-6.4 Written Notice and Report. The Contractor shall provide written notice to the Engineer within two hours of the beginning of any period that the Contractor has placed any workers or equipment on standby for any reason that the Contractor has determined to be caused by the Agency or by any organization that the Agency may otherwise be obligated by. The Contractor shall provide continuing daily written notice to the Engineer, each working day, throughout the duration of such period of delay. The initial and continuing written notices shall include the classification of each workman and supervisor and the make and model of each piece of equipment placed on standby, the cumulative duration of the standby, the Contractor’s opinion of the cause of the delay and a cogent explanation of why the Contractor could not avoid the delay by reasonable means. Should the Contractor fail to provide the notice(s) required by this section the Contractor agrees that no delay has occurred and that it will not submit anyclaim(s) therefor. 6-7 TIME OF COMPLETION. Add the following: The Contractor shall diligently prosecute the work to completion within 200 working days after the starting date specified in the Notice to Proceed. 6-7.2 Working Day. Add the following: Unless otherwise approved in writing by the Engineer, the hours of work shall be between the hours of 7:OO a.m. and 4:OO p.m. on Mondays through Fridays, excluding Agency holidays. The Contractor shall obtain the written approval of the Engineer if the Contractor desires to work outside said hours or at any time during weekends and/or holidays. This written permission must be obtained at least 48 hours prior to such work The Engineer may approve work outside the hours and/or days stated herein when, in hidher sole opinion, such work conducted by the Contractor is beneficial to the best interests of the Agency. The Contractor shall pay the inspection costs of such work. 6-8 COMPLETION AND ACCEPTANCE. Delete the second paragraph and add the following: The Engineer will not accept the Work or any portion of the Work before all of the Work is completed and all outstanding deficiencies that may exist are corrected by the Contractor and the Engineer is satisfied that all the materials and workmanship, and all other features of the Work, meet the requirements of all of the specifications for the Work. Use, temporary, interim or permanent, of all, or portions of, the Work does not constitute acceptance of the Work. If, in the Engineer’s judgment, the Work has been completed and is ready for acceptance the Engineer will so certify to the Board. Upon such certification by the Engineer the Board may accept the completed Work. Upon the Board’s acceptance of the Work the Engineer will cause a “Notice of Completion” to be filed in the ofice of the San Diego County Recorder. The date of recordation shall be the date of completion of the Work. Modify as follows: Delete the first sentence of the third paragraph and substitute the following two sentences: All work shall be warranted for one (1) year after recordation of the “Notice of Completion” and any faulty work or materials discovered during the warranty period shall be repaired or replaced by the Contractor, at its expense. Twenty-five percent of the faithful performance bond shall be retained as em %#Revised: 10/08/03 Contract No. 38891 Page 65 of 98 Pages a warranty bond for the one year warranty period. 6-9 LIQUIDATED DAMAGES. Modify the last sentence of the first paragraph and the first sentence of the second paragraph and add the following: For each consecutive calendar day in excess of the time specified 'for completion of Work, as adjusted in accordance with 6-6, the Contractor shall pay the Agency, or have withheld monies due it, the sum of one thousand dollars ($1,000.00). Execution of the Contract shall constitute agreement by the Agency and Contractor per day is the minimum value of costs and actual damages caused by the Contractor to complete the Work within the allotted time. Any progress payments made after the specified completion date shall not constitute a waiver of this paragraph or of any damages. SECTION 7 -- RESPONSIBILITIES OF THE CONTRACTOR 7-1.1 STAGING AND STOCKPILING AREAS. The Contractor is responsible for locating, and leasing all property necessary for, but not limited to the Contractor's facilities, and the stockpiling and storage of construction materials and equipment. The Contractor is solely responsible for the security and maintenance of the stockpile and storage areas according to all applicable sanitation and safety regulations. Staging areas shall be returned to their original condition upon completion of the work. 7-3 LIABILITY INSURANCE. Add the following: All insurance is to be placed with insurers that have a rating in Best's Key Rating Guide of at least A-:V and are admitted and authorized to conduct business in the state of California and are listed in the official publication of the Department of Insurance of the State of California. 7-4 WORKERS' COMPENSATION INSURANCE. Add the following: All insurance is to be placed with insurers that are admitted and authorized to conduct business in the state of California and are listed in the official publication of the Department of Insurance of the State of California. Policies issued by the State Compensation Fund meet the requirement for workers' compensation insurance. 7-5 PERMITS. Except as specified herein the Agency will obtain, at no cost to the Contractor, all encroachment, right-of-way, grading, resource agency and building permits necessary to perform work for this contract on Agency property, in streets, highways (except State highway right-of-way), railways or other rights-of-way. Contractor shall not begin work until all permits incidental to the work are obtained. The Contractor shall obtain and pay for any safety permits, air pollution permits, NPDES permits, and all permits for the disposal of all materials removed from the project. The cost of said permit@) shall be included in the price bid for the appropriate bid item and no additional compensation will be allowed therefor. Contractor shall comply with all permits, regulations, laws, ordinances, licenses, and authorizations from jurisdictional agencies. In the event of a conflict between the Contract and permit requirements, the most stringent shall prevail. All permit requirements shall be satisfied by the Contractor and accepted by all issuing agencies and the Engineer, before the project will be accepted and a Notice of Completion filed. Add the following section: 7-5.1 California Regional Water Quality Control Board, San Diego Region. Contractor shall, at his expense, obtain authorization to discharge water from ground water extraction (dewatering), line flushing, and testing operations from the California Regional Water Quality Control Board, San Diego Region (Regional Board). A copy of said discharge authorization shall be provided to the Agency. Contractor shall comply with conditions therein and perform the monitoring required. Contractor shall not allow any discharges from the construction site, which may have an adverse effect on receiving waters of the United States. Delete the first paragraph and add the following: e= Gs Revised: 1 0/08/03 Contract No. 38891 Paae 66 of 98 PR~S Contractor shall not allow any groundwater extraction water to be discharged from construction site except in full compliance with the General Waste Discharge Requirements for Ground Water Extraction and Similar Discharges from Construction and Remediation Projects (Order No. 96-41) adopted by the Regional Board. Prior to submitting Bid, Contractor shall obtain a copy of said Order No. 96-41 and review all compliance requirements therein, including monitoring, testing, and reporting. Contractor shall provide all labor, material, and equipment necessary to comply with Regional Board requirements for discharge water from groundwater extractions, line flushing, and testing operations, including all monitoring, testing, and reporting. Contractor shall perform all work in accordance with all applicable provisions of said discharge authorization and permit. Add the following section: 7-5.2 Carlsbad Conditional Use Permit. The Agency has obtained a Conditional Use Permit for the specified Work. A copy of said permit is included in Appendix B of these Supplemental Provisions. Contractor shall perform all work in accordance with all applicable provisions of said permits. The cost of compliance with permit provisions shall be included in the price for the appropriate bid item and no additional compensation hill be allowed therefore. Add the following section: 7-5.3 Carlsbad Business License. a valid City of Carlsbad Business License for the duration of the Contract. Contractor and all subcontractors shall procure and maintain 7-7 COOPERATION AND COLLATERAL WORK. Add the following section: 7-7.1 Coordination. Contractor shall coordinate and cooperate with Agency, San Diego Gas and Electric, other contractors, and all other jurisdictional agencies. Agency will have representatives on site to observe and verify compliance with Contract Documents. Contractor shall perform his work in accordance with the sequence of work as specified herein. Contractor shall coordinate all work with the Agency. Other contractors may be constructing recycled water piping adjacent to the project site with portion of the pipelines on the project site for connection of the pumping station suction and discharge piping. The Contractor shall coordinate and cooperate with all the utility companies during the relocation or construction of their lines. The Contractor may be granted a time extension if, in the opinion of the Engineer, a delay is caused by the utility company. No additional compensation will be made to the Contractor for any such delay. Contractor shall bear all costs and fees incurred as a result of inspection services furnished by utility companies or others, excluding the Agency. Add the following section: 7-7.2 SDG&E Electrical Power Service. ' Agency has coordinated with San Diego Gas and Electric Co. (SDG&E) for 480 volt, 3 phase, 4 wire electric power service to be provided to the project facilities. SDG&E will provide power from existing below grade facilities. As shown on the Drawings, the Contractor shall furnish and install a pull box and conduits to the proposed SDG&E transformer slab box and conduit between slab box to the proposed service equipment all in accordance with SDG&E requirements. Contractor shall furnish and install pull section, main circuit breaker, and metering equipment, all in accordance with SDG&E requirements. Contractor shall coordinate all work with SDG&E including installation of slab box service equipment and conductors. Contractor shall obtain all applications and permits and coordinate SDG&E work such that the Contract completion schedules are met. Agency will pay all application and permit fees. SDG&E service planner is Maria Higgins at (760) 480-7647. 4- ts Revised : 1 0108103 Contract No. 38891 Page 67 of 98 Pages Manufacturers shall furnish SDG&E approved equipment. Complete shop drawings and fabrication drawings of service equipment shall be submitted to SDG&E for review and approval prior to fabrication. Attached as Appendix C are SDG&E service order drawings for site plan, service equipment, and slab boxes for the proposed 480 volt service. 7-8 PROJECT SITE MAINTENANCE. 7-8.1 Cleanup and Dust Control. Add the following: Cleanup and dust control required herein shall also be executed on weekends and other non-working days when needed to preserve the health safety or welfare of the public. The Contractor shall conduct effective cleanup and dust control throughout the duration of the Contract. The Engineer may require increased levels of cleanup and dust control that, in hidher sole discretion, are necessary to preserve the health, safety and welfare of the public. Cleanup and dust control shall be considered incidental to the items of work that they are associated with and no additional payment will be made therefor. 7-8.5 Temporary Light, Power and Water. The Contractor shall obtain a construction meter for potable water used for the construction, plant establishment, maintenance, cleanup, testing and all other work requiring water related to this contract. The Contractor shall contact the appropriate water agency for requirements. The Contractor shall pay all costs of temporary light, power and water including hookup, service, meter and any, and all, other charges, deposits and/or fees therefor. Said costs shall be considered incidental to the items of work that they are associated with and no additional payment will be made therefor. Add the following: 7-8.6 Storm Water Pollution Prevention Requirements, Add the following: Prior to commencing construction activities, Contractor shall prepare a Storm Water Pollution Prevention Plan (SWPPP) for this project in accordance with the California State Water Resources Control Board Order No. 2001-01-DWQ, NPDES General Permit No. CAS0108758 the “Water Discharge Requirements for Discharges of Storm Water Runoff Associated with Construction Activity”. The SWPPP, including Storm Water Monitoring and Reporting Program, shall fully satisfy all applicable requirements of the General Permit and City of Carlsbad Requirements. The SWPPP shall include the Notice of Intent issued by the State Water Resources Control Board. Contractor shall submit a copy of the SWPPP to the Engineer for filing, and shall maintain a copy of the SWPPP on the job site at all times for review and inspection by the Regional Water Quality Control Board. Contractor shall implement the SWPPP, including training of personnel and implementation of all applicable Best Management Practices (BMPs). Contractor shall also perform the Monitoring and Reporting Program in accordance with the General Permit, maintain a copy of all inspection reports onsite, and submit copies of same to Engineer for filing within seven (7) days after each storm event. Add the following section: 7-8.8 Noise Control. All internal combustion engines used in the construction shall be equipped with mufflers in good repair when in use on the project with special attention to the City Noise Control Ordinance, Carlsbad Municipal Code Chapter 8.48. 7-10 PUBLIC CONVENIENCE AND SAFETY. 7-10.1 Traffic and Access. add the following: The Contractor shall schedule the work so as to prevent damage by all traffic, including but not limited to mail delivery. The Contractor shall not schedule work so as to conflict with trash pickup. The trash hauling schedule can be obtained by calling the City’s contracted waste disposal company, Coast Waste Management at 929-941 7. During overlay operations, the Contractors schedule for overlay application shall be designated to provide residents and business owners whose streets are to be overlaid sufficient paved parking @Revised: 10/08/03 Contract No. 38891 Paae 68 nf QFi Panoc within an 800 foot distance from their homes or businesses. Seventy two hours prior to the start of any construction in the public right-of-way that affects vehicular traffic and/or parking or pedestrian routes, the Contractor shall give written notification of the impending disruption. For a full street closure, all residences and/or businesses on the affected street or alley shall be notified. For partial street closures, or curb, sidewalk and driveway repairs, the residences and/or businesses directly affected by the work shall be notified. The notification shall be hand delivered and shall state the date and time the work will begin and its anticipated duration. The notification shall list two telephone numbers that may be called to obtain additional information. One number shall be the Contractor’s permanent office or field office and the other number shall be a 24 hour number answered by someone who is knowledgeable about the project. At least one of the phone numbers shall be in the (760) area code. An answering machine shall not be connected to either number. The notification shall also give a brief description of the work and simple instructions to the home or business owner on what they need to do to facilitate the construction. The Contractor shall submit the contents of the notification to the Engineer for approval. Notices shall not be distributed until approved by the Engineer. For residences, the notification shall be pre-cut in a manner that enables it to be affixed to a doorknob without adhesives. It shall be a minimum size of 3-1/2 inches by 8-1/2 inches and shall be brightly colored with contrasting printing. The material shall be equivalent in strength and durability to 65 Ib. card stock. The printing on the notice shall be no smaller than 12 point. An example of such notice is provided in Appendix “A. In addition to the notifications, the contractor shall post no parking signs 48 hours in advance of the work being performed. The no parking signs shall state the date and time of parking restriction for a duration not to exceed the time necessary to complete the work at that location. Failure of the contractor to meet the posted date requires re-posting the no parking signs 48 hours in advance of the rescheduled work. If the work is delayed or rescheduled the no parking signs shall be removed and re-posted 48 hours in advance of the rescheduled work. The preparation, materials, printing and distribution of the notifications shall be included in the contract price bid for traffic control and the Contractor will not be entitled to any additional compensation for printing and distributing these notices. 7-10.3 Street Closures, Detours, Barricades. Modify the second paragraph as follows: At least 5 working days prior to closing, detouring, partially closing or reopening any street, alley or other public thoroughfare the Contractor shall notify the following: 1) The Engineer ...................................................................................... (760) 438-1161 X-4411 4) Carlsbad Traffic Signals Maintenance ............................................... (760) 438-2980 X-2937 5) Carlsbad Traffic Signals Operations .................................................. (760) 438-1 161 X-4500 6) North County Transit District .............................................................. (760) 743-9346 7) Coast Waste Management ................................................................ (760) 929-9400 2) Carlsbad fire Department Dispatch .................................................... (760) 931-21 97 3) Carlsbad Police Department Dispatch .............................................. (769) 931-21 97 7-10.3 Street Closures, Detours, Barricades. Add the following: Traffic controls shall be in accordance with the plans, Chapter 5 of the California Department of Transportation “Manual of Traffic Controls,“ 1996 edition and these Supplemental Provisions. If any component in the traffic control system is damaged, displaced, or ceases to operate or function as specified, from any cause, during the progress of the work, the Contractor shall immediately repair said component to its original condition or replace said component and shall restore the component to its original location. In the event that the Contractor fails to install and/or maintain barricades or such other traffic signs, markings, delineation or devices as may be required herein, the Engineer may, at hidher sole option, install the traffic signs, markings, delineation or devices and charge the Contractor twenty dollars ($20.00) per day per traffic sign or device, or the actual cost of providing such traffic control facility, whichever is the greater. Add the following section: 4- %#Revised: 10/08/03 Contract No. 38891 Page 69 of 98 Pages 7-10.3.1 Construction Area Signs and Control Devices. All construction traffic signs and control devices shall be maintained throughout the duration of work in good order and according to the approved traffic control plan. All construction area signs shall conform to the provisions of section 206-7.2 et seq. All temporary reflective pavement markers shall conform to the provisions of section 214-5.1 .et seq. All temporary reflective channelizers shall conform to the provisions of section 214- 5.2 et seq. All paint for temporary traffic striping, pavement marking, and curb marking shall conform to the provisions of section 210-1.6 et seq. except that all temporary paint shall be rapid dry water borne conforming to section 210-1.6 for materials and section 310-5 et seq. For workmanship. Warning and advisory signs, lights and devices installed or placed to provide traffic control, direction and/or warning shall be furnished, installed and maintained by the Contractor. Warning and advisory signs, lights and devices shall be promptly removed by the Contractor when no longer required. Warning and advisory signs that remain in place overnight shall be stationary mounted signs. Stationary signs that warn of non-existent conditions shall be removed from the traveled way and from the view of motorists in the traveled way or shielded from the view of the traveling public during such periods that their message does not pertain to existing conditions. Care shall be used in performing excavation for signs in order to protect underground facilities. All excavation required to install stationary construction area signs shall be performed by hand methods without the use of power equipment. Warning and advisory signs that are used only during working hours may be portable signs. Portable signs shall be removed from the traveled way and shielded from the view of the traveling public during non-working hours. During the hours of darkness, as defined in Division 1, Section 280, of the California Vehicle Code, portable signs shall be illuminated or, at the option of the Contractor, shall be in conformance with the provisions in section 206-7.2 et seq. If illuminated traffic cones rather than post-type delineators are used during the hours of darkness, they shall be affixed or covered with reflective cone sleeves as specified in CALTRANS ‘Standard Specifications”, except the sleeves shall be 180 mm (7”) long. Personal vehicles of the Contractor‘s employees shall not be parked within the traveled way, including any section closed to public traffic. Whenever the Contractor’s vehicles or equipment are parked on the shoulder within 1.8 m (6’) of a traffic lane, the shoulder area shall be closed with fluorescent traffic cones or portable delineators placed on a taper in advance of the parked vehicles or equipment and along the edge of the pavement at 7.6 m (25’) intervals to a point not less than 7.6 m (25’) past the last vehicle or piece of equipment. A minimum of nine (9) cones or portable delineators shall be used for the taper. A C23 (Road Work Ahead) or C24 (Shoulder Work Ahead) sign shall be mounted, as required herein, on a sign post or telescoping flag tree with flags. The sign post or flag tree shall be placed where directed by the Engineer. Add the following section: 7-10.3.2 Maintaining Traffic. The Contractor’s personnel shall not work closer than 1.8 m (6’), nor operate equipment within 0.6 m (2’) from any traffic lane occupied by traffic. For equipment the 0.6 m (2’) shall be measured from the closest approach of any part of the equipment as it is operated and/or maneuvered in performing the work. This requirement may be waived when the Engineer has given written authorization to the reduction in clearance that is specific to the time, duration and location of such waiver, when such reduction is shown on the traffic control plans included in these contract documents, when such reduction is shown on the traffic control plans prepared by the Contractor and approved by the Engineer or for the work of installing, maintaining and removing traffic control devices. As a condition of such waiver the Engineer may require the Contractor to detour traffic, adjust the width of, or realign the adjacent traffic lane, close the adjacent traffic lane or provide barriers. During the entire construction, a minimum of (insert appropriate number of lanes) paved traffic lanes, not less than (insert appropriate minimum lane width 3.6m (12’)) wide, shall be open for use by public traffic in each direction of travel. Add the following section: 7-10.3.3 Traffic Control System for Lane Closure. A traffic control system consists of closing traffic lanes or pedestrian walkways in accordance with the details shown on the plans, CALTRANS “Manual of Traffic Control”, 1996 edition and provisions under “Maintaining Traffic” elsewhere in these Supplemental Provisions. The provisions in this section will not relieve the Contractor from its responsibility to provide such additional devices or take such measures as may be necessary to maintain public safety. em %#Revised: 10/08/03 Contract No. 38891 Paae 70 of 9R Panoc When lanes are closed for only the duration of work periods, all components of the traffic control system, except portable delineators placed along open trenches or excavation adjacent to the traveled way, shall be removed from the traveled way and shoulder at the end work period. If the Contractor so elects, said components may be stored at selected central locations, approved by the Engineer, within the limits of the right-of-way. Add the following section: 7-10.3.4 Traffic Control for Permanent and Temporary Traffic Striping. During traffic stripe operations, traffic shall be controlled with lane closures, as provided for under "Traffic Control System for Lane Closure" of these Supplemental Provisions or by use of an alternative traffic control plan proposed by the Contractor and approved by the Engineer. The Contractor shall not start traffic striping operations using an alternative plan until he has submitted its plan to the Engineer and has received the Engineer's written approval of said plan. Add the following section: 7-1 0.3.5 Temporary Pavement Delineation. Temporary pavement delineation shall be furnished, placed, maintained and removed in accordance with the minimum standards specified in Chapter 5 of the "Traffic Manual", 1996 edition published by CALTRANS. Whenever the work causes obliteration of pavement delineation, temporary or permanent pavement delineation shall be in place prior to opening the traveled way to public traffic. Lane line or centerline pavement delineation shall be provided at all times for traveled ways open to public traffic. All work necessary, including any required lines or marks, to establish the alignment of temporary pavement delineation shall be performed by the Contractor. When temporary pavement delineation is removed, all lines and marks used to establish the alignment of the temporary pavement delineation shall be removed by grinding. Surfaces to receive temporary pavement delineation shall be dry and free of dirt and loose material. Temporary pavement delineation shall not be applied over existing pavement delineation or other temporary pavement delineation. Temporary pavement delineation shall be maintained until superseded or replaced with permanent pavement delineation. Temporary pavement delineation shall be removed when, as determined by the Engineer, the temporary pavement delineation conflicts with the permanent pavement delineation or with a new traffic pattem for the area and is no longer required for the direction of public traffic. When temporary pavement delineation is required to be removed, all lines and marks used to establish the alignment of the temporary pavement delineation shall be removed. Add the following section: 7-10.3.6 Preparation of New, or Modifications and Additions to Existing, Traffic Control Plan Sheets. If no traffic control plans (TCP) or Traffic Control Staging plans (TCP) are included in the project plans, or if the Contractor elects to modify TCP included in the project plans, the Contractor shall have such new or modified TCP prepared and submitted as a part of the Work for any and all construction activities that are located within the travelled way. The Contractor shall have TCP prepared and submitted as a part of the Work for any construction activities that are a part of this project that are not included in the project plans. The Contractor must submit the TCP for the Engineer's review in conformance with the requirements of section 2-5.3, et seq. and obtain the Engineer's approval of the TCP prior to implementing them. The minimum 20 day review period specified in section 2-5.3.1 for shop drawings and submittals shall pertain to each submittal of TCP, new, modified or added to, for the Engineer's review. New or revised TCP submittals shall include all TCP needed for the entire duration of the Work. Each phase of the TCP shall be shown in sufficient scale and detail to show the lane widths, transition lengths, curve radii, stationing of features affecting the traffic control plan and the methodology proposed to transition to the subsequent TCP phase. When the vertical alignment of the travelled surface differs from the finished pavement elevation vertical curves must also be shown. Such modifications, supplements and/or new design of TCP shall meet the requirements of the Engineer and of the "MANUAL OF TRAFFIC CONTROLS", 1996 Edition as published by the State of California Department of Transportation. Such modification, addition, supplement, and/or new design of TCP shall be prepared by a registered professional engineer appropriately registered in the State of California. The Engineer shall be the sole judge of the suitability and quality of any such modifications, supplements, and/or new designs to TCP. The Engineer may approve any such modifications, 4- tSRevised: 10/08/03 Contract No. 38891 Page 71 of 98 Pages supplements, and/or new designs to the TCP when, in the Engineer's sole opinion, such modifications, supplements, and/or new designs to the TCP prepared by the registered professional engineer retained by the Contractor will be beneficial to the best interests of the Agency. Such modification, addition, supplement, and/or new design shall not be implemented and no work shall be commenced that is contingent on such approval until the changed TCP are approved by the Engineer. The preparation of such modification, addition, supplement, and/or new designs of TCP shall not presuppose their approval or obligate the Agency in any fashion. Submittal and review requirements for such modifications, supplements, and/or new designs to TCP shall conform to the requirements of section 2-5.3 Shop Drawings and Submittals. Add the following section: 7-10.3.7 Payment. The Contractor shall prepare and correct TCP and shall furnish all labor and materials to perform, install, maintain, replace and remove all traffic control as incidentals to the work with which they are associated and no other compensation will be allowed therefor. Add the following section: 7-10.4.4 Safety and Protection of Workers and Public. The Contractor shall take all necessary precautions for the safety of employees on the work and shall comply with all applicable provisions of Federal, State and Municipal safety laws and building codes to prevent accidents or injury to persons on, about, or adjacent to the premises where the work is being performed. The Contractor shall erect and properly maintain at all times, as required by the conditions and progress of the work, all necessary safeguards for the protection of workers and public, and shall use danger signs warning against hazards created by such features of construction as protruding nails, hoists, well holes, and falling materials. 7-12.1 Project Signs. The Contractor shall provide one (1) project sign at location determined by the Engineer. The project sign shall be 4' by 8' in size and supported by two (2) 6" x 6" pressure treated posts (Douglas Fir No. 1) at a height of 4' aboveground. The sign shall consist of 3/4" structural No. 1 Douglas Fir A-C plywood (touch sanded exterior glue) and painted front and back with one coat of primer and two coats of gloss white enamel with border and lettering being gloss black enamel. The City of Carlsbad decal and sign information will be provided by the Engineer. Payment for the sign (including all labor, equipment, and installation) shall be included in the bid item for mobilization. 7-13 LAWS TO BE OBSERVED. Add the following: Municipal ordinances that affect this work include Chapter 11.06. Excavation and Grading. If this notice specifies locations or possible materials, such as borrow pits or gravel beds, for use in the proposed construction project which would be subject to Section 1601 or Section 1603 of the Fish and Game Code, the conditions established pursuant to Section 1601 et seq. of the Fish and Game Code shall become conditions of the contract. SECTION 9 -- MEASUREMENT & PAYMENT 9-1 MEASUREMENT OF QUANTITIES FOR UNIT PRICE WORK 9-1.4 Units of Measurement, modify as follows: The system of measure for this contract shall be the U.S. Standard Measures. 9-3 PAYMENT. 9-3.1 General. Delete the eighth paragraph and substitute the following: Guarantee periods, shall not be affected by any payment but shall commence on the date of recordation of the "Notice of Com pletion ." e= %#Revised: 10/08/03 Contract No. 38891 Paae 72 of 938 Panoc 9-3.2 Partial and Final Payment. Delete the second paragraph and substitute the following: Each month, the Engineer will make an approximate measurement of the work performed to the closure date as basis for making monthly progress payments. The estimated value will be based on contract unit prices, completed change order work and as provided for in Section 9-2 of the Standard Specifications (SSPWC). Progress payments shall be made no later than thirty (30) calendar days after the closure date. Five (5) working days following the closure date, the Engineer shall complete the detailed progress pay estimate and submit it to the Contractor for the Contractor’s information. Should the Contractor assert that additional payment is due, the Contractor shall within ten (IO) days of receipt of the progress estimate, submit a supplemental payment request to the Engineer with adequate justification supporting the amount of supplemental payment request. Upon receipt of the supplemental payment request, the Engineer shall, as soon as practicable after receipt, determine whether the supplemental payment request is a proper payment request. If the Engineer determines that the supplemental payment request is not proper, then the request shall be returned to the Contractor as soon as practicable, but not later than seven (7) days after receipt. The returned request shall be accompanied by a document setting forth in writing the reasons why the supplemental payment request was not proper. In conformance with Public Contract Code Section 20104.50, the City shall make payments within thirty (30) days after receipt of an undisputed and properly submitted supplemental payment request from the Contractor. If payment of the undisputed supplemental payment request is not made within thirty (30) days after receipt by the Engineer, then the City shall pay interest to the Contractor equivalent to the legal rate set forth in subdivision (a) of Section 685.01 0 of the Code of Civil Procedure. Add paragraph 6 et seq. as follows: After final inspection, the Engineer will make a Final Payment Estimate and process a corresponding payment. The estimate will be in writing and shall be for the total amount owed the Contractor as determined by the Engineer and shall be itemized by the contract bid item and change order item with quantities and payment amounts and shall show all deductions made or to be made for prior payments and amounts to be deducted under provisions of the contract. All prior estimates and progress payments shall be subject to correction in the Final Payment Estimate. The Contractor shall have 30 calendar days from receipt of the Final Payment Estimate to make written statement disputing any bid item or change order item quantity or payment amount. The Contractor shall provide all documentation at the time of submitting the statement supporting its position. Should the Contractor fail to submit the statement and supporting documentation within the time specified, the Contractor acknowledges that full and final payment has been made for all contract bid items and change order items. If the Contractor submits a written statement with documentation in the aforementioned time, the Engineer will review the disputed item within 30 calendar days and make any appropriate adjustments on the Final Payment. Remaining disputed quantities or amounts not approved by the Engineer will be subject to resolution as specified in subsection 3-5, Disputed Work. The written statement filed by the Contractor shall be in sufficient detail to enable the Engineer to ascertain the basis and amount of said disputed items. The Engineer will consider the merits of the Contractor’s claims. It will be the responsibility of the Contractor to furnish within a reasonable time such further information and details as may be required by the Engineer to determine the facts or contentions involved in its claims. Failure to submit such information and details will be sufficient cause for denying payment for the disputed items. 9-3.2.1 Payment for Claims. Add the following: Except for those final payment items disputed in the written statement required in subsection 9-3.2 all claims of any dollar amount shall be submitted in a written statement by the Contractor no later than the date of receipt of the final payment estimate. Those final payment items disputed in the written statement required in subsection 9-3.2 shall be submitted no later than 30 days after receipt of the Final Payment estimate. No claim will be considered that was not included in this written statement, nor will any claim be allowed for which written notice or protest is required under any provision of this contract including sections 3-4 Changed Conditions, 3-5 Disputed Work, 6-6.3 Payment for Delays to Contractor, 6-6.4 Written Notice and Report, or 6-7.3 Contract Time Accounting, unless the Contractor has complied with notice or protest requirements. ern %#Revised: 10/08/03 Contract No. 38891 Page 73 of 98 Pages The claims filed by the Contractor shall be in sufficient detail to enable the Engineer to ascertain the basis and amount of said claims. The Engineer will consider and determine the Contractor’s claims and it will be the responsibility of the Contractor to furnish within a reasonable time such further information and details as may be required by the Engineer to determine the facts or contentions involved in its claims. Failure to submit such information and details will be sufficient cause for denying the claims. Payment for claims shall be processed within 30 calendar days of their resolution for those claims approved by the Engineer. The Contractor shall proceed with informal dispute resolution under subsection 3-5, Disputed Work, for those claims remaining in dispute. Add the following section: 9-3.3.1 Delivered Materials. into the work will be included in the progress estimate. Add the following section: 9-3.4.1 Mobilization, Preparatory Work, and Demobilization. Payment for mobilization, preparatory work, and demobilization will be made at the stipulated lumpsum price bid therefor in the bid schedule. The Contract lump-sum price includes full compensation for furnishing all insurance, bonds, licenses, labor, materials, utilities, tools, equipment and incidentals, and for doing all the work involved in mobilization and preparatory work and operations, including, but not limited to, those necessary for the movement of personnel, equipment, supplies, and incidental to preparing to conduct work on and off the project site and other offsite facilities necessary for work on the project; for all other facilities, sureties, work and operations which must be performed or costs incurred prior to beginning work on various contract items on or off the project site, excepting those specifically paid for under separate sections of these specifications. The Contractor hereby agrees that the stipulated lump sum amount is sufficient for Mobilization, Preparatory Work, and Demobilizaiton, as described in this section, and that the Contractor shall have no right to additional compensation for Mobilization, Preparatory Work, and Demobilization. The cost of materials and equipment delivered but not incorporated Progress payments for Mobilization, Preparatory Work, and Demobilization will be made as follows: For the first progress payment (after the issuance of the Notice to Proceed), forty percent (40%) of the amount bid for Mobilization, Preparatory Work, and Demobilization will be allowed. For the second progress payment, an additional thirty percent (30%) of the amount bid for mobilization, preparatory work, and demobilization will be allowed therefor. The remainder of the bid amount shall be paid after demobilization and site cleanup is complete to the satiskction of the Engineer. 4- %#Revised: 10/08/03 Contract No. 38891 Paae 74 nf CJR Panac SUPPLEMENTAL PROVISIONS TO STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART 2, CONSTRUCTION MATERIALS SECTION 203 -- BITUMINOUS MATERIALS 203-6 ASPHALT CONCRETE. DELETE sections 203-6.2 and 203-6.3.2 and ADD the following: 203-6.1 General. Add the following: The Contractor shall submit a design mix report and verification data for review by the Engineer for each source of supply and type of mixture specified. The design mix report shall indicate the results of all testing requirements identified in sections 203-1.2 and 203- 6.3 of the standard specifications for public works construction and these special provisions. 203-6.2 Materials. Add the following: Asphalt concrete shall be class C2-AR-4000 for surface course, and B-AR-4000 for base course. Asphalt concrete shall be class D2-AR-8000 for dikes and class E-AR-8000 ditches. 203-6.3.2 Composition and Grading. Add the following: Evaluation of asphalt concrete shall be determined from samples of asphalt concrete taken after completion of all processing (Wet Mix) or by core sample analysis of the in-place asphalt concrete or by direct central plant inspection that confirms the production of a particular mix design and verifies using samples of aggregate taken before the addition of asphalt and mineral filler (Bin). All samples shall be taken in accordance with Calif. Test 125. When Wet Mix or Core samples of asphalt concrete are to be used for evaluation, sufficient size samples shall be taken to ensure representative and adequate quantity of material for: 1. Asphalt Content and Gradation of Extraction using Calif. Test 382 or ASTM 2172, and Calif. Test 202. 2. Stability’ using: a. b. Stabilometer Value2 using Calif. Test 366 and shall be the average of three individual Stabilometer Values And/or Marshall Stability in accordance with the Asphalt Institute’s MS-2 fabricated and tested for traffic volume and shall be the average of three specimens. ’Stability will be waived provided the extracted asphalt concrete is within +/-.5 of mix design and the extracted gradation complies with Table 203-6.3.2 (A). Use Marshall Stability when the deviation between individual Stabilometer Values are greater than +/-4. 2 When using core sample analysis, the samples must be properly prepared to safeguard against influx of outside contaminates and so that the cut surfaces do not influence the test results. The amount of asphalt binder used in asphalt concrete placed in dikes, gutters, gutter flares, overside drains and aprons at the ends of drainage structures shall be increased one percent by mass of the aggregate over the amount of asphalt binder determined for use in asphalt concrete placed on the traveled way. 4- tSRevised: 10/08/03 Contract No. 38891 Page 75 of 98 Pages 203-6.3.3 Acceptance. Wet Mix or Core sampled asphalt concrete will be considered in conformance with the mix design when the asphalt content is within +/-.5 of the design mix and the gradation conforms to the grading as shown in Table 203-6.3.2 (A). Deviations in gradation may be considered in conformance with the mix design provided the stability of the completed mix complies with the requirements for Stabilometer Value per Table 203-6.3.2 (A) Marshall Stability using Asphalt Institute MS-2. Property Hardness (indentation) Tensile Strength Elongation Flex at 40°C Weathering Resistance Salt-Spray Resistance Dielectric Constant Plant inspected asphalt concrete will be considered in conformance with the mix design when visually inspected and the combined gradation of the Bin samples show conformance to the grading as shown in Table 203-6.3.2 (A). 203-6.6.2, Batch Plant Method, modify as follows: Third paragraph, last sentence, delete "and from the Engineer's field laboratory". Last paragraph, add after D 21 72: "method A or B." 203-6.7 Asphalt Concrete Storage. Open graded asphalt concrete stored in excess of 2 hours, and any other asphalt concrete stored in excess of 18 hours, shall not be used in the work. add the following: Measuring Standard Results Conditions (ASTM Designation) ASTM D 2240 Rex. 25°C @ 50% relative Type A, Model 1700 humidity ASTM D 412 Die C, pulled at 508 mm (20") per minute ASTM D 412 Die C, pulled at 508 mm (20") per minute 0.6 mm (25 mil) Free over 13 mm ('/2") Mandrel Film Bend (180") ASTM D 822 Slight chalking Cured 7 days at 25°C @ Weatherometer 350 h 50% relative humidity ASTM B 11 7 28 days 5% NaCI, Die C, pulled at at 38°C tensile; 400% minimum 508 mm (20") per minute ASTM D 150 over a temperature range of 65 - 85 3.45 MPa, minimum 400%, minimum No cracks 3.45 MPa, minimum Elongation Less than 25% change -30EC to 50EC Add the following section: 203-1 1 ASPHALT PAVEMENT CRACK SEALANTS 203-11.2 Asphaltic Emulsion Sealant. Asphaltic emulsion sealant shall conform to the State of California Specification 8040-41A-15 and shall be used only for filling slots in asphalt concrete pavement. This material shall not be used in slots which exceed 16 mm (5/8") in width or where the slope causes the material to run from the slot. The material shall not be thinned in excess of the manufacturer's recommendations and shall not be placed when the air temperature is less than 7°C (45°F). 203-1 1.3 Hot-Melt Rubberized Asphalt Sealant. Hot-melt rubberized asphalt shall be in solid form at room temperature and fluid at an application temperature of 190°C (375°F) to 205°C 4- tg Revised: 10/08/03 Contract No. 38891 Page 76 of 98 Paaes (400°F). Fumes from the material shall be non-toxic. Sealant shall be suitable for use in both asphalt concrete and portland cement concrete. Performance characteristics of the cured hot- melt rubberized asphalt shall be as per Table 203-1 1.3(A). Property Measuring Standard (ASTM Results Cone Penetration ASTM D 3407, Sec. 5 3.5 mm, max Flow, 60°C ASTM D 3407, Sec. 6 5 mm, max Resilience ,ASTM D 3407, Sec. 8 25%, min. Softening Point, ASTM D 36 82 “C, min. Duct i I it y, Flash Point, COC, “C ASTM D 92 288 “C, min. Viscosity, Brookfield ASTM D 4402 2.5-3.5 Pa-s Designation) ASTM D 113 300 mm, min. TABLE 203-1 I .3(A) Conditions 25”C, 150 g, 5 s 25°C 25”C, 50 mm/min No. 27 Spindle, 20 USES Headers for bituminous pavement up to 50 mm x 100 mm (Z”x4) Headers for bituminous pavement larger than 50 mm x 100 mm (Z”x4”) Thermosel, I I I rpm, 190”6, GRADES Construction grade Redwood or preservative treated construction grade Douglas Fir Number 1 grade Redwood, or preservative treated number 1 grade Douglas Fir SECTION 204 - LUMBER AND TREATMENT WITH PRESERVATIVES 204-1 LUMBER AND PLYWOOD SECTION 206 - MISCELLANEOUS METAL ITEMS Add the following section: 206-7 TRAFFIC SIGNS. Add the following section: 206-7.1 Permanent Traffic Signs Permanent traffic signs shall consist of IO-gage and 12-gage cold-rolled steel perforated tubing. This includes all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic upon the completion of the Work unless otherwise shown on the plans. Add the following section: 206-7.1.1 General. Materials, legend, proportion, size, and fabrication of all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall conform to the requirements of “SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993”, Sheets 1 through 5 that accompany “SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993” of dimensions and details, dated April 1987, and “OPAQUE COLOR CHART”, dated February 1980, all published by the State of California, Department of Transportation, Division of Procurement Services, Office of Material Operations, 1900 Royal Oaks Drive, Sacramento, CA 9581 9 and as modified herein. Where the “SPECIFICATION FOR REFLECTIVE SHEETING SIGNS, October 1993” require the Contractor or supplier to notify the Department of Transportation or to certify compliance to said SPECIFICATIONS, to provide a quality control program or to allow testing, approval, observation of manufacturing or assembly operations by the State of California, Department of Transportation andlor its employees or officials, such rights shall be vested in the Engineer. 4- tSRevised: 10/08/03 Contract No. 38891 Page 77 of 98 Pages Add the following section: 206-7.1.2 Sign Identification. Modify the “SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993” as follows: Sign identification shall be as per “SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993, except that the notation shall be “PROPERTY OF THE CITY OF CARLSBAD”. Add the following section: 206-7.1.3 Drawings. Modify the “Specifications For Reflective Sheeting Signs, October 1993” as follows: Standard signs shall be as per the most recently approved “Approved Sign Specification Sheets” of the State of California, Department of Transportation. The date of approval shall be the date most closely preceding the date of manufacture of the sign(s) or the date of the “Notice to Proceed” of this contract, whichever is most recent. Add the following section: 206-7.1.4 Reflective Sheeting. Modify the “Specifications For Reflective Sheeting Signs, October 1993” as follows: All advisory signs, warning signs and all regulatory signs shall be fabricated with Type Ill encapsulated lens sheeting confbrming to the requirements of this specification. Add the following section: 206-7.1.5 Substrate. Modify the “Specifications For Reflective Sheeting Signs, October 1993” as follows: All permanent traffic signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall use aluminum substrate. Add the following section: 206-7.1.6 Mounting Traffic Signs. Traffic signs shall be installed on IO-gage or 12-gage cold- rolled steel perforated tubing posts as shown on San Diego Regional Standard drawing M-45 or, when the sign area exceeds the maximum area allowed for on that drawing, on multiple 10-gage or 12-gage cold-rolled steel perforated tubing posts. The number of posts shall be determined by the parameters in SDRS drawing M-45 or as approved by the Engineer. Traffic signs will be provided with back braces and mounting blocks as approved by the Engineer consisting of IO-gage or 12-gage cold-rolled steel perforated tubing when multiple posts are used. Add the following section: 206-7.1.6 Traffic Sign Posts. perforated tubing posts as shown on San Diego Regional Standatd drawing M-45. Add the following section: 206-7.2 Temporary Traffic Signs. direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic during the Contractor’s performance of the Work. Temporary traffic signs include both stationary and portable signs. Posts shall be constructed of IO-gage or 12-gage cold-rolled steel Temporary traffic signs shall consist of all signs used for the Add the following section: 206-7.2.1 General. Materials, legend, proportion, size, and fabrication of all temporary traffic signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall conform to the requirements of “Specifications For Reflective Sheeting Signs, October 1993”, Sheets 1 through 5 that accompany “Specifications For Reflective Sheeting Signs, October 1993” of dimensions and details, dated April 1987, and “OPAQUE COLOR CHART”, dated February 1980, all published by the State of California, Department of Transportation, Division of Procurement Services, Office of Material Operations, 1900 Royal Oaks Drive, Sacramento, CA 95819 and as modified herein. Where The “Specification For Reflective Sheeting Signs, October 1993” require the Contractor or supplier to notify the Department of Transportation or to certify compliance to said “Specifications For Reflective Sheeting Signs, October 1993”, to provide a quality control program or to allow testing, approval, observation of manufacturing or assembly operations by the State of California, Department of Transportation and/or its employees or officials, such rights shall be vested in the Engineer. Add the following section: e= \#Revised: 10/08/03 Contract No. 38891 Pam 78 nf QR Pannc 206-7.2.2 Drawings. Modify the “Specifications For Reflective Sheeting Signs, October 1993” as follows: Standard temporary traffic signs shall be as per the most recently approved “Approved Sign Specification Sheets” of the State of California, Department of Transportation. The date of approval shall be the date most closely preceding the date of manufacture of the sign(s) or the date of the “Notice to Proceed” of this contract, whichever is most recent. Add the following section: 206-7.2.3 Reflective Sheeting. Modify the “Specifications For Reflective Sheeting Signs, October 1993” as follows: All advisory signs, warning signs and all regulatory signs shall be fabricated with Type Ill encapsulated lens sheeting conbrming to the requirements of this specification. Add the following section: 206-7.2.4 Substrate. Modify the “Specifications For Reflective Sheeting Signs, October 1993” as follows: Excepting only construction warning signs used at a single location during daylight hours for not more than five (5) consecutive days, all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall be stationary mounted and shall use aluminum substrate. Add the following section: 206-7.2.5 Stationary Mounted Temporary Traffic Signs. Stationary mounted temporary traffic signs shall be installed on 1 0-gage and 12-gage cold-rolled steel perforated tubing posts in the same manner shown on the State of California, Department of Transportation “Standard Plans” 1995 edition standard plans numbers RSI, RS2, RS3 and RS4 for installation of roadside signs, except as follows: a) Wood posts shall not be used. b) Back braces and blocks for sign panels will not be required. c) The height to the bottom of the sign panel above the edge of traveled way shall be at least 2.1 m (7’). d) Unless otherwise shown on the plans traffic sign posts shall conform in materials and installation to SDRS drawing M-45 and shall have one post provided for each 0.48 m2 (5 ft2)of sign area, or the signs may be installed on existing lighting standards when approved by the Engineer. e) Sign panels mounted on temporary traffic sign posts shall conform to the requirements specified for aluminum signs in the “Specifications For Reflective Sheeting Signs, October 1993”. Add the following section: 206-7.2.6 Temporary Traffic Sign Posts. Posts shall be IO-gage or 12-gage cold-rolled steel perforated tubing used for the support and stabilization of stationary mounted temporary signs. Post size and number of posts shall be as shown on the plans, except that when stationary mounted signs are installed and the type of sign installation is not shown on the plans, post size and the number of posts will be determined by the Engineer. Sign panels for stationary mounted signs shall consist of reflective sheeting applied to a sign substrate. Add the following section: 206-7.2.7 Portable Temporary Traffic Signs. Each portable temporary traffic sign shall consist of a base, standard or framework and a sign panel. The units shall be capable of being delivered to the site of use and placed in immediate operation. Sign panels for portable signs shall conform to the requirements of sign panels for stationary mounted signs in the “Specifications For Reflective Sheeting Signs, October 1993, or shall be cotton drill fabric, flexible industrial nylon fabric, or other approved fabric. Fabric signs shall not be used during the hours of darkness. Size, color, and leg- end requirements for portable signs shall be as described for stationary mounted sign panels in section 206-7.2 of these Supplemental Provisions. The height to the bottom of the sign panel above the edge of traveled way shall be at least 0.3-m (12”). All parts of the sign standard or framework shall be finished with 2 applications of an orange enamel which will match the color of the sign panel background. Testing of paint will not be required. %$Revised: 10/08/03 Contract No. 38891 Page 79 of 98 Pages Add the following section: 206-8 LIGHT GAGE STEEL TUBING AND CONNECTORS. mm (inches) (1 x 1) (1 ‘/4 X 1 ’/a) (1 ’12 x 1 ’/2) (1 “/4 x 1 ?4) 25 x 25 32 x32 38 x 38 44 x 44 51 x51 (2 x 2) 56 x 56 (2“/,6 x 2“/,6) 57 x 57 (2 x 21/4) 64 x 64 (2V2 x 2’/2) 51 x76 (2 x 3) Add the following section: 206-8.1 General. This Section pertains to IO-gage and 12-gage cold-rolled steel perforated tubing used for the support and stabilization of signs. All shapes shall have a galvanized finish and shall be cold-roll-formed steel conforming to ASTM Designation A-446, Grade A. Galvanizing shall conform to ASTM A-525, Designation G-90. Galvanizing shall be performed after all forming and punching operations have been completed. Cold-rolled steel perforated tubing shall be perforated on all four faces with 11 mm (7/16”) holes on 25 mm (1”) centers. mm (inches) 0.13 0.005 0.15 0.006 0.15 0.006 0.20 0.008 0.20 0.008 0.25 0.01 0 0.25 0.01 0 0.25 0.010 0.25 0.01 0 Add the following section: 206-8.2 Tolerances. Wall thickness tolerance shall not exceed +0.28 mm, -0.13 mm (+0.01 I”, -0.005”). Convexity and concavity measured in the center of the flat side shall not exceed a tolerance of +0.25 rnm (+0.010”) applied to the specific size determined at the corner. Straightness tolerance variation shall not exceed 1.6 mm in 1 m (1/16 “ in 3’). Tolerance for corner radius is 4.0mm (5/32”), plus or minus 0.40 mm (1/64). Weld flash on corner-welded square tubing shall permit 3.60 mm (9/64”) radius gage to be placed in the corner. Using IO-gage or 12-gage square tube, consecutive size tubes shall telescope freely for 3.lm (IO’). Tolerance on hole size is plus or minus 0.40 mm (1/64) on a size. Tolerance on hole spacing is plus or minus 3.2 mm in 6.1 m (1/8” in 20’). In addition, for the following specific sizes of light gage steel tubing, dimensional tolerances shall not exceed those listed in tables 2068.2 (A) and 206-8.2(8). TABLE 206-8.21Al LIGHT GAGE STEEL TUBINGBIZE TOLERANCE Nominal Outside Dimensions I Outside Tolerance for All Sides at Comers TABLE 206-8.21BI LIGHT GAGE STEEL TUBING SQUARENESS OF SIDES AND TWIST [’’ Tubing may have its sides failing to be 90 degrees to each other by the tolerance listed. Twist is measured by holding down the edge of one end of a square tube on a surface plate with the bottom side of the tube parallel to the surface plate, and noting the height that either corner on the opposite end of the bottom side is above the surface plate. 4- %#Revised: 10/08/03 Contract No. 38891 Add the following section: 206-8.3 Fasteners. Fasteners used to assemble cold-rolled steel perforated tubing shall be steel “pull-through” electrogalvanized rivets with 9.5 mm (3/8”) diameter shank, 22 mm (7/8”) diameter head, and a grip range of from 5 mm (0.200”) to 0.90 mm (0.356”). The fasteners shall conform to ASTM B-633, Type Ill 4- %#Revised: 10/08/03 Contract No. 38891 Page 81 of 98 Pages SUPPLEMENTAL PROVISIONS TO STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART 3, CONSTRUCTION METHODS SECTION 300 - EARTHWORK 300-1 CLEARING AND GRUBBING. 300-1 .I General. add the following to the third paragraph: During surface clearing operations, the Contractor shall not cover or bury any plant growth or other objectionable materials. If the Contractor cannot successfully separate the plant growth from the surface soil and advertently or inadvertently mixes organic or other objectionable materials with the soil, the soil so contaminated shall be removed from the site by the Contractor. All costs, if any, associated with removing the soil mixed with organic or other objectionable materials and importing soil to replace said contaminated soil shall be bome by the Contractor and no additional payment therefor shall be made to the Contractor. 300-1.3 Removal and Disposal of Materials. add the following: Also included in clearing and grubbing shall be removal and disposal of existing street poles and lights, metal guard rail, fences, asphalt concrete and aggregate base, concrete curb and gutter, concrete sidewalk, existing gate, existing headwalls, rip-rap, traffic signs, and other existing features which interfere with the work. Whether or not such items are shown on the plans they shall be removed as a part of clearing and grubbing. Existing underground pipes and conduits that are shown on the plans and designated to be removed shall be removed by the Contractor as a part of clearing and grubbing. 300-1.4 Payment. modify as follows: Payment for clearing and grubbing shall be made at the contract lump sum price for clearing and grubbing within the project limits and at stockpile locations and no other payments will be made. Unless otherwise noted on plans, the Contractor shall remove all existing abandoned pipelines and conduits of any type, or use, and pipelines and conduits of any type, or use, that are abandoned during the course of the work and shall replace said pipelines and conduits with properly compacted soils. Payment for removal and disposal of abandoned utilities shall be included in the lump-sum bid for Clearing and Grubbing, and no additional payment will be made. 300-3 STRUCTURE EXCAVATION AND BACKFILL 300-3.1 General. add the following: The Contractor shall excavate to the lines and levels required and/or shown on the Drawings. The Contractor shall provide all shoring, bracing, cribbing, pumping, and planking required. The Contractor shall excavate and maintain the bottom of all trenches in a condition that is level, firm, clean and free from all debris or foreign matter. Excavations shall be kept free from water at all times. The Contractor shall remove any unsuitable material encountered below grade as directed by the Engineer 300-4 UNCLASSIFIED FILL 300-4.2 Preparation of Fill Areas. add the following: Except as provided in section 300-4.7, “Compaction”, areas proposed for improvements all fill (including backfill and scarified ground surfaces) shall be compacted by the Contractor to no less than 90 percent of maximum dry density as determined in accordance with ASTM Test Procedure D1557-91. 300-4.6 Application of Water. add the following: The Contractor shall place all fill soil at a moisture content no less than one (I) percent below optimum moisture as determined by ASTM test D-1557- 91. a %#Revised: 10/08/03 Contract No. 38891 300-4.7 Compaction. add the following: The Contractor shall compact all fill soils placed within the top 1 m (3’) of roadway subgrade to a minimum of 95 percent relative compaction. On all areas to receive planting, the top 150 mm (6”) shall be compacted to 85’30, +2% -5%, to allow for plant growth. 300-4.8 Slopes. add the following: Feathering of fill over the tops of slopes will not be permitted. The Contractor shall compact the faces of fill slopes with a sheep’s foot roller at vertical intervals no greater than 600 mm (2’) or shall be built and cut back to finish grade. In addition, if not over built and cut back, the face of the slope shall be track walked upon completion. 300-5 BORROW EXCAVATION. Tests Test Method No. R-Va I ue Calif. 301 Expansion Index UBC Standard 18-2 Plasticity Index ASTM D 424 Sieve Analysis ASTM D 422 Add the following section: 300-5.2.1 Imported Borrow Properties. The Contractor shall provide imported borrow that is clean well graded soil consisting of material conforming to all of the requirements in Table 300- 5.2.1(A) and the following requirements. Rock included in the top 1 m (3’) of imported borrow shall be particles of less than 75 mm (3”). Rock included below the top 1 m (3’) of imported borrow shall be particles of less than 150 mm (6”). TABLE 300-5.2.1 IA) Requirements 40 Min. 10 Max. 4 Max. Percent Passing 75p (No. 200) 15 Max. 300-9 GEOTEXTILES FOR EROSION CONTROL. Modify as follows: 300-9 GEOTEXTILES FOR EROSION CONTROL AND WATER POLLUTION CONTROL. Add the following section: 300-9.2 General. The Contractor shall provide erosion control and water pollution control conforming to the requirements shown on the plans, as specified herein, and as elsewhere required by the Contract Documents. Erosion control and water pollution control shall include the work specified herein, and such additional measures, as may be directed by the Engineer, to meet Best Management Practices, as defined herein, and to properly control erosion and storm water damage to the limits of work and construction impacts upon areas receiving drainage flows from within the limits of work. Add the following section: 300-9.2.1 Grading Controls. The Contractor shall protect all areas that have been graded and/or cleared and grubbed as well as areas that have not been graded and/or cleared and grubbed within the limits of work from erosion. The Contractor shall provide temporary earth berms, gravel bags, silt fences, stabilized construction entrances and similar measures, coordinated with its construction procedures, as necessary and as shown on the plans to control on site and off site erosion during the construction period. The Contractor will be required to protect areas which have been cleared and grubbed prior to excavation or embankment operations, and which are subject to runoff during the duration of the contract. The criteria used to determine the appropriate erosion control measures shall be the “Best Management Practices”, hereinafter BMP, defined and described in the, “California Storm Water Best Management Handbook, Construction Activity”, latest edition as published by the Storm Water Quality Task Force. The Contractor shall maintain a copy of the “California Storm Water Best Management Handbook, Construction Activity”, .latest edition on the project site and shall conduct its operations in conformity to said Handbook. Temporary erosion control measures provided by the Contractor shall include, but not be limited to, the following: a) Embankment areas, while being brought up to grade and during periods of completion prior to final roadbed construction, shall be graded so as to direct runoff into impoundment areas within e= ESRevised: 10/08/03 Contract No. 38891 Page 83 of 98 Pages the limits of work where such runoff shall have pollutants removed by BMP methods . b) The Contractor shall provide protection by BMP measures to eliminate erosion and the siltation of downstream facilities and adjacent areas. These measures shall include, but shall not be limited to: temporary down drains, either in the form of pipes or paved ditches with protected outfall berms; graded berms around areas to eliminate erosion of embankment slopes by surface runoff; confined ponding areas to desilt runoff; and to desilt runoff. c) Excavation areas, while being brought to grade, shall be protected from erosion and the resulting siltation of downstream facilities and adjacent areas by the use of BMP measures . These measures shall include, but shall not be limited to, methods shown on the plans and described herein. SECTION 301 - TREATED SOIL, SUBGRADE PREPARATION AND PLACEMENT OF BASE MATERIALS 301-1 SUBGRADE PREPARATION. 301-1.2 Preparation of Subgrade. Modify the second and third paragraphs as follows: Change each instance reading “150mm (6 inches)” to “300 mm (12”)”. 301-1.3 Relative Compaction. Delete the first paragraph and substitute the following: The Contractor shall compact the upper 300 mm (12”) of subgrade beneath areas to be paved, have base or subbase material placed on them, or curb, gutter, curb and gutter, alley pavement, driveway or sidewalk constructed over them to no less than 95 percent maximum dry density as determined by ASTM test D-I 557-91. SECTION 302 - ROADWAY SURFACING 302-5 ASPHALT CONCRETE PAVEMENT. 302-5.1 General. add the following: The Contractor shall treat all vegetation within the limits of the paved area to receive asphalt concrete paving with a post emergent herbicide. Herbicide shall be applied at least 2 (two) working days prior to paving the area. Allowance for the two day period shall be shown in the schedule required per section 6-1. 302-5.2.5 Pavement Transitions. add the following: The Contractor shall ramp the approaches and termini to all structures and vertical joints in the cold-milled area which are transverse to through traffic with temporary asphalt concrete pavement as specified in section 306-1 5.1. Ramps shall be constructed the same day as cold milling and removed the same day as permanent paving. Ramp dimensions and compaction shall be as apptoved by the Engineer. 302-5.4 Tack Coat. add the following: The Contractor shall place a tack coat between the successive interfaces of existing pavement and new pavement when, in the opinion of the engineer, the Contractor has failed to maintain or prepare each existing or previously laid course of asphalt receiving the subsequent course of asphalt in a sufficiently clean state and the asphalt receiving the new pavement course is dirty enough to impair bonding between the next lift of asphalt. 302-5.5 Distribution and Spreading. modify as follows: After second sentence of sixth paragraph, add: The Contractor shall provide the spreading and finishing machine used to construct the asphalt concrete surface course with an automatic screed control for surface course paving. The automatic screed control shall be 9 m (30’) minimum length. The paving machine shall be operated by an operator and two full-time screed men during all paving. The surface course shall be 25 mm (1”) thick. Leveling courses will be required in a variable thickness pavement section. 302-5.6.1 General. modify as follows: Second paragraph, Part (2), add: Pinched joint rolling procedures shall be required, and vibratory rollers shall be limited to breakdown, unless otherwise directed by the Engineer. modify as follows: After last paragraph, add: Unless directed otherwise by the Engineer, the initial e- \#Revised: 10/08/03 Contract No. 38891 Paae 84 nf QR Panm breakdown rolling shall be followed by a pneumatic-tired roller as described in this section. Add the following section: 302-9 ASPHALT PAVEMENT REPAIRS AND REMEDIATION Add the following section. 302-9.1 General. Asphalt pavement Repairs and Remediation shall consist of the repair and restoration of existing asphalt pavement. Repair of asphalt pavement shall consist of the saw cutting, removal and disposal of existing asphalt pavement in conformance with section 300-1.3, compaction of existing subgrade in conformance with section 301-1, grading and compaction of base material in conformance with section 301-2, application of grade SS-1 h emulsified asphalt and the placement of asphalt concrete base and wearing courses as specified herein Add the following section. 302-9.2 Full Depth Asphalt Concrete Patch. Full depth asphalt concrete patch shall consist of removing asphalt concrete and/or aggregate basekubgrade to 300 mm (1 ’) below existing asphalt surface and replacing the material so removed with asphalt concrete. The area shown on the plans or set forth in the bid item are for estimating purposes only, final quantity will be as measured in the field. The Engineer will designate and mark the final limits of the asphalt patch area by outlining the area to be patched. The Contractor shall cut such areas to straight lines in square or rectangular areas as marked. The area so cut shall have two of the sides at right angles to the direction of traffic. The excavated faces of the basehubgrade shall be straight and vertical. The Contractor shall compact the upper 300mm (1’) of subgrade to 95% relative compaction. A tack coat of SS-lh emulsified asphalt shfll be applied uniformly to all asphalt to asphalt contact surfaces at a rate of 0.25 L/m2 to 0.45 L/m (0.05 to 0.lOgallons per square yard) in accordance with subsection 302-5.4, SSPWC. The Contractor shall fill and compact areas designated to be removed with 300 mm (1 .O’) full depth asphalt concrete. Asphalt concrete for full depth asphalt concrete patch shall be B-AR- 4000. The asphalt concrete so constructed shall have a finish surface and density conforming to subsection 302-5.6.2 SSPWC. Add the following section. 302-9.3 Crack Sealing The Contractor shall wash, blow out and thoroughly dry all cracks designated to be sealed before installing elastomeric sealant material. The Contractor shall dispose debris from crack cleaning outside the public way in accordance with Section 7-8.1, “Cleanup and Dust Control.” The hot-melt rubberized asphalt shall be melted in a jacketed, double boiler type melting unit. Temperature of the heat transfer medium shall not exceed 245°C (475°F). Application of the hot-melt sealant shall be made with a pressure feed applicator or pour pot. Sealant shall be applied when the pavement surface temperature is greater than 4°C (40°F). Containers of hot-melt sealant shall be delivered to the job-site in unopened containers that are clearly marked with data showing the manufacturer’s name, the product designation and the manufacturer’s batch number and lot numbers. The level of the sealant shall be flush with the surface of the existing pavement. All excess sealant shall be removed from the crack with a minimum overlap onto adjacent pavement. SECTION 310 - PAINTING 310-5 PAINTING VARIOUS SURFACES. 310-5.6 Painting Traffic Striping, Pavement Markings and Curb Markings. Modify the fifth paragraph as follows: The Contractor shall furnish all equipment, materials, labor, and supervision necessary for painting traffic lanes, directional arrows, guidelines, curbs, parking lines, crosswalks, and other designated markings in accordance with the Plans, or for approved temporary detours essential for safe control of traffic through and around the construction site. The Contractor shall remove by wet grinding all existing or temporary traffic markings and lines that may confuse the public. When temporary detour striping or markings are no longer required, they shall be removed prior to painting the new traffic stripes or markings. 31 0-5.6.3 Equipment. Delete the ninth paragraph and substitute the following: The Contractor shall provide a wet grinding machine with sufficient capacity to completely remove all existing or temporary 4- %#Revised: 10/08/03 Contract No. 38891 Page 85 of 98 Pages traffic striping or markings that conflict with the striping plan, or are contrary to the Traffic Manual, or that may be confusing to the public. The surface produced by grinding the existing or temporary traffic striping or markings on pavement shall not exceed variations from a uniform plane more than 3 mm (’/s”) in 3 m (10’) when measured parallel to the centerline of the street or more than 6 mm (‘L,’’) in 3 m (IO’) when measured perpendicular to the centerline of the street. The use of any equipment that leaves ridges, indentations or other objectionable marks in the pavement shall be discontinued, and equipment capable of providing acceptable surface shall be furnished by the Contractor, This equipment shall meet all requirements of the air pollution control district having jurisdiction. 31 0-5.6.6 Preparation of Existing Surfaces. Modify the first paragraph as follows: The Contractor shall remove all existing markings and striping, either permanent or temporary, which are to be abandoned, obliterated or that conflict with the plans by wet grinding methods. Removal of striping by high velocity water jet may be permitted when there is neither potential of the water and detritus from the high velocity water jetting to damage vehicles or private property nor to flow from the street into any storm drain or water course and when approved by the Engineer. The Contractor shall vacuum all water and detritus resulting from high velocity water jet striping removal from the pavement immediately after the water jetting and shall not allow such materials to flow in the gutter, enter the storm drain system or to leave the pavement surface. Surface variation limitations for high velocity water jet striping removal shall be the same as for grinding. The Contractor shall not use dry or wet sandblasting in any areas. Alternate methods of paint removal require prior approval of the Engineer. Obliteration of traffic striping with black paint, light emulsion oil or any other masking method other than a minimum 30mm (0. IO’) thick asphalt concrete overlay is not permitted. 310-5.6.7 Layout, Alignment, and Spotting. Modify the first paragraph as follows: The Contractor shall establish the necessary control points for all required pavement striping and markings by surveying methods. No layout of traffic striping shall be performed by the Contractor before establishment of the necessary control points. The Contractor shall establish all traffic striping between these points by string line or other method to provide striping that will vary less than 80mm per 100m (1/2 inch in 50 feet) from the specified alignment. The Contractor shall obliterate straight stripes deviating more than 80mm per 700mm (I/ 2 inch in 50 feet) by wet grinding, and then correcting the markings. The Contractor shall lay out (cat track) immediately behind installation of surface course asphalt and as the wnrk progresses. 310-5.6.8 Application of Paint. Modify the second paragraph as follows: The Contractor shall apply the first coat of paint immediately upon approval of striping layout by the Engineer. The Contractor shall paint the ends of each median nose yellow. Add the following to the eighth paragraph: The Contractor shall apply temporary traffic stripes in one coat. Temporary traffic stripes shall be maintained by the Contractor so that the stripes are clearly visible both day and night. 310-5.6.10 Measurement and Payment. Modify the first paragraph as follows: Final and temporary traffic striping, curb markings and pavement markings as shown on the plans and required by the specifications shall be included in the lump-sum price bid for temporary and final traffic striping, and no additional compensation will be allowed therefor. Reapplication of temporary stripes and markings shall be repainted at the Contractor‘s expense, and no additional compensation will be allowed therefor. The lump sum prices bid shall include all labor, tools, equipment, materials, and incidentals for doing all work in installing the final and temporary traffic striping. Add the following Section: Add the following Section: 310-7.1 General. Add the following section: The Contractor shall provide and install all permanent traffic control signs at locations shown on plans and as specified herein. 310-7 PERMANENT SIGNING Add the following section: 31 0-7.2 Measurement And Payment. Permanent signing and appurtenances thereto shown on the plans or required in the specifications are a part of the lump-sum item for permanent signing and payment therefor shall include full compensation for furnishing all labor, materials, tools, equipment, 4- t@ Revised: 1 0/08/03 Contract No. 38891 Pane RA nf a9 Panor and incidentals and for doing all the work involved in supplying and installing permanent signing and appurtenances, complete in place, as shown on the plans, as specified in the Standard Specification and these special provisions, and as directed by the Engineer. SECTION 313 - TEMPORARY TRAFFIC CONTROL DEVICES Add the following section: 313-1 TEMPORARY TRAFFIC PAVEMENT MARKERS. Add the following section: 313-1 .I General. The Contractor shall supply and install temporary traffic pavement markers, channelizers, signing, railing (type K), crash cushions and appurtenances at the locations shown on the plans and as required in the specifications, complete in place prior to opening the traveled way served by said final and temporary traffic pavement markers, signing, railing (type K) and appurtenances to public traffic. 313-1.2 Temporary Pavement Markers. Temporary reflective raised pavement markers shall be placed in accordance with the manufacturer’s instructions. Temporary reflective raised pavement markers shall be cemented to the surfacing with the adhesive recommended by the manufacturer, except epoxy adhesive shall not be used to place temporary reflective raised pavement markers in areas where removal of the markers will be required. Pavement striping, legends and markers which conflict with any traffic pattem shall be removed by grinding as determined by the Engineer. The Contractor shall use temporary reflective raised pavement markers for temporary pavement marking, except when the temporary pavement markers are used to replace patterns of temporary traffic stripe that will be in place for less than 30 days. Reflective pavement markers used in place of the removable-type pavement markers shall conform to the section 31 2 “Pavement Marker Placement and Removal”, except the 14-day waiting period before placing the pavement markers on new asphalt concrete surfacing as specified in section 312-1 ”Placement”, shall not apply; and epoxy adhesive shall not be used to place pavement markers in areas where removal of the markers will be required. Add the following section: 313-1.3 Channelizers. Channelizers shall be new surface-mounted type and shall be furnished, placed, and maintained at the locations shown on the plans. Channelizer posts shall be orange in color. Channelizers shall have affixed white reflective sheeting as specified in the special provisions. The reflective sheeting shall be 75 mm x 300 mm (3” x 12”) in size. The reflective sheeting shall be visible at 300 m (1000’) at night under illumination of legal high beam headlights, by persons with vision of or corrected to 20120. The channelizer bases shall be cemented to the pavement in the same manner as provided for cementing pavement markers to pavement in section 312-1, “Placement.” Channelizers shall be applied only on a clean, dry surface. Channelizers shall be placed on the alignment and location shown on the plans and as directed by the Engineer. The channelizers shall be placed uniformly, straight on tangent alignment and on a true arc on curved alignment. All layout work necessary to place the channelizers to the proper alignment shall be performed by the Contractor. If the channelizers are displaced or fail to remain in an upright position, from any cause, the channelizers shall immediately be replaced or restored to their original location, by the Contractor. The Contractor shall provide the Engineer with a Certificate of Compliance in accordance with the provisions of section 4-1.5, “Certification”. Said certificate shall certify that the channelizers comply with the plans and specifications and conform to the prequalified design and material requirements approved by the Engineer and were manufactured in accordance with a quality control program approved by the Engineer. Add the following section: 313-2 TEMPORARY TRAFFIC SIGNING. Add the following section: 313-2.1 General. The Contractor shall provide and install all temporary traffic control signs, markers, markings, and delineators at locations shown on plans and specified herein. 4i-i- %&Revised: 10/08/03 Contract No. 38891 Page 87 of 98 Pages Add the following section: 313-2.2 Maintenance of Temporary Traffic Signs. If temporary traffic signs are displaced or overturned, from any cause, during the progress of the work, the Contractor shall immediately replace the signs in their original approved locations. The Contractor shall maintain all temporary traffic signs used in the Work in a clean, reflective and readable condition. The Contractor shall replace or restore graffiti marked temporary traffic signs and posts used in the Work within 18 hours of such marking being discovered during non-working hours or, when the marking is discovered during working hours, within 2 hours of such discovery of marking. Add the following section: Add the following section: 313-3.1 Temporary Railing and Crash Cushions. Temporary railing (Type K) shall consisf of interconnected new or undamaged used precast concrete barrier units as shown on the plans. Temporary sand-filled crash cushions shall consist of new or undamaged used temporary sand-filled crash cushions units as shown on the plans. 313-3.1.1 Appearance. Exposed surfaces of new and used units of Temporary railing (Type K) shall be freshly coated with a white color paint prior to their first use on the project. The paint shall conform to the provisions in sections 210-1.5 “Paint Systems” and 310 “Painting”. Contractor shall be responsible for the removal and cleanup or painting over the graffiti from the K-Rails within 48 hours. The Contractor Shall replace or repaint units of Temporary railing (Type K) or shall remove graffiti, tire or vehicle marks, dirt or any and all materials such that said marks or discoloration mar the appearance of said units when ordered by the Engineer after the units are in place. Add the following section. 313-3.1.2 Manufacture of Temporary Railing. In addition to the requirements herein the temporary railing (Type K) shall be manufactured per CALTRANS Standard Drawing T3. Concrete used to manufacture Temporary railing (Type K) shall conform to the provisions in sections 201-1, “Portland Cement Concrete” and 303-1 “Concrete Structures”.” Load tickets and a Certificate of Compliance will not be required. Reinforcing steel shall conform to the provisions sections 201-1, “Portland Cement Concrete” and 303-1 “Concrete Structures”. Steel bars to receive bolts at ends of concrete panels shall conform to ASTM Designation: A 36/A 36M. The bolts shall conform to ASTM Designation: A 307. A round bar of the same diameter may be substituted for the end-connecting bolt shown on the plans. The bar shall conform to ASTM Designation: A 36/A 36M, shall have a minimum length of 660 mm and shall have a 75 mm (3”) diameter by 9 mm (3/8”) thick plate welded on the upper end with a 5-mm (3/16’’) fillet weld. The final surface finish of temporary railings (Type K) shall conform to the provisions in section 303-1.9.2 “Ordinary Surface Finish.” Exposed surfaces of concrete elements shall be cured by the water method, the forms-in-place method, or the pigmented curing compound method. The pigmented curing compound shall be type 2 curing compound. Temporary railing (Type K) may have the Contractor’s name or logo on each panel. The name or logo shall not be more than 100 mm in height and shall be located not more than 300 mm above the bottom of the rail panel. 313-3 TEMPORARY RAILING (TYPE K) AND CRASH CUSHIONS. Add the following section. 313-3.1.3 Installation of Temporary Railing. In addition to the requirements herein the temporary railing (Type K) shall be installed per CALTRANS Standard Drawing T3. Temporary railing (Type K) shall be set on firm, stable foundation. The foundation shall be graded to provide a uniform bearing throughout the entire length of the railing. Abutting ends of precast concrete units shall be placed and maintained in alignment without substantial offset to each other. The precast concrete units shall be positioned straight on tangent alignment and on a true arc on curved alignment Each rail unit placed within 3 m (IO’) of a traffic lane shall have a reflector installed on top of the rail as directed by the Engineer. Reflectors and adhesive will be furnished by the Contractor. A Type P marker panel conforming to the requirements of the CALTRANS Traffic Manual shall also be installed at each end of railing installed adjacent to a two-lane, two-way highway and at the end facing traffic of railing installed adjacent to a one-way roadbed. If the railing is placed on a skew, the marker shall be installed at the end of the skew nearest the traveled way. Type P marker panels shall conform to the provisions of section 206-7.2, “Temporary Traffic Signs”. Where shown on the plans, threaded rods e- t# Revised: 10/08/03 Contract No. 38891 Paae 88 of 98 Paaen or dowels shall be bonded in holes drilled in existing concrete. When temporary railings (Type K) are removed, any area where temporary excavation or embankment was used to accommodate the temporary railing shall be restored to its previous condition, or constructed to its planned condition. Add the following section: 31 3-3.2 Temporary Sand-Filled Crash Cushions. Temporary sand-filled crash cushion units shall be “Energite Ill” manufactured by Energy Absorption Systems, “Fitch Inertial Barrier System Modules” manufactured by Roadway Safety Service, or equal. Features required to determine equivalence of any other temporary sand-filled crash cushion units shall be approval of the system by CALTRANS and that the temporary sand-filled crash cushion units meet NCHRP 350 standards. Other features will be suitability to application, operational characteristics, durability and other such characteristics that the Engineer shall determine. Temporary sand-filled crash cushions (TSFCC) shall be of the type and array configurations shown on plans, and installed at every end of, or gap in, the temporary railing (Type K) whenever the closest point of approach of traffic, regardless of direction, is 4.6 m (15’) or less to the end of the temporary railing (Type K) being considered. The TSFCC shall be installed per CALTRANS Standard DrawingsTl and T2 for approach speeds no less than the posted speed of the street prior to construction or 55 kilometers per hour (35 mph), whichever is the greater. The TSFCC array shall be appropriate to the application as shown on said standard drawings. A Type J and/or P marker panel conforming to the requirements of the CALTRANS Traffic Manual shall also be installed at each TSFCC array as shown in CALTRANS Standard Drawings TI and T2. Particular care shall be taken to assure that crash cushions are installed with the soil supporting them and the adjacent soil leveled to match the elevation of the bottom of the temporary railing immediately adjacent to the crash cushion. All routes of approach to the TSCFF array shall be graded such that any vehicle diverging from the travelled way to strike the TSCFF will travel on a vertical alignment parallel to the segment of the travel lane that it departed from. Add the following section: 313-4 MEASUREMENT AND PAYMENT, Temporary traffic pavement markers, temporary channelizers, temporary signing, temporary railing (type K), temporary crash cushions and temporary appurtenances thereto shown on the plans or required in the specifications are a part of the lump- sum item for traffic control and payment therefor shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals and for doing all the work involved in applying, installing, maintaining, and removing temporary traffic pavement markers, channelizers, signing, railing (type K), crash cushions and appurtenances, complete in place, as shown on the plans, as specified in the Standard Specification and these special provisions, and as directed by the Engineer. Payment for temporary crash cushions, concrete barriers and the signs and reflectors marking them shall include the installation, grading for installation, grading for the approach path, maintenance, painting and re-painting, replacement of damaged units and removal and shall also be included in the lump-sum price bid for traffic control. Payment for relocation of K-rails and crash cushions when not shown on the plans and requested by the Engineer shall be made per section 3- 3, Extra Work, SSPWC. e= %@Revised: 10/08/03 Contract No. 38891 Page 89 of 98 Pages SUPPLEMENTAL PROVISIONS FOR ENCINA BASIN WATER RECLAMATION PROGRAM, PHASE II CALAVERA RECYCLED WATER PUMP STATION CONTRACT NO. 38891 SPECIAL CONSTRUCTION PROVISIONS I. Work Site The Contract work site is located in the City of Carlsbad as shown on Sheet 1 of the Construction Drawings. The Calavera Recycled Water Pump Station site is located approximately 1/2 mile south of the intersection of Carlsbad Village Drive and College Boulevard (along the future extension of College Boulevard). Bidders shall review the project site prior to submitting a bid. 2. Storage of Materials and Equipment Contractor shall not store materials or equipment on private or public property without written permission from the affected property owners approving such use. Said written permission shall be submitted to Ower prior to Contractor moving materials or equipment onto site. Contractor's equipment shall be removed from public or private right-of-way and placed in the Contractor's designated storage areas at the end of each work day. Contractor may utilize the Calavera Pump Station site and adjacent recreation lot for storage of materials and equipment. All storage locations shall be approved by the Owner. 3. Earthwork and Soil Compaction Tests Earthwork shall be performed in accordance with the Earthwork Specification Sections 02223 and 02300, except as modified herein or on the Contract Drawings. Contractor shall notify Owner when any work is complete and ready for compaction testing. After such notification, Owner will have all necessary tests made, by a Soils Engineer of his choosing, and Owner will pay for all tests which pass. Contractor shall pay for all tests which fail in the course of determining compliance of completed backfill with compaction requirements. Owner will not pay for any preliminary or progress tests; however, Contractor may do so at his own expense. Passing compaction tests will be required prior to construction of any structures. Excavation of native soil and recompaction shall be performed to provide proper foundation for structures as specified on the Drawings. 4. Preservation of Existing Improvements, Restoration of Work Site and Disposal of Spoil and Waste Materials ern t4Revised: 10/08/03 Contract No. 38891 Paae 90 nf QR Pannc A. Contractor shall perform his operations so that existing improvements (including roads and other paved surfaces adjacent to or in the vicinity of the work site) are not damaged. Contractor shall repair and restore any disturbed or damaged private or public improvements which results from his operations (except that which is specifically a part of the Contract Work) to the satisfaction of the Owner, or the agency having jurisdiction over said improvements, all at his expense. B. All work sites shall be restored to pre-job conditions and shall meet the requirements of Owner and property owner. Owner is obligated to keep visual impact of the work sites to a minimum; therefore, Contractor is required to restore all areas altered by construction to pre-existing conditions. Such areas shall include, but shall not be limited to, areas used for travel, parking, and storage of vehicles, equipment and materials. C. Contractor shall be responsible for the proper disposal of all waste materials resulting from his operations, including rubbish, packaging materials, discarded equipment parts, and damaged construction materials, in a manner and at locations suitable to the Owner and all health and other regulatory agencies. 5. Specified Model Numbers All model numbers used herein are provided for information only, to assist Contractor in selecting equipment that conforms to specifications. In case of any conflict between model numbers given herein and the descriptive specifications or performance specified, the descriptive specifications and performance specified shall govern. 6. Lateral Design All equipment, its major components, anchorage parts, and bolts shall withstand stresses caused by ground movement (seismic forces) in accordance with the requirements of the Uniform Building Code (1997 Edition) for Seismic Zone 4, Essential Facilities. Safety factor for overturning shall be 1.51, The following factors shall be utilized as defined by said UBC: Na = 1.00 Nv = 1.00 Z = 0.40 Ca = 0.36 Na Cv = 0.96 Nv Ts = 1.067 To = 0.213 Calculations and anchorage details shall be prepared by State of California licensed engineer (civil or structural) and submitted in accordance with General Mechanical and Equipment Specifications for the following equipment: A. Pumping Units (pump and motor). B. Electrical Switchgear and Motor Control Center 4.w tSRevised: 10/08/03 Contract No. 38891 Page 91 of 98 Pages C. Surge Arrestor Tank D. Air Compressor and Receiver 7. Location of Equipment and Ambient Environmental Conditions Derating and necessary oversizing to achieve performance shall be incorporated in equipment design. The project site is at an elevation approximately 200' above Mean Sea Level. Maximum design ambient temperature shall be 90°F and minimum design ambient temperature shall be 40°F. Relative humidity may range from 10% to 95%. 8. Equipment Performance Documentation Where performance testing of equipment (field or factory) is specified, the Contractor shall submit to Owner, three copies of performance test results for Owner's review and approval. Performance test data shall demonstrate compliance with the requirements specified in the Contract Documents. Prior to project completion, the Contractor shall combine all such performance test results and data in a standard size, 3-ring, loose leaf, vinyl plastic hard copy binder suitable for bookshelf storage. Each item of equipment shall be properly indexed. For each item of equipment there shall be a brief description of the equipment, description of the test conditions, and performance test results, including performance of the equipment at full load condition. Results shall be submitted to the Ower 60 days prior to project completion. 9. Operation and Maintenance Manuals and Training The Contractor shall provide six (6) approved copies of detailed operations and maintenance (O&M) manuals at least 30 days prior to startup and testing for all mechanical and electrical equipment he furnishes. O&M manuals shall be provided for all equipment and shall be in accordance with requirements specified herein. O&M manuals shall be submitted in accordance with the General Provisions, Section 2-5.3, and shall be subject to approval by the Owner. Each set of O&M Manuals shall consist of one (1) or more volumes, each volume shall be bound in a standard size, 3-ring, loose leaf, vinyl plastic hard cover binder suitable for bookshelf storage. Binder ring size shall not exceed 2.5 inches. Binder(s) shall be provided with the following identification inscribed on the cover(s): "Owner's name, project name, Equipment Operation and Maintenance Manual, Volume No." Each volume shall have a table of contents which indicates all equipment in the O&M manual and tabbed divider sheets placed before each section. The O&M manuals shall include (but not be limited to) the following information: Installation and Operation 1. 2. 3. 4. 5. 6. 7. 8. Installation instruction Design Capabilities Operating Parameters and recommended ranges Specific equipment installed, Model No., Serial No., etc. General literature Operating instructions Special problems or precautions and emergency procedures Safety provisions and precautions Maintenance 4- %#Revised: 10/08/03 Contract No. 38891 1. 2. 3. 4. 5. 6. 7. 8. 9. IO. Assembly, Disassembly, and Reassembly Parts list including drawings (blowup drawings preferred) Lubrication type and schedule Preventative maintenance schedule Recommended replacement parts inventory Details of calibration and adjustment Wiring diagrams (as installed) Completed maintenance card Equipment warranties Name, address, and phone number of local parts distributor and service center The Contractor shall cause the equipment manufacturers to provide experienced and when applicable, factory-trained personnel, to train the Owner's Operation and Maintenance personnel. Training shall include review of the O&M manuals as well as a hands on training period with each piece of equipment listed. No training shall be provided on Mondays or Fridays. The Contractor shall provide a minimum of 14 days advance notice of training sessions. Scheduled training shall be at a time acceptable to the Owner and the Manufacturer. Required training and minimum training time shall be as follows: Equipment Minimum Hours Vertical Turbine Pumps 4 Main Service and Motor Control Center 2 Variable Speed Drives 4 Hydraulic Operated Valves 2 Surge Arrestor System 2 Instrumentation and Controls Including System Interactions 8 Ventilation Equipment 2 The training shall be performed a minimum of 1 day after the completion of start-up. The training shall provide the Owner's Operation and Maintenance personnel with sufficient information on the theory, design, operation and maintenance practices (routine monitoring, eyeing abnormal and normal operation, troubleshooting techniques, and preventative and corrective maintenance) to ensure that equipment and systems can be efficiently and effectively operated and maintained upon training completion. A minimum of 10 training manuals shall be provided. A training manual on each piece of equipment listed shall be submitted to the Engineer for approval a minimum of one month prior to training. Training manuals shall include the experience and qualifications of each instructor. The Engineer or his designee will be attending and monitoring training sessions. If any session is deemed unacceptable by the Engineer, the contents or instructor shall be changed and the session repeated at no cost to the Onner. 10. Geological Conditions at Work Site A soils investigation dated February 25, 2004 by Vinje & Middleton Engineering, Inc. was performed to evaluate the surface and subsurface conditions at the site in order to provide recommendations for engineering design. The data can be used to assist in bid preparation, but said data shall not be construed as a warranty of the geologic conditions existing at the em tSRevised: 10/08/03 Contract No. 38891 Page 93 of 98 Pages site. Contractor shall, therefore, satisfy himself with regard to all geologic conditions which may affect Contract Work. Personal investigation by Contractor is mandatory. Contractor may perform excavations on site prior to bid opening. Contact the Owner to arrange for access to site. Excavations shall not be left open more than two hours. Excavations shall be backfilled and compacted as directed by the Owner. Neither the information contained in the Soil Investigation nor that derived from maps, drawings, or from Owner, his agents or employees shall act to relieve Contractor from any responsibility in fulfilling any and all of the terms and requirements specified herein. Said report is available at Owner's office for review by Contractors. I I. Reference Documents The following documents are available at the Owner's ofice for review by Contractor. These documents provide information relative to existing and proposed facilities. A. Grading Plans for Calavera Hills Phase II, Carlsbad Tract No. 00-02, Drawing No. 390-9. B. Improvement and Utility Plans for Calavera Hills Phase II, Carlsbad Tract No. 00-02, Drawing No. 390-9A. 12. Safety Requirement of Equipment Furnished by Contractor The equipment furnished by Contractor shall comply with the applicable requirements of the Safety Orders of the Division of Industrial Safety of the State of California. Copies of the Safety Orders as available at the Printing Division, Documents Section, State of California, Sacramento, California 95814. 13. Lubrication Contractor shall lubricate the bearing surfaces of all moving parts. Contractor shall be responsible to furnish lubricants and lubricate all equipment. Contractor is referred to the lubrication requirements specified in the General Mechanical and Equipment Technical Specifications. Prior to start-up, Contractor shall lubricate all equipment and arrange for the respective manufacturer's service engineer to inspect all lubrication. 14. Construction Mitigation Measures In accordance with CEQA requirements, the Contractor shall implement the following mitigation measures to reduce construction impacts: A. The areas under construction shall be adequately watered throughout each working day to keep dust to a minimum. Watering of the site shall include all areas void of vegetation so that there are no visible signs of dust. Watering shall be performed at least twice daily and more often if dust is observed. B. Contractor shall comply with all rules and regulations of the Air Pollution Control District of San Diego County. All construction equipment shall be properly maintained and tuned per manufacturer's recommendations to keep air emissions to a minimum. Contractor shall submit verification of same to Owner every six months for each item of equipment on the project site. %$Revised: 10/08/03 Contract No. 38891 Paae 94 of 98 PR~PC C. Project grading shall not occur on days with winds over 20 miles per hour. 15. D. Temporary drainage controls shall be implemented during construction to prevent storm water flow over graded areas and stock piles so as to cause emsion. E. If petroleum products are accidentally released to the environment by the Contractor, the area or contamination shall be defined and any contaminated soil or material shall be removed and disposed of legally. Identification, testing, and removal shall be performed by a properly licensed contractor. F. Contractor shall operate all construction equipment with required noise attenuation devices (such as mufflers) based on the regulations in place at the time of construction. Enforcement shall be accomplished by random field inspections by a qualified noise consultant during construction activities. Services of said consultant shall be paid for by the Contractor. Contractor shall be approved by the Owner. Contractor shall comply with City of Carlsbad, County of San Diego, and Cal OSHA noise regulations and requirements. G. In the unlikely event that cultural resources are encountered during construction activities, Contractor shall cease all work in the area of the find and a qualified archaeologist will be brought to the site by Owner to evaluate the find and determine appropriate measures. The archaeologist's recommendations shall be implemented to provide appropriate mitigation for potential impacts. Hydraulic Automatic Control Valves A. General Hydraulic automatic control valves shall be of the piston-type or diaphragm-actuated globe type as specified herein, with ductile iron body and stainless steel trim. Unless otherwise shown or specified, the valves shall have a pressure rating of not less than 400 psi, shall have 300 Ib flanges, and shall have all appurtenances to provide the control functions specified. Pilot (hydraulic) control lines shall be copper with isolation valve, needle for adjustable open and close rate, strainers and control valves to provide desired operation. Valves shall be manufactured by Cla-Val Company to match existing equipment and District's parts inventory (no substitutes). B. Pressure Relief Valves Valve shall open, modulate and close to maintain a constant upstream pressure. Valve shall be actuated by line pressure through the pilot control system. Valve shall provide protection to pumps for discharge pressure control. 16. Solenoid Valves Solenoid valves shall be of the size, type, and class shown and shall be designed for not less than 300 psi water-working pressure. Valves for water, air, or gas service shall have brass or bronze body with, unless specified otherwise, screwed ends, stainless steel trim and spring, Teflon or other resilient seals with material best suited for the temperature and fluid handled. Solenoid valves in corrosive environment shall have stainless steel bodies. For chemicals 4- %#Revised: 10/08/03 Contract No. 38891 Page 95 of 98 Pages and all corrosive fluids, solenoid valves with Teflon bodies and springs or other suitable materials shall be used. General purpose enclosures for indoors shall be NEMA type 2. For explosion proof, corrosive, special purpose, or outdoor locations NEMA type 4, 7, 8, 9, 9E, 9F, or 9G enclosures shall be used, as applicable. All coil ratings shall be for continuous duty. For electrical characteristics see electrical drawings or specifications. For general duty valve shall be as manufactured by Automatic Switch Co. (ASCO), Model "RED HAT", Skinner Valve Division of Honeywell, Model "LANCER", Magnatrol Valve Corporation, or equal. 17. Swing Check Valves (3 Inch and Smaller) Swing check valves shall be minimum Class 200 with minimum rated working pressures of 300 psi. Valves shall be bronze construction with screwed ends. Valves shall have a bronze disk, stainless steel or bronze pin, and have a screwed cap to access disk. Swing check valves shall be the product of a single manufacturer and shall be by Milwaukee #508, Stockham #B-345, Powell #560, or equal. 18. Silent Check Valves Pumping unit check valves shall be globe style flanged silent check valve type, APCO Series 600, Val Matic Series 1800, Crispin Model GC, or equal. Check valves shall have a service pressure rating of not less than 300 psi and shall be provided with 250 Ib flanges. Check valve shall be of the silent operating type that begins to close as the forward flow velocity diminishes and be fully closed at zero velocity preventing flow reversal and resultant water hammer or shock. Valve design shall incorporate a center guided, spring loaded poppet, guided at opposite ends and haLing a short linear stroke that generates a flow area at least equal to the pipe. Operation of the valve shall not be affected by the position of installation. It shall be capable of operating in the horizontal or vertical position with the flow up or down. All component parts shall be field replaceable without the need of special tools. A replaceable guide bushing shall be provided and held in position by the valve's spring. The spring shall be designed to withstand 100,000 cycles without failure and exert a force which allows the valve to start operating at a differential pressure of .5 psi and to fully open at a flow velocity of 4 fps. The valve disc shall be concave to the flow direction providing for disc stabilization, maximum strength and a minimal flow velocity to fully open the valve. Valve interior shall be contoured and unrestricted to achieve maximum flow capacity with minimum pressure drop. The valves disc and seat shall be field replaceable and have a seating surface finish of 32 micro-inch or better to insure positive seating at all pressures unless otherwise specified, a buna-n seal shall be furnished to provide zero leakage. The seal design shall provide for both a metal to metal seal and a metal to buna-n seal to achieve resilient sealing at both low and high pressures without overloading or damaging the buna-n seal. Valves shall be hydrostatically tested at 1.5 times their rated working pressure and suitable for field testing at this pressure. Factory testing of each valve supplied shall be required for any manufacturer not specified herein. 4- \@Revised: 10/08/03 Contract No. 38891 Valve shall be provided with cast or ductile iron body, bronze plug and seat, and stainless steel spring. Contractor shall furnish connecting pipe with flat face flange, full face gaskets and a rating internal diameter as recommended by the valve manufacturer. %#Revised: 10/08/03 Contract No. 38891 Page 97 of 98 Pages e= %#Revised: 10/08/03 BLANK PAGE Contract No. 38891 Page 98 of 98 Pages STATE WATER RESOURCES CONTROL BOARD CONTRACT REQUIREMENTS STATE WATER RESOURCES CONTROL BOARD CONTRACT REQUIREMENTS . . 1 - STATE WAGE RATE CLAUSES (Facilities Plan Approval after June 18, 1998, Federal Wage Rates are not required) Pursuant to Sections 1720 et seq., and 1770 et seq., of the California Labor Code, the successful bidder shall pay not less than the prevailing rate of per diem wages as determined by the Director of the California Department of Industrial Relations for public works projects of more than one thousand dollars ($l,OOO). Copies of such prevailing rate or per diem wage are on file at lloan reciuient's mincipal office), which copies shall be made available to any interested party on request. The successful bidder shall post a copy of such determinations at each job site. The successful bidder intending to use a craft or classification not shown on the prevailing rate determinations may be required to pay the rate of the craft or classification most closely related to it. 2- LABOR CODE SECTION 1776 COMPLETE PAYROLL RECORDS: CERTIFIED AND AVAILABLE (a) Each contractor and subcontractor shall keep accurate payroll records, showing the name, address, social security number, work classification, straight time and overtime hours worked each day and week, and the actual per diem wages paid to each journeyman, apprentice, worker, or other employee employed by him or her in connection with the public work. Each payroll record shall contain or be verified by a written declaration that it is made under penalty of perjury, stating both of the following: (1) The information contained in the payroll record is true and correct. (2) The employer has complied with the requirements of Sections 1771, 1811, and 1815 for any work performed by his or her employees on the public works project. (b) The payroll records enumerated under subdivision (a) shall be certified and shall be available for inspection at all reasonable hours at the principal office of the contractor on the following basis: (1) A certified copy of an employee's payroll record shall be made available for inspection or furnished to the employee or his or her authorized representative on request. furnished upon request to a representative of the body awarding the contract, the Division of Labor Standards Enforcement, and the Division of Apprenticeship Standards of the Department of Industrial Relations. (3) A certified copy of all payroll records enumerated in subdivision (a) shall be made available upon request by the public for inspection or for copies thereof. However, a request by the public shall be made through either the body awarding the contract, the Division of Apprenticeship Standards, or the Division of Labor Standards Enforcement. If the requested payroll records have not been provided pursuant to paragraph (2), the requesting party shall, prior to being provided the records, reimburse the costs of preparation by the contractor, subcontractors, and the entity through which the request was made. The public shall not be given access to the records at the principal office of the contractor. (2) A certified copy of all payroll records enumerated in subdivision (a) shall be made available for inspection or (c) The certified payroll records shall be on forms provided by the Division of Labor Standards Enforcement or shall contain the same information as the forms provided by the division. (d) A contractor or subcontractor shall file a certified copy of the records enumerated in subdivision (a) with the entity that requested the records within 10 days after receipt of a written request. BP- 14 Issue Date: November 7, 2003 State Revolving Fund Loan Program CCR and Boilelplate (e) Any copy of records made available for inspection as copies and furnished upon request to the public or any public agency by the awarding body, the Division of Apprenticeship Standards, or the Division of Labor Standards Enforcement shall be marked or obliterated to prevent disclosure of an individual's name, address, and social security number. The name and address of the contractor awarded the contract or the subcontractor performing the contract shall not be marked or obliterated. Any copy of records made available for inspection by, or furnished to, a joint labor-management committee established pursuant to the federal Labor Management Cooperation Act of 1978 (Section 175a of Title 29 of the United States Code) shall be marked or obliterated only to prevent disclosure of an individual's name and social security number. A joint labor management Committee may maintain an action in a court of competent jurisdiction against an employer who fails to comply with Section 1774. The court may award restitution to an employee for unpaid wages and may award the joint labor management committee reasonable attorney's fee and costs incurred in maintaining the action. An action under this subdivision may not be based on the employer's misclassification of the craft of a worker on its certified payroll records. Nothing in this subdivision limits any other available remedies for a violation of this chapter. (f) The contractor shall inform the body awarding the contract of the location of the records enumerated under subdivision (a), including the street address, city and county, and shall, within five working days, provide a notice of a change of location and address. (g) The contractor or subcontractor shall have 10 days in which to comply subsequent to receipt of a written notice requesting the records enumerated in subdivision (a). In the event that the contractor or subcontractor fails to comply within the 10-day period, he or she shall, as a penalty to the state or political subdivision on whose behalf the contract is made or awarded, forfeit twenty-five dollars ($25) for each calendar day, or portion thereof, for each worker, until strict compliance is effectuated. Upon the request of the Division of Apprenticeship Standards or the Division of Labor Standards Enforcement, these penalties shall be withheld from progress payments then due. A contractor is not subject to a penalty assessment pursuant to this section due to the failure of a subcontractor to comply with this section. (h) The body awarding the contract shall cause to be inserted in the contract stipulations to effectuate this section. (i) The director shall adopt rules consistent with the California Public Records Act, (Chapter 3.5 (commencing with Section 6250), Division 7, Title 1, Government Code) and the Information Practices Act of 1977, (Title 1.8 (commencing with Section 1798), Part 4, Division 3, Civil Code) governing the release of these records, including the establishment of reasonable fees to be charged for reproducing copies of records required by this section. 3- LABOR CODE SECTION 1777.5 EMPLOYMENT OF PROPERLY REGISTERED APPRENTICES (a) Nothing in this chapter shall prevent the employment of properly registered apprentices upon public works. (b) Every apprentice employed upon public works shall be paid the prevailing rate of per diem wages for apprentices in the trade to which he or she is registered and shall be employed only at the work of the craft or trade to which he or she is registered. approved by the Chief of the Divjsion of Apprenticeship Standards and who are parties to written apprentice agreements under Chapter 4 (commencing with Section 3070) of Division 3 are eligible to be employed at the apprentice wage rate on public works. The employment and training of each apprentice shall be in accordance with either of the following: (c) Only apprentices, as defined in Section 3077, who are in training under apprenticeship standards that have been (1) The apprenticeship standards and apprentice agreements under which he or she is training. (2) The rules and regulations of the California Apprenticeship Council. (d) When the contractor to whom the contract is awarded by the state or any political subdivision, in performing any of the work under the contract, employs workers in any apprenticeable craft or trade, the contractor shall employ apprentices in at least the ratio set forth in this section and may apply to any apprenticeship program in the craft or trade that can provide apprentices to the site of the public work for a certificate approving the contractor under the apprenticeship standards for the employment and training of apprentices in the area or industry affected. However, the decision of the apprenticeship program to approve or deny a certificate shall be subject to review by the Administrator of Apprenticeship. The apprenticeship program or programs, upon approving the contractor, BP- 15 Issue Date: November 7, 2003 State Revolving Fund Loan Program CCR and Boilerplate shall arrange for the dispatch of apprentices to the contractor. A contractor covered by an apprenticeship program's standards shall not be required to submit any additional application in order to include additional public works contracts under that program. "Apprenticeable craft or trade," as used in this section, means a craft or trade determined as an apprenticeable occupation in accordance with rules and regulations prescribed by the California Apprenticeship Council. As used in this section, "contractor" includes any subcontractor under a contractor who performs any public works not excluded by subdivision (0). information to an applicable apprenticeship program that can supply apprentices to the site of the public work. The information submitted shall include an estimate of journeyman hours to be performed under the contract, the number of apprentices proposed to be employed, and the approximate dates the apprentices would be employed. A copy of this information shall also be submitted to the awarding body if requested by the awarding body. Within 60 days after concluding work on the contract, each contractor and subcontractor shall submit to the awarding body, if requested, and to the apprenticeship program a verified statement of the journeyman and apprentice hours performed on the contract. The information under this subdivision shall be public. The apprenticeship programs shall retain this information for 12 months. (e) Prior to commencing work on a contract for public works, every contractor shall submit contract award (f) The apprenticeship program that can supply apprentices to the area of the site of the public work shall ensure (g) The ratio of work performed by apprentices to journeymen employed in a particular craft or trade on the public equal employment and affirmative action in apprenticeship for women and minorities. work may be no higher than the ratio stipulated in the apprenticeship standards under which the apprenticeship program operates where the contractor agrees to be bound by those standards, but, except as otherwise provided in this section, in no case shall the ratio be less than one hour of apprentice work for every five hours of journeyman work. (h) This ratio of apprentice work to journeyman work shall apply during any day or portion of a day when any journeyman is employed at the jobsite and shall be computed on the basis of the hours worked during the day by journeymen so employed. Any work performed by a journeyman in excess of eight hours per day or 40 hours per week shall not be used to calculate the ratio. The contractor shall employ apprentices for the number of hours computed as above before the end of the contract or, in the case of a subcontractor, before the end of the subcontract. However, the contractor shall endeavor, to the greatest extent possible, to employ apprentices during the same time period that the journeymen in the same craft or trade are employed at the jobsite. Where an hourly apprenticeship ratio is not feasible for a particular craft or trade, the Chief of the Division of Apprenticeship Standards, upon application of an apprenticeship program, may order a minimum ratio of not less than one apprentice for each five journeymen in a craft or trade classification. upon the issuance of the approval certificate, or that has been previously approved for an apprenticeship program in the craft or trade, shall employ the number of apprentices or the ratio of apprentices to journeymen stipulated in the applicable apprenticeship standards, but in no event less than the 1-to-5 ratio required by subdivision (8). on all of his or her contracts on an annual average of not less than one hour of apprentice work for every five hours of labor performed by journeymen, the Chief of the Division of Apprenticeship Standards may grant a certificate exempting the contractor from the 1-to-5 hourly ratio, as set forth in this section for that craft or trade. (k) An apprenticeship program has the discretion to grant to a participating contractor or contractor association a certificate, which shall be subject to the approval of the Administrator of Apprenticeship, exempting the contractor from the 1 -to-5 ratio set forth in this section when it finds that any one of the following conditions is met: (1) Unemployment for the previous three-month period in the area exceeds an average of 15 percent. (2) The number of apprentices in training in the area exceeds a ratio of 1 to 5. (3) There is a showing that the apprenticeable craft or trade is replacing at least one-thirtieth of its journeymen annually through apprenticeship training, either on a statewide basis or on a local basis. (4) Assignment of an apprentice to any work performed under a public works contract would create a condition that would jeopardize his or her life or the life, safety, or property of fellow employees or the public at large, or the specific task to which the apprentice is to be assigned is of a nature that training cannot be provided by a journeyman. (1) When an exemption is granted pursuant to subdivision (k) to an organization that represents contractors in a specific trade from the 1-to-5 ratio on a local or statewide basis, the member contractors shall not be required to submit individual applications for approval to local joint apprenticeship committees, if they are already covered by the local apprenticeship standards. (i) A contractor covered by this section that has agreed to be covered by an apprenticeship program's standards (i) Upon proper showing by a contractor that he or she employs apprentices in a particular craft or trade in the state Issue Date: November 7,2003 BP-16 State Revolving Fund Loan Program CCR and Boilerplate (m) (1) A contractor to whom a contract is awarded, who, in performing any of the work under the contract, employs journeymen or apprentices in any apprenticeable craft or trade shall contribute to the California Apprenticeship Council the same amount that the director determines is the prevailing amount of apprenticeship training contributions in the area of the public works site. A contractor may take as a credit for payments to the council any amounts paid by the contractor to an approved apprenticeship program that can supply apprentices to the site of the public works project. The contractor may add the amount of the contributions in computing his or her bid for the contract. Council shall distribute training contributions received by the council under this subdivision, less the expenses of the Division of Apprenticeship Standards for administering this subdivision, by making grants to approved apprenticeship programs for the purpose of training apprentices. The funds shall be distributed as follows: area for which the training contributions were made to the council, a grant to that program shall be made. geographic area for which the training contributions were made to the council, the grant shall be divided among those programs based on the number of apprentices registered in each program. expenses of the Division of Apprenticeship Standards. Training Contribution Fund, which is hereby created in the State Treasury. Notwithstanding Section 13340 of the Government Code, all money in the Apprenticeship Training Contribution Fund is hereby continuously appropriated for the purpose of carrying out this subdivision and to pay the expenses of the Division of Apprenticeship Standards. The stipulations shall fix the responsibility of compliance with this section for all apprenticeable occupations with the prime contractor. (2) At the conclusion of the 2002-03 fiscal year and each fiscal year thereafter, the California Apprenticeship (A) If there is an approved multiemployer apprenticeship program serving the same craft or trade and geographic (B) If there are two or more approved multiemployer apprenticeship programs serving the same craft or trade and (C) All training contributions not distributed under subparagraphs (A) and (B) shall be used to defray the future (3) All training contributions received pursuant to this subdivision shall be deposited in the Apprenticeship (n) The body awarding the contract shall cause to be inserted in the contract stipulations to effectuate this section. (0) This section does not apply to contracts of general contractors or to contracts of specialty contractors not bidding for work through a general or prime contractor when the contracts of general contractors or those specialty contractors involve less than thirty thousand dollars ($30,000). (p) All decisions of an apprenticeship program under this section are subject to Section 3081. 4- LABOR CODE SECTION 18 10 DEFINITION: A LEGAL DAY'S WORK Eight hours labor constitutes a legal day's work in all cases where the same is performed under the authority of any law of this State, or under the direction, or conmol, or by the authority of any officer of this State acting in his official capacity, or under the direction, or control or by the authority of any municipal corporation, or of any officer thereof. A stipulation to that effect shall be made a part of all contracts to which the State or any municipal corporation therein is a Party. 5- LABOR CODE SECTION 18 13 PENALTY FOR OVERTIME ON ANY PUBLIC WORK CONTRACT The contractor or subcontractor shall, as a penalty to the state or political subdivision on whose behalf the contract is made or awarded, forfeit twenty-five dollars ($25) for each worker employed in the execution of the contract by the respective contractor or subcontractor for each calendar day during which the worker is required or permitted to work more than 8 hours in any one calendar day and 40 hours in any one calendar week in violation of the provisions of this article. In awarding any contract for public work, the awarding body shall cause to be inserted in the contract a stipulation to this effect. The awarding body shall take cognizance of all violations of this article committed in the course of the execution of the contract, and shall report them to the Division of Labor Standards Enforcement. Issue Date: November 7,2003 BP-17 State Revolving Fund Loan Program CCR and Boilelplate 6 - LABOR CODE SECTION 1815 MINIMUM OVERTIME PAY Notwithstanding the provisions of Sections 18 10 to 1814, inclusive, of this code, and notwithstanding any stipulation inserted in any contract pursuant to the requirements of said sections, work performed by employees of contractors in excess of 8 hours per day, and 40 hours during any one week, shall be permitted upon public work upon compensation for all hours worked in excess of 8 hours per day at not less than one and one-half (1.5) times the basic rate of pay. 7- LABOR CODE SECTION 1860 CONTRACT PROVISION The awarding body shall cause to be inserted in every public works contract a clause providing that, in accordance with the provisions of Section 3700 of the Labor Code, every contractor will be required to secure the payment of compensation to his employees. 8- LABOR CODE SECTION 1861 CONTRACTOR CERTIFICATION TO LABOR CODE SECTION 3700 Each contractor to whom a public works contract is awarded shall sign and file with the awarding body the following certification prior to performing the work of the contract: “I am aware of the provisions of Section 3700 of the Labor Code which require every employer to be insured against liability for workers’ compensation or to undertake self-insurance in accordance with the provisions of that code, and I will comply with such provisions before commencing the performance of the work of this contract.” 9- CULTURAL RESOURCES In accordance with the National Historic Preservation Act of 1966, (16 U.S.C. 470), and State statutes regarding the unexpected discovery of human remains, the following procedures are implemented to insure historic preservation and fair compensation to the Contractor for delays attendant to cultural resources investigations. In the event potential Historical, Archeological, or Cultural Resources (herein after cultural resources) are discovered during subsurface excavations at the site of construction, the following procedures shall be instituted: 1) The Engineer shall issue a “Stop Work Order” directing the Contractor to cease all construction operations at the location of such potential cultural resources find. If the find includes human remains, the County Coroner must be contacted immediately. 2) Such “Stop Work Order” shall be effective until such time as a qualified archeologist can be called to evaluate the importance of these potential cultural resources and make recommendations to the State Water Resources Control Board Cultural Resources Officer (CRO). Any “Stop Work Order” shall contain the following: a) A clear description of the work to be suspended; b) Any instructions regarding issuance of further orders by the Contractor for material services; c) Guidance as the action to be taken on subcontracts; d) Any suggestions to the Contractor as to minimization of his costs; ’ e) Estimated duration of the temporary suspension. If the archeologist in consultation with the SWRCB CRO determines that the potential find is an important resource and warrants further investigation and/or mitigation, the Engineer shall extend the duration of the “Stop Work Order” in writing, and the Contractor shall suspend work at the location of the find. Equitable adjustment of the construction contract shall be made in the following manner: 1) Time Extension If the work temporarily suspended is on the “critical path”, the total number of days for which the suspension is in effect shall be added to the number of allowable contract days. BP-18 Issue Date: November 7,2003 State Revolving Fund Loan Program CCR and Boilerplate If a portion of work at the time of such suspension is not on the “critical path”, but subsequently becomes work on the critical path, the allowable contract time will be computed from the date such work is classified as on the critical path. 2) Additional Compensation If, as a result of a suspension of the work, the Contractor sustains a loss which could not have been avoided by his judicious handling of forces, and equipment, or redirection of forces or equipment to perform other work on the contract, there shall be paid to the Contractor an amount as determined by the Engineer to be fair and reasonable compensation for the Contractor’s actual loss in accordance with the following: a) Idle Time of Eauipment Compensation for equipment idle time will be determined on a force account (time and materials) basis, and shall include the cost of extra moving of equipment and rental loss. The right-of-way delay factor for each classification of equipment shown in the California Department of Transportation publication entitled, EquiDment Rental Rates and the General Prevailing Wage Rates, will be applied to any equipment rental rates. b) Idle Time of Labor Compensation for idle time of workers will be determined by the Engineer as “Labor“ less any actual productivity factor of this portion of the work force. c> Increased Costs of Labor and Materials Increased costs of labor and materials will be compensated only to the extent such increase was in fact caused by the suspension, as determined by the Engineer. Compensation for actual loss due to idle time of either equipment or labor shall not include markup for profit. The hours for which compensation will be paid will be the actual normal working time during which such delay condition exists, but will in no case exceed eight hours in any one day. The days for which compensation will be paid shall be full or partial calendar days, excluding Saturdays, Sundays, and legal holidays, during the existence of such delay. BP- 19 Issue Date: November 7,2003 State Revolving Fund Loan Program CCR and Boilerplate 10 - COMPLIANCE GUIDELINES FOR SRF LOAN PROGRAM MBE/WBE CONTRACT PROVISIONS OF THE STATE WATER RESOURCES CONTROL BOARD (SWRCB) DIVISION OF FINANCIAL ASSISTANCE RELATIVE TO THE UTILIZATION OF MINORITY BUSINESS ENTERPRISE (MBE) AND WOMEN BUSINESS ENTERPRISE (WE) ON CLEAN WATER PROGRAM CONSTRUCTION CONTRACTS IN CALIFORNIA This document and attachments shall be included by the owner as a contract provision for all construction contracts exceeding $10,000. Compliance with the requirements of this document and attachments satisfies the MBE/WBE requirements of the U. S. Environmental Protection Agency and the SWRCB. This document supersedes any conflicting requirements. Failure to take the five (5) affirmative steps listed under Requirements, Section A, prior to bid opening and to submit “Minority Business Enterprisernomen Business Enterprise Information” (Form 4) with the bid shall cause the bid to be rejected as a non-responsive bid. Table of Contents Section Description & 1 Approval to Award (ATA) Process .................................................................. BP-21 2 Prime Contractor & Recipient Responsibilities ................................................ BP-2 1 3 “Good Faith” Effort Process ............................................................................. BP-22 4 Non-Governmental Local Contacts .................................................................. BP-24 5 Reporting Requirements .................................................................................. BP-25 .. 6 Definitions ......................................................................................................... BP-25 7 MBENBE FOJXLS ............................................................................................. BP-27 Form 1: “Good Faith” Effort List of Contractors Solicited ........................................................ BP-28 Form 2: “Good Faith” Effort Bids Received List ....................................................................... BP-29 Form 3: Contractor Self Certification ......................................................................................... BP-30 Form 4: Prime Contractorhtecipient Selected MBE/WBEs ........................................................ BP-3 1 Form 5: Sample Summary of Bids Received from Subcontractors ........................................... BP-32 Form 6: Positive Effort Certification .......................................................................................... BP-33 Issue Date: November 7, 2003 BP-20 State Revolving Fund Loan Program CCU and Boilerplate Section 1: APPROVAL TO AWARD (ATA) PROCESS REQUIRED FOR STATE REVOLVING FUND LOANS DMSION OF FINANCIAL ASSISTANCE (DFA) The purpose of this document is to provide a summary of the MBE/WBE “good faith” effort for SRF Loan contractors and recipients. Section 1 provides the contractor and recipient with a brief overview of the ATA process. The MBE/WBE “good faith” effort is one element of the ATA process summarized below. The ATA request package submitted to DFA for approval must contain all of the following: 1. 2. 3. 4. 5. 6. 7. 8. Completed ATA form (original must be signed by the recipient’s authorized representative or designee). A legal description of the site on which the project is to be constructed and an opinion signed by competent title counsel describing the interest the applicant has in the site, including information as to any easements and rights-of-way and certifying that the estate or interest is legal and valid. Tabulation of all bids received and the engineer’s estimate. Copy of the bid proposal chosen. Evidence of advertising (submit a copy of newspaper advertisement for the project). All MBENBE documentation, which includes Forms 1 through 6. Also, documentation that the local Small Business Administration and Minority Business Development Agency centers were contacted at least five (5) working days by the prime contractor prior to the need for referrals to MBENBE subcontractors and documentation that invitations were sent to MBENBE subcontractors at least seven (7) working days prior to bid opening. A dedicated source of revenue (ordinance or resolution). Disbursements of SRF funds may take up to 90 days. Some construction costs may be ineligible for SRF funding. Provide a cash flow projection showing the source and expected time of receipt of funds needed to meet project cash requirements. Detailed directions for completing the ATA form are provided on the form. If you have any questions regarding the ATA process, please contact Ken Gonzales of DFA at (916) 341-5683 or gonzalek@swrcb.ca.gov. Section 2: PRIME CONTRACTOR & RECIPIENT RESPONSIBILITIES PARTICIPATION RESPONSIBILITIES FOR PRIMES AND THEIR SUBCONTRACTORS All recipients of federal funds from USEPA, as well as their prime contractors and subcontractors, must make every effort to solicit bids from eligible MBENBEs. This information must be documented and reported to DFA as described in this document. The MBEMTBE responsibilities of the prime contractor are: 1. 2. 3. Conduct a “good faith” effort to ensure maximum MBEME participation in the project, Complete or obtain from MBENBE subcontractors, all of the completed forms required in these guidelines and submit them to the recipient. Report actual MBE/WBE participation on a quarterly basis to the recipient. The MBENBE responsibilities of the recipient are: 1. Ensure that the prime contractor meets the responsibilities identified in these guidelines. 2. Submit all documentation identified in these guidelines to DFA and maintain all records in the project files for later access or auditing. BP-2 1 Issue Date: November 7. 2003 State Revolving Fund Loan Program CCR and Boilerplate 3. Provide quarterly reports on MBENVBE procurements to DFA. Section 3: “Good Faith” Effort Process Any public or private entity receiving federal funds must demonstrate that efforts were made to attract MBE/WBEs on any SRF contracts. The process to attract MBE/WBEs is referred to as the “good faith” effort. This effort requires the recipient, prime contractor and any subcontractors to take the steps listed below to assure that MBENVBEs are used whenever possible as sources of supplies, construction, equipment or services. Failure to take the steps outlined below and submit Form 4, Prime Contractor/Recipient Selected MBE/WBEs, prior to bid opening, shall cause the bid to be rejected as non-responsive. Use Forms 1 through 6 to document the process. If it is not practical or possible to comply with one or more of the five steps, prepare an explanation and submit it with the ATA package. STEP 1: Divide the total requirements, when economically feasible, into small tasks or quantities to permit maximum participation. Evidence submitted must illustrate that the work was divided into small proprietary portions (e.g. paving, electrical, landscaping, revegetation). STEP 2: Establish delivery schedules, when work requirements permit, that encourage maximum MBE/WBE participation. STEP 3: Use the services of the U.S. Small Business Administration (SBA) and the Minority Business Development Agency (MBDA) of the U. S. Department of Commerce IDOC) in soliciting: qualified MBENVBEs. Utilization of these resources is required at no cost. These agencies offer several services, including Internet access to databases of MBENBEs. For additional assistance, the recipient or contractor could telephone the local offices of both agencies in their area (SBA Minority Enterprise Development Offices and DOC MBDA Regional Centers). The Internet web sites also include names, addresses, and phone or fax numbers of local SBA and MBDA centers. There are contact phone numbers listed in Step 5 that will assist you in reaching the two offices if the Internet is unavailable. Do not write to these sources. The prime contractor must provide documentation that the local SBA/MBDA offices or web sites were notified of the contracting opportunity (allow at least five working days for a response). Documentation must not only include the efforts to contact the information sources and list the contract opportunity, but also the solicitation and response to the bid request. STEP 4: Include qualified MBE/WBEs on solicitation lists and record the information. Solicitation should be as broad as possible. The following web sites include a list of available sources for expanding the search for eligible MBE/WBEs: http://www.sba.g:ov and http://www.mbda.gov. If MBENBE sources are not located, explain why and describe the efforts made. See Step 5 for more detailed information. For all contracts, the prime contractor must send invitations to at least three (or all, if less than three) MBE/WBE vendors for each item of work referred by sources contacted. The invitations must adequately specify the items for which bids are requested. The record of “good faith” efforts must indicate a real desire for a positive response, such as a certified mail receipt or a documented telephone conversation. (A regular letter or an BP-22 Issue Date: November 7, 2003 State Revolving Fund ban Program CCR and Boilerplate unanswered telephone call is not an adequate “good faith” effort}. A list of all sub- bidders, including the bidders not selected, and bid amount for each item of work must be submitted. A sample list is shown in Form 5, Sample Summary of Bids Received from Subcontractors. If a low bid was not accepted, an explanation must be provided. Name and Address U.S. Small Business Administration 455 Market Street, Suite 600 San Francisco, CA 94105 RE: Minority Enterprise Development Offices STEP 5: Solicit available MBEs and WBEs whenever thev are potential sources. The Telephone and Web Site (415) 744-6820 Extension 0 PRO-Net Database: httu://www.sba.gov/’ Bid Notification: httD://web.sba.gov/subnet/ prime contractor must provide invitations to MBE/WBE sub-bidders at least seven working days prior to the bid opening date. U.S. Department of Commerce Minority Business Development Agency 21 1 Main Street, Room 1280 San Francisco, CA 94105 (415) 744-3001 Phoenix/ Opportunity Database: httri://www.mbda.gov , RE: Business Development Centers Name and Address California Department of Transportation (CAL”S) Business Enterprise Program’ 1820 Alhambra Blvd. Telephone and Web Site Mailing Address: PO Box 942874 Sacramento, CA 94274-0015 (9 16) 227-9599 I Sacramento. CA 958 16 1 www.dot.caxovhahep I m 505 Van Ness Avenue San Francisco, CA 94102-3298 http://www.cpuc.ca.gov/static/aboutcpuc/ divisions/executive+office/wmbe ’ PRO-Net is the SBA’s electronic search engine, containing business profiles for nearly 200,000 businesses. The SBA requests Internet contact only. A list of potential firms downloaded from PRO-Net will verify that the bidder made the required contact with the SBA. Based on the federal Disadvantaged Business Enterprises (DBE) program, CALTRANS maintains a CPUC maintains a database of MBEWBE-owned business enterprises and serves to inform the public. database and provides directories of minority and woman-owned firms. BP-23 Issue Date: November 7,2003 State Revolving Fund Loan Program CCR and Boilerplate Section 4: Non-Governmental Local Contacts MINORITY BUSINESS ENTERPRISEAVOMAN BUSINESS ENTERPRISE (MBEAVBE) RESOURCES The following organizations provide services to identify potential MBE/WBEs. Some of the organizations charge a fee or require membership fees to provide their services. Services provided may include the entire good faith eflort process for recipients that need comprehensive assistance. Humboldt Builder's Exchange Inc. 2355 Myrtle Ave. Eureka, CA 95501 Phone #: (707) 442-3708 FAX #: (707) 442-6051 www. humvx.com Cali forniu Daily Bid Advisor/Challenge News I2 76 Lincoln Ave. #203 San Jose, CA 95125 Phone #: (408) 998-0241 or (800) 298-0240 FAX #: (408) 998-2534 California Procurement Training and Assistance Center at West Valley 1 West Campbell Ave., Ste J70 Campbell CA 95008 Phone #: (408) 871 -4390 FAX #: (408) 378-2034 Contractors Assistance Center PO Box 7675 Redlands, CA 92375 Phone #: (800) 742-4124 FAX#: (800) 742-4125 Eldridge Bid Reporter, M/W/DVBE Assistance PO Box 699 West Sacramento, CA 95691 Phone #: (916) 444-7618 FAX #: (91 6) 444-7731 www. ebrbids.com Renk Communications Construction Bid Source Interactive (CBSI) PO Box 568 Burson, CA 95225-0568 Phone #: (209) 772-3670 www. Regis- usa. com FAX #: (800) 560-7266 1-800-962-41 62 Riverside Communitv College District Procurement Assistance Center 2038 Iowa Ave., Ste. 100 Riverside, CA 92507 Phone #: (909) 788-2559 www. resources4u. codpac FAX#: (909) 788-2515 Small Business Exchange 703 Market St., Ste. IO00 San Francisco, CA 94103 Phone #: (415) 778-6250 www. sbeinc. corn FAX#: (415) 778-6255 BP-24 Issue Date: November 7,2003 State Revolving Fund Loan Program CCR and Boilerplate Section 5: Reporting Requirements All requests for services, supplies, equipment or construction solicited by the SWRCB, other governmental agencies, non-profit agencies, or private businesses are subject to the MBWE requirements. These requirements apply to the prime contractor and all subcontractors. The only exceptions to this requirement are contracts with governmental or non-profit agencies. - For the duration of the contract, all primary and subcontractors will be required to report progress made in fulfilling the “good faith” effort in their quarterly reports. Failure to provide this information as stipulated in the contract language will be cause for contract termination. DFA staff will provide recipients with the forms and instructions to report their “good faith” efforts after the ATA. Once a bidder is selected, the prime contractor should compile the information required by the “good faith” effort process. AU information supporting the “good faith” effort must be submitted within ten working days after the bid opening. Recipient shall review the successful bidder’s records closely to be sure that, prior to bid opening, all required “good faith” efforts were made. Failure of either the bidder or prime contractor/subcontractor to follow the process and provide the necessary information to DFA could jeopardize the bidding process. The following situations and circumstances require actions as indicated: 1. 2. 3. 4. 5. 6. If the apparent successful low bidder was rejected a complete explanation must be provided. Each MBE/WBE firm utilized must complete and submit the Form 3, Contractor Self-certification with the bid. If additional subcontracts become necessary after the award of the prime contract, provide Form 3 to DFA within ten working days following the award of each new subcontract. Any deviation from the information provided at the time of the bid shall not result in a reduction of MBE/WBE participation without prior approval of Failure of the apparent low bidder to perform the five “good faith” effort steps prior to bid opening and submittal of Form 4 with the bid, will result in its bid being declared non-responsive. The contract may then be awarded to the next low, responsive, responsible bidder that meets the requirements or the recipient may re- advertise the project. The apparent successful low bidder must submit documentation to the recipient within ten working days following bid opening showing that, prior to the bid opening, all required “good faith” efforts were made. Section 6: Definitions A bona fide minority or women-owned business enterprise (MBETWBE) is a: (1) MBE or WE that has submitted a “Minority or Women-Owned Business Enterprise Contractor Self-certification” Form 3, and (2) A fm that has been accepted as a bona fide MBE or WBE by the recipient. In addition, a bona fide MBE/WBE must be an independent business concern that is at least 5 1 % owned, controlled, and operated by minority group members (see definition of minority group member) or women. Ownership and control can be measured by: 0 Contract work performance responsibility. 0 Management responsibility. 0 At least 51% share of profits and risk. 0 Other data (such as voting rights) that may clarify ownership or control. Control means exercising the power to make policy decisions. Operate means being actively involved in the day-to-day management of the business. BP-25 Issue Date: November 7, 2003 State Revolving Fund Loan Program CCR and Boilerplate Determination of whether a business is at least 5 1 % owned by a woman or women shall be made without regard to community property laws. An otherwise qualified WE which is 5 1 % owned by a married woman in a community property state will not be disqualified because her husband has a 50% interest in her share. Similarly, a business that is 5 1 % owned by a married man and 49% by an unmarried woman does not become a qualified WBE by virtue of the wife's 50% interest in the husband's share of the business. A joint venture is a business enterprise formed by a combination of firms under a joint venture agreement. To qualify as a bona fide MBE/WBE, the minority-owned or women-owned and controlled firms in the joint venture must: . Satisfy all requirements for bona fide MBE/WBE participation in their own rights. Share a clearly defined percentage of the ownership, management responsibilities, risks, and profits of the joint venture. Only this percentage of ownership will be credited towards the MBE/WBE goal. 0 1. 2. 3. 4. 5. 0 0 0 I A minority group member is a citizen of the United States and one of the following: 1 Native American consists of American Indian, Eskimo, Aleut, and native Hawaiian. To qualify, the person must meet one of the following criteria: Native Americans are at least one-fourth Indian descent (as evidenced by registration with the Bureau of Indian Affairs). Characteristic Indian appearance and features. Characteristic Indian name. Recognition in the community as an Indian. Membership in a tribe, band, or group of American Indians (recomized by the Federal Government), as evidenced by a tribal enrollment number or similar indication. African-American consists of individuals having origins in any of the black racial groups of Africa. Asian-Pacific American consists of individuals having origins in any of the original peoples of the Far East, Southeast Asia, and the Indian subcontinent. This area includes, for example, China, Japan, Korea, the Philippines, Vietnam, Samoa, Guam, U.S. Trust Territories of the Pacific, Northern Marianas, Laos, Cambodia, and Taiwan. The Indian subcontinent takes in the countries of India, Pakistan, Bangladesh, Sri Lanka, Nepal, Sikkim, and Bhutan. Hispanic American consists of individuals with origins from Puerto Rico, Mexico, Cuba, or South or Central America. Only those persons from Central and South American countries who are of Spanish origin, descent, or culture should be included in this category. Persons from Brazil, Guyana, Surinam or Trinidad, for example, would be classified according to their race and would not necessarily be included in the Hispanic category. In addition, this category does not include persons from Portugal, who should be classified according to race. In cases where a fm is owned and controlled by a minority woman or women, the percentage may be credited towards MBE participation or as WBE participation, or allocated, but may not be credited fully to both. Recipient - An agency (County, City, Special District, etc.) applying for a SRF loan to construct a project. Issue Date: November 7, 2003 BP-26 State Revolving Fund Loan Program CCR and Boilerplate Contractor - Refers to any recipient of funds who will participate in some phase of construction. The contractor receiving funds directly from the recipient for construction is the prime contractor. Contractors working for the prime contractor are subcontractors. Project Manager - If DFA staff is responsible for managing the project, the ProjectlContract Manager is responsible for review during the planning, design and contract development phases. Section 7: MBE/WBE Forms The following forms are provided to report project MBE/WBE information. They are available in electronic form from Ken Gonzales at (916) 341-5683 or gonzalek@swrcb.ca.gov. If you have any questions about completing these forms or when to turn them in, please contact Mr. Gonzales. All Forms, where applicable, must have original signature and date. The following table provides information on who completes each form and where the forms are to be sent: BP-27 Issue Date: November 7,2003 ..-. a E P Q) > 2 State Revolving Fund Loan Program CCR and Boilerplate FORM 2 MINORITY AND WOMEN OWNED BUSINESS ENTERPRISE (MBEIWBE) “GOOD FAITH” EFFORT BIDS RECEIVED LIST Form for information required to be submitted with the ATA package. BP-29 Issue Date: November 7. 2003 State Revolving Fund Loan Program CCR and Boilerplate FORM 3 (Attachment A) (MBWBE) MINORITY- OR WOMEN-OWNED BUSINESS ENTERPRISE CONTRACTOR SELF CERTIFICATION Firm Name: Phone: Address: Principal Service or Product: PLEASE INDICATE PERCENTAGE OF OWNERSHIP Ll MBE YO Ownership CI WBE % Ownership I I D Prime Contractor Ci Subcontractor Ll Broker Cl Supplier of MateriaWervice I I CI Sole Ownership CI Corporation 0 Partnership 0 Joint Venture 1 I hereby certify that this firm is a Minority or Women Business Enterprise as defined in Public Contract Code, Section 101 15.1. In making this certification, I am aware of Sections 12650 et seq. of the Government Code, providing for the imposition of treble damages for making false claims against the State and Section 101 15.10 of the Public Contract Code, making it a crime to intentionally make an untrue statement in this certificate. Certified by: Title: MBE/WBE 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. This form must be submitted within 10 working days after the bid opening date. Issue Date: November 7,2003 BP- 30 CONTRACT RECIPIENTS NAME PROJECT DESCRIPTION PRIME CONTRACTOR INFORMATION CONTRACT NO. OR SPECIFCATION NO PROJECT LOCATION ~ ~~ ~~~ ~ _____ NAME AND ADDRESS (Include ZIP Code, Federal Employer Tax ID #) QSUBCONTRACTOR 0 JOINT VENTURE I D MBE a WBE c1 SUPPLIEWSERVICE Q BROKER PHONE AMOUNT OF CONTRACT $ AMOUNT OF CONTRACTS 1 PHONE MBWE INFORMATION 3 NONE* AMOUNT OF CONTRACT $ a MBE 0 WBE PHONE 1 NAME AND ADDRESS (Include ZIP Code,) 0 WBE 3 MBE NAME AND ADDRESS (Include ZIP Code,) WORKTO BE PERFORMED Q MBE 0 WBE NAME AND ADDRESS (Include ZIP Code) SUBCONTRACTOR 0 JOINT VENTURE I D SUPPLIEWSERVICE Q BROKER OSUBCONTRACTOR 0 JOINT VENTURE D SUPPLIEWSERVICE D BROKER AMOUNT OF CONTRACT $ PHONE MBE 0 WBE NAME AND ADDRESS (Include ZIP Code) TITLE: PHONE: DATE: a SUBCONTRACTOR Q JOINT VENTURE *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. 0 SUPPLIEWSERVICE D BROKER Issue Date: November 7, 2003 AMOUNT OF CONTRACT $ BP- 31 PHONE State Revolving Fund Loan Program CCR and Boilerplate Electrical FORM 5 Alotta Boring $227,472 X Square Fasteners, Inc $20,190 X REM Sleep Co X" $24,189 X Tram Electic $30,120 X SAMPLE SUMMARY OF BIDS RECEIVED FROM SUBCONTRACTORS (MBE/WBE & NON-MBE/WBE) THIS SUMMARY IS PREPARED BY THE PRIME CONTRACTOR Masonry Striping Welch, Inc. X $20,383 X Orange Peel X $8,597 X Crispy Boys Co. $9,370 X Cheatum $36,000 X Sweat Co. $11.785 X *REM Sleep Co. selected over Square Fasteners, Inc. due to incomplete bid by Square Fasteners. List type of jobs alphabetically, from low to high in each category and selected low bidder. All other types of bidders such as DBE, SWBE SMBE, and Non MBE/WBE should be shown in the "Non" column. Form for information required to be submitted with the ATA package. Issue Date: November 7,2003 BP- 32 State Revolving Fund ban Program CCR and Boilerplate FORM 6 MINORITY BUSINESS ENTERPIUSWOMEN BUSINESS ENTERPRISE (MBEYWBE) POSITIVE EFFORT CERTIFICATION BY APPLICANT/RECIPIENT 1. The apparent successful low bidder on Clean Water Program 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 To Award (ATA) to any bidder the applicantkecipient must certify to the following: MINORITY BUSINESS ENTERPRISE (MBE) The bidder has obtained % of MBE participation for this contract. WOMEN BUSINESS ENTERPRISE (WBE) The bidder has obtained Also submitted are Forms 3 and 4 which contain a complete list of those MBE and WBE 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. % of WBE participation for this contract. The following affirmative steps as required by 40 CFR 35.3150 (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. The contractor established delivery schedules, where the requirements of the work permitted, which encouraged participation by minority and women’s business. (2) (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. The contractor used the services and assistance of the Small Business Administration and the Office of Minority Business Development Agency of the US. Department of Commerce. (5) It must be understood that the applicanthecipient in its role as a public trustee assumes primary responsibility to achieve an acceptable level of MBE/WBE utilization. This primary responsibility is a basic condition of the award of any State Revolving Fund financial assistance. Where an applicatiodrecipient fails to meet its obligations under these requirements the applicanthecipient may be declared nonresponsible and may have funding either annulled, suspended or terminated. In accepting these responsibilities, I hereby certify to the above. Name of ApplicantlRecipient Signature of Authorized Representative Date Name and Title of Authorized Representative This form must be submitted with the ATA package. Bob- section D below looks out of place??? Issue Date: November 7,2003 BP- 33 State Revolving Fund Loan Program CCR and Boilerplate 11 - THE SUBLETT’ING AND SUBCONTRACTING FAIR PRACTICES ACT Any person making a bid or offer to perform a contract shall, in his or her bid or offer, set forth the following: 1) The name and the location of the place of business of each subcontractor who will perform work or labor or render service to the prime contractor in or about the construction of the work or improvement, or a subcontractor licensed by the State of California who, under subcontract to the prime contractor, specially fabricates and installs a portion of the work or improvement according to detailed drawings contained in the plans and specifications, in an amount in excess of one-half of 1 percent of the prime contractor’s total bid or in the case of bids or offers for the construction of streets or highways, including bridges in excess of one-half or 1 percent of the prime contractor’s total bid or ten thousand dollars ($lO,OOO), whichever is greater. 2) The portion of work that will be done by each subcontractor under this act. The prime contractor shall list only one subcontractor for each portion of work as is defined by the prime contractor in his or her bid or offer. These requirements apply to the information required relating to subcontractors certified as minority or women business enterprises. For purposes of this requirement, “subcontractor” and “prime contractor” shall have the same meaning as those terms are defined in Section 41 13 of the Public Contract Code. 12 - Executive Order 11246: 40 CFR 7.3 - EQUAL OPPORTUNITY CLAUSE (in relevant Dart) ‘During the performance of this contract, the contractor agrees as follows: (1) The contractor will not discriminate against any employee or applicant for employment because of race, creed, color, or national origin. The contractor will take affirmative action to ensure that applicants are employed, and that employees are treated during employment, without regard to their race, creed, color, or national origin. Such action shall include, but not be limited to the following: employment, upgrading, demotion, or transfer; recruitment or recruitment advertising; layoff or termination; rates of pay or other forms of compensation; and selection for training, including apprenticeship. The contractor agrees to post in conspicuous places, available to employees and applicants for employment, notices to be provided by the contracting officer setting forth the provisions of this nondiscrimination clause. contractor, state that all qualified applicants will receive consideration for employment without regard to race, creed, color, or national origin. bargaining agreement or other contract or understanding, a notice, to be provided by the agency contracting officer, advising the labor union or workers’ representative of the contractor’s commitments under Section 202 of Executive Order No. 11246 of September 24, 1965, and shall post copies of the notice in conspicuous places available to employees and applicants for employment. rules, regulations, and relevant orders of the Secretary of Labor. 24, 1965, and by the rules, regulations, and orders of the Secretary of Labor, or pursuant thereto, and will permit access to his books, records, and accounts by the contracting agency and the Secretary of Labor for purposes of investigation to ascertain compliance with such rules, regulations, and orders. (6) In the event of the contractor‘s noncompliance with the nondiscrimination clauses of this contract or with any of such rules, regulations, or orders, this contract may be cancelled, terminated or suspended in whole or in part and the contractor may be declared ineligible for further Government contracts in accordance with procedures authorized in Executive Order No. 11246 of Sept. 24, 1965, and such other sanctions may be imposed and remedies invoked as provided in Executive Order No. 11246 of September 24, 1965, or by rule, regulation, or order of the Secretary of Labor, or as otherwise provided by law. unless exempted by rule, regulations, or orders of the Secretary of Labor issued pursuant to Section 204 of Executive Order No. 11246 of Sept. 24, 1965, so that such provisions will be binding upon each subcontractor or vendor. The contractor will take such action with respect to any subcontract or purchase order as the contracting agency may direct as a means of enforcing such provisions including sanctions for noncompliance: Provided, (2) The contractor will, in all solicitations or advertisements for employees placed by or on behalf of the (3) The contractor will send to each labor union or representative of workers with which he has a collective (4) The contractor will comply with all provisions of Executive Order No. 11246 of Sept. 24, 1965, and of the (5) The contractor will furnish all information and reports required by Executive Order No. 11246 of September (7) The contractor will include the provisions of Paragraphs (1) through (7) in every subcontract or purchase order Issue Date: November 7,2003 BP- 34 State Revolving Fund Loan Program CCR and Boilerplate however, That in the event the contractor becomes involved in, or is threatened with, litigation with a subcontractor or vendor as a result of such direction by the contracting agency, the contractor may request the United States to SEC. 203 (a) Each contractor having a contract containing the provisions prescribed in Section 202 shall file, and shall cause each of his subcontractors to file, Compliance Reports with the contracting agency or the Secretary of Labor as may be directed. Compliance Reports shall be filed within such times and shall contain such information as to the practices, policies, programs, and employment policies, programs, and employment statistics of the contractor and each subcontractor, and shall be in such form, as the Secretary of Labor may prescribe. any previous contract subject to the provisions of this Order, or any preceding similar Executive order, and in that event to submit, on behalf of themselves and their proposed subcontractors, Compliance Reports prior to or as an initial part of their bid or negotiation of a contract. understanding with a labor union or an agency referring workers or providing or supervising apprenticeship or training for such workers, the Compliance Report shall include such information as to such labor union's or agency's practices and policies affecting compliance as the Secretary of Labor may prescribe: Provided, That to the extent such information is within the exclusive possession of a labor union or an agency referring workers or providing or supervising apprenticeship or training and such labor union or agency shall refuse to furnish such information to the contractor, the contractor shall so certify to the contracting agency as part of its Compliance Report and shall set forth what efforts he has made to obtain such information. (d) The contracting agency or the Secretary of Labor may direct that any bidder or prospective contractor or subcontractor shall submit, as part of his Compliance Report, a statement in writing, signed by an authorized officer or agent on behalf of any labor union or any agency referring workers or providing or supervising apprenticeship or other training, with which the bidder or prospective contractor deals, with supporting information, to the effect that the signer's practices and policies do not discriminate on the grounds of race, color, creed, or national origin, and that the signer either will affirmatively cooperate in the implementation of the policy and provisions of this Order or that it consents and agrees that recruitment, employment, and the terms and conditions of employment under the proposed contract shall be in accordance with the purposes and provisions of the Order. In the event that the union, or the agency shall refuse to execute such a statement, the Compliance Report shall so certify and set forth what efforts have been made to secure such a statement and such additional factual material as the contracting agency or the Secretary of Labor may require. enter into such litigation to protect the interests of the United States. (b) Bidders or prospective contractors or subcontractors may be required to state whether they have participated in (c) Whenever the contractor or subcontractor has a collective bargaining agreement or other contract or 13 - 4 1 CFR 60-1.4 NONDISCRIMINATION CLAUSE NONDISCRIMINATION CLAUSE During the performance of this contract, the contractor agrees as follows: religion, sex, or national origin. The contractor will take affirmative action to ensure that applicants are employed, and that employees are treated during employment, without regard to their race, color, religion, sex, or national origin. Such action shall include, but not be limited to the following: Employment, upgrading, demotion, or transfer, recruitment or recruitment advertising; layoff or termination; rates of pay or other forms of compensation; and selection for training, including apprenticeship. The contractor agrees to post in conspicuous places, available to employees and applicants for employment, notices to be provided by the contracting officer setting forth the provisions of this nondiscrimination clause. state that all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, or national origin. bargaining agreement or other contract or understanding, a notice to be provided by the agency contracting officer, advising the labor union or workers' representative of the contractor's commitments under section 202 of Executive Order 11246 of September 24, 1965, and shall post copies of the notice in conspicuous places available to employees and applicants for employment. rules, regulations, and relevant orders of the Secretary of Labor. (1) The contractor will not discriminate against any employee or applicant for employment because of race, color, (2) The contractor will, in all solicitations or advertisements for employees placed by or on behalf of the contractor, (3) The contractor will send to each labor union or representative of workers with which he has a collective (4) The contractor will comply with all provisions of Executive Order 11246 of September 24,1965, and of the Issue Date: November 7,2003 BP- 35 State Revolving Fund Loan Program CCR and Boilerplate (5) The contractor will furnish all information and reports required by Executive Order 11246 of September 24, 1965, and by the rules, regulations, and orders of the Secretary of Labor, or pursuant thereto, and will permit access to his books, records, and accounts by the contracting agency and the Secretary of Labor for purposes of investigation to ascertain compliance with such rules, regulations, and orders. (6) In the event of the contractor's non-compliance with the nondiscrimination clauses of this contract or with any of such rules, regulations, or orders, this contract may be canceled, terminated or suspended in whole or in part and the contractor may be declared ineligible for further Government contracts in accordance with procedures authorized in Executive Order 11246 of September 24,1965, and such other sanctions may be imposed and remedies invoked as provided in Executive Order 11246 of September 24, 1965, or by rule, regulation, or order of the Secretary of Labor, or as otherwise provided by law. (7) the contractor will include the provisions of paragraphs (1) through (7) in every subcontract or purchase order unless exempted by rules, regulations, or orders of the Secretary of Labor issued pursuant to section 204 of Executive Order 11246 of September 24, 1965, so that such provisions will be binding upon each subcontractor or vendor. The contractor will take such action with respect to any subcontract or purchase order as may be directed by the Secretary of Labor as a means of enforcing such provisions including sanctions for noncompliance: Provided, however, that in the event the contractor becomes involved in, or is threatened with, litigation with a subcontractor or vendor as a result of such direction, the contractor may request the United States to enter into such litigation to protect the interests of the United States. (b) Federally assisted construction contracts. (1) Except as otherwise provided, each administering agency shall require the inclusion of the following language as a condition of any grant, contract, loan, insurance, or guarantee involving federally assisted construction which is not exempt from the requirements of the equal opportunity clause: The applicant hereby agrees that it will incorporate or cause to be incorporated into any contract for construction work, or modification thereof, as defined in the regulations of the Secretary of Labor at 41 CFR Chapter 60, which is paid for in whole or in part with funds obtained from the Federal Government or borrowed on the credit of the Federal Government pursuant to a grant, contract, loan insurance, or guarantee, or undertaken pursuant to any Federal program involving such grant, contract, loan, insurance, or guarantee, the following equal opportunity clause: During the performance of this contract, the contractor agrees as follows: (1) The contractor will not discriminate against any employee or applicant for employment because of race, color, religion, sex, or national origin. The contractor will take affirmative action to ensure that applicants are employed, and that employees are treated during employment without regard to their race, color, religion, sex, or national origin. such action shall include, but not be limited to the following: Employment, upgrading, demotion, or transfer; recruitment or recruitment advertising; layoff or termination; rates of pay or other forms of compensation; and selection for training, including apprenticeship. The contractor agrees to post in conspicuous places, available to employees and applicants for employment, notices to be provided setting forth the provisions of this nondiscrimination clause. state that all qualified applicants will receive considerations for employment without regard to race, color, religion, sex, or national origin. bargaining agreement or other contract or understanding, a notice to be provided advising the said labor union or workers' representatives of the contractor's commitments under this section, and shall post copies of the notice in conspicuous places available to employees and applicants for employment. (4) The contractor will comply with all provisions of Executive Order I 1246 of September 24, 1965, and of the rules, regulations, and relevant orders of the Secretary of Labor. (5) The contractor will furnish all information and reports required by Executive Order 11246 of September 24, 1965, and by rules, regulations, and orders of the Secretary of Labor, or pursuant thereto, and will permit access to his books, records, and accounts by the administering agency and the Secretary of Labor for purposes of investigation to ascertain compliance with such rules, regulations, and orders. the said rules, regulations, or orders, this contract may be canceled, terminated, or suspended in whole or in part and the contractor may be declared ineligible for further Government contracts or federally assisted construction contracts in accordance with procedures authorized in Executive Order 11246 of September 24, 1965, and such other sanctions may be imposed and remedies invoked as provided in Executive Order 11246 of September 24, 1965, or by rule, regulation, or order of the Secretary of Labor, or as otherwise provided by law. (2) The contractor will, in all solicitations or advertisements for employees placed by or on behalf of the contractor, (3) The contractor will send to each labor union or representative of workers with which he has a collective (6) In the event of the contractor's noncompliance with the nondiscrimination clauses of this contract or with any of Issue Date: November 7, 2003 BP- 36 State Revolving Fund Loan Program CCR and Boilerplate (7) The contractor will include the portion of the sentence immediately preceding paragraph (1) and the provisions of paragraphs (1) through (7) in every subcontract or purchase order unless exempted by rules, regulations, or orders of the Secretary of Labor issued pursuant to section 204 of Executive Order 11246 of September 24, 1965, so that such provisions will be binding upon each subcontractor or vendor. The contractor will take such action with respect to any subcontract or purchase order as the administering agency may direct as a means of enforcing such provisions, including sanctions for noncompliance: Provided, however, That in the event a contractor becomes involved in, or is threatened with, litigation with a subcontractor or vendor as a result of such direction by the administering agency the contractor may request the United States to enter into such litigation to protect the interests of the United States. The applicant further agrees that it will be bound by the above equal opportunity clause with respect to its own employment practices when it participates in federally assisted construction work: Provided, that if the applicant so participating is a State or local government, the above equal opportunity clause is not applicable to any agency, instrumentality or subdivision of such government which does not participate in work on or under the contract. The applicant agrees that it will assist and cooperate actively with the administering agency and the Secretary of Labor in obtaining the compliance of contractors and subcontractors with the equal opportunity clause and the rules, regulations, and relevant orders of the Secretary of Labor, that it will furnish the administering agency and the Secretary of Labor such information as they may require for the supervision of such compliance, and that it will otherwise assist the administering agency in the discharge of the agency's primary responsibility for securing compliance. Executive Order 11246 of September 24, 1965, with a contractor debarred from, or who has not demonstrated eligibility for, Government contracts and federally assisted construction contracts pursuant to the Executive order and will carry out such sanctions and penalties for violation of the equal opportunity clause as may be imposed upon contractors and subcontractors by the administering agency or the Secretary of Labor pursuant to Part 11, Subpart D of the Executive order. In addition, the applicant agrees that if it fails or refuses to comply with these undertakings, the administering agency may take any or all of the following actions: Cancel, terminate, or suspend in whole or in part this grant (contract, loan, insurance, guarantee); refrain from extending any further assistance to the applicant under the program with respect to which the failure or refund occurred until satisfactory assurance of future compliance has been received from such applicant; and refer the case to the Department of Justice for appropriate legal proceedings. The applicant further agrees that it will refrain from entering into any contract or contract modification subject to (c) Subcontracts. Each nonexempt prime contractor or subcontractor shall include the equal opportunity clause in each of its nonexempt subcontracts. (d) Incorporation by reference. The equal opportunity clause may be incorporated by reference in all Government contracts and subcontracts, including Government bills of lading, transportation requests, contracts for deposit of Government funds, and contracts for issuing and paying U.S. savings bonds and notes, and such other contracts and subcontracts as the Deputy Assistant Secretary may designate. considered to be a part of every contract and subcontract required by the order and the regulations in this part to include such a clause whether or not it is physically incorporated in such contracts and whether or not the contract between the agency and the contractor is written. (0 Adaptation of language. Such necessary changes in language may be made in the equal opportunity clause as shall be appropriate to identify properly the parties and their undertakings. [43 FR 49240, Oct. 20, 1978, as amended at 62 FR 6697 1, Dec. 22, 19971 (e) Incorporation by operation of the order. By operation of the order, the equal opportunity clause shall be Issue Date: November 7, 2003 BP- 37 State Revolving Fund Loan Program CCR and Boilerplate During the performance of this contract, contractor and its subcontractors shall not unlawfully discriminate against any employee or applicant for employment because of sex, race, religion, color, national origin, ancestry, physical disability (including HIV and AIDS), mental disability, medical condition (cancer), marital status, age (over 40) or denial of family care leave. Contractors and subcontractors shall insure that the evaluation and treatment of their employees and applicants for employment are free of such discrimination and harassment. Contractors and subcontractors shall comply with the provisions of the Fair Employment and Housing Act (Government Code Section 12900 (a-f) et seq.) and the applicable regulations promulgated thereunder (California Administrative Code, Title 2, Section 7285.0 et seq.). The applicable regulations of the Fair Employment and Housing Commission implementing Government Code, Section 12900 (a-f), set forth in Chapter 5 of Division 4 of Title 2 or the California Administrative Code are incorporated into thls contract by reference and made a part hereof as if set forth in full. Contractor and its subcontractor shall give written notice of their obligations under this clause to labor organizations with which they have a collective bargaining or other agreement. 2. The contractor shall include the nondiscrimination and compliance provisions of this cIause in all subcontracts to perform work under the contract. THE UNDERSIGNED CERTIFIES THAT THE CONTRACTOR WILL COMPLY WITH THE ABOVE REQUIREMENTS. CONTRACTOR OR SUBCONTRACTOR NAME: CERTIFIED BY: NAME: TITLE: SIGNATURE: DATE: Issue Date: November 7, 2003 BP- 38 State Revolving Fund Loan Program CCR and Boilerplate 14 - 41 CFX 60-4.2 CONSTRUCTION CONTRACTORS--AFFIRMATIVE ACTION REQUIREMENTS (in relevant part) Notice of requirement for Affirmative Action to ensure Equal Employment Opportunity (EEO) by Executive Order 11246, as amended by Executive Order 11375. 1. The Offeror's or Bidder's attention is called to the "Equal Opportunity Clause" and the "Standard Federal Equal Employment Specifications" set forth herein. 2. The goals and timetables for minority and female participation, expressed in percentage terms for the contractor's aggregate workforce in each trade on all construction work in the covered area, are as follows: Time- Goals for minority participation Goals for female participation tables for each trade for each trade Contract Dates : 16.9% 6.9% Contact the Division of Financial Assistance, Ken Gonzales at (91 6) 341-5683 for assistance with the minority goal and tables (gonzalesk@swrcb.ca.gov). The Office of Federal Contract Compliance Programs' web site for compliance issues and preaward registry is at http:Nwww.dol.gov/esa/welcome. These goals are applicable to all the Contractor's construction work (whether or not it is Federal or federally assisted) performed in the covered area. If the contractor performs construction work in a geographical area located outside of the covered area, it shall apply the goals established for such geographical area where the work is actually performed. With regard to this second area, the contractor also is subject to the goals for both its federally involved and non-federally involved construction. The Contractor's compliance with the Executive Order and the regulations in 41 CFR Part 60-4 shall be based on its implementation of the Equal Opportunity Clause, specific affirmative action obligations required by the specifications set forth in 41 CFR 60-4.3(a), and its efforts to meet the goals. The hours of minority and female employment and training must be substantially uniform throughout the length of the contract, and in each trade, and the contractor shall make a good faith effort to employ minorities and women evenly on each of its projects. The transfer of minority or female employees or trainees from Contractor to Contractor or from project to project for the sole purpose of meeting the Contractor's goals shall be a violation of the contract, the Executive Order and the regulations in 41 CFR Part 60-4. Compliance with the goals will be measured against the total work hours performed. 3. The Contractor shall provide written notification to the Director of the Office of Federal Contract Compliance Programs (notify the applicable Regional Office found at www.dol.eov/esa) within 10 working days of award of any construction subcontract in excess of $lO,OOO at any tier for construction work under the contract resulting from this solicitation. The notification shall list the name, address and telephone number of the subcontractor; employer identification number of the subcontractor: estimated dollar amount of the subcontract; estimated starting and completion dates of the subcontract; and the geographical area in which the subcontract is to be performed. 4. As used in this Notice, and in the contract resulting from this solicitation, the "covered area" is (insert description of the geographical areas where the contract is to be performed giving the state, county and city, if any). 8 60-4.3 Equal opportunity clauses (in relevant part) Standard Federal Equal Employment Opportunity Construction Contract Specifications (Executive Order 1 1246) Issue Date: November 7, 2003 BP- 39 State Revolving Fund Loan Program CCR and Boilerplate 1. As used in these specifications: a. "Covered area" means the geographical area described in the solicitation from which this contract resulted; b. "Director" means Director, Office of Federal Contract Compliance Programs, United States Department of Labor, or any person to whom the Director delegates authority; c. "Employer identification number" means the Federal Social Security number used on the Employer's Quarterly Federal Tax Return, U.S. Treasury Department Form 941. d. "Minority" includes: (i) Black (all persons having origins in any of the Black African racial groups not of Hispanic origin); (ii) Hispanic (all persons of Mexican, Puerto Rican, Cuban, Central or South American or other Spanish Culture or origin, regardless of race); (iii) Asian and Pacific Islander (all persons having origins in any of the original peoples of the Far East, Southeast Asia, the Indian Subcontinent, or the Pacific Islands); and (iv) American Indian or Alaskan Native (all persons having origins in any of the original peoples of North America and maintaining identifiable tribal affiliations through membership and participation or community identification). 2. Whenever the Contractor, or any Subcontractor at any tier, subcontracts a portion of the work involving any construction trade, it shall physically include in each subcontract in excess of $10,000 the provisions of these specifications and the Notice which contains the applicable goals for minority and female participation and which is set forth in the solicitations from which this contract resulted. 3. If the Contractor is participating (pursuant to 41 CFR 60-4.5) in a Hometown Plan approved by the US. Department of Labor in the covere4 area either individually or through an association, its affirmative action obligations on all work in the Plan area (including goals and timetables) shall be in accordance with that Plan for those trades which have unions participating in the Plan. Contractors must be able to demonstrate their participation in and compliance with the provisions of any such Hometown Plan. Each Contractor or Subcontractor participating in an approved Plan is individually required to comply with its obligations under the EEO clause, and to make a good faith effort to achieve each goal under the Plan in each trade in which it has employees. The overall good faith performance by other Contractors or Subcontractors toward a goal in an approved Plan does not excuse any covered Contractor's or Subcontractor's failure to take good faith efforts to achieve the Plan goals and timetables. 4. The Contractor shall implement the specific affirmative action standards provided in paragraphs 7 a through p of these specifications. The goals set forth in the solicitation from which this contract resulted are expressed as percentages of the total hours of employment and training of minority and female utilization the Contractor should reasonably be able to achieve in each construction trade in which it has employees in the covered area. Covered Construction contractors performing construction work in geographical areas where they do not have a Federal or federally assisted construction contract shall apply the minority and female goals established for the geographical area where the work is being performed. Goals are published periodically in the Federal Register in notice form, and such notices may be obtained from any Office of Federal Contract Compliance Programs office or from Federal procurement contracting officers. The Contractor is expected to make substantially uniform progress in meeting its goals in each craft during the period specified. 5. Neither the provisions of any collective bargaining agreement, nor the failure by a union with whom the Contractor has a collective bargaining agreement, to refer either minorities or women shall excuse the Contractor's obligations under these specifications, Executive Order I 1246, or the regulations promulgated pursuant thereto. 6. In order for the non-working training hours of apprentices and trainees to be counted in meeting the goals, such apprentices and trainees must be employed by the Contractor during the training period, and the Contractor must have made a commitment to employ the apprentices and trainees at the completion of their training, subject to the availability of employment opportunities. Trainees must be trained pursuant to training programs approved by the U.S. Department of Labor. Issue Date: November 7,2003 BP- 40 State Revolving Fund Loan Program CCR and Boilerplate 7. The Contractor shall take specific affirmative actions to ensure equal employment opportunity. The evaluation of the Contractor's compliance with these specifications shall be based upon its effort to achieve maximum results from its actions. The Contractor shall document these efforts fully, and shall implement affirmative action steps at least as extensive as the following: a. Ensure and maintain a working environment free of harassment, intimidation, and coercion at all sites, and in all facilities at which the Contractor's employees are assigned to work. The Contractor, where possible, will assign two or more women to each construction project. The Contractor shall specifically ensure that all foremen, superintendents, and other on-site supervisory personnel are aware of and carry out the Contractor's obligation to maintain such a working environment, with specific attention to minority or female individuals working at such sites or in such facilities. b. Establish and maintain a current list of minority and female recruitment sources, provide written notification to minority and female recruitment sources and to community organizations when the Contractor or its unions have employment opportunities available, and maintain a record of the organizations' responses. c. Maintain a current file of the names, addresses and telephone numbers of each minority and female off-the-street applicant and minority or female referral from a union. a recruitment source or community organization and of what action was taken with respect to each such individual. If such individual was sent to the union hiring hall for referral and was not referred back to the Contractor by the union or, if referred, not employed by the Contractor, this shall be documented in the file with the reason therefore, along with whatever additional actions the Contractor may have taken. d. Provide immediate written notification to the Director when the union or unions with which the Contractor has a collective bargaining agreement has not referred to the Contractor a minority person or woman sent by the Contractor, or when the Contractor has other information that the union referral process has impeded the Contractor's efforts to meet its obligations. e. Develop on-the-job training opportunities and/or participate in training programs for the area which expressly include minorities and women, including upgrading programs and apprenticeship and trainee programs relevant to the Contractor's employment needs, especially those programs funded or approved by the Department of Labor. The Contractor shall provide notice of these programs to the sources compiled under 7b above. f. Disseminate the Contractor's EEO policy by providing notice of the policy to unions and training programs and requesting their cooperation in assisting the Contractor in meeting its EEO obligations; by including it in any policy manual and collective bargaining agreement; by publicizing it in the company newspaper, annual report, etc.; by specific review of the policy with all management personnel and with all minority and female employees at least once a year; and by posting the company EEO policy on bulletin boards accessible to all employees at each location where construction work is performed. g. Review, at least annually, the company's EEO policy and affirmative action obligations under these specifications with all employees having any responsibility for hiring, assignment, layoff, termination or other employment decisions including specific review of these items with onsite supervisory personnel such as Superintendents, General Foremen, etc., prior to the initiation of construction work at any job site. A written record shall be made and maintained identifying the time and place of these meetings, persons attending, subject matter discussed, and disposition of the subject matter. h. Disseminate the Contractor's EEO policy externally by including it in any advertising in the news media, specifically including minority and female news media, and providing written notification to and discussing the Contractor's EEO policy with other Contractors and Subcontractors with whom the Contractor does or anticipates doing business. i. Direct its recruitment efforts, both oral and written, to minority, female and community organizations, to schools with minority and female students and to minority and female recruitment and training organizations serving the Contractor's recruitment area and employment needs. Not later than one month prior to the date for the acceptance of applications for apprenticeship or other training by any recruitment source, the Contractor shall send written notification to organizations such as the above, describing the openings, screening procedures, and tests to be used in the selection process. Issue Date: November 7, 2003 BP- 41 State Revolving Fund Loan Program CCR and Boilerplate j. Encourage present minority and female employees to recruit other minority persons and women and, where reasonable, provide after school, summer and vacation employment to minority and female youth both on the site and in other areas of a Contractor's work force. k. Validate all tests and other selection requirements where there is an obligation to do so under 41 CFR Part 60-3. 1. Conduct, at least annually, an inventory and evaluation at least of all minority and female personnel for promotional opportunities and encourage these employees to seek or to prepare for, through appropriate training, etc., such opportunities. m. Ensure that seniority practices, job classifications, work assignments and other personnel practices, do not have a discriminatory effect by continually monitoring all personnel and employment related activities to ensure that the EEO policy and the Contractor's obligations under these specifications are being carried out. n. Ensure that all facilities and company activities are Non-Segregated except that separate or single-user toilet and necessary changing facilities shall be provided to assure privacy between the sexes. 0. Document and maintain a record of all solicitations of offers for subcontracts from minority and female construction contractors and suppliers, including circulation of solicitations to minority and female contractor associations and other business associations. p. Conduct a review, at least annually, of all supervisors' adherence to and performance under the Contractor's EEO policies and affirmative action obligations. 8. Contractors are encouraged to participate in voluntary associations which assist in fulfilling one or more of their affirmative action obligations (7a through p). The efforts of a contractor association, joint contractor-union, contractor-community, or other similar group of which the contractor is a member and participant, may be asserted as fulfilling any one or more of its obligations under 7a through p of these Specifications provided that the contractor actively participates in the group, makes every effort to assure that the group has a positive impact on the employment of minorities and women in the industry, ensures that the concrete benefits of the program are reflected in the Contractor's minority and female workforce participation, makes a good faith effort to meet its individual goals and timetables, and can provide access to documentation which demonstrates the effectiveness of actions taken on behalf of the Contractor. The obligation to comply, however, is the Contractor's and failure of such a group to fulfill an obligation shall not be a defense for the Contractor's noncompliance. 9. A single goal for minorities and a separate single goal for women have been established. The Contractor, however, is required to provide equal employment opportunity and to take affirmative action for all minority groups, both male and female, and all women, both minority and non-minority. Consequently, the Contractor may be in violation of the Executive Order if a particular group is employed in a substantially disparate manner (for example, even though the Contractor has achieved its goals for women generally, the Contractor may be in violation of the Executive Order if a specific minority group of women is underutilized). 10. The Contractor shall not use the goals and timetables or affirmative action standards to discriminate against any person because of race, color, religion, sex, or national origin. 11. The Contractor shall not enter into any Subcontract with any person or firm debarred from Government contracts pursuant to Executive Order 11246. 12. The Contractor shall carry out such sanctions and penalties for violation of these specifications and of the Equal Opportunity Clause, including suspension, termination and cancellation of existing subcontracts as may be imposed or ordered pursuant to Executive Order 1 1246, as amended, and its implementing regulations, by the Office of Federal Contract Compliance Programs. Any Contractor who fails to carry out such sanctions and penalties shall be in violation of these specifications and Executive Order 11246, as amended. 13. The Contractor, in fulfilling its obligations under these specifications, shall implement specific affirmative action steps, at least as extensive as those standards prescribed in paragraph 7 of these specifications, so as to achieve maximum results from its efforts to ensure equal employment opportunity. If the Contractor fails to comply with the requirements of the Executive Order, the implementing regulations, or these specifications, the Director shall proceed in accordance with 41 CFR 60-4.8. Issue Date: November 7, 2003 BP- 42 State Revolving Fund Loan Program CCR and Boilerplate 14. The Contractor shall designate a responsible official to monitor all employment related activity to ensure that the company EEO policy is being carried out, to submit reports relating to the provisions hereof as may be required by the Government and to keep records. Records shall at least include for each employee the name, address, telephone numbers, construction trade, union affiliation if any, employee identification number when assigned, social security number, race, sex, status (e.g., mechanic, apprentice trainee, helper, or laborer), dates of changes in status, hours worked per week in the indicated trade, rate of pay, and locations at which the work was performed. Records shall be maintained in an easily understandable and retrievable form; however, to the degree that existing records satisfy this requirement, contractors shall not be required to maintain separate records. 15. Nothing herein provided shall be construed as a limitation upon the application of other laws which establish different standards of compliance or upon the application of requirements for the hiring of local or other area residents (e.g., those under the Public Works Employment Act of 1977 and the Community Development Block Grant Program). 15 - ELIMINATION OF SEGREGATED FACILITIES NOTICE TO PROSPECTJYE FEDERALLY-ASSISTED CONSTRUCTION CONTRACTORS (a) A Certification of Non-Segregated Facilities, as required by the May 9, 1967 Order (32 F.R. 7439, May 19, 1967) on Elimination of Segregated Facilities, by the Secretary of Labor, must be submitted prior to the award of a Federally-assisted construction contract exceeding $10,000 which is not exempt from the provisions of the Equal Opportunity Clause. (b) Contractors receiving Federally-assisted construction contract awards exceeding $10,000 which, are not exempt from the provisions of the Equal Opportunity Clause, will be required to provide for the forwarding of the following notice to prospective subcontractors for supply and construction contracts where the subcontracts exceed $10,000 and are not exempt from the provisions of the Equal Opportunity Clause. NOTICE TO PROSPECTIVE SUBCONTRACTORS OF REQUIREMENT FOR CERTIFICATION OF NON-SEGREGATED FACILITIES (a) A Certification of Non-Segregated Facilities, as required by the May 9, 1967 Order (32 F.R. 7439, May 19, 1967) on Elimination of Segregated Facilities, by the Secretary of Labor, must be submitted prior to the award of a subcontract exceeding $10,000 which is not exempt from the provisions of the Equal Opportunity Clause. (b) Contractors receiving subcontract awards exceeding $10,000 which are not exempt from the provisions of the Equal Opportunity Clause will be required to provide for the forwarding of this notice to prospective subcontractors for supply and construction contracts where the subcontracts exceed $10,000 and are not exempt from the provisions of the Equal Opportunity Clause. Issue Date: November 7,2003 BP- 43 State Revolving Fund Loan Program CCR and Boilerplate I6 - CERTIFICATION OF NON-SEGREGATED FACILITIES Environmental Protection Agency Region IX 75 Hawthorne Street San Francisco, California 94105 CERTIFICATION OF NON-SEGREGATED FACILITIES (Applicable to federally assisted construction contracts and related subcontracts exceeding $lO,OOO which are not exempt from the Equal Opportunity Clause.) The federally assisted construction contractor certifies that he does not maintain or provide for his employees any segregated facilities at any of his establishments, and that he does not permit his employees to perform their services at any location, under his control, where segregated facilities are maintained. The federally assisted construction contractor certifies further that he will not maintain or provide for his employees any segregated facilities at any of his establishments, and that he will not permit his employees to perform their services at any location, under his control, where segregated facilities are maintained. The federally assisted construction contractor agrees that a breach of this certification is a violation of the Equal Opportunity Clause in this contract. As used in this certification, the term “segregated facilities” means any waiting rooms, work areas, restrooms and wash rooms, restaurants and other eating areas, time clocks, locker rooms and other storage or dressing areas, transportation, and housing facilities provided for employees which are segregated by explicit directive or are in fact segregated on the basis of race, creed, color, or national origin, because of habit, local custom, or otherwise. The federally assisted construction contractor agrees that (except where he has obtained identical certifications from proposed subcontractors for specified time period) he will obtain identical certifications from proposed subcontractors prior to the award of subcontracts exceeding $lO,OOO which are not exempt form the provisions of the Equal Opportunity Clause, and that he will retain such certifications in his files. Signature Date Name and Title of Signer (Please Type) Note: The penalty for making false statements in offers is prescribed in 18 U.S.C. 1001. Issue Date: November 7, 2003 BP- 44 State Revolving Fund Loan Program CCR and Boilelplate 17 - DRUG-FREE WORKPLACE CERTIFlCATlON DRUG-FREE WORKPLACE CERTIFICATION CONTRACTOWAPPLICANT: The contractor or applicant named above hereby certifies compliance with Government Code Section 8355 in matters relating to providing a drug-free workplace. The above named contractor or applicant will: 1. Publish a statement notifying employees that unlawful manufacture, distribution, dispensation, possession, or use of a controlled substance is prohibited and specifying actions to be taken against employees for violations, as required by Government Code Section 8355(a). 2. Establish a Drug-Free Awareness Program as required by Government Code Section 8355(b), to inform employees about all of the following: (a) The dangers of drug abuse in the workplace, (b) The person’s or organization’s policy of maintaining a drug-free workplace, (c) Any available counseling, rehabilitation and employee assistance programs, and (d) Penalties that may be imposed upon employees for drug abuse violations. 3. Provide as required by Government Code Section 8355(c), that every employee who works on the proposed contract or loan: (a) Will receive a copy of the company’s drug-free policy statement, and (b) Will agree to abide by the terms of the company’s statement as a condition of employment on the contract or loan. CERTIFICATION I, the official named below, hereby swear that I am duly authorized legally to bind the contractor or loan recipient to the above described certification. I am fully aware that this certification, executed on the date and in the county below, is made under penalty of perjury under the laws of the State of California. OFFlCIAL’S NAME: DATE EXECUTED: CONTRACTOWAPPLICANT SIGNATURE: TITLE: EXECUTED IN COUNTY OF: Issue Date: November 7, 2003 BP- 45 State Revolving Fund Loan Program CCR and Boilerplate 18 - PART 32--GOVERNMENT WIDE DEBARMENT AND SUSPENSION (NONPROCUREMENT) AND GOVERNMENT WIDE REQUIREMENTS FOR DRUG-FREE WORKPLACE (GRANTS) Appendix A to Part 32--Certification Regarding Debarment, Suspension, and Other Responsibility Matters--Primary Covered Transactions Instructions for Certification 1. By signing and submitting this proposal, the prospective primary participant is providing the certification set out below. 2. The inability of a person to provide the certification required below will not necessarily result in denial of participation in this covered transaction. The prospective participant shall submit an explanation of why it cannot provide the certification set out below. The certification or explanation will be considered in connection with the department or agency's determination whether to enter into this transaction. However, failure of the prospective primary participant to furnish a certification or an explanation shall disqualify such person from participation in this transaction. 3. The certification in this clause is a material representation of fact upon which reliance was placed when the department or agency determined to enter into this transaction. If it is later determined that the prospective primary participant knowingly rendered an erroneous certification, in addition to other remedies available to the Federal Government, the department or agency may terminate this transaction for cause or default. 4. The prospective primary participant shall provide immediate written notice to the department or agency to which this proposal is submitted if at any time the prospective primary participant learns that its certification was erroneous when submitted or has become erroneous by reason of changed circumstances. 5. The terms covered transaction, debarred, suspended, ineligible, lower tier covered transaction, participant, person, primary covered transaction, principal, proposal, and voluntarily excluded, as used in this clause, have the meanings set out in the Definitions and Coverage sections of the rules implementing Executive Order 12549. You may contact the department or agency to which this proposal is being submitted for assistance in obtaining a copy of those regulations. 6. The prospective primary participant agrees by submitting this proposal that, should the proposed covered transaction be entered into, it shall not knowingly enter into any lower tier covered transaction with a person who is proposed for debarment under 48 CFR part 9, subpart 9.4, debarred, suspended, declared ineligible, or voluntarily excluded from participation in this covered transaction, unless authorized by the department or agency entering into this transaction. 7. The prospective primary participant further agrees by submitting this proposal that it will include the clause titled "Certification Regarding Debarment, Suspension, Ineligibility and Voluntary Exclusion-Lower Tier Covered Transaction," provided by the department or agency entering into this covered transaction, without modification, in all lower tier covered transactions and in all solicitations for lower tier covered transactions. 8. A participant in a covered transaction may rely upon a certification of a prospective participant in a lower tier covered transaction that it is not proposed for debarment under 48 CFR part 9, subpart 9.4, debarred, suspended, ineligible, or voluntarily excluded from the covered transaction, unless it knows that the certification is erroneous. A participant may decide the method and frequency by which it determines the eligibility of its principals. Each participant may, but is not required to, check the List of Parties Excluded from Federal Procurement and Non- procurement Programs. 9. Nothing contained in the foregoing shall be construed to require establishment of a system of records in order to render in good faith the certification required by this clause. The knowledge and information of a participant is not required to exceed that which is normally possessed by a prudent person in the ordinary course of business dealings. 10. Except for transactions authorized under paragraph 6 of these instructions, if a participant in a covered transaction knowingly enters into a lower tier covered transaction with a person who is proposed for debarment under 48 CFX part 9, subpart 9.4, suspended, debarred, ineligible, or voluntarily excluded from participation in this Issue Date: November 7, 2003 BP- 46 State Revolving Fund Loan Program CCR and Boilerplate transaction, in addition to other remedies available to the Federal Government, the department or agency may terminate this transaction for cause or default. Certification Regarding Debarment, Suspension, and Other Responsibility Matters--Primary Covered Transactions (1) The prospective primary participant certifies to the best of its knowledge and belief, that it and its principals: (a) Are not presently debarred, suspended, proposed for debarment, declared ineligible, or voluntarily excluded by any Federal department or agency; (b) Have not within a three-year period preceding this proposal been convicted of or had a civil judgment rendered against them for commission of fraud or a criminal offense in connection with obtaining, attempting to obtain, or performing a public (Federal, State or local) transaction or contract under a public transaction; violation of Federal or State antitrust statutes or commission of embezzlement, theft, forgery, bribery, falsification or destruction of records, making false statements, or receiving stolen property: (c) Are not presently indicted for or otherwise criminally or civilly charged by a governmental entity (Federal, State or local) with commission of any of the offenses enumerated in paragraph (I)(b) of this certification; and (d) Have not within a three-year period preceding this applicatiodproposal had one or more public transactions (Federal, State or local) terminated for cause or default. (2) Where the prospective primary participant is unable to certify to any of the statements in this certification, such prospective participant shall attach an explanation to this proposal. Appendix B to Part 32--Certification Regarding Debarment, Suspension, Ineligibility and Voluntary Exclusion--Lower Tier Covered Transactions Instructions for Certification 1. By signing and submitting this proposal, the prospective lower tier participant is providing the certification set out below. 2. The certification in this clause is a material representation of fact upon which reliance was placed when this transaction was entered into. If it is later determined that the prospective lower tier participant knowingly rendered an erroneous certification, in addition to other remedies available to the Federal Government the department or agency with which this transaction originated may pursue available remedies, including suspension and/or debarment. 3. The prospective lower tier participant shall provide immediate written notice to the person to which this proposal is submitted if at any time the prospective lower tier participant learns that its certification was erroneous when submitted or had become erroneous by reason of changed circumstances. 4. The terms covered transaction, debarred, suspended, ineligible, lower tier covered transaction, participant, person, primary covered transaction, principal, proposal, and voluntarily excluded, as used in this clause, have the meaning set out in the Definitions and Coverage sections of rules implementing Executive Order 12549. You may contact the person to which this proposal is submitted for assistance in obtaining a copy of those regulations. 5. The prospective lower tier participant agrees by submitting this proposal that, should the proposed covered transaction be entered into, it shall not knowingly enter into any lower tier covered transaction with a person who is proposed for debarment under 48 CFR part 9, subpart 9.4. debarred, suspended, declared ineligible, or voluntarily excluded from participation in this covered transaction, unless authorized by the department or agency with which this transaction originated. 6. The prospective lower tier participant further agrees by submitting this proposal that it will include this clause titled "Certification Regarding Debarment, Suspension, Ineligibility and Voluntary Exclusion-Lower Tier Covered Transaction," without modification, in all lower tier covered transactions and in all solicitations for lower tier covered transactions. Issue Date: November 7, 2003 BP- 47 State Revolving Fund Loan Program CCR and Boilerplate 7. A participant in a covered transaction may rely upon a certification of a prospective participant in a lower tier covered transaction that it is not proposed for debarment under 48 CFR part 9, subpart 9.4, debarred, suspended, ineligible, or voluntarily excluded from covered transactions, unless it knows that the certification is erroneous. A participant may decide the method and frequency by which it determines the eligibility of its principals. Each participant may, but is not required to, check the List of Parties Excluded fiom Federal Procurement and Nonprocurement Programs. 8. Nothing contained in the foregoing shall be construed to require establishment of a system of records in order to render in good faith the certification required by this clause. The knowledge and information of a participant is not required to exceed that which is normally possessed by a prudent person in the ordinary course of business dealings. 9. Except for transactions authorized under paragraph 5 of these instructions, if a participant in a covered transaction knowingly enters into a lower tier covered transaction with a person who is proposed for debarment under 48 CFR part 9, subpart 9.4, suspended, debarred, ineligible, or voluntarily excluded from participation in this transaction, in addition to other remedies available to the Federal Government, the department or agency with which this transaction originated may pursue available remedies, including suspension andor debarment. Certification Regarding Debarment, Suspension, Ineligibility and Voluntary Exclusion--Lower Tier Covered Transactions (1) The prospective lower tier participant certifies, by submission of this proposal, that neither it nor its principals is presently debarred, suspended, proposed for debarment, declared ineligible, or voluntarily excluded from participation in this transaction by any Federal department or agency. (2) Where the prospective lower tier participant is unable to certify to any of the statements in this certification, such prospective participant shall attach an explanation to this proposal. 19 - RESPONSIBILITY FOR REMOVAL, RELOCATION, OR PROTECTION OF EXISTING UTILITIES; CONTRACTS AND PROVISIONS GOVERNMENT CODE SECTION 4215 (in relevant part) In any contract to which a public agency as defined in Section 4401 is a party, the public agency shall assume the responsibility, between the parties to the contract, for the timely removal, relocation, or protection of existing main or trunkline utility facilities located on the site of any construction project that is a subject of the contract, if such utilities are not identified by the public agency in the plans and specifications made a part of the invitation for bids. The contract documents shall include provisions to compensate the contractor for the costs of locating, repairing damage not due to the failure of the contractor to exercise reasonable care, and removing or relocating such utility facilities not indicated in the plans and specifications with reasonable accuracy, and for equipment on the project necessarily idled during such work. The contract documents shall include provisions that the contractor shall not be assessed liquidated damages for delay in completion of the project, when such delay was caused by the failure of the public agency or the owner of the utility to provide for removal or relocation of such utility facilities. 20 - SUBMI"G OF BIDS AND AGREEING TO ASSIGN GOVERNMENT CODE SECTION 4552 (in relevant Dart) In submitting a bid to a public purchasing body, the bidder offers and agrees that if the bid is accepted, it will assign to the purchasing body all rights, title, and interest in and to all causes of action it may have under Section 4 of the Clayton Act (15 U.S. C. Sec. 15) or under the Cartwright Act (Chapter 2 (commencing with Section 16700) of Part 2 of Division 7 of the Business and Professions Code), arising from purchases of goods, materials, or services by the bidder for sale to the purchasing body pursuant to the bid. Such assignment shall be made and become effective at the time the purchasing body tenders final payment to the bidder. (1978) Issue Date: November 7, 2003 BP- 48 State Revolving Fund Loan Program CCR and Boilerplate 2 1 - NON-COLLUSION AFFIDAVIT PUBLIC CONTRACT CODE SECTION 7106 NON-COLLUSION AFFIDAVIT TO BE EXECUTED BY BIDDER AND SUBMI'ITED WITH BID State of California County of ss ; being first duly sworn, deposes and says that he or she is of the party making the foregoing bid, that the bid is not made in the interest of, or on behalf of, any undisclosed person, partnership, company, association, organization, or corporation; that the bid is genuine and not collusive or sham; that the bidder has not directly or indirectly induced or solicited any other bidder to put in a false or sham bid, and has not directly or indirectly colluded, conspired, connived, or agreed with any bidder or anyone else to put in a sham bid, or that anyone shall refrain from bidding; that the bidder has not in any manner, directly or indirectly, sought by agreement, communication, or conference with anyone to fix the bid price of the bidder or any other bidder, or to fix any overhead, profit, or cost element of the bid price, or of that of any other bidder, or to secure any advantage against the public body awarding the contract of anyone interested in the proposed contract; that all statements contained in the bid are true; and, further, that the bidder has not, directly or indirectly, submitted his or her bid price or any breakdown thereof, or the contents thereof, or divulged information or data relative thereto, or paid, and will not pay, any fee to any corporation, partnership, company association, organization, bid depository, or to any member or agent thereof to effectuate a collusive or sham bid. personally known to me OR proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) is/are subscribed to the within instrument and acknowledged to me that he/she/they executed the same in hidheritheir authorized capacity(ies), and that by his/her/their signatures(s) on the instrument the person(s), or entity upon behalf of which the person(s) acted, executed the instrument. Subscribed and sworn to before me on (Notary Public) Issue Date: November 7,2003 BP- 49 State Revolving Fund Loan Program CCR and Boilerplare 23- LABOR CODE SECTION 6500 6500. injury, the division shall require the issuance of a permit prior to the initiation of any practices, work. method. operation, or process of employment. The permit requirement of this section is limited to employment or places of employment that are any of the following: (a) For those employments or places of employment that by their nature involve a substantial risk of (1) Construction of trenches or excavations that are five feet or deeper and into which a person is required to descend. (2) The construction of any building. structure, falsework, or scaffolding more than three stories high or the equivalent height. (3) The demolition of any building, structure, falsework, or scaffold more than three stones high or the equivalent height. (4) The underground use of diesel engines in work in mines and tunnels. This subdivision does'not apply to motion picture, television, or theater stages or sets, including, but not (b) limited to, scenery, props, backdrops, flats, greenbeds, and grids. stages or sets, if there has occurred within any one prior calendar year in any combination at separate locations three serious injuries, fatalities, or serious violations related to the construction or demolition of sets more than 36 feet in height for the motion picture, television, and theatrical production industry. An annual permit shall be required for employers who construct or dismantle motion picture, television, or theater stages or sets that are more than three stories or the equivalent height. A single permit shall be required under this subdivision for each employer, regardless of the number of locations where the stages or sets are located. An employer with a currently valid annual permit issued under this subdivision shall not be required to provide notice to the division prior to commencement of any work activity authorized by the permit. The division may adopt procedures to permit employers to renew by mail the permits issued under this subdivision. For purposes of this subdivision, "motion picture, television, or theater stages or sets" include, but are not limited to, scenery, props, backdrops, flats, greenbeds, and grids. On or after January 1, 2000. this subdivision shall apply to motion picture, television, or theater 24 - PUBLIC CONTRACT CODE SECTION 7 105 7105. cost of repairing or restoring damage to the work, which damage is determined to have been proximately caused by an act of God, in excess of 5 percent of the contracted amount, provided, that the work damaged is built in accordance with accepted and applicable building standards and the plans and specifications of the awarding authority. However, contracts may include provisions for terminating the contract. The requirements of this section shall not be mandatory as to construction contracts financed by revenue bonds. This section shall not prohibit a public agency from requiring that a contractor obtain insurance to indemnify the public agency for any damage to the work caused by an act of God if the insurance premium is a separate bid item. If insurance is required, requests for bids issued by public agencies shall set forth the amount of the work to be covered and the contract resulting from the requests for bids shall require that the contractor furnish evidence of satisfactory insurance coverage to the public agency prior to execution of the contract. (a) Construction contracts of public agencies shall not require the contractor to be responsible for the (b) (1) For the purposes of this section: "Public agency" shall include the state, the Regents of the University of California, a city, county, district, public authority, public agency, municipal utility, and any other political subdivision or public corporation of the state. "Acts of God" shall include only the following occurrences or conditions and effects: earthquakes in excess of a magnitude of 3.5 on the Richter Scale and tidal waves. Public agencies may make changes in construction contracts for public improvements in the course of construction to bring the completed improvements into compliance with environmental requirements or standards established by state and federal statutes entered into. The contractor shall be paid for the changes in accordance with the provisions of the contract governing payment for changes in the work or, if no provisions are set forth in the contract, payment shall be as agreed to by the parties. include the power, by mutual consent of the contracting parties, to terminate, amend, or modify any contract within the scope of such authority. (2) (c) (d) (I) Where authority to contract is vested in any public agency, excluding the state, the authority shall BP-50 State Revolving Fund Loan Program CCR and Boilerplate (2) Paragraph (1) shall not apply to contracts entered into pursuant to any statute expressly requiring that contracts be let or awarded on the basis of competitive bids. Contracts of public agencies, excluding the state, required to be let or awarded on the basis of competitive bids pursuant to any statute may be terminated, amended. or modified only if the termination, amendment, or modification is so provided in the contract or is authorized under provision of law other than this subdivision. The compensation payable, if any, for amendments and modifications shall be determined as provided in the contract. The compensation payable, if any, in the event the contract is so terminated shall be determined as provided in the contract or applicable statutory provision providing for the termination. (3) at the discretion of the public agencies. Contracts of public agencies may include provisions for termination for environmental considerations 25 - PUBLIC CONTRACT CODE SECTION 9203 9203. improvement of any public structure, building, road, or other improvement, of any kind which will exceed in cost a total of five thousand dollars ($5,000), shall be made as the legislative body prescribes upon estimates approved by the legislative body, but progress payments shall not be made in excess of 95 percent of the percentage of actual work completed plus a like percentage of the value of material delivered on the ground or stored subject to, or under the control of, the local agency, and unused. The local agency shall withhold not less than 5 percent of the contract price until final completion and acceptance of the project. However, at any time after 50 percent of the work has been completed, if the legislative body finds that satisfactory progress is being made, it may make any of the remaining progress payments in full for actual work completed. to a twenty-five thousand dollar ($25,000) limit for purposes of subdivision (a). (a) Payment on any contract with a local agency for the creation, construction, alteration, repair, or (b) Notwithstanding the dollar limit specified in subdivision (a), a county water authority shall be subject BP-51 TECHNICAL SPECIFICATIONS ' SECTION 01 026 SCHEDULE OF VALUES PART 1 - GENERAL 1.01 REQUIREMENTS A. Within thirty (30) days of the Notice to Proceed, the CONTRACTOR shall submit a Schedule of Values for the OWNER'S approval. The Schedule of Values is a detailed itemized breakdown of all lump sum bid items. B. The Schedule of Values shall be used as a basis for determining progress payments on a lump sum contract or any designated lump sum bid item. The Schedule of Values shall be a schedule of cost loaded construction activities equal, in total, to the lump sum bid and shall be in such form and sufficient detail to correctly represent a reasonable apportionment of the lump sum. Prior to submitting a monthly payment request, the CONTRACTOR shall have submitted a detailed Schedule of Values and obtained approval from the OWNER. C. Each lump sum bid item on the Bid Schedule(s), as set forth in the Contractor's Bid Proposal must be broken down separately. The breakdown of each lump sum bid item must cover the cost of construction required by the Contract Drawings and Specifications for that item. The sum of the values for the construction activities, within a bid item, must equal the total bid amount for that item. The breakdown shall include subcontract amounts, which shall not deviate from the amounts submitted in the Bid Proposal. The CONTRACTOR shall provide certification from the Subcontractors certifying the subcontract amounts. D. Each activity in the Schedule of Values shall delineate one construction activity. For example, the placement of concrete between construction joints, the construction of an electrical duct bank or pipeline between points A & B. The costing for each activity should include all costs for the labor and materials or equipment required to complete the activity. For example, concrete construction activities should include all costs for the forming, placing of reinforcement, placing concrete, and curing. The cost for pipeline construction activities should include materials, equipment and installation including pipeline supports or thrust blocks. The excavation and backfill for a pipeline or structure may be separate activities. The Bid Proposal breakdown shall include the itemized costs for the plant startup and testing to be performed before the final project acceptance is made. No non-construction activity shall be cost loaded. E. Where Contract Documents require a CPM Construction Schedule, the CONTRACTOR shall use cost loaded construction activities from the Construction Schedule as a Schedule of Values. Each construction activity shall be encoded to its bid item and a sort provided for each bid item totaling the cost loaded amount. The total of the Cost Loaded amounts for each bid item shall equal the amount bid for that item. November 2003 Calavera Pump Station (860-3-Cal) Contract 3889 1 Schedule of Values 01 026-1 F. The total of the Schedule of Values shall equal the current Contract value at all times. At any time during the progress of the Contract Work, the OWNER reserves the right to review the cost loading of the Schedules of Values and direct necessary revisions. When requested by the OWNER, the CONTRACTOR shall provide all information necessary to substantiate the cost loading. November 2003 Calavera Pump Station (860-3-Cat) Contract 38891 Schedule of Values 01 026-2 SECTION 01 500 START-UP, FIELD TESTING, AND ACCEPTANCE OF EQUIPMENT TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 1.02 1.03 DESCRI PTlON The Contractor shall furnish all labor, equipment, and material necessary to perform start-up, field testing, and acceptance of equipment for the Recycled Water Pump Station and all related appurtenances. SUBMllTALS All submittals shall be in accordance with the General Provisions, Section 2-53, START-UP The Contractor shall provide fourteen days advance notice to the Owner prior to start-up of any equipment. Training will not be allowed until at least one day after start-up is complete. Prior to the start-up of systems, each equipment manufacturer shall provide written certification that their equipment has been installed properly and in accordance with the manufacturer's recommendations and is ready to start-up. The Contractor shall coordinate start-up of the control panel, pumping units and instrumentation on the same day unless otherwise approved by the Owner. A. At a minimum, start-up shall include: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Meggering all motors. Visually inspecting field wiring against approved shop drawings. Checking for abnormalities that may have occurred during shipping or installation of all equipment and components including loose wiring, physical damage, or insecure mounting of components. Energizing all panels. Simulate all controls and equipment start, stop, and shutdown, including checking discrete signals locally at the panel and by jumpering remote devices at the field end to simulate signals. Testing all interlock and maintenance switches. Checking analog signals by utilizing loop calibrator as required. Calibrating all control instrumentation and monitoring equipment (flow, level, pressure, etc.). Calibrating panel devices as required including timers and controllers. Cycle motors in both automatic and manual modes of operation. Checking out main control panel in conjunction with all associated equipment. Measuring and recording voltage and amperage draw readings for all equipment motors under loaded conditions. Testing and calibrating VFD's. September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Start-up 01 500-1 14. Testing all components of the main control panel including control systems, autodialer, and SCADA systems. Autodialer and SCADA systems shall be tested to the SCADA Central at the Carlsbad Municipal Water District. Checking proper operation of equipment hatches. 15. All manufacturer certifications for equipment and system components shall be accepted by the Owner prior to commencing Field Testing as specified in Section 1.03, herein. 1.04 FIELD TESTING AND EQUIPMENT ACCEPTANCE A. The Contractor shall submit for Owner's approval the testing procedures for all equipment. The testing procedures at a minimum shall define required instrumentation to test the equipment and describe how the equipment will be tested in order to determine compliance with the Specification requirements and recognized standards of the industry. A master log book shall be furnished and maintained by the Contractor and provided to the Owner for approval showing the test equipment, the compliance values, and the actual field measurements. 6. A full field test shall be performed by the Contractor after the start-up acceptance of all equipment by the Owner. This field test shall include operating all equipment and control systems including simulating various reservoir levels (hydropneumatic tank pressures) for normal operation and emergency conditions. It is anticipated two days will be required to verify operation. Thereafter, the Contractor shall commence a full fourteen-day "live test" under actual conditions. Owner will operate the facilities and Contractor shall provide personnel to be onsite (or available within one hour) to repair or correct any deficiencies. Acceptance of the Pump Station shall begin after successful completion of the fourteen-day "live test". If any problems need to be fixed during the test period, the test shall start over. All costs for repairdreplacement are the responsibility of the Contractor. All warranties for labor, equipment, and materials shall begin on the date of acceptance of the fourteen-day test. An acceptance letter will be provided by the Engineer to the Contractor, acknowledging successful completion of the fourteen-day test. C. Pumping unit field performance testing shall be as specified in Section 1 131 0. September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 start-up 01 500-2 SECTION 02223 TRENCHING EARTHWORK PART 1 - GENERAL 1 .I 1.2 1.3 DESCRIPTION The work of this Section includes clearing and grubbing, demolition, removal and disposal of surplus and objectionable materials, and trenching and backfilling at the locations indicated on the Plans. Trenching earthwork shall include the loosening, removing, loading, transporting, depositing, and compacting in its final location of all materials, wet and dry, as required for purposes of construction of all facilities and such other purposes as indicated on the Plans; the furnishing, placing, and removing of all sheeting and bracing necessary to safely support the sides of the excavations; all pumping, ditching, draining, and other required measures for the removal or exclusion of water; the supporting of structures above and below the ground; all backfilling around structures and all backfilling of trenches and pits; the disposal of excess excavated materials, and all other incidental earthwork as indicated on the plans and as specified herein. The Contractor shall furnish all tools, equipment, materials, and supplies and shall perform all labor necessary in connection with all earthwork and incidental appurtenant work, complete, as specified herein and as indicated on the Plans. PAYMENT Payment for trenching earthwork and for conforming to all of the provisions of these Specifications, unless otherwise specified and itemized on the bid form, shall be considered to be included in the contract unit or lump sum price paid for the various items of work wherein trenching earthwork is required and no additional allowance will be made therefore. SUBMllTALS All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. Dewatering Prior to dewatering submit shop plans showing the complete proposed dewatering system including all material for the intake and discharge of the system per the plans and contract documents. During the period that the dewatering system is in operation - after the complete dewatering system submittal has been approved - a daily record of the average flow rate and elevation of ground water shall be provided. This daily record shall be posted in the jobsite trailer; and, it shall be submitted to the Engineer and reviewed at the weekly project meetings. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-1 6. Excavation Safety Drawings Prior to excavating any earth or soil to a depth of five (5) feet or more, Contractor shall, pursuant to California Labor Code Section 6705, submit to the Engineer detailed drawings (hereafter referred to as excavation safety drawings) showing design of shoring, bracing, sloping, or other provisions to be made for worker, individual, or property protection. Said excavation safety drawings shall comply with OSHA Construction Safety Orders (Cal/OSHA or Federal OSHA, whichever is applicable at time of construction) and shall be prepared and certified by a registered civil or structural engineer, engaged by Contractor at his expense, who shall affix his signature and seal to each sheet of said excavation safety drawings. Contractor shall not excavate until the Engineer has received and acknowledged properly certified excavation safety drawings. Contractor shall comply with all other applicable requirements of Labor Code Section 6705 and, as therein provided, no requirements of that Section shall be construed to impose tort liability on Owner or Owner's representatives, including Owner's Engineer. C. Pipe Zone and Bedding Material Submit current certification and test results for all utility pipe zone and bedding material. Pipe zone and bedding material will conform in all respects to the latest edition of the Carlsbad Municipal Water District Engineers Design and Processing Manual. PART 2 - MATERIALS 2.1 2.2 2.3 2.4 ONSITE MATERIAL Material obtained from the required site excavations. IMPORT MATERIAL Owner-approved material obtained from off-site borrow areas. SUITABLE MATERIAL As specified herein, shall be any material imported or excavated from the cut areas that are free from shale, sod, large clods of earth, stones, roots, trash, lumber, and other debris that, in the opinion of the Owner, is suitable for use and can be readily compacted to the densities specified. GRANULAR SOIL AND IMPORTED SAND Whenever the term "granular soil" is used in the Plans and Specifications, it shall be defined as soil having a minimum 'sand equivalence of 30, as determined by the latest revision in accordance with State of California, Department of Transportation , Test Method No. Calif. 217, and not more than 12 percent of the material will pass through a January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-2 200-mesh sieve for pipeline bedding, and not more than 5 percent for neutral sand bedding around valves and fittings. Whenever the term "imported sand" is used in the Plans and Specifications, it shall be defined as sand having a minimum sand equivalence of 30 as determined by the latest revision of Test Method No. Calif. 217. 2.5 SOIL STERILANT The sterilant shall be Oust (EPA regulation #352-401) as manufactured by E.I. DuPont Nemours and Company (Wilmington, Delaware), or approved equal. 2.6 STRUCTURE BACKFILL Backfill shall consist of loose earth or sand free from stones, clods or other deleterious materials. When material from the excavation is unsuitable for use in backfill, it shall be disposed of and suitable material which is capable of attaining the required relative density shall be arranged for and furnished by the Contractor at his expense. 2.7 PIPEZONE Material used as pipe bedding within the Pipe Zone shall comply with the Carlsbad Municipal Water District Standard Specifications. 2.8 TRENCH ZONE Material excavated from the trench may be used for backfill from 12-inches above the pipe to the finished grade or, if applicable, street grade, provided that such material is free of vegetation, 2-inch and larger rocks, debris, and material of a spongy or perishable nature. No material greater than two inches in any dimension shall be placed within one foot of any pipe, valve, or structure. All backfill within 24-inches of ductile- iron fittings or valves shall be clean, washed sand. PART 3 - EXECUTION 3.1 GENERAL The Contractor shall perform all site grading, soil sterilant application, structure excavation and backfill, trench excavation and backfill for pipelines and conduits, and other earthwork required to complete the work under this contract. Included are all necessary clearing, grubbing, grading, and excavation of all classes and of whatever substance encountered, stockpiling, backfilling, compaction, controlling water, bracing excavations, stabilizing subgrade, protecting existing structures and facilities, complying with conditions of permits and safety regulations, cleaning up debris, papers and loose rocks, restoring fences and other disturbed property, maintaining trees which are not permitted to be removed, and disposing of excess material, and such supplementary operations as are necessary to properly complete the entire work indicated or specified. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-3 3.2 EARTHWORK SUBJECT TO PERMIT CONDITIONS Earthwork within public rights-of-way controlled by a state, county or city, or earthwork within railroad rights-of-way shall be in accordance with requirements and provisions of the permits issued by those agencies for the construction within their respective rights- of-way. Such permit requirements and provisions which are more restrictive than those specified herein, shall take precedence and supersede the provisions of these Specifications. 3.3 PROTECTION OF WORKMEN Excavations shall be so braced or sheeted so as to provide conditions under which workmen may work safely and efficiently at all times. The latest revision of the rules, orders and regulations of the Division of Industrial Safety of the State of California shall be complied with. 3.4 PUBLIC SAFETY Barriers shall be placed at each end of all excavations and such places as may be necessary along excavations to warn all pedestrian and vehicular traffic of such excavations. At the Engineer's request, Contractor shall use trench plates to cover trenches. Lights shall also be placed along excavations from sunset each day to sunrise of the next day until such excavation is entirely refilled or plated. Material for backfill or for protection of excavation in public roads from surface drainage shall be neatly placed and kept shaped so as to cause the least possible interference with public travel. Free access must be provided to all fire hydrants, water valves, meters, and private drives, or other property or facilities that may have routine use. 3.5 SUPPORT OF ADJACENT PROPERTY Excavations shall be so braced, sheeted, and supported that the ground alongside the excavation will not slide or settle, and all existing improvements of any kind, either on public or private property, will be fully protected from damage. Damage to adjacent property or to the work occurring through settlements, water or earth pressures, slides, caves or other causes due to failure of lack of sheeting or bracing or improper bracing, or through negligence or fault of the Contractor in any other manner, shall be repaired by the Contractor at his own expense. 3.6 EXISTING IMPROVEMENTS The Contractor's attention is directed to the possible existence of pipe and other underground improvements which may or may not be shown on the plans. The Contractor shall preserve and protect any such improvements whether shown on the plans or not. Where it is necessary to remove and replace or to relocate such improvements in order to prosecute the work, they shall be removed, maintained, and permanently replaced by the Contractor at his expense, except as otherwise provided in the General Provisions. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-4 3.7 DRAINAGE CONTROL A. Control of Surface Drainage The Contractor shall control grading in a manner to prevent water running into excavations. Obstruction of surface drainage shall be avoided and means shall be provided whereby storm and wastewater can flow uninterrupted in existing gutters, other surface drains or temporary drains. B. Preservation of Existing Drainage Except as shown on the Plans, existing drainage patterns shall be preserved. Where construction methods cause a temporary obstruction of drainage patterns temporary facilities adequate for expected flows and a means of emergency removal of the obstruction shall be provided. 3.8 DEWATERING The Contractor shall keep the excavation free from water during construction. Where ground water is encountered, the static water level shall be drawn down a minimum of two (2) feet below the trench bottom, unless otherwise permitted by the Engineer. Maintain groundwater level a minimum of four (4) feet below the prevailing level of backfill after installation of pipe being placed. The Contractor shall provide and maintain ample means and devices and shall promptly remove and properly dispose of all water from any source entering the excavation or other parts of the work. Dewatering shall be continuous and shall be accomplished by methods which will ensure the preservation of the final lines and grades of the bottoms of excavations. Said methods may include well points, piezometers, sump points, suitable rock or gravel placed below the required bedding for drainage and pumping purposes, temporary pipelines, and other means that will not be detrimental to the proposed construction. The Contractor is responsible for obtaining all water discharge permits that are required. Dewatering for the structures and pipelines shall commence when ground water is first encountered and shall be continued until such times as water can be allowed to rise in accordance with the provision of this section. No concrete (i.e. footings, floors, pipeline thrust blocks, and pipeline anchor blocks) shall be laid in water. Water shall not be allowed to rise until the concrete has cured and been backfilled. The Contractor shall dispose of the water from the work in a suitable manner without damage to adjacent property. No water shall be drained 'into work built or under construction without prior consent of the Engineer. Water shall be disposed of in such a manner as not to be a menace to the public health. Silting basins shall be provided in accordance with regulatory Agency requirements. Do not drain trench water through the pipeline under construction. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-5 3.9 3.10 3.1 1 3.12 A. Dewatering Records 1. Provide a daily record of the average flow rate. Provide water quality testing as required by the Regional Water Quality Control Board. 2. Observe and record the elevation of the ground water during the period that the dewatering system is in operation. CORRECTION OF FAULTY GRADES Where excavation is inadvertently carried below pipe or concrete structure subgrade, it shall be rectified for a pipe by backfilling with approved sand or gravel compacted to 95% of maximum density, at the expense of the Contractor. SURPLUS EXCAVATED MATERIAL The Contractor shall make the necessary arrangements for and shall remove and dispose of all surplus excavated material, unless provided for on the Plans or in the Special Provisions. All costs for the disposal of surplus waste material shall be borne by the Contractor. It is the intent of these Specifications that all surplus material not required for backfill or fill shall be disposed of by the Contractor outside the limits of the public rights-of-way and/or easements at no cost or liability to the Owner. No excavated material shall be deposited on private property unless written permission from the Owner thereof is secured by the Contractor. Before the Owner will accept the work as being completed, the Contractor shall file a written release signed by all property owners with whom he has entered into agreements for disposal of surplus excavated material absolving the Owner from any liability connected therewith. IMPORTED BACKFILL MATERIAL Whenever the excavated material is not suitable for backfill, the Contractor shall at his own expense arrange for and furnish suitable imported backfill material which is capable of attaining the required relative density. COMPACTION TESTS Compaction tests will be made by the Engineer or laboratory designated by him. The number of tests and their location and depth shall be determined by the Engineer. The Contractor shall make all necessary excavations for compaction tests as directed by the Engineer and shall refill and re-compact these excavations to the densities as specified herein. Compaction shall be tested in accordance with the latest revision of Test Method No. Calif. 216. The Owner will pay for the initial cost of all compaction tests. If the backfill compaction fails to meet the relative compaction requirements set forth herein, the Contractor shall pay for subsequent compaction tests. All work in connection with compaction testing by the Contractor shall be included in the various contract bid prices and no additional allowance will be made therefore. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-6 3.13 BLASTING AND EXPLOSIVES Written permission of the Owner shall be obtained prior to any blasting or use of explosives. 3.14 SITE GRADING Haul routes shall be planned to avoid passing heavy off-highway equipment over pipelines with less than 6-feet of cover. Where crossings must be made, the Contractor shall provide concrete encasement or approved bridging. All areas covered by the work, including excavated and filled sections and transition areas, shall be uniformly graded to the elevations shown on the Plans. The finished surface shall be reasonably smooth, compacted, and free from any irregular surface changes. Edges of spoil and borrow areas shall be rounded to blend into natural contours. The degree of finish ordinarily obtainable from a blade grader will be satisfactory for open areas, but hand grading and raking will be required .around structures and walkways. The finished surface shall be not more than 0.1-foot above or below the required grade and sloped to prevent ponding. 3.15 SOIL STERILANT A. General The Contractor shall treat the finished subgrade of specified areas with an approved soil sterilant. 6. Areas Requiring Soil Sterilant All areas which are to receive biturnastic pavement, including embankments, walkways, drainage structures, parking, and road areas, require soil sterilant. Other areas requiring soil sterilant are storage reservoir or pond surfaces which are to receive any lining material of less than 3-inches in thickness and lining perimeter areas to a distance of 5-feet from the edge of lining material. C. Material and Application The sterilant shall be applied in a liquid or dry form and at a uniform rate of 10 to 12 ounces of dry sterilant per acre in accordance with the manufacturer's directions. At the option of the Engineer, the area shall then be lightly sprinkled with water to prevent loss of sterilant or scuffing. 3.16 TRENCH EXCAVATION AND BACKFILL FOR PIPELINES AND CONDUITS A. Alignment and Grades The alignment and grade for pipe shall be as shown on the Plans. When flow line is shown, it shall be the invert or interior bottom of the pipe. When top of pipe is shown, it shall be the exterior of the pipe barrel. In the absence of such January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-7 profile grade, the pipe shall be laid on a straight grade to permit complete drainage and to provide a minimum of 36-inches of cover to finish ground or street subgrade unless otherwise specified. Where the natural ground above the pipeline trench has been over excavated andlor the pipeline is to be placed in new embankment, embankment material shall be placed and compacted to an elevation of not less than two feet above the top of pipe prior to trench excavation. B. Length of Open Trench Except where detailed in the Special Provisions or included in permits, the maximum length of open trench shall be 600-feet, or the distance necessary to accommodate the amount of pipe installed in a single day, whichever is the greater. The distance is the collective length at any location, including open excavation, pipe laying, and appurtenance construction and backfill which has not been temporarily resurfaced. C. Trench Width The overall trench width measured at a level of one foot above top of pipe for pipelines and appurtenances shall not exceed the limits listed in the following table: Nominal Inside Pipe Diameter Minimum Maxim um (Inches) Trench Width Trench Width 4 through 12 OD plus 12" OD plus 16" 14 through 48 OD plus 16" OD plus 24" Excavating and trenching shall be true to line so that the pipe is centered in the trench. D. Trench Bottom The trench bottom shall be graded to provide a smooth, firm, and stable foundation at every point throughout the length of pipe. The Contractor shall transfer construction stake grades into the trench as necessary to ensure that the trench bottom is accurately graded. Where specified, special bedding required by the Plans and Special Provisions shall be placed. Pipe subgrade at the trench bottom shall be prepared for the specific type of pipe material being installed in accordance with the Standard Specifications for said pipe. Should large gravel and cobbles be encountered at the trench bottom or pipe subgrade, they shall be removed from beneath the pipe and replaced with granular material which shall be compacted to provide uniform support and a firm foundation. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-8 Whenever the trench bottom does not afford a sufficiently solid and stable base to support the pipe or appurtenance, the Contractor shall excavate below normal trench bottom and replace it with crushed rock or gravel of sufficient thickness to form an unyielding foundation. E. Foundations in Poor Soil If excessively wet, soft, spongy, unstable, or similarly unsuitable material is encountered at the subgrade, it shall be removed and replaced by crushed rock or gravel of sufficient thickness to form an unyielding foundation. Removal of the material and additional backfill required will be paid for by the unit price in the schedule of work items unless otherwise specified. However, if the necessity for such additional bedding material has been occasioned by an act or failure to act on the part of the Contractor, the Contractor shall bear the expense of the additional excavation and backfill to the required depth. The Contractor's attention is called to his responsibilities in maintaining adequate dewatering procedures to ensure that an otherwise stable foundation will not be rendered unfit due to accumulation of water in the trench excavation. F. Foundations in Rock Where rock is encountered, it shall be removed below grade and the trench backfilled with clean imported sand to provide a compacted foundation cushion with a minimum allowable thickness of 6 inches under the outside diameter of the pipe barrel and a clear space of 4 inches under the pipe bell. Payment for the removal of rock and additional backfill shall be provided for in the schedule of work items unless otherwise specified. G. Backfilling After the pipe has been properly laid, exterior joints grouted (if appropriate) and inspected, backfilling shall be commenced. Mechanical densification or compaction of backfill shall be accomplished by rolling, vibrating, or a combination thereof. The method or methods used shall result in obtaining the compaction of the backfill in the various specified zones and within the maximum lifts specified herein. The densification or compaction method or methods used shall not result in damage to the pipe, adjacent ground, existing improvements, or improvements installed as part of this project. Material for mechanically compacted backfill shall be placed in lifts which, prior to compaction, shall not exceed the depths specified below for the various types of equipment. Impact, free-fall, or "stomping" equipment shall not be allowed. 1. Vibratory equipment with smooth contact surface - maximum lift thickness of 2 feet. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-9 2. Rolling equipment, including, vibratory interrupted surface equipment - maximum lift thickness of 1 foot. 3. Hand directed mechanical tampers - maximum lift thickness of 6 inches. H. Control of Trench Backfill by Zones Backfill shall be constructed by zones and the compaction requirement for each zone in the various portions of the project shall be as scheduled in the Special Provisions and/or Plans. Zone requirements are defined in the following paragraph for pipe zone, trench zone and street zone. 1. Pipe Zone The trench shall be bedded in lifts to a height of 12-inches above the top of the pipe with selected material as described in 2.7, Pipe Zone. Bedding shall be placed in layers simultaneously on each side of the pipe for the full width of the trench. In placing and compacting the backfill, particular attention is to be given to the underside of the pipe and fittings to provide firm support along the full length of the pipe. Care shall be exercised in backfilling to avoid damage to the pipe coating. Unless specified otherwise on the Plans or in the Special Provisions, the bedding shall be compacted and/or consolidated to obtain a relative compaction of 95%. 2. Trench Zone Unless specified otherwise on the Plans or in the Special Provisions, the backfill material shall be compacted to obtain a relative compaction of 95%. Either mechanical compaction or water settling may be used, depending on the nature of the material. Trench zone compaction shall be completed prior to covering it with street zone material. 3. Street Zone Backfill in traveled ways and public streets shall be in accordance with the right-of-way agreement, encroachment permit or applicable regulations of the agency having jurisdiction over the road. In the absence of such provisions, the following shall apply. The top 12-inches below the roadway subgrade or ground surface, as the case may be, shall be compacted by approved hand-, pneumatic-, or mechanical-type tampers to obtain a relative compaction of 95%. Consolidation will not be permitted in this upper 12-inches. The material for this backfill may contain stones ranging in sizes up to two inches in diameter in quantity not exceeding 20% of the volume where said coarse January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-1 0 materials are well distributed throughout the finer material and the specified compaction can be obtained. The pavement section shall be constructed in accordance with the Plans and Specifications. 3.17 FINAL CLEANUP After backfill has been completed, the site shall be dressed smooth and left in a neat and presentable condition, free of all cleared vegetation, rubbish and other construction wastes. Surplus rock and soil which cannot be used for backfill shall be hauled away and disposed of by the Contractor and at the Contractor’s expense. Areas next to structures where blade-type equipment cannot reach shall be hand raked. END OF SECTION January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Trenching Earthwork 02223-1 1 SECTION 02300 BASIC EARTHWORK SPECIFICATIONS 1. Scope Contractor shall furnish all labor, equipment, and material and perform all operations necessary for earthwork construction including clearing, excavating, filling, backfilling, compacting, and grading specified or reasonably required. All debris or material unsuitable for construction shall be removed from site. Adequate drainage shall be provided at all times and accumulation of water in excavated areas shall be prevented. All work shall be protected by pumping, ditching, and other measures required for the removal and exclusion of water. Any work damaged by the effects of rain runoff or other weather conditions during any phase of construction shall be reconstructed to conform to the specified requirements. Contractor shall not pass equipment over or alongside facilities that are not protected by ample fill material, properly compacted. Unless otherwise specified or herein modified, all earthwork shall conform to Section 300 of the Standard Specifications for Public Works Construction, published by Building News, Inc., Los Angeles, California, latest edition, hereinafter "Standard Specifications". 2. Protection of Existing Work Before beginning any cutting or demolition work for removals, Contractor shall carefully survey the existing work and examine the drawings and Specifications to determine the extent of the work. Contractor shall take all necessary precautions to insure against damage to existing work to remain in place or to be reused and any damage to such work shall be repaired or replaced as approved by Owner at no additional cost to Owner. Contractor shall carefully coordinate the work of this section with all other work and construct and maintain shoring, bracing, and supports as required. Contractor shall insure that structural elements are not overloaded and be responsible for increasing structural supports or adding new supports as may be required as a result of any cutting, removal, or demolition work performed under any part of this Contract. 3. Grade Control Contractor shall furnish all construction staking required to perform the Work. Contractor shall utilize survey control as shown on the Drawings. Benchmarks, monuments, and other reference points, if disturbed or destroyed by Contractor, will be restored by Owner at Contractor's expense. 4. Clearing and Grubbing Except as otherwise specified, indicated areas should be cleaned and grubbed conforming to Section 300-1 of the Standard Specifications. All removed materials shall be disposed off-site in a location approved by Owner. Bituminous pavement to be removed shall be saw cut to clean, straight lines. Se ternber 2003 CaLvera Pump Station (860-3-Cal) Contract 38891 Earthwork 02300-1 Field Compaction Tests 5. 6. 7. 8. Where reference is made to relative compaction, it shall be deemed to mean ASTM D1557, latest, using ten-pound hammer at 18-inch drop. Cost of all compaction tests having relative compaction less than specified shall be borne by Contractor. Cost of all compaction tests having relative compaction greater than specified will be borne by Owner. Owner will select soil testing engineer. Materials to be Excavated Materials to be excavated shall be non-classified and shall include all materials encountered in excavating and grading operations hereunder. Materials shall be excavated to the depth and extent specified. Excavation Contractor shall excavate to the elevations and dimensions indicated, plus ample space for construction operations and inspection of facilities. All facilities to be constructed shall bear on undisturbed natural ground or material compacted to the relative compaction specified which shall not be less than 90% relative compaction. If so ordered in writing by Owner, Contractor shall perform additional excavation beyond limits originally specified. Concrete shall not be placed in any excavation which has not been approved by Owner. Care shall be taken not to disturb the excavation prepared for concrete and excess material shall not be removed to make grade until just before concrete is to be placed. This work shall conform to Sections 300-2 and 300-3 of the Standard Specifications unless otherwise specified. Fill and Backfill Fill and backfill shall not be placed until all work to be concealed has been inspected and approved by Owner. No fill or backfill material shall be deposited against concrete structures until the concrete has developed its design strength unless authorized by Owner. Fill and backfill around structures shall be placed in uniform horizontal layers not exceeding 12 inches in loose thickness before compaction and shall be brought up uniformly on all sides of the structure. Regardless of the specified depth of the layers of material to be compacted, Contractor shall place the material at depths required to obtain the specified relative compaction. Each layer of material shall be moistened as required and thoroughly tamped, rolled, or otherwise compacted to the relative compaction specified. Fill and backfill shall be made with clean, unclassified material excavated from site as approved by Owner. Unless permitted otherwise, said material shall consist of loose earth or sand free from stones, clods, or other deleterious materials larger than 6 inches in greatest dimension. Whenever permitted by Owner, rock may be placed in certain fills. Rock fragments or boulders up to 24 inches in greatest dimension may be utilized provided that the Se tember 2003 Caravera Pump Station (860-3-Cal) Contract 38891 Earthwork 02300-2 specified degree of compaction is obtained in the fill material surrounding the rock. The rock fragments or boulders shall be placed in rows on the fill surface so that they are not in contact with one another and fill material shall be placed between and over the rows of rock fragments or boulders and compacted with a sheeps foot or other suitable rollers. Ample water and compactive effort shall be applied so that the resulting fill is free of uncompacted material surrounding the rock. The rows of rock fragments or boulders shall be as specified with regard to spacing and location within any fill; however, subsequent rows shall be staggered so that one row does not lie directly over another row. 9. Finish Grading Upon completion of construction, Contractor shall bring to finish grade all portions of site affected by contract work. Grading shall be to the finish grade elevations specified. Contractor shall dispose of excess material as directed by Owner. Se tember 2003 CaLvera Pump Station (860-3-Cal) Contract 38891 Earthwork 02300-3 SECTION 02500 BASIC PAVING SPECIFICATIONS 1. 2. Scope a. General Contractor shall furnish all labor, materials, and equipment and perform all operations necessary for construction of pavement surfacing and resurfacing in all areas of construction as specified by the Owner or as shown by the Drawings. Drawings shall consist of construction drawings, standard drawings, and clarifying diagrams or sketches. Whenever pavement surfacing or resurfacing is to be constructed in rights-of- way not under jurisdiction of the Owner (public highways, thoroughfares, streets), it shall be constructed in accordance with permits issued by the agency having jurisdiction (State, County, City). Whenever pavement surfacing or resurfacing is to be constructed in rights-of- way over which the Owner has jurisdiction (pumping plants, reservoirs, service yards, access roads), it shall be constructed in accordance with the specifications. Whenever the words "Standard Specifications" are used herein, they shall mean the Standard Specifications for Public Works Construction as published by Building News, Inc., Los Angeles, California, latest edition. The Standard Specifications shall augment, not supersede, these specifications. As used herein, the Standard Specifications shall not apply to measurement, payment, schedule, delays, or extra work. New Pavement Surfacing New pavement surfacing shall be asphalt concrete or Portland cement concrete placed on a prepared surface in accordance with the specifications and in conformance with the lines, grades, and dimensions as specified in the Drawings. a. Subqrade Preparation Subgrade shall be brought to proper grade, prepared, and compacted in conformance with the requirements of Subsection 301 -1 of the Standard Specifications. All organic material shall be removed and discarded at legal disposal site(s), at Contractor's expense. The top 12 inches of such subgrade material shall be scarified, cultivated and then compacted to not less than 95 percent relative compaction (ASTM D1557). January 2004 Calavera Pump Station (860-3-Cal) Contract 38891 Paving 02500-1 b. Aqaresate Base 1) General Aggregate base material shall be furnished, placed, and compacted at the locations and thickness as specified in the Contract Documents. 2) Materials Aggregate base material shall consist of crushed aggregate base conforming to requirements of Subsection 200-2.2 of the Standard Specifications. 3) Placement of Aaqreaate Base Aggregate base material shall be spread and compacted in conformance with the requirements of Subsection 301-2.3 of the Standard Specifications. Aggregate base material shall be compacted to a relative compaction of not less than 95 percent (ASTM 01557). C. AsDhalt Concrete Pavement 1) General Asphalt concrete pavement shall be furnished, placed, and compacted at the locations and thicknesses specified. 2) Materials a) AsDhalt Asphalt to be mixed with mineral aggregate shall conform to Subsection 203-6.3.1 of the Standard Specifications. The viscosity grade shall be AR-4000 unless specified otherwise. b) Aqareqate Aggregate shall conform to the requirements in Subsection 203-6.3.2 of the Standard Specifications. Course aggregate shall be crushed rock. January 2004 Calavera Pump Station (860-3-Cat) Contract 38891 Paving 02500-2 c) Asphalt Concrete Mixtures The grading of combined aggregates and percentage asphalt shall be in accordance with Subsection 203-6.4 of the Standard Specifications. Unless otherwise specified the following asphalt concrete mixtures shall be used: Base Course shall be: B-AR-4000 Surface Course shall be: C2-AR-4000 Overlays (1 %" maximum) shall be: Dl-AR-4000 3) Placement of Asphalt Concrete a) General Asphalt concrete pavement shall be no less than the thickness shown on the Drawings and shall be applied in two (2) lifts. The first lift shall be the base course and the second lift shall be the surface course, not less than 1" thick, and shall bring the pavement to full thickness. All construction methods shall conform to the requirements of Subsection 302-5 of the Standard Specifications, as modified by the Supplemental Provisions. b) Weed Killer Weed killer, "SPIKE" (manufactured by Dow Elanco) or equal shall be applied to the area to be paved at the rate of 100 gallons per 10,000 square feet. The mixture applied shall consist of 1 pound of chemical per 100 gallons of water or per manufacturer's recommendations. Contractor shall obtain a permit to use "SPIKE" weed killer prior to its application. c) Prime Coat A prime coat consisting of grade SC-250 liquid asphalt shall be applied at a rate between 0.10 and 0.25 gallons per square yard. Grade SC-70 liquid asphalt may be used when approved by the Owner. Unless otherwise specified prime coat shall be required on all aggregate base material or untreated subgrade on which asphalt concrete pavement is to be directly placed. The prime coat shall be allowed to cure 24 hours and any excessively oily areas shall be blotted with sand in preparation for application of asphalt concrete. January 2004 Calavera Pump Station (860-3-Cal) Contract 38891 Paving 02500-3 A tack coat shall be required at all joints, overlays and overlaps. Tack coat shall conform to the requirements of Subsection 302- 5.4 of the Standard Specifications and shall be Grade SS-lh emulsified asphalt. Tack coat shall be applied at approximate rates of 0.05 gallon per square yard for leveling courses and overlays, and 0.10 gallon per square yard for asphalt concrete roll berms and dikes. Pavina Headers Along all pavement edges which will not abut existing concrete paving, building 'foundations, curbs, gutters, or other similar structures, a firmly staked 2 inch x 4 inch redwood header shall be placed unless specified otherwise. Asphalt Curbs Asphalt concrete curbs shall be provided where shown on the Drawings. Automatic curbing machines shall be used to construct asphalt curbs. The curb cross section used shall be as shown on the Drawings or as approved by the Owner. Geotextile Fabric Geotextile fabric shall be provided where shown on the Drawings and shall conform to the requirements in Subsections 213 and 302-7 of the Standard Specifications. Geotextile fabric shall be placed such that wrinkles large enough to cause laps do not occur. Geotextile fabric shall be placed in accordance with manufacturer's recommendations. Slurrv Seal Slurry seal shall be provided over existing asphalt concrete pavement where shown on the Drawings. Slurry seal mix design shall conform to Type I composition as specified in Subsection 203-5 of the Standard Specifications. Slurry seal shall be mixed and placed in accordance with Subsection 302-4 of the Standard Specifications. 4) Temporarv Surfacing Unless permanent pavement is to be placed immediately, temporary cold mix surfacing 2 inches thick, or as otherwise specified, shall be placed and properly maintained as determined by the Owner until the permanent pavement is placed at locations specified. In any event, in paved streets where immediate access is required to provide for public or private use, Contractor shall place and maintain said temporary pavement. January 2004 Calavera Pump Station (860-3-Cat) Contract 38891 Paving 02500-4 Temporary pavement shall be placed at all locations which are not barricaded and are open to traffic. When Contractor delays the placing or repairing of temporary pavement, Owner reserves the right to have such pavement placed or repaired at Contractor's expense. Temporary resurfacing shall conform to Subsection 306-1.5.1 of the Standard Specifications and shall be placed as soon as trench backfill is 95% compacted and shall remain in place until permanent resurfacing is placed. Prior to permanent resurfacing, temporary resurfacing shall be removed and discarded at legal disposal site(s) at Contractor's expense. The cost of furnishing, placing, maintaining, removing and disposing of temporary resurfacing shall be included in the Contractor's bid price for related work if no bid item is specifically called out in the bid sheets. At the end of each day, temporary striping shall be placed complying with the Drawings and State, County, or City requirements. Temporary striping shall conform with Section 21 4 of the Standard Specifications. 5) Permanent Resurfacinq Unless otherwise specified, all permanent resurfacing shall be 1" or greater in thickness than the original surfacing removed. Contractor shall remove all loose pieces of existing pavement prior to placing any pavement. Said pavement shall be replaced in accordance with requirements of the agency (State, County, City) having jurisdiction over the roadway. d. Portland Cement Concrete Pavement 1) General Portland cement concrete shall comply with the Basic Concrete Specifications unless specified otherwise. Construction methods shall comply with Subsection 302-6 of the Standard Specifications. Portland cement concrete shall be furnished and placed at the locations and thicknesses specified. 2) Concrete Desiqn Mix All concrete shall be 560-(2-3250 concrete in accordance with Subsection 201 -1.1.2 of the Standard Specifications, as modified by the Supplemental Provisions. Design mix shall be approved by the Owner prior to purchase or placing of concrete. 3) Reinforcement Replacement concrete pavement shall have equal or better reinforcement than original concrete pavement. Reinforcement shall be provided whenever and wherever specified. Grade 60 reinforcing steel shall be used unless specified otherwise. January 2004 Calavera Pump Station (860-3-Cal) Con tract 3889 1 Paving 02500-5 4) Admixtures Admixtures shall conform to Subsection 201-1.2.4 of the Standard Specifications, as modified by the Supplemental Provisions. Unless otherwise specified, concrete mixtures shall have air entrainment of 5% 2 1 %. 5) Placina Concrete Concrete shall be placed on an aggregate base sufficiently dampened to ensure that no moisture will be absorbed from the newly placed concrete. Concrete shall be placed on the aggregate base to specified uniform depth. 6) Finishinq Concrete shall be distributed uniformly between forms as soon as it is placed, struck off, and tamped. Tamping shall continue until concrete is thoroughly consolidated into the specified cross-section and sufficient mortar for finishing purposes has been brought to the surface. After tamping, surface of concrete shall be floated and finished. Where the concrete placed is to abut existing concrete surfaces, it shall be finished to match existing concrete as nearly as practical. Vat black or other approved pigments shall be added to concrete to obtain required result. Edges which do not abut existing concrete shall be rounded to a 1/2 inch radius. Upon completion of final finishing, work surface shall be free of any unevenness greater than 1/8 inch when checked with a 10-foot straightedge placed on the surface. 7) Curing Pavement shall be cured by a pigmented sealing compound method. Curing shall commence as soon as free water leaves the concrete surface but no later than 3 hours following initial placement of concrete upon aggregate base. Curing compound shall be applied to the entire surface by spraying at the rate of one gallon per 200 square feet. All curing compounds shall be approved by the Owner. Curing compound shall conform to the requirements of Subsection 201-4 of the Standard Specifications. 8) Temporarv Striping At the end of each day, temporary striping shall be placed complying with the Drawings and State, County, or City requirements. Temporary striping shall conform with Section 21 4 of the Standard Specifications. January 2004 Calavera Pump Station (860-3-Cal) Contract 38891 Paving 02500-6 3. Pavement Removal Pavement removal shall be limited to the maximum trench width as shown by the standard drawings plus a reasonable allowance for sloping sides of trench as required by appropriate safety standards or as otherwise specified. Pavement shall be removed to clean straight lines. Pavement edges shall be saw cut unless an acceptable alternative method is permitted. Contractor shall discard all removed pavement at legal disposal site(@ at Contractor's expense. Removal and disposal of materials shall conform to the requirements of Subsection 300-1.3 of the Standard Specifications, as modified by the Supplemental Provisions. 4. Finishing Pavement Surfaces a. General Upon completion of all construction operations the entire roadway area or newly surfaced areas shall be finished, cleaned, and left in a neat, presentable condition. b. Shoulders The shoulders around paved surfaces shall be trimmed and shaped to produce a smooth uniform cross section. Shoulders shall be finished, graded, and compacted so as to match the finish grade of the newly paved surfacing. Excess earth, debris, or other waste material shall be removed and discarded at legal disposal site@) at Contractor's expense. C. Paved Surfaces All finished paved surfaces shall be clean of all dirt, debris, and foreign material. All manholes, boxes, and covers, shall be raised to finished grade. All curbs, gutters, and cross gutters shall be broomed clean and flushed with water to insure proper drainage. All street signs and striping shall comply with the construction drawings, specifications, and Section 21 4 of the Standard Specifications. d. Survev Monuments Prior to construction, Contractor shall have a registered civil engineer or licensed land surveyor set at least 4 ties for each monument within the construction area. After construction, Contractor shall have the same civil engineer or licensed land surveyor use the aforementioned ties to replace any monuments which have been disturbed or destroyed. Contractor shall file a corner record for all replaced monuments. Contractor shall also place monument wells in compliance with City or County standards over all monuments in the construction area. January 2004 Calavera Pump Station (860-3-Cai) Contract 38891 Paving 02500-7 - ORNAMENTAL STEEL FENCING AND GATES PART 1 - GENERAL 1.01 General Contractor shall furnish and install ornamental steel fencing system, including fence panels, posts, gates, and accessories, as shown on the Drawings and as specified herein. 1.02 Related Work Specified Elsewhere A. Section 03300 - Cast-in-Place Concrete: Concrete footings for support of fence and gate posts. 1.03 Applicable Specifications and Standards The following documents of issue in effect on the date of bid form a part of this specification to the extent specified herein: A. American Society for Testing and Materials (ASTM) Publications: 1. 2. 3. 4. 5. 6. 7. 8. 9. ASTM A36 - Carbon Structural Steel. ASTM A121 - Zinc-Coated (Galvanized) Steel Barbed Wire. ASTM A123 - Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products. ASTM A500 - Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes. ASTM A51 3 - Electric-Resistance-Welded Carbon and Alloy Steel Mechanical Tubing. ASTM A653 Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process. ASTM A787 - Electric-Resistance-Welded Metallic-Coated Carbon Steel Mechanical Tubing. ASTM 8117 - Standard Practice for Operating Salt Spray (Fog) Apparatus. ASTM D822 - Tests on Paint and Related Coatings Using Filtered Open- Flame Carbon-Arc Exposure Apparatus. June 2004 Ornamental Steel Fencing and Gates Calavera Pump Station (860-3-Cal) Contract 38891 02833-1 10. ASTM D1794 - Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact). 11. I .04 Contractor Submittals ASTM D3363 - Test Method for Film Hardness by Pencil Test. A. All submittals shall be in accordance with the General Provisions, Section 2-5.3. 6. Submittals shall include, but not be limited to, the following: 1, Product data for all fence and gate components and accessories. 2. Shop drawings showing layout, dimensions, and spacing of all fence and gate components, and anchorage and installation details. 3. Coating color chart of available fence and gate colors for selection by Owner. 3. Sample: 8 by 10 inches minimum size sample of fence panel illustrating design, fabrication workmanship, and selected color coating. 4. Copy of warranty specified in Paragraph 1.05. I .05 Warranty Manufacturer shall provide 10 years (minimum) warranty for factory finish against cracking, peeling, and blistering. 1.06 Quality Assurance Ornamental steel fencing and gates shall be as manufactured by Morgan Fence Company, Builders Fence Company, Inc., or equal. PART 2 - PRODUCTS 2.01 Fencing A. Fence framework, including pickets, rails, and posts, shall be manufactured from electrically welded pre-galvanized tubing conforming to ASTM A5 13 and having minimum yield strength of 45,000 psi. Zinc coating with a minimum weight of 0.90 ounces per square foot (coating designation G-90) shall meet the requirements of ASTM 653. 6. Fence panel sections shall be capable of supporting a 1000-pound load applied at the mid-span with deflection limited to U240 and no permanent deformation. June 2004 Calavera Pump Station (860-3-Cal) Ornamental Steel Fencing and Gates 02833-2 Contract 38891 C. Pickets shall be minimum 3/4" diameter round tubing with 14-gauge wall thickness, built on 4-1/2" centers. D. Rails shall be minimum 1-3/8" diameter round tubing with Il-gauge wall thickness. E. Posts shall be minimum 1-7/8" diameter round tubing with ll-gauge wall thickness. F. Fence panel geometry, length, and height shall be comply with the nominal dimensions shown on the Construction Drawings. Minor variations in dimensions may be necessary to accommodate actual field conditions and selected fence components. Pickets, rails and posts shall be assembled in accordance with the manufacturer's approved shop drawings and the Construction Drawings. Prior to commencing fabrication, Contractor shall field verify all fence dimensions, including post locations and fence segment lengths. G. Pickets, rails and posts shall be Electro-MIG welded per the final approved shop drawings. All joints shall be fully welded (seal welded) to prevent corrosion from moisture. Kit type field assembled fence panels are not acceptable. H. Posts shall be provided with zinc plated press-on type steel caps. Post bases shall be drilled base plate or sleeve for mounting to concrete footing or pier as indicated on the Construction Drawings. 2.02 Gates A. General Contractor shall provide gates of type and size indicated on the Drawings. Manufacturer shall equip gates with all hardware and appurtenances as required for complete functional operation. Gate framework, including pickets, rails, and posts, shall be manufactured from structural tubing conforming to ASTM A36/A500 and having a minimum yield strength of 46,000 psi or from electrically welded pre-galvanized tubing conforming to ASTM A513 and having a minimum yield ,strength of 45,000 psi. All gate framework shall be provided with zinc coating with a minimum weight of 0.90 ounces per square foot (coating designation G-90) shall meet the requirements of ASTM A123/A653. d Swmgv7a Gates .. A. 1. Construction: Frames fabricated from minimum 2" square steel tubing with Il-gauge wall thickness. Frames shall be fully welded. Unless shown otherwise on the Drawings, gate configuration shall be similar to fence sections. Gate pickets shall match fence pickets. Where shown on the Drawings, gates shall be provided with perforated metal backing June 2004 Ornamental Steel Fencing and Gates Calavera Pump Station (860-3-Cat) Contract 38891 02833-3 (18 gauge minimum) attached to gate frame and pickets. Attachment system shall be unobtrusive and not visible from outside the gate. 2. Gate Size: Gates shall be single or double with heights and widths as shown on the Drawings. 3. Hardware: a. Hinges: Size and type as determined by manufacturer. Unless shown otherwise on the Drawings, provide 3 hinges for each gate leaf up to 6 feet high and 1 additional hinge for each additional 24 inches in height or fraction thereof. Hinges shall be manufactured to allow 90-degree opening of gate(s). b. Latch: 3/4-inch diameter slide bolt to accommodate padlock. C. For double gates provide padlockable, 5/8-inch diameter center cane bolt assembly and strike. B. 1. Construction: Frames fabricated from minimum 3" wide by 4" high rectangular steel tubing with 1 l-gauge wall thickness. Frames shall be fully welded. Unless shown otherwise on the Drawings, gate configuration shall be similar to fence sections. Gate pickets shall match fence pickets. Where shown on the Drawings, gates shall be provided with perforated metal backing (18 gauge minimum) attached to gate frame and pickets. Attachment system shall be unobtrusive and not visible from outside the gate. 2. Gate Opening and Size: Gate opening shall be as shown on the Drawings. Gate height shall match adjacent fence or wall heights. Gate length and travel distance shall be as required to accommodate the gate support system and electric gate operator (where specified). 3. Support Posts: Pair of minimum 4" square steel tubing with Il-gauge wall thickness and solid cap. 4. Rolling Mechanism: Steel wheels with V-shaped edge groove and 6 inches (152 mm) diameter, mounted to gate frame and riding on ground set V-track. Assembly braced at top by adjustable guide wheels mounted with brackets to support posts. 2.03 Accessories A. Unless specified otherwise, all fence and gate hardware and accessories shall be carbon steel or malleable iron. B. All fasteners shall be 304 (or better) stainless steel. June 2004 Ornamental Steel Fencing and Gates Calavera Pump Station (860-3-Cal) Contract 38891 02833-4 C. All ferrous metal hardware and accessories shall be hot dipped galvanized and finish coated as specified herein. 2.04 Finish Coating A. Preparation: Upon completion of fabrication, all fence and gate assemblies shall receive a three stage pretreatment to clean and prepare galvanized surfaces for finish coating. First stage shall consist of iron phosphate surface pretreatment to clean and promote coating adhesion. Second stage shall consist of clean water rinse. Third stage shall consist of non-chromate conversion coating to seal all surfaces and provide additional corrosion protection. B. All fence and gate assemblies, including hardware and accessories, shall receive an electrostatically applied colored polyester powder coating heat cured to 450 degrees F to chemically bond finish to metal substrate. Polyester powder coating shall be applied to a thickness of 3 mils (minimum). 1. Minimum hardness measured in accordance with ASTM D3363: 2H. 2. Direct impact resistance tested in accordance with ASTM D2794. Withstand 160 inch-pounds. 3. Salt spray resistance tested in accordance with ASTM 8117: No undercutting, rusting, or blistering after 500 hours in 5 percent salt spray at 95 degrees F and 95 percent relative humidity and after 1000 hours less than 3/16 inch undercutting. 4. Weatherability tested in accordance with ASTM D822: No film failure and 85 percent (minimum) gloss retention after 1 -year outdoor exposure. 5. Where perforated metal backing is specified, care shall be taken with the coating material to preclude the coating from “bridging” the perforations. C. Color: Finish color shall be as selected by Owner. Manufacturer shall submit color chart to Owner showing all available colors. PART 3 - EXECUTION 3.01 General A. Prior to fabrication, field verify required fence and gate dimensions. 6. Contractor shall install fencing in accordance with manufacturer’s written installation instructions and approved shop drawings. C. Verify areas to receive fencing are completed to final grades, elevations, and materials. D. Do not install bent, bowed, or otherwise damaged panels. Remove damaged components from site and replace. June 2004 Ornamental Steel Fencing and Gates Calavera Pump Station (860-3-Cal) Contract 38891 02833-5 3.02 Installation Unless shown otherwise on the Drawings, fence and gate installation shall comply with the following requirements. A. Where independent concrete footings are specified, provide footings in accordance with requirements herein, Specification Section 03300 - Cast-in- Place Concrete, and as shown on the Drawings and approved shop drawings. 1. Post footing soil shall be firm and undisturbed. 2. Minimum footing diameter: a. Terminal fence posts and gate posts: 12 inches. b. Intermediate fence line posts: 10 inches. 3. Minimum post embedment: a. Terminal fence posts and gate posts: 36 inches. b. Intermediate fence line posts: 30 inches. 4. Provide 6 inches minimum concrete beneath post bottom. 5. Trowel finish around posts and provide slope to direct water away from posts. B. Where fence installation is specified in existing concrete slabs or structures, core drill existing concrete for embedment of fence and gate posts. Core drill hole shall be 2 inches (minimum) greater than post width. C. Where fence and gate post installation is specified in masonry walls, provide galvanized steel post sleeves with 112" +/- annular space and grout to fill post and sleeve. Grout shall be non-shrink type, pre-mixed compound consisting of non-metallic aggregate, cement, and water reducing and plasticizing additives. D. Where surface mounting of posts is specified, provide flange type base plates with 4 holes. Anchor bolts shall be 304 stainless steel wedge anchors with size and embedment as required for design loads. Provide leveling nuts beneath base plate for post adjustment and fill space beneath plate with non-shrink grout, 3/4" minimum thickness. E. Fence and gate posts shall be installed plumb and level. Temporarily brace posts with 2 by 4 wood supports until concrete or grout is set. F. Gates: I. Concrete footings for gate posts shall attain full design strength before gates are hung. June 2004 Calavera Pump Station (860-3-Cal) Ornamental Steel Fencing and Gates 02833-6 Contract 38891 2. Install gates and adjust hardware for smooth operation. 3. Provide concrete center foundation for drop rod retainers at center of double swinging gate openings. 4. Provide concrete foundation (6" minimum thickness) for length of operation of V-wheeled rolling gate. Anchor gate track to concrete with stainless steel countersunk fasteners. 5. Upon completion of gate installation, test gate operation. Correct deficiencies and adjust for smooth and easy operation. G. Touch-up damaged finish with paint supplied by manufacturer and matching original coating. June 2004 Calavera Pump Station (860-3-Cal) Con tract 3889 1 Ornamental Steel Fencing and Gates 02833-7 SECTION 03100 BASIC CONCRETE FORMWORK SPECIFICATIONS PART 1 - GENERAL 1.01 General Requirements Contractor shall furnish all materials for concrete formwork, bracing, shoring, and supports and shall design and construct all falsework, all in accordance with the provisions of the Contract Document. 1.02 Reference Specifications, Codes, and Standards The Building Code, as referenced herein, shall be the Uniform Building Code (UBC) of the International Conference of Building Officials (ICBO), latest edition. B. Commercial Standards ACI 347 Recommended Practice for Concrete Formwork, latest edition. 1.03 Contractor Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. Falsework Calculations and Drawinas Contractor shall comply with the provisions of Section 1717 of the Division of Industrial Safety, Construction Safety Orders, as revised November 1973, which requires that all falsework or vertical shoring installations where the heights of the falsework or vertical shoring, as measured from the top of the sills to the soffit of the superstructure, exceeds 14 feet, or where individual horizontal span lengths exceed 16 feet, or provision for vehicular or railroad traffic through falsework or vertical shoring is made, shall be approved and signed by a Civil Engineer, registered in the State of California; provided further, that a copy of the falsework plan or shoring layout shall be available on the job site at all times. B. Contractor shall submit detailed plans of the falsework proposed to be used. Such plans shall be in sufficient detail to indicate the general layout, sizes of members, anticipated stresses, grade of materials to be used in the falsework, and typical soil conditions. 1.04 Quality Assurance Tolerances The variation from established grade, line, plumbness, or thickness shall be as set forth in Section 1.04F of the Basic Concrete Specification, and there shall be no offsets or September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete Formwork 03 1 00- 1 visible waviness in the finished surface. All other tolerances shall be within the “Suggested Tolerances” specified in Section 203 of ACI 347. PART 2 - PRODUCTS 2.01 General Except as otherwise expressly accepted by the Engineer, all lumber brought on the job site for use a forms, shoring, or bracing shall be new materials. All forms shall be smooth surface forms and shall be of the following materials: Walls Steel or plywood panel Columns All other work Steel, plywood, or fiber glass Steel panels, plywood or tongue and groove lumber Roof and Floor slabs - Plywood 2.02 Form and Falsework Materials A. Materials for concrete forms, formwork, and falsework shall conform to the following requirements: 1. Lumber shall be Douglas Fir or Southern Pine, construction grade or better, in conformance with U.S. Product Standard PS20. 2. Plywood for concrete formwork shall be new, waterproof, synthetic resin bonded, exterior type Douglas Fir or Southern Pine plywood manufactured especially for concrete formwork and shall conform to the requirements of PS 1 for Concrete Forms, Class I, and shall be edge sealed. 3. Form materials shall be metal, wood, plywood, or other approved material that will not adversely affect the concrete and will facilitate placement of concrete to the shape, form, line, and grade shown. Metal forms shall be an approved type that will accomplish such results. Wood forms for surfaces to be painted shall be Medium Density Overlaid plywood, MOO Ext. Grade. B. Unless otherwise shown, exposed edges and corners in concrete members shall be provided with 3/4-inch chamfers. Re-entrant corners in concrete members shall not have fillets unless otherwise shown. C. Forms and falsework to support the roof and floor slabs shall be designed for the total dead load, plus a live load of 30 psf (minimum). 2.03 Form Ties A. Form ties with integral waterstops shall be provided with a plastic cone or other suitable means for forming a conical hole to insure that the form tie may be broken off back of the face of the concrete. The maximum diameter of removable cones for rod ties, or of other removable form-tie fasteners having a September 2003 Calavera Pump Station (860-3-Gal) Contract 38891 Concrete Formwork 031 00-2 circular cross-section, shall not exceed 1-1/2 inches; and all such fasteners shall be such as to leave holes of regular shape for reaming. B. Form ties for water-retaining structures shall have integral waterstops. Removable taper ties may be used when approved by the Engineer. A preformed neoprene or polyurethane tapered plug sized to seat at the center of the wall shall be inserted in the hole left by the removal of the taper tie. PART 3 - EXECUTION 3.01 3.02 General A. Forms to confine the concrete and shape it to the required lines shall be used wherever necessary. Contractor shall assume full responsibility for the adequate design of all forms, and any forms which are unsafe or inadequate in any respect shall promptly be removed from the work and replaced at the Contractor's expense. A sufficient number of forms of each kind shall be provided to permit the required rate of progress to be maintained. The design and inspection of concrete forms, falsework, and shoring shall comply with applicable local, state and federal regulations. Plumb and string lines shall be installed before concrete placement and shall be maintained during placement. Such lines shall be used by the Contractor's personnel and by the Engineer and shall be in sufficient number and properly installed. During concrete placement, the Contractor shall continually monitor plumb and string line form positions and immediately correct deficiencies. B. Concrete forms shall conform to the shape, lines, and dimensions of members as called for on the Contract Drawings, and shall be substantial, free from surface defects, and sufficiently tight to prevent leakage. Forms shall be properly braced or tied together to maintain their position and shape under a load of freshly-placed concrete. If adequate foundation for shores cannot be secured, trussed supports shall be provided. Form Design All forms shall be true in every respect to the required shape and size, shall conform to the established alignment and grade, and shall be of sufficient strength and rigidity to maintain their position and shape under the loads and operations incident to placing and vibrating the concrete. Suitable and effective means shall be provided on all forms for holding adjacent edges and ends of panels and sections tightly together and in accurate alignment so as to prevent the formation of ridges, fins, offsets, or similar surface defects in the finished concrete. Plywood, 5/8-inch and greater in thickness, may be fastened directly to studding if the studs are spaced close enough to prevent visible deflection marks in the concrete. Forms shall be tight so as to prevent the loss of water, cement and fines during placing and vibrating of the concrete. Specifically, the bottom of wall forms that rest on concrete footings or slabs shall be provided with a gasket to prevent loss of fines and paste during placement and vibration of concrete. Such gasket may be a 1 to 1-1/2 inch diameter polyethylene rod held in position to the underside of the wall form. Adequate clean-out holes shall be provided at the bottom of September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete Formwork 031 00-3 each lift of forms. The size, number, and location of such clean-outs shall be as acceptable to the Engineer. 3.03 Construction A. Vertical Surfaces All vertical surfaces of concrete members shall be formed, except where placement of the concrete against the ground is shown. Not less than 1-inch of concrete shall be added to the thickness of the concrete member as shown where concrete is permitted to be placed against trimmed ground in lieu of forms. Such permission will be granted only for members of comparatively limited height and where the character of the ground is such that it can be trimmed to the required lines and will stand securely without caving or sloughing until the concrete has been placed. B. Construction Joints Concrete construction joints shall not be placed at locations other than those shown or specified, except as may be acceptable to the Engineer. When a second lift is placed on hardened concrete, special precautions shall be taken in the way of the number, location, and tightening of ties at the top of the old lift and bottom of the new to prevent any unsatisfactory effect whatsoever on the concrete. Pipe stubs and anchor bolts shall be set in the forms where required. C. Form Ties 1. Embedded Ties Holes left by the removal of form tie cones shall be reamed with suitable toothed reamers so as to leave the surface of the holes clean and rough before being filled with mortar as specified in Section 3.12C of the Basic Concrete Specifications. Wire ties for holding forms shall not be used. Form-tying devices or parts thereof, other than metal, shall not be left embedded in the concrete. Ties shall not be removed in such manner as to leave a hole extending through the interior of the concre.te members. Contractor shall not use snap-ties which cause spalling of the concrete upon form stripping or tie removal. If steel panel forms are used, rubber grommets shall be provided where the ties pass through the form in order to prevent loss of cement paste. Where metal rods extending through the concrete are used to support or to strengthen forms, the rods shall remain embedded and shall terminate not less than l-inch back from the formed face or faces of the concrete. 2. Removable Ties Where taper ties are approved for use, the larger end of the taper tie shall be on the wet side of walls in water retaining structures. After the taper tie is removed, the hole shall be thoroughly cleaned and roughened for bond. A precast neoprene or polyurethane tapered plug shall be September 2003 Calavera Pump Station (860-3-CaI) Contract 38891 Concrete Formwork 031 00-4 located at the wall centerline. The hole shall be completely filled with non-shrink grout for water bearing and below-grade walls. The hole shall be completely filled with non-shrink or regular cement grout for above- grade walls which are dry on both sides. Exposed faces of walls shall have the outer 2 inches of the exposed face filled with a cement grout which shall match the color and texture of the surrounding wall surface. 3.04 Reuse of Forms Forms may be reused only if in good condition and only if acceptable to the Engineer. Light sanding between uses will be required wherever necessary to obtain uniform surface texture on all exposed concrete surfaces. Exposed concrete surfaces are defined as surfaces which are permanently exposed to view. In the case of forms for the inside wall surfaces of hydraulic/water retaining structures, unused tie rod holes in forms shall be covered with metal caps or shall be filled by other methods acceptable to the Engineer. 3.05 Removal of Forms Careful procedures for the removal of forms shall be strictly followed, and this work shall be done with care so as to avoid injury to the concrete. Contractor shall not apply heavy loading on green concrete. In the case of roof slabs and above-ground floor slabs, forms shall remain in place until test cylinders for the roof concrete attain a minimum compressive strength of 75 percent of the 28-day strength specified in the Basic Concrete Specifications; provided, that no forms shall be disturbed or removed under an individual panel or unit before the concrete in the adjacent panel or unit has attained 75 percent of the specified 28-day strength and has been in place for a minimum of 14 days. The time required to establish said strength shall be as determined by the Engineer who will make several test cylinders for this purpose from concrete used in the first group of roof panels placed. If the time so determined is more than the 14-day minimum, then that time shall be used as the minimum length of time. Forms for all vertical walls and columns shall remain in place at least 72 hours after the concrete has been placed. Forms for all parts of the work not specifically mentioned herein shall remain in place for periods of time as determined by the Engineer. 3.06 Maintenance of Forms Forms shall be maintained at all times in good condition, particularly as to size, shape, strength, rigidity, tightness, and smoothness of surface. Forms, when in place, shall conform to the established alignment and grades. Before concrete is placed, forms shall be thoroughly cleaned. Form surfaces shall be treated with a nonstaining mineral oil or other lubricant acceptable to the Engineer. Any excess lubricant shall be satisfactorily removed before placing the concrete. Where field oiling of forms is required, Contractor shall perform the oiling at least two weeks in advance of their use. Oil shall be kept off the surfaces of steel reinforcement and other metal items to be embedded in concrete. If oil is inadvertently placed on said metal surfaces, Contractor shall remove oil by sandblasting. September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete Formwork 031 00-5 3.07 Falsework A. Contractor shall be responsible for the design, engineering, construction, maintenance, and safety of all falsework, including staging, walkways, forms, ladders, and similar appurtenances, which shall equal or exceed the applicable requirements of the provisions of the OSHA Safety and Health Standards for Construction, the requirements of the Construction Safety Orders of the California Division of Industrial Safety, and the requirements specified herein. 8. All falsework shall be designed and constructed to provide the necessary rigidity and to support the loads. Falsework for the support of a superstructure shall be designed to support the loads that would be imposed if the entire superstructure were placed at one time. C. Falsework shall be placed upon a solid footing, safe against undermining, and protected from softening. When the falsework is supported on timber piles, the maximum calculated pile loading shall not exceed 20 tons. When falsework is supported on any portion of the structure which is already constructed, the load imposed by the falsework shall be spread, distributed, and braced in such a way as to avoid any possibility of damage to the structure. September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete Formwork 031 00-6 SECTION 03200 BASIC CONCRETE REINFORCEMENT SPECIFICATIONS PART 1 - GENERAL 1.01 1.02 1.03 General Requirements Contractor shall furnish, fabricate, and place all concrete reinforcement steel, welded wire fabric, couplers, and concrete inserts for use in reinforced concrete and masonry construction and shall perform all appurtenant work, including all the wires, clips, supports, chairs, spacers, and other accessories, all in accordance with the Contract Documents. Reference Specifications, Codes, and Standards A. Codes The Building Code, as referenced herein, shall be the Uniform Building Code (UBC) of the International Conference of Building Officials (ICBO), latest edition. B. Commercial Standards Where not covered in this specification, all work shall comply with the following standards, latest editions: ACI 315 ACI 318 W RI AWS D1.4 Contractor Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. Details and Detailing of Concrete Reinforcement. Building Code Requirements for Reinforced Concrete. Manual of Standard Practice for Welded Wire Fabric. Structural Welding Code - Reinforcing Steel. Contractor shall furnish shop bending diagrams, placing lists, and drawings of all reinforcement steel prior to fabrication. Details of concrete reinforcement steel and concrete inserts shall be submitted by the Contractor at the earliest possible date after receipt by the Contractor of Notice to Proceed. Said details of reinforcement steel for fabrication and erection shall conform to ACI 315 and the requirements specified and shown. Shop bending diagrams shall show the actual lengths of bars, to the nearest inch measured to the intersection of the extensions (tangents for bars of circular cross section) of the outside surface. Shop drawings shall include bar placement diagrams which clearly indicate the dimensions of each bar splice. B. September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete Reinforcement 03200- 1 C. Where mechanical couplers are required or permitted to be used to splice reinforcement steel, Contractor shall submit manufacturer’s literature which contains instructions and recommendations for installation for each type of coupler used; certified test reports which verify the load capacity of each type and size of coupler used; and shop drawings which show the location of each coupler with details of how they are to be installed in the formwork. D. If reinforcement steel is spliced by welding at any location, Contractor shall submit mill test reports which shall contain the information necessary for the determination of the carbon equivalent as specified in AWS D1.4. Contractor shall submit a written welding procedure for each type of weld for each size of bar which is to be spliced by welding; merely a statement that AWS procedures will be followed is not acceptable. 1.04 Quality Assurance A. If requested by the Engineer, Contractor shall provide samples from each heat of reinforcement steel delivered in a quantity adequate for testing. Costs of initial tests will be paid by the Owner. Costs of additional tests due to material failing initial tests shall be paid by the Contractor. 6. If reinforcement steel is spliced by welding at any location, Contractor shall submit certifications of procedure qualifications for each welding procedure used and certification of welder qualifications, for each welding procedure, and for each welder performing the work. Such qualifications shall be as specified in AWS D1.4. C. If requested by the Engineer, Contractor shall provide samples of each type of welded splice used in the work in a quantity and of dimensions adequate for testing. At the discretion of the Engineer, radiographic testing of direct butt welded splices will be performed. Contractor shall provide assistance necessary to facilitate testing. Contractor shall repair any weld which fails to meet the requirements of AWS D1.4. The costs of testing will be paid by the Owner; except, the costs of all tests which fail to meet specified requirements shall be paid by the Contractor. PART 2 - PRODUCTS 2.01 Reinforcement Steel A. All reinforcement steel for all cast-in-place reinforced concrete construction shall conform to the following requirements: 1. Bar reinforcement shall conform to the requirements of ASTM A 615 for Grade 60 Billet Steel Reinforcement with supplementary requirement S-1 , or as otherwise shown. 2. Welded wire fabric reinforcement shall conform to the requirements of ASTM A 185 and the details shown; provided, that welded wire fabric with longitudinal wire of W9.5 size wire shall be either furnished in flat sheets September 2003 Calavera Pump Station (860-3-Cat) Contract 38891 Concrete Reinforcement 03200-2 or in rolls with a core diameter of not less than 10 inches; and provided further, that welded wire fabric with longitudinal wires larger than W9.5 size shall be furnished in flat sheets only. 3. Spiral reinforcement shall be cold-drawn steel wire conforming to the requirements of ASTM A 82. B. Accessories 1. Accessories shall include all necessary chairs, slab bolsters, concrete blocks, tie wires, dips, supports, spacers, and other devices to position reinforcement during concrete placement. Slab bolsters shall have gray plastic-coated legs. 2. Concrete blocks (dobies), used to support and position reinforcement steel, shall have the same or higher compressive strength as specified for the concrete in which it is located. Where the concrete blocks are used on concrete surfaces exposed to view, the color and texture of the concrete blocks shall match that required for the finished surface. Wire ties shall be embedded in concrete block bar supports. 2.02 Mechanical Couplers A. Mechanical couplers shall be provided where shown and where approved by the Engineer. The couplers shall develop a tensile strength which exceeds 125 percent of the yield strength of the reinforcement bars being spliced at each splice. B. Where the type of coupler used is composed of more than one component, all components required for a complete splice shall be supplied. This shall apply to all mechanical splices, including those splices intended for future connections. C. The reinforcement steel and coupler used shall be compatible for obtaining the required strength of the connection. D. Couplers which are located at a joint face shall be a type which can be set either flush or recessed from the face as shown. The couplers shall be sealed during concrete placement to completely eliminate concrete or cement paste from entering. After the concrete is placed, Contractor shall plug and seal couplers intended for future connections to prevent any contact with water or other corrosive materials. Threaded couplers shall be plugged with plastic plugs which have an O-ring seal. 2.03 Welded Splices A. Welded splices shall be provided where shown and where approved by the Engineer. All welded splices of reinforcement steel shall develop a tensile strength which exceeds 125 percent of the yield strength of the reinforcement bars which are connected. September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete Reinforcement 03200-3 B. All materials required to perform the welded splices to the requirements of AWS D1.4 shall be provided. PART 3 - EXECUTION 3.01 3.02 3.03 General All reinforcement steel, welded wire fabric, couplers, and other appurtenances shall be fabricated, and placed in accordance with the requirements of the Building Code and the supplementary requirements specified herein. Fabrication A. General Reinforcement steel shall be accurately formed to the dimensions and shapes shown, and the fabricating details shall be prepared in accordance with ACI 315 and ACI 318, except as modified by the Drawings. Stirrups and tie bars shall be bent around a pin having a diameter not less than 1-1/2 inch for No. 3 bars, 2- inch for No. 4 bars, and 2-1/2 inch for No. 5 bars. Bends for other bars shall be made around a pin having a diameter not less than 6 times the minimum thickness, except for bars larger than 1 inch, in which case the bends shall be made around a pin of 8 bar diameters. Bars shall be bent cold. B. Contractor shall fabricate reinforcement bars for structures in accordance with bending diagrams, placing lists, and placing drawings. C. Fabricatina Tolerances Bars used for concrete reinforcement shall meet the following requirements for fabricating tolerances: 1. Sheared length: * 1 inch 2. Depth of truss bars: + 0, - 1/2 inch 3. Stirrups, ties, and spirals: r 112 inch 4. AI1 other bends: * 1 inch Placing A. Placinq Reinforcement steel shall be accurately positioned as shown, and shall be supported and wired together to prevent displacement, using annealed iron wire ties or suitable clips at intersections. All reinforcement steel shall be supported by concrete, plastic or metal supports, spaces or metal hangers which are strong and rigid enough to prevent any displacement of the reinforcement steel. Where concrete is to be placed on the ground, supporting concrete blocks (or dobies) September 2003 Calavera Pump Station (860-3-Gal) Contract 38891 Concrete Reinforcement 03200-4 shall be used, in sufficient numbers to support the bars without settlement, but in no case shall such support be continuous. All concrete blocks used to support reinforcement steel shall be tied to the steel with wire ties which are embedded in the blocks. For concrete over formwork, Contractor shall furnish concrete, metal, plastic, or other acceptable bar chairs and spacers. B. The portions of all accessories in contact with the formwork shall be made of concrete, plastic, or steel coated with a 1/8 inch minimum thickness of plastic which extends at least 1/2 inch from the concrete surface. Plastic shall be gray in color. C. Tie wires shall be bent away from the forms in order to provide the specified concrete coverage. D. Bars additional to those shown which may be found necessary or desirable by the Contractor for the purpose of securing reinforcement in position shall be provided by the Contractor at its own expense. E. Placinu Tolerances Unless otherwise specified, reinforcement placing tolerances shall be within the limits specified in Section 7.5 of ACI 318 except where in conflict with the requirements of the Building Code. F. Bars may be moved as necessary to avoid interference with other reinforcement steel, conduits, or embedded items. If bars are moved more than one bar diameter, or enough to exceed the above tolerances, the resulting arrangement of bars shall be as acceptable to the Engineer. G. Welded wire fabric reinforcement placed over horizontal forms shall be supported on slab bolsters having gray, plastic-coated standard type legs as specified in Paragraph B herein. Slab bolsters shall be spaced not less than 30 inches on centers, shall extend continuously across the entire width of the reinforcement mat, and shall support the reinforcement mat in the plane shown. H. Welded wire fabric placed over the ground shall be supported on wired concrete blocks (dobies) spaced not more than 3 feet on centers in any direction. Contractor shall not utilize the construction practice of placing welded wire fabric on the ground and hooking into place in the freshly placed concrete. 3.04 Spacing of Bars A. The clear distance between parallel bars (except in columns and between multiple layers of bars in beams) shall be not less than the nominal diameter of the bars nor less than 1-1/3 times the maximum size of the coarse aggregate, nor less than 1 inch. B. Where reinforcement in beams or girders is placed in 2 or more layers, the clear distance between layers shall be not less than 1 inch. September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete Reinforcement 03200-5 C. In columns, the clear distance between longitudinal bars shall be not less than 1- 1/2 times the bar diameter, not less than 1-1/2 times the maximum size of the coarse aggregate, nor less than 1 -1/2 inches. D. The clear distance between bars shall also apply to the distance between a contact splice and adjacent splices or bars. 3.05 Splicing A. General Reinforcement bar splices shall only be used at locations shown. When it is necessary to splice reinforcement at points other than where shown, the character of the splice shall be as acceptable to the Engineer. 6. Splices of Reinforcement The length of lap for reinforcement bars, unless otherwise shown shall be in accordance with ACI 318, Section 12.15.1 for a class B splice. C. Laps of welded wire fabric shall be in accordance with the ACI 318. Adjoining sheets shall be securely tied together with No. 14 tie wire, one tie for each 2 running feet. Wires shall be staggered and tied in such a manner that they cannot slip. D. Splices in column spiral reinforcement, when necessary, shall be made by welding or by a lap of 1 -1/2 turns. E. Bendins or Straiahtenina Reinforcement shall not be straightened or rebent in a manner which will injure the material, Bars with kinks or bends not shown shall not be used. All bars shall be bent cold, unless otherwise permitted by the Engineer. No bars partially embedded in concrete shall be field-bent except as shown or specifically permitted by the Engineer. 3.06 Cleaning and Protection A. Reinforcement steel shall at all times be protected from conditions condusive to corrosion until concrete is placed around it. B. The surfaces of all reinforcement steel and other metalwork to be in contact with concrete shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar and other foreign substances immediately before the concrete is placed. Where there is delay in depositing concrete, reinforcement shall be reinspected and, if necessary recleaned. September 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete Reinforcement 03200-6 SECTION 03300 BASIC CONCRETE SPECIFICATIONS PART 1 - GENERAL 1.01 General Requirements A. Contractor shall furnish all materials for concrete in accordance with the provisions of this Section and shall form, mix, place, cure, repair, finish, and do all other work as required to produce finished concrete, all in accordance with the requirements of the Contract Documents. B. All cast-in-place concrete falls into one of the following categories and shall comply with all requirements of this basic specification. 1. Structural Concrete (or Class "A" Concrete). Concrete to be used in all cases except where noted otherwise in the Contract Documents. 2. Sitework Concrete (or Class "B" Concrete). Concrete to be used for curbs, gutters, catch basins, sidewalks, pavements, fence and guard post embedment, underground duct bank encasement and all other concrete appurtenant to electrical facilities unless otherwise shown. 3. Lean Concrete (or Class "C" Concrete). Concrete to be used for thrust blocks, pipe trench cut-off blocks and cradles, where the preceding items are detailed on the drawings as unreinforced. Concrete to be used as protective cover for dowels intended for future connection. 1.02 Reference Specifications, Codes, and Standards A. Specifications Items specified elsewhere in these Contract Documents: Concrete Formwork - See Basic Concrete Formwork SDecification. Concrete Reinforcement - See Basic Concrete Reinforcement Specification. B. Codes The Building Code, as referenced herein, shall be the Uniform Building Code (UBC), of the International Conference of Building Officials (ICBO), latest edition. C. Commercial Standards Where not covered in this specification, all work shall comply with the following standards, latest editions: ACI 214 Recommended Practice for Evaluation of Strength Test Results of Concrete October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 ACI 301 Specifications for Structural Concrete for Buildings ACI 315 Details and Detailing of Concrete Reinforcement ACI 347 Recommended Practice for Concrete Formwork ACI 318 Building Code Requirements for Reinforced Concrete ASTM C 494 Specification for Chemical Admixtures for Concrete 1.03 Contractor Submittals All submittals shall be in accordance with General Provisions, Section 2-5.3. A. Mix Desiqns Prior to beginning the work, Contractor shall submit to Engineer, for review, preliminary concrete mix designs which shall show the proportions and gradations of all materials proposed for each class and type of concrete to be used on the job. The mix designs shall be designed by an independent testing laboratory acceptable to Engineer. All costs related to such mix design shall be borne by the Contractor. B. Certified Delivew Tickets Where ready-mix concrete is used, Contractor shall provide certified delivery tickets at the time of delivery of each load of concrete. Each certificate shall show the total quantities (by weight) of cement, sand, each class of aggregate, and admixtures, and the amounts of water (by gallons) in the aggregate and added at the batching plant as well as the amount of water allowed to be added at the site for the specific design mix. Each certificate shall, in addition, state the mix number, total yield in cubic yards, and the time of day, to the nearest minute, corresponding to when the batch was dispatched, when it left the plant, when it arrived at the job, the time that unloading began, and the time that unloading was finished. 1.04 Quality Assurance A. Tests on component materials and for compressive strength of concrete will be performed as specified herein. Test for determining slump will be in accordance with the requirements of ASTM C 143. B. The cost of all laboratory tests on concrete will be borne by the Owner. However, Contractor shall be charged for the cost of any additional tests and investigation on work performed which fails to meet specification. C. Concrete for testing shall be supplied by Contractor at no cost to the Owner, and Contractor shall provide assistance to the Engineer in obtaining samples, and disposal and cleanup of excess material. October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-2 D. Field Compression Tests 1. Compression test specimens will be taken during construction from the first placement of each class of concrete specified herein and at intervals thereafter as selected by the Engineer to insure continued compliance with these specifications. Each set of test specimens will be a minimum of 4 cylinders. 2. Compression test specimens for concrete shall be made in accordance with ASTM C 31. Specimens shall be 6 inch diameter by 12 inch high cylinders. 3. Compression tests shall be performed in accordance with ASTM C 39. One test cylinder will be tested at 7 days and 2 at 28 days. The remaining cylinder will be held to verify test results, if needed. E. Evaluation and Acceptance of Concrete 1. Evaluation and acceptance of the compressive strength of concrete shall be according to the requirements of ACI 318, Chapter 4 "Concrete Quality", and as specified herein. 2. If any concrete fails to meet these requirements, immediate corrective action shall be taken to increase the compressive strength for all subsequent batches of the type of concrete affected. 3. All concrete which fails to meet the ACI requirements and these specifications is subject to removal and replacement at the cost of the Contractor. F. Construction Tolerances Contractor shall set and maintain concrete forms and perform finishing operations so as to insure that the completed work is within the tolerances specified herein. Surface defects and irregularities are defined as finishes and are to be distinguished from tolerances. Tolerance is the specified permissible variation from lines, grades, or dimensions shown. Where tolerances are not stated in the specifications, permissible deviations will be in accordance with ACI 347. G. The following construction tolerances are hereby established and apply to finished walls and slab unless otherwise shown: Tolerance Variation of the constructed linear outline from the established position in plan Variation from the level or from the grades shown In 10 feet: 1/4 inch; In 20 feet or more: 1/2 inch In 10 feet: 1/8 inch; In 20 feet or more: 1/4 inch October 2003 Calavera Pump Station (860-3-Cat) Contract 38891 Concrete 03300-3 - I tem Variation from the plumb Tolerance In 10 feet: 1/8 inch; In 20 feet or more: 1/4 inch Variation in the thickness of slabs and walls Minus 1/4 inch; Plus 1/2 inch Variation in the locations and sizes of slab and wall openings Plus or minus 1/4 inch Regardless of the tolerances listed herein, it shall be the responsibility of the Contractor to limit deviations in line and grade to tolerances which will permit proper installation and operation of mechanical equipment and piping. PART 2 - PRODUCTS 2.01 Concrete Materials A. Materials shall be delivered, stored, and handled so as to prevent damage by water or breakage. Only one brand of cement shall be used. Cement reclaimed from cleaning bags or leaking containers shall not be used. All cement shall be used in the sequence of receipt of shipments. B. All materials furnished for the work shall comply with the requirements of Sections 201 , 203, and 204 of ACI 301, as applicable. C. Storage of materials shall conform to the requirements of Section 205 of ACI 301. 0. Materials for concrete shall conform to the following requirements: 1. Cement shall be standard brand portland cement conforming to ASTM C 150 for Type II or Type V. Portland cement shall contain not more than 0.60 percent alkalies. A single brand of cement shall be used throughout the work, and prior to its use, the brand shall be acceptable to the Engineer. The cement shall be suitably protected from exposure to moisture until used. Cement that has become lumpy shall not be used. Stacked cement shall be stored in such a manner so as to permit access for inspection and sampling. Certified mill test reports for each shipment of cement to be used shall be submitted to the Engineer if requested regarding compliance with these specifications. 2. Water shall be potable, clean, and free from objectionable quantities of silty organic matter, alkali, salts and other impurities. The water shall be considered potable, for the purposes of this section only, if it meets the requirements of the local governmental agencies. Agricultural water with high total dissolved solids (over 1000 mg/l TDS) shall not be used. 3. Anareqates shall be obtained from pits acceptable to the Engineer, shall be non-reactive, and shall conform to ASTM C 33. Maximum size of October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-4 4. 5. 6. coarse aggregate shall be as specified in Paragraph 2.07B. Lightweight sand for fine aggregate will not be permitted. a. Coarse aggregates shall consist of clean, hard, durable gravel, crushed gravel, crushed rock or a combination thereof. The coarse aggregates shall be prepared and handled in two or more size groups for combined aggregates with a maximum size greater than 314 inch. When the aggregates are proportioned for each batch of concrete the two size groups shall be combined. b. Fine aggregates shall be natural sand or a combination of natural and manufactured sand that are hard and durable. c. Combined aggregates shall be well graded from coarse to fine sizes, and shall be uniformly graded between screen sizes to produce a concrete that has optimum workability and consolidation characteristics. Where a trial batch is required for a mix design, the final combined aggregate gradations will be established during the trial batch process. Readv-mix concrete shall conform to the requirements of ASTM C 94. Air-entraining aaent meeting the requirements of ASTM C 260, shall be used. Sufficient air-entraining agent shall be used to provide a total air content of 4 to 6 percent; provided that, when the mean daily temperature in the vicinity of the worksite falls below 40 degrees F for more than one day, the total air content provided shall be 5 to 7 percent. The Owner reserves the right, at any time, to sample and test the air-entraining agent received on the job by the Contractor. The air-entraining agent shall be added to the batch in a portion of the mixing water. The solution shall be batched by means of a mechanical batcher capable of accurate measurement. Admixtures. Admixtures shall be required as stated herein and at the Engineer's discretion or, if not required, may be added at the Contractor's option to control the set, effect water reduction, and increase workability. In either case, the addition of an admixture shall be at the Contractor's expense. The use of an admixture shall be subject to acceptance by the Engineer. Concrete containing an admixture shall be first placed at a location determined by the Engineer. If the use of an admixture is producing an inferior end result, Contractor shall discontinue use of the admixture. Admixtures specified herein shall conform to the requirements of ASTM C 494. The required quantity of cement shall be used in the mix regardless of whether or not an admixture is used. Admixtures shall contain no free chloride ions, be non-toxic after 30 days, and shall be compatible with and made by the same manufacturer as the air entraining admixture. a. Low ranqe water reducer sitework concrete and shall shall be used in all structural and conform to ASTM C 494, Type A. It October 2003 Calavera Pump Station (860-3-Cat) Contract 38891 Concrete 03300-5 shall be either a hydroxylated carboxylic acid type or a hydroxylated polymer type. The quantity of admixture used and the method of mixing shall be in accordance with the manufacturer's instructions and recommendations. b. Set controllina admixture shall be either with or without water- reducing properties. Where the air temperature at the time of placement is expected to be consistently over 80 degrees F, a set retarding admixture such as Sika Chemical CorDoration's Plastiment, Master Builder's Pozzolith 300R, or eaual shall be used. Where the air temperature at the time of placement is expected to be consistently under 40 degrees F, a set accelerating admixture such as Sika Chemical Corporation's Plastocrete 161 FL, Master Builder's Pozzolith 50C, or eaual shall be used. c. Hioh ranae water reducer may be used if approved by Engineer. If allowed it shall be sulfonated polymer conforming to ASTM C 494, Type F or G. High range water reducing agent shall only be added to the concrete at the batch plant. It shall be second generation type, Daracem 100, as manufactured bv W.R. Grace & Co.; Rhedbuild 1000, as manufactured bv Masterbuilders; or eaual. High range water reducer shall be added to the concrete after all other ingredients have been mixed and initial slump has been verified. Concrete shall be mixed at mixing speed for a minimum of 30 mixer revolutions after the addition of the high range water reducer. 7. Calcium Chloride shall not be added to or used in concrete. 8. Floor Hardener shall be provided where specified on the Drawings. Floor hardener shall be natural aggregate dry shake hardener for concrete. Hardener shall be composed of crushed, washed, and specially graded quartz silica aggregate, cementitious binders, plasticizers, dispersing agents and stable colorants. Contractor shall coordinate adjustments in concrete mix design necessary to accommodate proposed floor hardener, including air entrainment and admixtures. Unless specified otherwise, hardener color shall be natural light gray. Floor hardener shall be ConColor by ChemMasters, Lithochrome by L.M.Scofield Co., Colorcron by Master Builders, or equal. Floor hardener shall be applied in strict accordance with the manufacturer's printed instructions. October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-6 2.02 Curing Materials Materials for curing concrete shall conform to the following requirements: A. B. C. D. E. F. Concrete curinq compound shall be Masterkure manufactured bv Masterbuilders, Cleveland, OH, or approved equal. The curing compound shall contain a fugitive dye so that areas of application will be readily distinguishable. Polvethvlene sheet for use as concrete curing blanket shall be white, and shall have a nominal thickness of 6 mils. The loss of moisture when determined in accordance with the requirements of ASTM C 156 shall not exceed 0.055 grams per square centimeter of surface. Polvethvlene-coated waterproof paper sheetinq for use as concrete curing blanket shall consist of white polyethylene sheeting free of visible defects, uniform in appearance, having a nominal thickness of 2 mils and permanently bonded to waterproof paper conforming to the requirements of Federal Specification UU-B-790A (Int. Amd. 1). The loss of moisture, when determined in accordance with the requirements of ASTM C 156, shall not exceed 0.055 gram per square centimeter of surface. Polvethvlene-coated burlap for use as concrete curing blanket shall be 4 mil thick, white opaque polyethylene film impregnated or extruded into one side of the burlap. Burlap shall weigh not less than 9 ounces per square yard. The loss of moisture, when determined in accordance with the requirements of ASTM C 156, shall not exceed 0.055 grams per square centimeter of surface. Curinq mats for use in Curing Method 6 as specified in Paragraph 3.09G herein, shall be heavy shag rugs or carpets or cotton mats quilted at 4 inches on center. Curing mats shall weigh a minimum of 12 ounces per square yard when dry. Evaporation retardant shall be a material such as Confilm as manufactured by Masterbuilders, Cleveland, OH; or eaual. 2.03 Waterstop A. Contractor shall provide waterstops at all construction and expansion joints in all water holding structures. Waterstop shall be greenstreak PVC Style 732, 6 inches wide, or Style 735, 9 inches wide, as specified on drawings. B. Contractor shall heat fuse joints and connections in strict compliance with manufacturer's instructions using heating tools and devices recommended by same. Waterstops shall be continuous in joints, following offsets and angles in joint until spliced to waterstops at intersecting joints, completely sealing the structure. Waterstops shall be aligned and centered in joints. Contractor shall secure flanges of waterstops to reinforcing bars with 18 gauge wire ties spaced maximum 18 inches on center. Waterstop joints shall be properly heat-spliced at ends and crosses to preserve continuity. Contractor shall locate waterstops where shown on drawings and in all waterbearing walls and slabs where October 2003 Calavera Pump Station (860-3-Cal) Contract 3889 1 Concrete 03300-7 common to: earth-bearing or earth-support; occupied areas; or above-grade exposed surfaces. C. All joints with waterstops involving more than 2 ends to be jointed together, and all joints which involve an angle cut, alignment change, or the joining of 2 dissimilar waterstop sections shall be prefabricated by the Contractor prior to placement in the forms, allowing not less than 24 inch long strips of waterstop material beyond the joint. Upon being inspected and approved, such prefabricated waterstop joint assemblies shall be butt welded to the straight run portions of waterstop. D. Waterstop splices shall have a tensile strength of not less than 60 percent of the unspliced materials tensile strength. 2.04 Expansion Joints A. Contractor shall provide expansion joints where indicated on Construction Drawings. Expansion joints shall consist of joint filler material and joint sealant. Filler material shall be held down 112 inch for sealant unless otherwise shown. B. Expansion joint filler material shall be preformed sponge neoprene or cork conforming to ASTM D 1752. Filler material containing asphalt shall not be used. 2.05 Joint Sealant A. Joint sealant for use in construction, control, and expansion joints shall be select seal U-227 reservoir grade as supplied by Select Products Co., or approved equal. Joint primer shall be as produced andor recommended by sealant manufacturer. B. Contractor shall clean all locations where sealant is placed by sandblasting and be free from oil, foreign materials, and moisture. Lower surfaces of joints shall be isolated with a bond breaker such as polyethylene, polyethylene tape, or equal as recommended by sealant manufacturer. C. Sealant shall be placed in strict accordance with manufacture's recommendations by a firm specializing in this type of work, or by the Contractor under direct supervision of the manufacturer. If the Contractor chooses to apply sealant, manufacturer's technical representative shall be present at the beginning of sealant placement to observe and advise on methods for mixing, joint preparation, and application of sealant. 2.06 Concrete Bond Breaker A. Bond breaker shall be Super Bond Breaker as manufactured bv Burke Companv, San Mateo, California; Select Cure CRB as manufactured bv Select Products Co., Upland, CA; Tilt-EEZ Bond Breaker as manufactured bv Conspec; October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-8 or approved equal. It shall contain a fugitive dye so that areas of application will be readily distinguishable. B. Contractor shall strictly follow manufacturer's application guidelines. Just prior to application, joint shall be thoroughly soaked so that concrete contains approximately the same surface moisture as newly cast concrete. Bond breaker shall be brush applied with a minimum of two coats. Extreme care must be taken to prevent any bond breaker from contacting waterstops. If necessary, wrap waterstop during bond breaker application. 2.07 Concrete Design Requirements A. General Concrete shall be composed of cement, admixtures, aggregates and water. These materials shall be of the qualities specified. The exact proportions in which these materials are to be used for different parts of the work will be determined during the trial batch. In general, the mix shall be designed to produce a concrete capable of being deposited so as to obtain maximum density and minimum shrinkage and, where deposited in forms, to have good consolidation properties and maximum smoothness of surface. Mix designs shall not contain more than 43 percent of sand of the total weight of fine and coarse aggregate. The aggregate gradations shall be formulated to provide fresh concrete that will not promote rock pockets around reinforcing steel or embedded items. The proportions shall be changed whenever necessary or desirable to meet the required results at no additional cost to the Owner. All changes shall be approved by Engineer. B. Water-Cement Ratio and Compressive Strength The minimum compressive strength and cement content of concrete shall be not less than that specified in the following tabulation. Min. 28-Day Compressive Strength Tvpe of Work (DSI) Structural Concrete (Class "A"): Walls, roof slabs, floor slabs,3,500 columns, and footings and all other concrete items not specified elsewhere Sitework concrete (Class "B"):3,000 Lean concrete (Class "C"): 2,000 Note: One sack of cement equals 94 Ibs. October 2003 Calavera Pump Station (860-3-Cat) Contract 38891 Max. Min. Size Cement Max. W/C Aggregate per cu yd Ratio (sacks) /bv wt.1 1 6.2 0.48 1 5.5 0.52 1 4.0 0.60 Concrete 03300-9 C. Adiustments to Mix Desian Mixes used shall be changed whenever such change is necessary or desirable to secure required strength,' density, workability, and surface finish and Contractor shall be entitled to no additional compensation because of such changes. Approval shall be obtained from Engineer prior to any changes. 2.08 Consistency The quantity of water entering into a batch of concrete shall be just sufficient, with a normal mixing period, to produce concrete which can be worked properly into place without segregation, and which can be compacted by vibratory methods herein specified to give desired density, impermeability and smoothness of surface. The quantity of water shall be changed as necessary, with variations in the nature of moisture content of the aggregates, to maintain uniform production of desired consistency. The consistency of the concrete in successive batches shall be determined by slump tests in accordance with ASTM C 143. The slumps shall be as follows: Part of Work Slump (in.) Structural concrete 3 inches (kl inch) Other work 4 inches (il inch) With high range water reducer added 8 inches max. 2.09 Ready-Mixed Concrete A. At Contractor's option, ready-mixed concrete may be used provided it meets all requirements as to materials, batching, mixing, transporting, and placing as specified herein and in accordance with ASTM C 94, including the supplementary requirements specified in Paragraphs 2.098 through 2.09F, herein. 6. Ready-mixed concrete shall be delivered to the site of the work, and discharge shall be completed within 90 minutes after the addition of the cement to the aggregates or before the drum has been revolved 250 revolutions, whichever is first. In hot weather (ambient temperature above 95°F) or under conditions contributing to quick stiffening of the concrete, or when the temperature of the concrete is 85 degrees F or above, the time between the introduction of the cement to the aggregates and discharge shall not exceed 45 minutes. C. Truck mixers shall be equipped with electrically-actuated counters by which the number of revolutions of the drum or blades may be readily verified. The counter shall be of the resettable, recording type, and shall be mounted in the driver's cab. The counters shall be actuated at the time of starting mixers at mixing speeds. D. Each batch of concrete shall be mixed in a truck mixer for not less than 70 revolutions of the drum or blades at the rate of rotation designated by the manufacturer of equipment. Additional mixing, if any, shall be at the speed October 2003 Calavera Pump Station (860-3-Cal) Contract 3889 1 Concrete 03300-1 0 designated by the manufacturer of the equipment as agitating speed. All materials including mixing water shall be in the mixer drum before actuating the revolution counter for determining the number of revolution of mixing. E. Truck mixers and their operation shall be such that the concrete throughout the mixed batch as discharged is within acceptable limits of uniformity with respect to consistency, mix, and grading. If slump tests taken at approximately the 1/4 and 3/4 points of the load during discharge give slumps differing by more than 1 inch when the specified slump is 4 inches or less, or if they differ by more than 2 inches when the specified slump is more than 4 inches, the mixer shall not be used on the work unless the causing condition is corrected and satisfactory performance is verified by additional slump tests. All mechanical details of the mixer, such as water measuring and discharge apparatus, condition of the blades, speed of rotation, general mechanical condition of the unit, and clearance of the drum, shall be checked before a further attempt to use the unit will be permitted. F. Each batch of ready-mixed concrete delivered at the job site shall be accompanied by a certified weighmaster delivery ticket furnished to the Engineer in accordance with Paragraph 1.03B, herein. G. Non-agitating equipment for transporting ready-mixed concrete shall not be used. Combination truck and trailer equipment for transporting ready-mixed concrete shall not be used. The quality and quantity of materials used in ready- mixed concrete and in batch aggregates may be subject to continuous inspection at the batching plant by the Engineer. H. Transit mix trucks delivering concrete to the site shall have full water tanks upon arrival at the site. Any addition of water must be approved by Engineer. Added water must be incorporated by additional mixing of at least 35 revolutions. PART 3 - EXECUTION 3.01 Proportioning and Mixing A. Proportioninq Proportioning of the concrete mix shall conform to the requirements of Chapter 3 "Proportioning" of ACI 301 ; provided, that the maximum slump for any concrete shall not exceed 4 inches except when the use of high range water reducer is permitted which increases the maximum slump to 8 inches. B. Mixinq Mixing of concrete shall conform to the requirements of Chapter 7 of said ACI 301 specifications. C. Slump Maximum slumps shall be as specified in Paragraph 2.08A, herein. October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 1 D. RetemDerinq Concrete or mortar which has partially hardened shall not be retempered. 3.02 Preparation of Surfaces for Concreting A. General Earth surfaces shall be thoroughly wetted by sprinkling, prior to placing any concrete, and these surfaces shall be kept moist by frequent sprinkling up to the time of placing concrete thereon. These surfaces shall be free from standing water, mud, and debris at the time of placing concrete. B. Joints in Concrete The location of all construction joints not specifically noted or shown shall be approved by Engineer. Concrete surfaces upon or against which concrete is to be placed, where the placement of the old concrete has been stopped or interrupted so that, as determined by the Engineer, the new concrete cannot be incorporated integrally with that previously placed, are defined as construction joints. The surfaces of horizontal joints shall be given a compacted, roughened surface for good bond. Except where the drawings call for joint surfaces to be coated, the joint surfaces shall be cleaned of all laitance, loose or defective concrete, and foreign material. Such cleaning shall be accomplished by sandblasting to remove laitance and to provide a uniform surface texture with approximately 114 inch of surface sandblasted off. Sandblasting shall be followed by thorough washing. All pools of water shall be removed from the surface of construction joints before the new concrete is placed. C. Placinq Interruptions When placing of concrete is to be interrupted long enough for the concrete to take a set, the working face shall be given a shape by the use of forms or other means, that will secure proper union with subsequent work; provided that construction joints shall be made only where acceptable to the Engineer. D. Embedded Items Concrete shall not be placed until all formwork, installation of parts to be embedded, reinforcement steel, and preparation of surfaces involved in the placing have been completed and accepted by the Engineer at least 4 hours before placement of concrete. All surfaces of forms and embedded items that have become encrusted with dried grout from concrete previously placed shall be cleaned of all such grout before the surrounding or adjacent concrete is placed. E. All inserts or other embedded items shall conform to the requirements herein. October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 2 F. All reinforcement, anchor bolts, sleeves, inserts, and similar items shall be set and secured in the forms where shown on Contract Drawings and shall be acceptable to the Engineer before any concrete is placed. Accuracy of placement is the responsibility of the Contractor. G. Concrete anchor bolts and expansion anchors shall be inserted to the minimum depths listed below unless noted otherwise: Reinforced - Size Concrete 1/4" 310" 112" 3/4" 3" 4" 5" 6" Expansion anchors shall be red head wedge, self-driving, stud, multi-set, or equal. H. All smooth dowels shall have at least one side coated with a bond breaker. Dowel bond breaker shall be a heavy duty industrial grease hand applied. A wax paper or PVC sleeve may be used at the Contractor's option if specifically manufactured to create slip dowels. Paper tubing shall be multi-ply stock and heavily impregnated with paraffin. Maximum sleeve thickness shall be 1/16" and sleeve shall fit snugly over dowel. I. Castinq New Concrete Aqainst Old Where concrete is to be cast against old concrete (any concrete which is greater than 60 days of age), surfaces of the old concrete shall be thoroughly cleaned and roughened by sand-blasting (exposing aggregate) prior to placement. J. Concrete shall not be placed in any old or new structure until all water entering the space to be filled with concrete has been properly cut off or has been diverted by pipes, or other means, and carried out of the forms, clear of the work. Concrete shall not be deposited underwater nor shall the Contractor allow still water to rise on any concrete until the concrete has attained its initial set. Water shall not be permitted to flow over the surface of any concrete in such a manner and at such velocity as to injure the surface finish of the concrete. Contractor shall provide pumping or other necessary dewatering operations for removing groundwater, if required, with methods subject to review by Engineer. K. Corrosion Protection Pipe, conduit, dowels, and other ferrous items required to be embedded in concrete construction shall be so positioned and supported prior to placement of concrete that there will be a minimum of 2 inches clearance between said items and any part of the concrete reinforcement. Contractor shall not secure such items in position by wiring or welding them to the reinforcement. October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 3 L. Anchor Bolts shall be accurately set, and shall be maintained in position by templates while being embedded in concrete. M. Cleaninq Surfaces of all metalwork to be in contact with concrete shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar, and other foreign substances immediately before concrete is placed. 3.03 Handling, Transporting, and Placing A. General Placing of concrete shall conform to the applicable requirements of Chapter 8 of ACI 301 and the requirements of this section. 6. Non-Conformina Work or Materials Concrete which upon or before placing is found not to conform to the requirements specified herein shall be rejected and immediately removed from the work. Concrete which is not placed in accordance with these specifications, or which is of inferior quality, shall be removed and replaced by and at the expense of the Contractor. C. Unauthorized Placement Concrete shall not be placed except in the presence of duly authorized representative of the Engineer. Contractor shall notify Engineer at least 24 hours in advance of placement of any concrete. D. Placement in Wall Forms Concrete shall not be dropped through reinforcement steel or into any deep form, whether reinforcement is present or not, causing separation of the coarse aggregate from the mortar on account of repeatedly hitting rods or the sides of the form as it falls, nor shall concrete be placed in any form in such a manner as to leave accumulation of mortar on the form surfaces above the placed concrete. In such cases, some means such as the use of hoppers and, if necessary, vertical ducts of canvas, rubber, or metal shall be used for placing concrete in the forms in a manner that it may reach the place of final deposit without separation. In no case shall the free fall of concrete exceed 4 feet below the ends of ducts, chutes, or buggies. Concrete shall be uniformly distributed during the process of depositing and in no case after depositing shall any portion be displaced in the forms more than 6 feet in horizontal direction. Concrete in forms shall be deposited in uniform horizontal layers not deeper than 2 feet; and Contractor shall take care to avoid inclined layers or inclined construction joints except where such are required for sloping members. Each layer shall be placed while the previous layer is still soft. October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 4 E. Placement in Slabs Concrete placed in sloping slabs shall proceed uniformly from the bottom of the slab to the top, for the full width of the placement. As the work progresses, concrete shall be vibrated and carefully worked around the slab reinforcement, and the sutface of the slab shall be screeded in an up-slope direction. F. TemPerature of Concrete Temperatures of concrete when it is being placed shall be not more than 90 degrees F nor less than 40 degrees F in moderate weather, and not less than 50 degrees F in weather during which the mean daily temperature drops below 40 degrees F. Concrete ingredients shall not be heated to a temperature higher than that necessary to keep the temperature of the mixed concrete, as placed, from falling below the specified minimum temperature. If concrete is placed when the weather is such that the temperature of the concrete would exceed 90 degrees F, Contractor shall employ effective means, such as precooling of aggregates and mixing water using ice or placing at night, as necessary to maintain the temperature of the concrete, as it is placed, below 90 degrees F. Contractor shall be entitled to no additional compensation on account of the foregoing requirements. G. Cold Weather Placement Earth foundations shall be free from frost or ice when concrete is placed upon or against them. Fly ash concrete shall not be placed when the air temperature falls below 50 degrees F. 3.04 Pumping of Concrete A. General If the pumped concrete does not produce satisfactory end results, Contractor shall discontinue the pumping operation and proceed with the placing of concrete using conventional methods. B. Pumping Equipment Pumping equipment must have 2 cylinders and be designed to operate with one cylinder only in case the other one is not functioning. In lieu of this requirement, Contractor may have a standby pump on the site during pumping. C. The minimum diameter of hose (conduits) shall be 4 inches. D. Contractor shall replace pumping equipment and hoses (conduits) that are not functioning properly. E. Contractor shall not use aluminum conduits for conveying the concrete. October 2003 Calavera Pump Station (860-3-Cal) Con tract 3889 1 Concrete 03300-1 5 F. Proportioninq Minimum compressive strength, cement content, and maximum size of aggregates shall be as specified in Paragraph 2.07, herein. G. Gradation of coarse aggregates shall conform to ASTM C 33 and shall be as close to the middle range as possible. H. Gradation of fine aggregate shall conform to ASTM C 33, with 15 to 30 percent passing the number 50 screen and 5 to 10 percent passing the number 100 screen. The fineness modules of sand used shall not be over 3.00. I. Water and slump requirements shall conform to Paragraphs 2.010.2 and 2.078 for water and 2.08A for slump. J. Cement and admixtures shall conform to Paragraph 2.01 D, herein. 3.05 Order of Placing Concrete The order of placing concrete in all parts of the work shall be acceptable to the Engineer. In order to minimize the effects of shrinkage, the concrete shall be placed in units as bounded by construction joints shown. The placing of units shall be done by placing alternate units in a manner such that each unit placed shall have cured at least 7 days before the contiguous unit or units are placed. 3.06 Tamping and Vibrating A. As concrete is placed in the forms or in excavations, Contractor shall insure it is thoroughly settled and compacted, throughout the entire depth of the layer which is being consolidated, into a dense, homogeneous mass, filling all corners and angles, thoroughly embedding the reinforcement, eliminating rock pockets, and bringing only a slight excess of water to the exposed surface of concrete during placement. Vibrators shall be high speed power vibrators (8000 to 10,000 rpm) of an immersion type in sufficient number and with (at least one) standby units as required. B. Contractor shall take care in placing concrete around waterstops. Contractor shall carefully work concrete by rodding and vibrating to make sure that all air and rock pockets have been eliminated. Where flat-strip type waterstops are placed horizontally, the concrete shall be worked under the waterstops by hand, making sure that all air and rock pockets have been eliminated. Concrete surrounding the waterstops shall be given additional vibration, over and above that used for adjacent concrete placement to assure complete embedment of the waterstops in the concrete. C. Concrete in walls shall be internally vibrated and at the same time rammed, stirred, or worked with suitable appliances, tamping bars, shovels, or forked tools until it completely fills the forms or excavations and closes snugly against all surfaces. Subsequent layers of concrete shall not be placed until the layers previously placed have been worked thoroughly as specified. Vibrators shall be October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 6 inserted vertically into the concrete and pulled out slowly, penetrating 1/3 of the layer depth of the layer previously placed. Vibrators shall be provided in sufficient numbers, with standby units as required, to accomplish the results herein specified within 15 minutes after concrete of the prescribed consistency is placed in the forms. The vibrating head shall be kept from contact with the surfaces of the forms. Care shall be taken not to vibrate concrete excessively or to work it in any manner that causes segregation of its constituents. 3.07 Finishing Concrete Surfaces A. General Surfaces shall be free from fins, bulges, ridges, offsets, honeycombing, or roughness of any kind, and shall present a finished, smooth, continuous hard surface. Allowable deviations from plumb or level and from the alignment, profiles, and dimensions shown are defined as tolerances and are specified in Paragraphs 1.04F and 1.04G, herein. These tolerances are to be distinguished from irregularities in finish as described herein. Aluminum finishing tools shall not be used. B. Formed Surfaces On surfaces not exposed to view, no treatment is required after form removal except for curing, repair of defective concrete, and treatment of surface defects. An architectural finish is required on exposed to view surfaces in accordance with Section 3.08 unless otherwise specified. C. Unformed Surfaces After proper and adequate vibration and tamping, all unformed top surfaces of slabs, floors, walls, and curbs shall be brought to a uniform surface with suitable tools. The classes of finish specified for unformed concrete surfaces are designated and defined as follows: 1. Class "1". After the floated surface (as specified for Class "3") has hardened sufficiently to prevent excess of fine material from being drawn to the surface, steel troweling shall be performed with firm pressure such as will flatten the sandy texture of the floated surface and produce a dense, uniform surface free from blemishes, ripples, and trowel marks. The finish shall be smooth and free of all irregularities. 2. Class "2". Steel trowel finish (as specified for Class "1") without local depressions or high points. In addition, the surface shall be given a light hairbroom finish with brooming perpendicular to drainage unless otherwise shown. The resulting surface shall be rough enough to provide a nonskid finish. 3. Class "3". After sufficient stiffening of the screeded concrete, surfaces shall be float finished with wood or metal floats or with a finishing machine using float blades. Contractor shall not excessivly float concrete October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 7 surfaces while the concrete is plastic or dust concrete surfaces with dry cement and sand to absorb excess moisture. Floating shall be the minimum necessary to produce a surface that is free from screed marks and is uniform in texture. Surface irregularities shall not exceed 1/4 inch. Joints and edges shall be tooled where shown or as determined by the Engineer. 4. Class "4". Contractor shall provide sufficient leveling and screeding to produce an even, uniform surface with surface irregularities not to exceed 3/8 inch. No further special finish is required. Contractor shall finish unformed surfaces according to the following schedule unless otherwise shown or specified: Unformed Surface Finish Schedule - Area - Finish Grade slabs and foundations to be covered with concrete or fill material Class "4" Floors to be covered with grouted tile or topping grout Class "3" Slabs which are water bearing with slopes 10 percent and lessclass "1 I' Sloping slabs which are water bearing with slopes greater Class "2" than 10 percent Slabs not water bearing Class "2" Slabs to be covered with built-up roofing Class "3" Interior slabs and floors to receive architectural finish Class "3" 3.08 Architectural Finish A. Smooth Sacked Finish Contractor shall provide architectural finish for exposed to view concrete surfaces. Exposed concrete surfaces include the exterior of structures beginning one foot below grade, the tops of walls, and the interior of water holding structures beginning at the top of wall and extending to one foot below the low water line. Architectural finish shall also be provided for interior exposed to view concrete surfaces. All other incidental exposed to view concrete surfaces shall be provided with an architectural finish such as concrete stairways, concrete containment facilities around chemical storage tanks, elevated walkways, and the like. Architectural finish (Le., smooth sacked finish) shall also be provided where shown. 6. Immediately after the forms have been stripped, the concrete surface shall be inspected by Engineer and any pour joints, voids, rock pockets, or other defective areas shall be repaired by Contractor and all form-tie fastener holes filled as required in Paragraphs 3.12 and 3.13, herein. October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 8 C. After the concrete has cured at least 14 days, Contractor shall remove curing compound by sandblasting, the surface shall be wetted, and a grout shall be applied with a brush. The grout shall be made by mixing one part portland cement and one part of fine sand that will pass a No. 16 sieve with sufficient water to give it the consistency of thick paint. The cement used in said grout shall be 1/2 gray and 112 white portland cement, as determined by the Engineer. White portland cement shall be Atlas white, or equal, furnished by the Contractor. The freshly applied grout shall be vigorously rubbed into the concrete surface with a wood float filling all small air holes. After all the surface grout had been removed with a steel trowel, the surface shall be allowed to dry and, when dry, shall be vigorously rubbed with burlap to remove completely all surface grout so that there is no visible paint-like film of grout on the concrete. The entire cleaning operation for any area shall be completed the day it is started, and grout shall not be left on the surface overnight. D. Surface Overniaht Cleaning operations for any given day shall be terminated at panel joints. Contractor shall insure that the various operations be carefully timed to secure the desired effect which is a light-colored concrete surface of uniform color and texture without any appearance of a paint or grout film. E. In the event that improper manipulation results in an inferior finish, Contractor shall rub such inferior areas with carborundum bricks. F. Before beginning any of the final treatment on exposed surfaces, Contractor shall treat in a satisfactory manner a trial area of at least 200 square feet in some inconspicuous place selected by the Engineer and shall preserve said trial area undisturbed until the completion of the job. G. All architecturally-treated concrete surfaces shall conform to the accepted sample in texture, color, and quality. It shall be the Contractor's responsibility to maintain and protect the concrete finish. 3.09 Curing and Dampproofing A. General All concrete shall be cured for not less than 14 days after placing in accordance with the methods specified herein for the different parts of the work as follows: Surface to be Cured or Dammroofed Unstripped forms Method 1 Wall sections with forms removed Construction joints between footings and walls, and between floor slab and columns Encasement concrete and thrust blocks 4 2 3 4 All concrete surfaces not specifically provided for October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-1 9 elsewhere in this Paragraph Floor slabs on grade in hydraulic structures Roof and slabs not on grade 5 6 B. Method 1 Wooden forms shall be wetted immediately after concrete has been placed and shall be kept wet with water until removed. If steel forms are used the exposed concrete surfaces shall be kept continuously wet until the forms are removed. If forms are removed within 14 days of placing the concrete, curing shall be continued in accordance with Method 4, Paragraph 3.09E herein. C. Method 2 The surface shall be covered with burlap mats which shall be kept wet with water for the duration of the curing period, until the concrete in the walls has been placed. No curing compound shall be applied to surfaces cured under Method 2. D. Method 3 The surface shall be covered with moist earth not less than 4 hours, nor more than 24 hours, after the concrete is placed. Earthwork operations that may damage the concrete shall not begin until at least 7 days after placement of concrete. E. Method 4 The surface shall be sprayed with a liquid curing compound. 1. Curing compound shall be applied in accordance with the manufacturer's printed instructions at a maximum coverage rate of 175 square feet per gallon and in such a manner as to cover the surface with a uniform film which will seal thoroughly. Two spray coats shall be applied, with the second coat sprayed at right angle direction from first coat. 2. Where the curing compound method is used, care shall be exercised to avoid damage to the seal during the curing period. Should the seal be damaged or broken before the expiration of the curing period, Contractor shall repair break immediately by the application of additional curing compound over the damaged portion. 3. Wherever curing compound may have been applied by mistake to surfaces against which concrete subsequently is to be placed and to which it is to adhere, said compound shall be entirely removed by wet sandblasting just prior to the placing of new concrete. 4. Where curing compound is specified, it shall be applied as soon as the concrete has hardened enough to prevent marring on unformed surfaces, and within 2 hours after removal of forms from contact with formed October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-20 surfaces. Repairs required to be made to formed surfaces shall be made within the said 2-hour period; provided, however, that any such repairs which cannot be made within the said 2-hour period shall be delayed until after the curing compound has been applied. When repairs are to be made to an area on which curing compound has been applied, the area involved shall first be wet-sandblasted to remove the curing compound, following which repairs shall be made as specified herein. F. Method 5 Immediately after the concrete has been screeded, it shall be treated with a liquid evaporation retardant. The retardant shall be used again after each work operation as necessary to prevent drying shrinkage cracks. 1. 2. Immediately after each square foot of the concrete has been finished, it shall be given a coat of curing compound in accordance with Method 4, Paragraph 3.09E herein. Not less than one hour nor more than 4 hours after the coat of curing compound has been applied, the surface shall be wetted with water delivered through a fog nozzle, and concrete-curing blankets shall be placed on the slabs. The curing blankets shall be polyethylene sheet, polyethylene-coated waterproof paper sheeting or polyethylene-coated burlap. The blankets shall be laid with the edges butted together and with the joints between strips sealed with 2 inch wide strips of sealing tape or with edges lapped not less than 3 inches and fastened together with a waterproof cement to form a continuous watertight joint. Curing blankets shall be left in place during the 14 day curing period and shall not be removed until after concrete for adjacent work has been placed. Should the curing blankets become torn or otherwise ineffective, Contractor shall replace damaged sections. During the first 3 days of the curing period, Contractor shall not allow traffic of any nature or depositing, temporary or otherwise, of any materials on the curing blankets. During the remainder of the curing period, foot traffic and temporary depositing of materials that impose light pressure will be permitted only on top of plywood sheets 5/8 inch minimum thickness, laid over the curing blanket. Contractor shall add water under the curing blanket as often as necessary to maintain damp concrete surfaces at all times. G. Method6 Concrete slabs shall be treated with an evaporation retardant as specified in Method 5. The concrete shall be kept continuously wet by the application of water for a minimum period of at least 14 consecutive days beginning immediately after the concrete has been placed or forms removed. Heavy curing mats shall be used as a curing medium to retain the moisture during the curing period. The curing medium shall be weighted or otherwise held in place to prevent being dislodged by wind or any other causes. Until the concrete surface is covered with the curing medium, the entire surface shall be kept damp by October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-21 applying water using novles that atomize the flow so that the surface is not marred or washed. Curing blankets and concrete shall be kept continuously wet by the use of sprinklers or other means both during and after normal working hours. Immediately after the application of water has terminated at the end of the curing period, the curing medium shall be removed and curing compound immediately applied in accordance with Method 4, Paragraph 3.09E herein. Contractor shall dispose of excess water from the curing operation to avoid damage to the work. 3.1 0 Protection Contractor shall protect all concrete against injury until final acceptance by the Owner. Fresh concrete shall be protected from damage due to rain, hail, sleet, or snow. Contractor shall provide such protection while the concrete is still plastic and whenever such precipitation is imminent or occurring. Immediately following the first frost in the fall, Contractor shall be prepared to protect all concrete against freezing. After the first frost, and until the mean daily temperature in the vicinity of the worksite falls below 40 degrees F for more than one day, the concrete shall be maintained at a temperature not lower than 50 degrees F for at least 72 hours after it is placed. 3.11 Curing in Cold Weather A. Water curing of concrete may be reduced to 6 days during periods when the mean daily temperature in the vicinity of the worksite is less than 40 degrees F; provided that, during the prescribed period of water curing, when temperatures are such that concrete surfaces may freeze, water curing shall be temporarily discontinued. B. Concrete cured by an application of curing compound will require no additional protection from freezing if the protection at 50 degrees F for 72 hours is obtained by means of approved insulation in contact with the forms or concrete surfaces; otherwise, concrete shall be protected against freezing temperatures for 72 hours immediately following 72 hours protection at 50 degrees F. Concrete cured by water curing shall be protected against freezing temperatures for 3 days immediately following the 72 hours of protection at 50 degrees F. C. Discontinuance of protection against freezing temperatures shall be such that the drop in temperature of any portion of the concrete will be gradual and will not exceed 40 degrees F in 24 hours. In the spring, when the mean daily temperature rises above 40 degrees F for more than 3 successive days, the specified 72 hour protection at a temperature not lower than 50 degrees F may be discontinued for as long as the mean daily temperature remains above 40 degrees F; provided, that the concrete shall be protected against freezing temperatures for not less than 48 hours after placement. D. Where artificial heat is employed, Contractor shall take special care to prevent the concrete from drying. Use of unvented heaters will be permitted only when unformed surfaces of concrete adjacent to the heaters are protected for the first 24 hours from an excessive carbon dioxide atmosphere by application of curing October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-22 compound; provided, that the use of curing compound for such surfaces is otherwise permitted by these specifications. 3.12 Treatment of Surface Defects A. As soon as forms are removed, all exposed surfaces shall be carefully examined by Engineer and any irregularities shall be immediately rubbed or ground by the Contractor in a satisfactory manner in order to secure a smooth, uniform, and continuous surface. Contractor shall not plaster or coat surfaces to be smoothed. Repairs shall not be made until after inspection by the Engineer. Contractor shall not in any case perform extensive patching of honeycombed concrete. Concrete containing minor voids, holes, honeycombing, or similar depression defects shall be repaired as specified herein. Concrete containing extensive voids, holes, honeycombing, or similar depression defects, shall be completely removed and replaced. All repairs and replacements herein specified shall be promptly executed by the Contractor at its own expense. B. Defective surfaces to be repaired as specified in Paragraph 3.12A, shall be cut back from trueline a minimum depth of 1/2 inch over the entire area. Edges shall not be feathered. Where chipping or cutting tools are not required in order to deepen the area properly, the surface shall be prepared for bonding by the removal of all laitance or soft material, and not less than 1/32 inch depth of the surface film from all hard portions, by means of an efficient sandblast. After cutting and sandblasting, the surface shall be wetted sufficiently in advance of applying cement mortar so that while the repair material is being applied, the surfaces under repair will remain moist, but not so wet as to overcome the suction upon which a good bond depends. The concrete shall then be patched as follows: A bonding material such as acryl 60 shall be applied to the surface of the area to be repaired just prior to application of the repair mixture. The repair mixture shall consist of one part of Type II, low alkali, portland cement to 3 parts concrete sand. Mix solution shall contain 1/3 bonder, such as acryl 60, to 2/3 water and added in quantities sufficient to allow placement but not cause hairchecking or slippage. Quantities prepared should be limited to that able to be completed within 30 minutes. Areas repaired shall be compacted with a wood ramming device and cured with the water/acryl 60 solution. Repair mixture shall be applied in maximum 1 inch lifts. For exposed walls, the cement shall contain such a proportion of Atlas white portland cement as is required to make the color of the patch match the color of the surrounding concrete. C. Holes left by tie-rod cones shall be reamed with suitable toothed reamers so as to leave the surfaces of the holes clean and rough. These holes then shall be repaired as described in Paragraph 3.12B. D. All repairs shall be built up and shaped in such a manner that the completed work will conform to the requirements of Paragraph 3.08 or 3.09, as applicable, October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-23 using approved methods which will not disturb the bond, cause sagging, or cause horizontal fractures. 3.13 Testing of Hydraulic Structures A. General Contractor shall water test all concrete tanks, hydraulic channels, sumps, basins, and other structures designed to contain water prior to backfilling. Testing shall be accomplished by filling the structure with water. Testing shall not be performed until roof is in place (if applicable) and all concrete has attained full design strength. Contractor shall provide the following: 1. All pumps, power, piping, and any other equipment required to fill tanks for testing. 2. Necessary provisions to dispose of test water after testing, including pumping if necessary. At completion of tests all temporary piping and connections shall be removed. Waste water shall be disposed of without creating a nuisance or damage to adjacent property. B. Test Procedure The structure shall be full to high water level at beginning of test. Contractor may elect to keep the tank full of water for as long as 48 hours prior to the test to allow for water absorption by the concrete. Test period shall be 5 consecutive 24 hour periods totaling 5 consecutive days. Liquid level shall be accurately measured at the beginning and end of test to determine amount of leakage. All visible leaks shall be marked for repair after draining. Permissible leakage from the structure shall not exceed 0.5 gpm per million gallon storage capacity in each 24 hour period over a period of 5 consecutive days after allowance is made for evaporation. If the leakage exceeds the permissible amount, the structure shall be emptied, leaks shall be repaired (in a manner favorably reviewed by the Engineer), and the test rerun. Even if structure passes water loss test, all visible leakage shall be repaired. 3.14 Care and Repair of Concrete Contractor shall protect all concrete against injury or damage from excessive heat, lack of moisture, overstress, or any other cause until final acceptance of the Owner. Particular care shall be taken to prevent the drying of concrete and to avoid roughening or otherwise damaging the surface. Any concrete found to be damaged, or which may have been originally defective, or which becomes defective at any time prior to the final acceptance of the completed work, or which departs from the established line or grade, or which, for any other reason, fails to conform to the requirements of the Contract Documents, shall be satisfactorily repaired or removed and replaced with acceptable concrete at the Contractor's expense. October 2003 Calavera Pump Station (860-3-Cal) Contract 38891 Concrete 03300-24 SECTION 03482 PRECAST CONCRETE MOLDINGS PART 1 - GENERAL 1.01 SUMMARY A. Provide pre-cast concrete moldings including concrete out-spout where shown on the Drawings, as specified herein, and as needed for a complete and proper installation. B. Related work: 1. Documents affecting work of this Section include, but are not necessarily limited to, General Provisions, Supplemental Provisions, Special Construction Provisions, and sections in Division I of these Specifications. 1.02 SUBMllTALS A. All submittals shall be in accordance with the General Provisions. Section 2-5.3. B. Product data: Contractor shall submit complete information, drawings, and technical data for all material and components, including, but not limited to, the following: 1. Materials list of items proposed to be provided under this Section; 2. Manufacturer's specifications and other data needed to prove compliance with the specified requirements; 3. Shop Drawings showing complete information for fabricating and erecting the work of this Section including, but not necessarily limited to: a. Member dimensions and cross section; b. Location, size, and type of reinforcement and provisions for anchoring; C. Similar data required to fully describe the proposed method of fabricating, erecting, and installing the work of this Section. 4. Manufacturer's recommended installation procedures which, when approved by the Owner's Designated Representative, will become the basis for accepting or rejecting actual installation procedures used on the Work. 1.03 QUALITY ASSURANCE A. Use adequate numbers of skilled workmen thoroughly trained and experienced in the necessary crafts and completely familiar with the specified requirements and methods needed for proper performance of the work of this Section. PART 2 - PRODUCTS 2.01 PRECAST CONCRETE MOLDINGS A. Where called for on the Drawings, provide pre-cast concrete moldings in the March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Precast Concrete Moldings 03482-1 shapes and dimensions indicated, complete with required anchorage system. Pre-cast concrete moldings shall be as manufactured by Concrete Designs, Inc., 2940 South Palo Verde, Tucson, Arizona 85713 (602) 624-6653, Seawright Custom Pre-cast, Inc. 85-61 0 Grapefruit Boulevard, Coachella, CA 92236, (760) 398-1515, or provide an equal product approved in advance by the Owner's Designated Representative. B. Concrete Moldings based on Concrete Design, Inc. products shall be as follows to make a complete and finished appearance: 1. Door Frame - Molding # 42 - Mitered 2. Window Frame - Molding #42 - Mitered 3. Wall Cap - a combination of the following - M20-2, M20-20, and M50-12 4. Building Base - M59 - 19-3/4" high - Mitered 5. Out-spout (canale) - No. 10 6. Out-spout canale collar - CCM17H 7. Ground canale - RLB4 2.02 OTHER MATERIALS A. Provide other materials, not specifically described but required for a complete and proper installation, as selected by the Contractor subject to the approval of the Owner's Designated Representative. PART 3 - EXECUTION 3.01 SURFACE CONDITIONS A. Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not proceed until unsatisfactory conditions are corrected. 3.02 FABRICATION A. Manufacture the work of this Section in strict accordance with the approved Shop Drawings and the requirements of governmental agencies having jurisdiction. 3.03 INSTALLATION A. install the work of this Section in strict accordance with the manufacturer's recommendations as approved by the Owner's Designated Representative, anchoring all components firmly into position level, square, and plumb. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Precast Concrete Moldings 03482-2 SECTION 04200 BASIC CONCRETE MASONRY SPECIFICATIONS PART 1 - GENERAL 1.01 General Requirements A. Contractor shall furnish all labor, material, and equipment and perform all operations necessary to execute all concrete masonry construction as required in the Contract Documents. B. Contractor shall make all preparations and do all work necessary to receive and adjoin other work. C. Contractor shall give the work his personal supervision and shall keep a competent foreman on the job at all times. D. Contractor shall inspect and verify position of all dowels required for masonry on other construction including foundations. E. Contractor shall arrange necessary storage space for construction materials at the job site. F. Contractor shall call for all inspections required in the course of his work. 1.02 Reference Codes, Specifications, and Standards Whenever reference is made herein to Building Code, it shall mean the Uniform Building Code (UBC), latest edition, as published by the International Conference of Building Officials. B. Specifications Whenever reference is made herein to Standard Specifications, it shall mean the Standard Specifications for Public Works Construction, latest edition, as published by Building News Incorporated of Los Angeles, California. C. Commercial Standards Whenever reference is made herein to ASTM, it shall mean the Annual Book of ASTM Standards, latest edition, as published by the American Society for Testing and Materials. 1.03 Quality Assurance A. All concrete masonry shall comply with the Building Code and reference material published by the Masonry Institute of America. . March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Masonry 04200-1 B. Contractor shall submit samples of the block units for approval of type and color by Owner prior to commencing with work. C. Certification Concrete block manufacturer shall certify that the masonry units furnished meet or exceed the requirements of this specification. D. Sample Panel Contractor shall build a sample panel, approximately 4 feet by 6 feet, for review and approval by Engineer before any masonry construction is performed. Said sample panel may be part of the project and incorporated into the wall system. Full size concrete masonry units which have been selected and approved by the Engineer to show color range, maximum texture range, bond, mortar, tooling of joints, and quality of workmanship shall be used in the sample panel. Sample panel shall remain on the project for comparison purposes with the actual masonry work. If the sample panel is not part of the wall system, it shall be demolished and removed from the site after completion and acceptance for the project concrete masonry work, unless Contractor is directed otherwise by Owner. E. Testinq of Grout 1. Test Specimens and Samples a. Contractor shall take field samples on the first day of masonry construction, at any change in materials during construction, and whenever, in the judgment of the Engineer, tests are necessary to determine the quality of the materials. b. Contractor shall prepare three grout specimens per sample. Each grout specimen shall be a square prism, nominally 3 inches or larger on the sides and twice as high as the width. 2. Procedures a. Contractor shall construct samples in the presence of the Engineer or his representative. The same personnel who lays the block in the structure shall construct the grout specimens. b. Contractor shall prepare each specimen in a mold consisting of masonry units proposed for construction with the same moisture condition as those being laid. The units shall form a space with dimensions of 3-518 inches by 3-5/8 inches by 7-5/8 inches. The space shall be lined with a permeable paper (such as a paper towel) or porous separator to prevent bonding to the masonry units, but still allowing the excess water to be absorbed. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Masonry 04200-2 Contractor shall place a representative sample of the grout into the molds, puddle, and keep damp and undisturbed for 48 hours. After 48 hours, Owner's Representative will transport the specimens to a test laboratory for storage. 1.04 Product Storage Contractor shall store and protect all materials as follows: A. Masonrv Units Masonry units shall be carefully stacked prior to use and shall be properly protected from weather by cover or inside storage. All units shall be handled with reasonable care to prevent marring or damaging of faces, edges, and corners of units. All marred or damaged units shall be discarded. B. Lime and Cement Lime and cement shall be delivered in original packages and stored on platforms above ground, protected against moisture. C. Amregates Aggregates shall be stored on platforms so as to exclude dirt. D. Reinforcing Steel Reinforcing steel shall be stored above ground to prevent bending or rusting. PART 2 - PRODUCTS 2.01 Materials All products shall conform to the following requirements: A. Concrete Masonry Units 1. Masonry units shall be hollow load-bearing concrete masonry, Grade N, Type I units conforming to ASTM C90, latest, and manufactured in accordance with requirements of the Concrete Masonry Association Specifications. 2. Masonry units shall have maximum shrinkage of .08 of 1% from the saturated to the oven dry condition. 3. Unless specified otherwise on the Drawings, masonry units shall be medium weight units (105 to 125 Ib/cu.ft.) manufactured by a member of the Concrete Masonry Association. Masonry units may be high temperature steam cured. Owner shall select color of masonry units. March 2004 Calavera Pump Station (860-3-CAL) Contract 3889 1 Masonry 04200-3 B. C. D. E. F. March 2004 Cement 1. Cement for mortar shall be Type I (or Type II, or Type Ill) Portland cement conforming to ASTM C150, latest. 2. Air-Entrained Portland Cement for mortar shall be Type I-A (or 11-A, or Ill-A) conforming to ASTM C175, latest. (Note: When using air-entrained cements, mortar shall not contain more than 1/10 part lime putty). 3. Plastic cement shall have less than 12% total volume in approved plasticizing agents and shall conform to all of the requirements for Portland cement in ASTM C150, latest, except with respect to limitations on insoluble residue, air-entrained, and additions subsequent to calcination. AQQ reg ate 1. Aggregate shall be clean, sharp, and well graded, and free from injurious quantities of dust, lumps, shale, alkali, surface coatings, and organic matter. 2. Sand shall conform to ASTM C144, latest. 3. Pea gravel shall be graded with 100% passing the 318 inch sieve and not more than 5% passing the No. 8 sieve. Lime Putty 1. Lime putty shall be made from approved hydrated lime or quicklime and shall weigh not less than 83 pounds per cubic foot. 2. Hydrated lime shall conform to ASTM C207, latest. 3. Quicklime shall conform to ASTM C5, latest. Quicklime shall be slaked and then screened through a 16-mesh sieve. After slaking, screening, and before using, it shall be stored and protected for minimum 10 days. Admixtures Admixtures shall not be used in mortar or grout unless specifically approved by Engineer. Reinforcinn Steel 1. Reinforcing steel shall be Grade 60 deformed bars conforming to ASTM A615, latest, except that 1/4 inch ties may be plain bars. 2. Reinforcing steel shall be clean and free from loose rust, scale, and dirt, and coatings that reduce bond. Masonry Calavera Pump Station (860-3-GAL) Contract 38891 04200-4 2.02 Mortar & Grout A. - Mortar Unless specified otherwise on the Drawings, mortar shall be Type S per UBC Standard 21-14 with a minimum compressive strength of 2100 psi. Mortar shall be freshly prepared and uniformly mixed. Mortar shall conform to ASTM C270, latest. B. Grout 1. Unless specified otherwise on the Drawings, grout shall have minimum compressive strength of 2,000 psi. Grout shall be of fluid consistency and mixed in ratio 1 part cement, 3 parts sand for grout spaces less than 4 inches in any dimension. Grout shall be of fluid consistency and mixed in ratio 1 part cement, 2 parts sand, and 2 parts pea gravel for grout spaces greater than 4 inches. Fluid consistency shall mean that consistency of fluid shall be enough for pouring and yet not so fluid that the constituent parts of the grout separate when grout is poured (slump equals 9 inches 2. 3. 1 inch). PART 3 - EXECUTION 3.01 Workmanship A. B. C. D. E. F. G. March 2004 Masonry work shall be started only when horizontal and vertical alignment of foundation is within 1 inch of plumb or line. Contractor shall prevent grout and mortar stains. Contractor shall keep wall continually clean. If grout runs over, Contractor shall clean wall immediately. All masonry shall be laid true, level and plumb in accordance with the Construction Drawings. Contractor shall cut all masonry units accurately to fit all openings, conduit, ducts, and plumbing. All holes shall be neatly patched. Construction support shall not be attached to the wall except where specifically permitted by the Engineer. The top surface of the concrete foundation shall be clean and free of laitance and the aggregate exposed by sandblasting prior to starting masonry construction. Where no bond pattern is shown, walls shall be laid up in straight, uniform courses with regular half or running bond. Masonry Calavera Pump Station (860-3-CAL) Contract 38891 04200-5 3.02 3.03 3.04 H. All work, bond patterns, or special details shown on the Construction Drawings shall be accurately and uniformly executed. Protection of the Work A. Contractor shall protect all sills, ledges, and offsets from mortar droppings or other damage during construction. Contractor shall prevent visible mortar and grout stains on the exterior of the work. Contractor shall remove stains immediately if they occur. 8. Masonry Units A. All masonry units shall be sound, free of cracks, or other defects that would interfere with the proper placing of the unit or impair the strength of construction. All masonry units shall be stored on the job so that they are kept off the ground and protected from the elements. Wetting of units is not permitted. Proper masonry units shall be used to provide for all windows, doors, bond beams, lintels, pilasters, and knockouts, with a minimum unit cutting. Where masonry unit cutting is necessary, Contractor shall utilize a masonry saw making all cuts neat and true. B. C. D. Joints A. 6. C. D. E. F. G. Starting joints on foundations shall be laid with full mortar coverage on the bed joints except that the area where grout occurs shall be free from mortar so that the grout will be in contact with the foundation. Mortar joints shall be straight, clean, and uniform in thickness and shall be tooled as specified. Contractor shall tool exposed wall joints with a round bar (or V-shaped bar) 2 feet long to produce a dense, slightly concave surface well bonded to the block at the edges. Tooling shall be done when the mortar is partially set but sufficiently plastic to bond. All tooling shall be done with a tool which compacts the mortar, pressing the excess mortar out of the joint rather than dragging it out. Where walls are to receive plaster, Contractor shall strike joints flush. Where joints are to be concealed under paint, Contractor shall fill joints flush and then sack to produce a dense surface without sheen. Unless otherwise specified, horizontal and vertical mortar joints shall be 3/8 inch thick with full mortar coverage on the face shells and on the webs surrounding cells to be filled. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Masonry 04200-6 H. Vertical head joints shall be buttered well for a thickness equal to the face shell of the block and these joints shall be shoved tightly so that the mortar bonds well to both blocks. Joints shall be solidly filled from the face of the block to the depth of the face shell. I. If it is necessary to move a block so as to open a joint, Contractor shall remove block from wall and set in fresh mortar. J. Intersecting masonry walls and partitions shall be bonded by the use of steel ties at 24 inch centers maximum. K. Where stack bond is specified, approved metal ties shall be provided horizontally at 24 inch centers maximum. 3.05 Reinforcing A. When a foundation dowel does not line up with a vertical core, it shall not be sloped at more than one horizontal to six vertical. Dowels shall be grouted into a core in vertical alignment even though it is in an adjacent cell to the vertical wall reinforcing. B. Reinforcing bars shall be straight except for bends around corners or where bends or hooks are detailed on the drawings. C. Reinforcing steel where spliced shall be lapped a minimum of 40 bar diameters. D. When full length vertical bars are used, they shall be held in position at top and bottom at intervals not exceeding 48 inches along the reinforcement. E. Horizontal reinforcing shall be laid on the webs of bond beam units and shall be solidly grouted in place. Reinforcing in channel units shall be spaced off the bottom of the unit. F. Vertical reinforcing shall have a minimum clearance of 1/4” from the masonry. G. Wire reinforcement shall be completely imbedded in mortar or grout. Mortar joints with wire reinforcement shall be at least twice the thickness of the wire. H. Wire reinforcement shall be lapped at least 8 inches at splices and shall contain at least 1 cross wire at each piece of reinforcement in the lap distance. 3.06 Grouting A. Reinforcing steel shall be in place and inspected by Engineer before grouting starts. B. Unless specified otherwise on drawings, all walls shall be solid grouted. Unless specifically allowed on drawings, height of grout pours shall not exceed 4 feet. All debris and projecting mortar shall be cleaned out before pouring grout. Pours March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Masonry 04200-7 C. D. E. F. G. H. shall be stopped 1-1/2 inches below the top of a course to form a key at pour joints. Contractor shall consolidate grout by mechanical vibration during placement before loss of plasticity in a manner to fill the grout space. Grout pours greater than 12 inches shall be reconsolidated by mechanical vibration after 3 to 5 minutes to minimize voids due to water loss. Grout pours 12 inches or less in height shall be mechanically vibrated or puddled. Vertical cells to be filled shall have vertical alignment to maintain a continuous unobstructed cell area not less than 2 inches by 3 inches. When higher pours are specified, grout lifts shall not exceed 8 feet. A cleanout hole shall be provided at the bottom of each cell to be poured. Contractor shall grout beams over openings in a continuous operation. Contractor shall cover the tops of unfilled cell columns under a horizontal masonry beam with metal lath, or special units shall be used to confine the grout fill to the beam section. Contractor shall install all bolts, anchors, and similar wall inserts prior to grouting and solidly grout them in place. 3.07 Cleaning and Protection A. Masonry walls are to be left bare or unpainted unless otherwise specified; Contractor shall prevent mortar splotches. B. Construction supports shall not be attached to the wall except where specifically permitted by Engineer. C. All forms shall be made tight (special attention is necessary for bottom form of block bond beams) and concrete and grout spilled on the wall shall be washed off immediately. D. Walls shall have their surfaces dampened for three days with a light fog spray during the mortar curing period. They shall not be saturated with water for curing or any other purposes. E. At the conclusion of work, Contractor shall clean down all masonry walls, remove his scaffolding and equipment used in the work, clean up all debris, refuse, and surplus material, and remove them from the premises. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Masonry 04200-8 SECTION 051 00 BASIC STRUCTURAL STEEL AND MISCELLANEOUS METAL WORK SPECIFICATIONS PART 1 - GENERAL 1.01 General Requirements Contractor shall furnish all labor, equipment, and material and perform all operations necessary for fabrication, construction, and installation of structural and miscellaneous metal specified. Where miscellaneous metal and equipment items are required to fit spaces previously constructed, measurements for the fabrication of such items shall be made at the site so that items fit as required. Standard commercial products which meet general requirements, and vary only in nonessential detail, will be acceptable, subject to Owner's approval. All work shall be executed and finished in accordance with approved shop drawings and conform with the best practice required to produce the highest grade construction. Contractor shall be solely responsible for errors of fabrication and correct fitting of structural members shown on the shop drawings. 1.02 Quality Assurance Unless otherwise specified, all work specified in the Contract Documents shall comply with requirements of the following specifications and codes: A. Steel Work Fabrication and erection of structural steel shall be in accordance with AlSC "Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings," and "Code of Standard Practice for Steel Buildings and Bridges", latest editions. B. Aluminum Work Fabrication and erection of aluminum shall be in accordance with the applicable requirements of Chapter 28 of the Uniform Building Code, latest edition, and herein referenced standards of the Aluminum Association. C. Weldinq Inspection All welding of structural steel assemblies shall be performed under continuous inspection of a "Special Inspector" selected by the Owner. Should such fabrication be performed in the shop of a licensed fabricator approved by the governing Building Official, only the field welding of structural steel assemblies will be required to be performed under continuous inspection of the "Special Inspector". Contractor shall notify inspector at least 24 hours in advance of September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Metal 051 00-1 needed inspections. Contractor shall provide copies of Inspection Reports for Owner. 1.03 Submittals AI1 submittals shall be in accordance with the General Provisions, Section 2-5.3. A. ShoD Drawinas Contractor shall submit shop drawings for approval before fabrication of any of the work. Shop drawings shall show complete fabrication details with material lists, including all welds, fabrication and finish details, and shop painting. In approved shop drawings, the Owner does not assume responsibility for accuracy of the work relative to other components as constructed. Also refer to applicable requirements hereafter specified in paragraph "Substitutions". All dimensions shall be field verified by the Contractor prior to fabrication. B. Test ReDorts Contractor shall furnish notarized certified physical and chemical mill test reports for material used for major structural members. All tests shall be performed in accordance with applicable ASTM Standards. C. Shop Paintina Data In coordinated manner with requirements for Painting and Protective Coatings, Contractor shall submit product list with product data sheets of intended shop coats which, for compatibility, shall be the same products and manufacturer as those field-applied systems specified in the Basic Painting Specifications. PART 2 - PRODUCTS 2.01 Materials - General Materials shall be new, sound, and shall comply with the following: A. - Steel Rolled shapes, plates, and bars shall conform to AlSC "Manual of Steel Construction" and ASTM Specification A-36, latest editions. 1. Stainless Steel Unless otherwise designated or approved, Contractor shall use Type 31 6 stainless steel alloy conforming to ASTM A-167 and ASTM A-276, latest editions, for plates and bars. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Metal 051 00-2 2. Steel Pipe B. C. D. E. F. Material shall conform to ASTM A-53, Grade B seamless galvanized as required, Schedule 40. Cast Iron Material shall conform to ASTM A-48, Class 30, except as specifically designated otherwise. Ductile Iron Material shall conform to ASTM A-536 using grade 60-40-18 or better, except as specifically designated otherwise. Aluminum 1. All plate, pipe, and structural shapes shall be new and shall conform to ASTM B209 (Plate), 8308 (Shapes), B429 (Pipe and Tubing), 8211 (Bar Stock), and applicable Federal Specifications for 6061 -T6 alloy, unless otherwise designated. 2. Aluminum pipe rail shall be of 6061-T6 alloy and be Schedule 40 or greater. 3. Alloys and tempers for various members where not otherwise designated, shall be as required for proper forming and fabrication to meet or exceed structural requirements, and shall be of alloys specially produced to best achieve specified color anodized finishes. Contractor shall provide supporting printed recommendations from parent aluminum producer. For sheet fabricated members Contractor shall use only homogenous aluminum products and no clad products. Contingent upon alloys being welded, Contractor shall use only inert gas shielded arc or resistance welding process with filler alloys as specified in the UBC. Contractor shall not use any process requiring a welding flux. 4. Checkered Plate Raised lugs shall be diamond shaped and have an angled and opposed pattern. Contractor shall use 6061-T6 alloy aluminum, except where steel is specified. Steel shall be of ASTM A36 carbon steel, hot dip galvanized. Manhole Covers Castings for manhole covers and frames shall be of tough gray iron free from cracks, holes, and swells, and of workmanlike finish. They shall conform to ASTM A-48, latest, Class 30, and shall be of the type specified. September 2003 Calavera Pump Station (860-3-GAL) Contract 38891 Metal 051 00-3 G. Common Bolts Except as otherwise designated or specified, bolts shall be standard commercial quality steel units conforming to ASTM A-307; galvanize where used with galvanized work. H. Hiuh Strenuth Bolts & Studs Except as otherwise designated or specified, bolts shall conform to ASTM A325; studs shall conform to ASTM A449; nuts shall conform to ASTM A194, 2H heavy hex; washers shall conform to ASTM F436. They shall be galvanized where specified or where used with galvanized steel. I. Stainless Steel Bolts Except as otherwise designated or specified, bolts, cap screws, and studs shall be Type 31 6L conforming to ASTM F-593; nuts shall conform to ASTM F-594. J. Deferred Boltinq Devices (Noted D.B.D. or ExDansion Anchor on Contract Drawinus) Deferred bolting devices shall be used in lieu of anchor bolts only where specifically noted or detailed; they shall be installed in accordance with current I.C.B.O. Research Report Approval and shall consist of the following: 1. D.B.D. shall be Molly Parabolt Concrete Anchors, Phillips Wedge Anchors, Hilti Anchors, or approved equal. 2. D.B.D. shall not be used for anchorage of any vibrating machinery or equipment. K. Galvanizinq 1. Iron and Steel Galvanizing shall conform to ASTM A123, with minimum weight per square foot of 1.25 ounces. 2. Ferrous Metal Hardware Items Galvanizing shall conform to A153, with average coating weight of 1.25 ounces per square foot. 3. Touch-Up Material for Galvanized Coatinus Galvanized coatings marred or damaged during erection or fabrication shall be repaired by use of DRYGALV as manufactured by the American Solder and Flux Company, GalvaUoy, Gabion, or equal, applied in accordance with the manufacturer's instructions. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Metal 051 00-4 L. Weldina Electrodes 1. Steel Electrodes Contractor shall use E70XXX rod for shielded metal arc welding conforming to AWS A5.1 or A5.5 and F7X-EXXX for submerged arc welding conforming to AWS A5.17. For steel alloys other than ASTM A- 36 and A-53, Contractor shall use electrodes recommended in writing by AWS and by the parent steel manufacturer. 2. Aluminum Electrodes Contingent upon alloys being welded, Contractor shall use only inert gas shielded arc or resistant welding process with filler alloys conforming to U.B.C. Standard No. 28, Table 28-1-C. Contractor shall not use any process requiring a welding flux. 3. Stainless Steel Electrodes Contractor shall weld stainless steel with electrodes and by techniques specified in pertinent AWS A5 Series Specification, and as recommended in Welded Austenitic Chromium-Nickel Stainless Steel Techniques and Properties as published by the International Nickel Company, Inc., New York, N.Y. M. ShoD Prime Paint To assure compatibility with field-applied paint or coating systems, for ferrous metals other than stainless steel, galvanized steel, and cast iron, Contractor shall use same shop prime paint product and manufacturer as painting or protective coating system intended for field application specified in the Basic Painting Specifications. Contractor shall not shop prime portions of work immediately adjacent to intended field welds or portions intended for embedment in concrete. N. Storaqe of Materials Structural material, either plain or fabricated, shall be stored above ground upon platforms, skids, or other supports. Material shall be kept free from dirt, grease, and other foreign matter and shall be protected from corrosion. PART 3 - EXECUTION 3.01 Fabrication A. Workmanship shall conform to AISC specifications, latest edition. Work shall conform to the Contract Documents and approved shop drawings. Work shall be performed by Fabricator approved by governing Code Authorities. Aluminum work shall conform to the applicable requirements of "Specifications for Aluminum Structures, Aluminum Construction Manual" of the Aluminum Association, latest edition. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Metal 051 00-5 1. Shop connections shall be welded or bolted unless otherwise indicated. 2. Insofar as possible, Contractor shall fit and assemble all work in shop, ready for erection. B. Members 1. All members shall be free from twists, kinks, buckles, or open joints. 2. All members, holes, and their spacing shall be so accurately made that, when assembled, the parts shall come together and bolt without distortion. 3. Parts assembled with bolts shall be in close contact, except where separators are required. Where unlike metals are in contact, Contractor shall insulate as necessary to prevent corrosion. Bearing surfaces shall be planned to true'beds. Abutting surfaces shall be closely fitted. Steel requiring accurate alignment shall be provided with slotted holes and/or washers for aligning the steel members. 4. C. Weldinq 1. Welding in shop and field shall be done by operators who have previously been qualified by tests, as prescribed in the American Welding Society, "Standards Qualifications Procedure". All welds shall exhibit characteristics required by AWS D1 .O. 2. All welds shall be made with E70-XX classification mild or low-alloy steel covered arc-welding electrodes conforming to AWS A51 and A5.5 Specifications for filler metal, except as otherwise designated on Structural Drawings and except as otherwise recommended by AWS and AISC for welding high strength steel alloys other than ASTM A36 and A53 Steels. 3. All steel, before being fabricated, shall be thoroughly wire brushed, cleaned of all scale and rust, and thoroughly straightened by approved methods that will not injure the materials being used. Welding shall be continuous along the entire line of contact except where tack or intermittent welding is permitted by Engineer. Where exposed, welds shall be cleaned of flux and slag and ground smooth. 4. Welding of aluminum shall conform to the applicable requirements of Uniform Building Code, Chapter 28 and to the detail requirements of "Welding Aluminum" by the American Welding Society and the Aluminum Association. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Metal 051 00-6 3.02 Erection A. Erection shall include the installation and erection of all steel referred to in this Basic Specification. Contractor shall verify correctness before starting erection. Erection shall be performed in accordance with the latest edition of AlSC Code of Standard Practice. B. As erection progresses, Contractor shall securely bolt up all members to take care of all dead-load, wind, and erection stresses. C. Contractor shall not perform final bolting or welding until each portion of the structure has been properly aligned and plumbed. D. Contractor shall insure bolts are drawn up tight and threads set so that nuts cannot become loose. E. Damaaed Members During erection, members which are bent, twisted, or damaged shall be straightened or replaced by Contractor as directed. If heating is required in straightening, heating shall be done in the presence of the inspector and a heating method shall be used which will ensure uniform temperature throughout the entire member. Members, which, in the opinion of the Owner, are damaged to an extent impairing their appearance, strength, or serviceability, shall be removed and replaced with new members by Contractor. F. Anchor Bolts and Anchors Anchor bolts and anchors shall be properly located and built into connection work in accordance with the Contract Documents. Bolts and anchors shall be preset by the use of templates or such other methods as may be required to locate the anchors and anchor bolts accurately. Embedded anchor bolts that are submerged in process water or sludge, or are in enclosed tanks or spaces exposed to process gas or moisture, shall be Type 316 stainless steel with nuts of the same material. To such stainless steel bolts Contractor shall apply a non- oxidizing lubricant grease before bolting using a molybdenum disulphide grease compound or a NO-OX-10 type compound. Specialty anchoring systems shall be as specified or shown on Construction Drawings. G. Steel and Aluminum Pipe Rails and Railinqs Pipe rail shall be painted steel or anodized aluminum as specified in Contract Documents. Steel and aluminum pipe rails and railings, complete with stanchions, toe plates, welded and bolted fittings, and attachments shall be fabricated true to size configurations and detail shown on Construction Drawings. Grind and polish welds flush and smooth. Curves, where indicated or necessary, shall be bent on a radius of not less than six (6) inches. 1. All pipe materials shall be Schedule 40 steel or aluminum. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Metal 051 00-7 2. If proprietary substitutions are proposed for railings and attachments, Submittals shall be accompanied by acceptable test data by an independent testing laboratory showing that: the fitting and attachment will withstand the bending moment induced by a 200 Ib. force applied at the top of the stanchion in any direction; and the railings will safely resist forces as required by CaVOSHA and the Uniform Building Code. Test data shall be for attachments in similar materials as the field condition. 3. Safety chains shall be 5/16 inch carbon steel minimum grade 30 link chain with common swivel bolt harness type snap, all hot dip galvanized. 4. Contractor shall isolate aluminum from dissimilar metals and concrete for protection from galvanic deterioration. Aluminum shall be mill finished and free of damage and detracting appearance flaws. Contractor shall provide uniform AA-KA41 Architectural Class I clear anodic finish. 5. Contractor shall not provide attachments which require the post to be embedded in concrete or grout. H. Bearinq Plates Contractor shall provide bearing plates under beams and columns resting on walls or footings. Bearing plates may be attached or loose and aligned on steel wedges or shims. After the supported members have been plumbed and properly positioned and the anchor nuts tightened, Contractor shall solidly dry- pack entire bearing area under the plate with approved bedding mortar. Wedges and shims shall be cut off flush with edge of bearing plate, and shall be left in place. I. Substitutions Unless otherwise directed, the exact sections, shapes, thicknesses, sizes, weights, and the details of construction shown for the structural steelwork shall be furnished as specified in the Contract Documents; however, Contractor, because of his stock or shop practices, may suggest substitutes if the net section area is not thereby reduced, if the section properties are at least equivalent, and if the overall dimensions are not exceeded. All substitutions or other deviations from Contract Drawings and/or Specifications shall be specifically noted or "clouded" on the shop drawing submittals. J. Flame Cutting Contractor shall not flame cut with a gas cutting torch in the field to correct fabrication errors on any major member in the structural framing. Contractor may flame-cut on minor members, when the member is not under stress, and then only following Owner's approval. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Metal 051 00-8 K. Dissimilar Metals Contractor shall isolate aluminum from contact with dissimilar metals and materials, other than stainless steel, as follows: 1. Metals Contractor shall apply on contact surfaces a heavy brush coat of approved zinc chromate primer made with a synthetic resin vehicle, followed by two brush coats of approved aluminum metal and masonry paint or a heavy coat of approved alkali-resistant bituminous paint. Alternatively, Contractor may separate surfaces with a non-absorptive tape or gasket. 2. Masonrv, Concrete, or Plaster Contractor shall apply a heavy brush coat of approved, alkali-resistant bituminous paint, or separate surfaces with non-absorptive tape or gasket. 3. Moisture-Absorbent Materials and Preservativelv Treated Wood Contractor shall paint such absorbent materials with two coats of approved aluminum house paint and protect aluminum contact surfaces with bituminous paint. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Metal 051 00-9 SECTION 05300 METAL DECKING PART 1 - GENERAL 1.01 General Contractor shall furnish and install all metal decking, accessories, and complete appurtenant work, as shown on the Drawings and specified herein. 1.02 Contractor Submittals A. All submittals shall be in accordance with the General Provisions, Section 2-5.3, and shall include, but not be limited to, the following: manufacturer's specifications, material data sheets, and installation instructions. B. Prior to commencement of any work, the metal decking manufacturer shall furnish an affidavit to the Owner certifying to the yield strength, design thickness, and section properties of the metal deck. The decking manufacturer shall also furnish the diaphragm shear values for the deck supplied using the welding pattern shown on the Drawings. C. The decking manufacturer shall submit to the Owner an erection layout drawing showing the location of deck sheets, end laps, side laps, types and locations of welds, and details of accessories. PART 2 - PRODUCTS 2.01 Metal Deck A. Metal deck shall be manufactured from steel conforming to ASTM Designation A 446, having a minimum yield strength of 38,000 psi. All deck units shall be coated with a G-90 galvanized coating in accordance with ASTM A 525. B. The metal deck structural properties shall be as follows: Deck shall be capable of withstanding a diaphragm shear load of 1340 plf and a vertical live and dead load of 90 psf when spanning 8'-0" between supports (double span). C. Metal roof deck shall be IMSA Building Products Type B-36 16 gauge; 1 -1/2" deep x 36" wide, or equal. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Metal Decking 05300-1 D. Steel deck accessories shall be fabricated from the same gauge and materials as adjacent steel deck. E. Metal deck shall have a sheet length that covers two or more spans where multiple spans are indicated on the Drawings. F. Metal deck sheets shall be formed at the longitudinal sides in such a manner that they will interlock. Where the end of sheets overlap, they shall be die-formed in such a manner that the sheet in the next row telescopes and snugly overlaps the sheet laid previously. G. All sheet metal flashings necessary to make building weathertight shall be provided, whether or not specifically identified herein or shown on the Drawings. Flashing which is not welded to the metal deck shall be aluminum. Aluminum shall be 0.032-inch minimum thickness and shall conform to ASTM B 209, alloy 3003-H 14, with "Mill Finish". Thickness of aluminum to be welded shall be as necessary for welding method being used. PART 3 - EXECUTION 3.01 General A. B. C. D. E. March 2004 The Contractor shall inspect supporting members for correct layout and alignment, and shall not proceed with installation until defects are corrected and supporting members are completely installed and secured. Metal deck sheets and accessories shall be placed in accordance with manufacturer's recommendations and shop drawings. Roofs having a slope of 1/4 inch per foot or more and shall be erected starting at the lowside to ensure that end laps are shingle fashion. Metal deck sheets shall be positioned on supporting steel framework and adjusted to final position with ends bearing a minimum of 2 inches on supporting members. Units shall be placed end to end with all ribs aligned over entire length of run , before being permanently fastened. Special care shall be exercised not to damage or overload the deck during installation. The deck shall not be used for storage or working platforms until permanently secured in position. Construction load shall not exceed deck carrying capacity. All openings in the deck shall be cut and fitted neatly and shall be reinforced with structural steel members to distribute the load. Contract 38891 Metal Decking 05300-2 Calavera Pump Station (860-3-CAL) F. Contractor shall provide perimeter closures and flashings at wall ends of all units, open ends and sides of panels, and at columns, and weld to decking to provide tight closures. G. Contractor shall provide all flashing, rubber or metal closure pieces, transition pieces, reinforcement, and accessories required to make decking complete. H. Edges of any cut openings or any minor surface damage areas shall be repaired in accordance with applicable requirements of the Miscellaneous Metal Work Specifications. 3.02 Welding A. B. C. D. E. Unless specified otherwise on the Drawings, the metal deck shall be welded to all interior supporting members with 1/2 inch effective diameter puddle welds at 12" O.C. center. Unless specified otherwise on the Drawings, side laps shall be welded with 1 -1/2" inch long top seam welds spaced at 12" O.C. Unless specified otherwise on the Drawings, attachment of deck to angle ledger shall be made with 1/2" effective diameter puddle welds at 12" O.C. and in every other flute where support is perpendicular to direction of deck flutes. All welds shall be free of sharp points or edges. All welds shall be cleaned immediately by chipping or wire bruising and shall be coated with a zinc dust type primer paint. Welding shall conform with the applicable requirements of AlSC "Light Gauge Steel Design" and AWS D.1 .I and D.1.3. Welders shall be AWS certified. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Metal Decking 05300-3 SECTION 071 12 BITUMINOUS WATERPROOFING PART 1 - GENERAL 1.01 SUMMARY A. Provide bituminous waterproofing at all subterranean concrete walls at the building, as specified herein, and as needed for a complete and proper watertight installation. B. Related work: 1. Documents affecting work of this Section include, but are not necessarily limited to, General Provisions, Supplemental Provisions, Special Construction Provisions, and Sections in Division I of these Specifications. 1.02 SUBMllTALS A. All submittals shall be in accordance with the General Provisions, Section 2-5.3. B. Product data: Contractor shall submit complete information and technical data for all material, including, but not limited to, the following: 1. Materials list of items proposed to be provided under this Section; 2. Manufacturer's specifications and other data needed to prove compliance with the specified requirements; 3. Manufacturer's recommended installation procedures which, when approved by the Owner's Designated Representative, will become the basis for accepting or rejecting actual installation procedures used on the Work. 1.03 QUALITY ASSURANCE A. Use adequate numbers of skilled workmen thoroughly trained and experienced in the necessary crafts and completely familiar with the specified requirements and methods needed for proper performance of the work of this Section. B. Use a subcontractor currently approved in writing by the manufacturer of the approved waterproofing. C. Cooperate as required in performance of the specified testing and inspecting. PART 2 - PRODUCTS 2.01 BITUMINOUS WATERPROOFING Contractor shall furnish and install one of the following bituminous waterproofing systems, or an alternate system approved by the Owner's Designated Representative. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Waterproofing 071 12-1 A. Fluid applied waterproofing system as manufactured by Liquid Boot, LBI Technologies, Anaheim, CA, 92807-1 722, Phone No. 71 4-575-9200. Single course, high build, polymer modified asphaltic emulsion with a prefabricated drainage mat bonded to a geotextile. Nominal thickness shall be 80 Mils. Dry (60 mils. Minimum). 6. Fluid applied waterproofing system as manufactured by Grace Construction Products, 62 Wittemore Avenue Cambridge MA 02140, Phone No. 800-892- 1 165 System shall be Procore by Grace Construction Products. 2.02 OTHER MATERIALS A. Provide other materials, not specifically described but required for a complete and proper system and installation, as selected by the Contractor subject to the approval of the Owner’s Designated Representative. PART 3 - EXECUTION 3.01 3.02 SURFACE CONDITIONS A. Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not proceed until unsatisfactory conditions are corrected. INSTALLATION A. Prior to start of installation, Contractor shall meet with the Owner’s Designated Representative to reach agreement on procedures to be followed. It is imperative that the application be supervised by the Owner’s Designated Representative. No backfilling at the bermed walls shall be commenced until the entire waterproofing installation is complete and signed off by the Owner’s Designated Representative. 6. Except as may be modified with the advance approval of the Owner’s Designated Representative, install the work of this Section in strict accordance with the manufacturer’s recommendations. END OF SECTION September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Waterproofing 071 12-2 SECTION 07500 BUILT-UP ROOF SYSTEM PART 1 - GENERAL 1.01 Description Contractor shall furnish and install the built-up roofing system including rigid insulation and all appurtenant work, complete, as shown on the Drawings and specified herein. 1.02 Submittals The manufacturer's specifications and installation instructions for each roof element, product, or system shall be submitted for Owner's approval in accordance with the requirements of the General Provisions, Section 2-5.3. 1.03 QUALITY ASSURANCE A. Contractor shall comply with all governing codes and regulations. Contractor shall provide products of acceptable manufacturers, which have been in satisfactory use in similar service for three years. Contractor shall use experienced installers. Contractor shall deliver, handle, and store materials in accordance with manufacturer's instructions. 6. Listing: UL Class A external fire exposure, and Class 90 wind uplift. C. Listing: FM Class I construction. PART 2 - PRODUCTS 2.01 General The built-up roofing system shall be composed of a three (3) ply roof system with mechanically fastened insulation, hot asphalt applied base sheet, heat welded interply sheet, and heat welded cap sheet. Contractor shall issue to the Owner a maintenance bond to maintain the roofing membrane and flashings in a watertight condition for a period of 2 years from the date of Contract completion. Manufacturer shall supply a 20 year full value, non-prorated, no dollar limit guarantee on the built-up roof system. 2.02 Rigid Insulation The materials and application of building insulation shall conform to the applicable requirement of the Underwriters Laboratories "Fire Resistance Index", Factory Mutual requirements, manufacturer's printed recommendations and specifications, and Federal specifications. Thermal and acoustical insulation shall have a flame-spread rating of 25 or less and a smoke density not exceeding 450 when tested in accordance with UBC Standard 42-1. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Built-up Roof System 07500-1 Roof insulation shall be a perlite board as manufactured by BMCA Insulation Products, or equal. The "R" value of the board shall be 5.56 for 2" thickness. Unless shown otherwise on the Drawings, roof insulation shall be a minimum of 2" thick. Roof insulation for obtaining roof slope or for cricket construction shall be a rigid sloping perlite board having a minimum "R" value of 2.7 per inch of thickness, BMCA Insulation Products, Inc., or equal. Unless otherwise shown, insulation shall be not less than 2" in thickness. Factory tapered boards shall slope at 1/4" per 12" unless otherwise shown. 2.03 Built-up Roofing Built-up, modified bitumen roofing system shall be US Intec, Inc. "GBFR-B3P-RI", or approved equal. Roofing products shall be of a single manufacturer. Asphalt primer shall meet the requirements of ASTM D41. Roofing sheet materials shall consist of a glass fiber base sheet "Intec/Permaglas Ultra Base", modified bitumen interply sheet "Intec SP-4", and a modified bitumen cap sheet "Intec GBSP-4 FR". Cant strips and tapered edge strips shall be fabricated from wood fiber insulation board. Cant strips shall be 4" high. Base flashing at concrete masonry parapets with reglets shall be US Intec, Inc. Mini SP- 4 and GBS P-4, or approved equal. PART 3 - EXECUTION 3.01 Installation The installation shall conform to applicable codes and standards and the manufacturer's written recommendations, specifications, and installation instructions for the type of work being performed. Roof deck shall be smooth, dry, and free of dirt and foreign materials. Decks shall have projections removed, and depressions and holes shall be properly filled before roof is installed. Insulation shall be installed in accordance with the manufacturer's printed installation instructions. Insulation shall be installed to provide maximum thermal benefits for material specified. The insulation shall be installed to completely fill or cover voids, providing a continuous plane of insulation. Insulation shall be cut neatly to snugly fit angles, corners, and irregular areas and carefully fitted around pipes, conduits, etc., to maintain continuity of insulation. Gaps or ridges shall be avoided. Rqofing shall be applied by a roofing contractor approved by the roofing manufacturer, with written approval submitted to the Owner. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Built-up Roof System 07500-2 SECTION 07600 FLASHING AND SHEET METAL PART 1 - GENERAL 1.01 Description A. Contractor shall furnish and install all sheet metal work and appurtenant work, complete, in accordance with the requirements of the Contract Documents. B. Sheet metal work shall include, but not be limited to the following: sheet metal flashings, collars, pitch pockets (pans), equipment platforms, and equipment (sleeper) supports at all roof penetrations. 1.02 Reference Specifications, Codes, and Standards A. Commercial Standards ASTM A 176 ASTM A 653 Stainless and Heat-Resisting Chromium Steel Plate, Sheet, and Strip Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy Coated (Galvannealed) by the Hot-Dip Process ASTM B 32 Specification for Solder Metal ASTM B 209 Specification for Aluminum and Aluminum-Alloy Sheet and Plate ASTM D 11 87 Standard Specification for Asphalt-Base Emulsions for Use as Protective Coatings for Metal ASTM D 2822 Specification for Asphalt Roof Cement B. Trade Standards Sheet Metal and Air Conditioning Contractors National Association "Architectural Sheet Metal Manual" (ASMM). The Aluminum Association "Specifications for Aluminum Sheet Metal Work in Building Construction. I' American Welding Society (AWS). C. Manufacturer's Standards In addition to the standards listed above, the flashing products and their installation shall be in accordance with the manufacturer's published recommendations and specifications. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Flashing and Sheet Metal 07600-1 1.03 Contractor Submittals A. General All submittals shall be in accordance with the General Provisions, Section 2-5.3. Contractor shall submit complete information, drawings, and technical data for all material and components, including, but not limited to, the following: B. Samples Color samples and samples shall be submitted where required for color selections and/or review by the Owner. C. ShoD Drawinas Shop drawings showing materials, gages, finishes, layout, jointing, profiles, fasteners, fabrication of special shapes, and method of attachment to adjacent construction shall be submitted. D. Manufacturer's Information Manufacturers literature indicating materials, finish, construction, and method of installation of prefabricated items and sealants. PART 2 - PRODUCTS 2.01 2.02 2.03 General A. Sheet metal shall be galvanized steel unless otherwise specified or shown on the Drawings. Sheet metal work in connection with roofing shall be in accordance with roofing manufacturer's published specifications. B. All sheet metal flashings necessary to make building weathertight shall be provided, whether or not specified or shown on the Drawings. C. Metal flashing, counterflashing and gravel stops shall be fabricated of galvanized steel as specified in this Section. Ferrous Metals A. Galvanized steel shall be 24-gage minimum thickness conforming to ASTM A 653 with coating designation conforming to G90. B. Stainless steel shall be 24-gage minimum thickness conforming to ASTM A 176, Type 304, Dull No. 2D finish. Lead and Soldering Materials A. Lead shall be 4 to 6 percent antimony and remainder shall be lead. Lead sheet shall be soft temper, except hard temper for flanges. Weight shall be not less than 4 Ib/sq ft unless otherwise shown. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Flashing and Sheet Metal 07600-2 B. Solder shall conform to ASTM B 32 Alloy 5b, 50 percent tin, 50 percent lead. C. Soldering flux shall meet Federal Specification O-F-506C, of a type not injurious to metal surface being treated. 2.04 Fasteners Fastening devices shall be of the same material as the sheet metal being used or corrosion-resistant metal compatible with sheet metal being used. Fasteners exposed to the weather shall have neoprene washers beneath the washer or fastener head. 2.05 Asphalt Roof Cement Asphalt roof cement shall conform to ASTM D 2822. 2.06 SEALING MATERIALS A. Sealants shall be silicone base, single-component, chemical curing; ASTM C 920, Type S, Grade NS, Class 25. Sealants shall be capable of withstanding movement up to 50 percent of joint width. Sealant colors shall be as selected by the Owner. B. Sealer tape shall be polyisobutylene sealer tape specifically formulated for setting flanges on bituminous roofing. 2.07 Shop Fabrication Requirements A. Gutters and downspouts shall be of sizes as shown with wire basket type strainers of 14-gage stainless steel wire or cast bronze. Built-in gutters shall be stainless steel. B. All aluminum shall be welded where specified or shown. Welding shall conform to Reference Standards. C. Galvanized steel corner joints shall be soldered. Other joints shall be as specified, or as required by the Reference Standards. D. All work and finishes shall be protected from scratches and abrasions. E. All flashings, reglets and counter-flashing shall be fabricated by the same manufacturer and be installed as a complete flashing system. All flashings shall be creased longitudinally or otherwise formed with sufficient spring action to hold bottom edges firmly against base flashing or similar material. F. Intersecting corners of copings shall be accurately fitted and welded. Corners may be shop-assembled, manufactured, or extruded units. 2.08 Fabricated Sheet Metal Work A. Scuppers in walls and parapets shall be constructed of 16 gage material similar to design shown on ASMM Plate 26 with all joints soldered. Scuppers through top course without head shall be similar to ASMM Plate 28. The scupper inlet shall be installed no more than 2 inches above roof drain rim (low point of roof). March 2004 Calavera Pump Station (860-3-CAL) Contract 3889 1 Flashing and Sheet Metal 07600-3 B. C. D. E. F. G. Stamped sheet metal vents or louver-type vents (where shown) shall be designed to provide watertight flush corners and shall be of size shown. Each vent shall be equipped with 1/4-inch square galvanized or aluminum mesh hardware cloth insect screen. Stamped metal items shall be made of coated aluminum or galvanized sheet metal. Downspouts with conductor head 1/2-inch below gutter or scupper and hangers shall be designed similar to design shown on ASMM Plates 32, 25, and 34, Figure B or D. Downspout and conductor head shall be constructed of 16 gage metal and shall have all joints soldered except joint between head outlet pipe and downspout. Built-in gutter, downspout and hangers shall be designed similar to design shown on ASMM Plates 4 Gutter (similar), 9 and 10 Gutter Expansion Joint, 32 Downspout, and 34, Figure B or D. Downspout shall be constructed of 16-gage metal and shall have all joints soldered except joint between gutter outlet pipe and downspout. Expansion joints shall be spaced not more than 34-feet on centers, or as shown. Pitch pockets and equipment supports conforming to Reference Standards shall be provided where required or necessary and shall be of galvanized steel construction unless otherwise shown. The roof penetrations sheet metal work items shall be provided and shall be coordinated with the roofing system. The design and details shall conform to the Reference Standards unless otherwise shown. The roof penetrations shall be provided with the following flashing: 1. 2. 3. 4. 5. 6. Single pipes: Sheet metal or lead collars with sheet metal or lead draw band with sealant or cap top. Ref. ASMM. Plate 58 & 59. Equipment support: Sheet metal. Ref. ASMM. Plate 60 & 61. Sleeper covers: Sheet metal. Ref. ASMM. Plate 60, Fig. C & D. Pitch pockets for supports: Sheet metal with all joints welded or soldered. Ref. ASMM. Plate 61, Fig. E. Ducts with curb (1): Sheet metal. Ref. ASMM. Plate 113. Equipment platform (1): Sheet metal. Ref. ASMM. Plate 101, Fig. B. Note: Prefabricated products, curbs, supports, and platforms which are part of mechanical equipment may be specified in other Sections of these Specifications. PART 3 - EXECUTION 3.01 General A. The Contractor shall coordinate the flashings necessary with the different trades to make sure all items which penetrate the roof are provided with all necessary sheet metal items and work, such as (but not limited to) the following: pipes, ducts, support March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Flashing and Sheet Metal 07600-4 B. C. D. E. F. G. H. I. racks, equipment platforms or sleepers, and supports. Sheet metal shop manufactured curbs, equipment supports, and equipment platforms shall be provided where prefabricated items are not specified in other Sections of these Specifications. All work shall conform to Reference Standards unless otherwise indicated. Flashing work shall be coordinated with roofing work. Sheet metal and roofing shall provide a weather-tight and watertight assembly. Sheet metal work shall be accurately formed to dimensions and shapes shown. Work shall be fitted snugly, with straight, true lines with exposed faces aligned in proper plane, free from waves and buckles. Arises and angles shall have true and sharp lines, and surfaces shall be free from waves and buckles. All exposed edges shall be hemmed. Holes for fasteners within sheet metal work exposed to temperature changes shall be elongated holes for material expansion and movement. All sheet metal work shall be furnished complete with supports, hangers, bracing, anchors, and other devices as required for reinforcement and proper attachment to adjacent construction. Fastenings shall be concealed wherever possible. Joints, fastenings, reinforcements, and supports shall be sized and located as required to preclude distortion or displacement due to thermal expansion and contraction. All surfaces upon which sheet metal is to be placed shall be dry, smooth, even, and free of small projections and hollows. Sheet metal shall be laid with all joints true and even and firmly attached with all fastener heads flush with the top surface. The underlayment shall be overlapped at least 2 inches so as to shed water and shall be secured along the lapped edges. Aluminum fasteners shall be used with aluminum sheet metal. Dissimilar materials shall be isolated with 2 coats of asphaltic paint, asphaltic coating compound, or sealer tape. Only stainless steel fasteners shall be used to connect isolated dissimilar metals. Joints shall be sized and spaced to permit sheet movement for thermal expansion and contraction of 1/4-inch per 104 length, on 100 degree F temperature difference. Holes for fasteners or anchors shall be elongated to provide for movement. Roofing sheet metal items shall be built into the roofing in strict accordance with directions of roofing manufacturer. 3.02 INSTALLATION A. Flashings at vertical surfaces shall be installed at intersections of roof with vertical surfaces and at projections through roof. Corner units shall be factory-fabricated and shall have mitered soldered or welded corner joints, and shall be installed with 3-inch (min) lap joint over flashings on each side. B. Gutters shall be provided to indicated cross-sections, complete with shop-fabricated corners, nipple sections, joining plates, concealed hangers and downspouts with standoff brackets. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Flashing and Sheet Metal 07600-5 C. Gravel stops and copings shall have joints at 10-ft (ma) spacing and at 2-1/2 feet from corners. Joints shall be butted with 3/16-inch space centered over matching 8- inch long backing plate with sealer tape in laps. Corner units shall be welded or soldered units. All joints shall be provided with cover plates. D. Gravel stops with joint covers shall be constructed to form a combination fascia and gravel stop. Lengths of gravel stops shall not exceed 10 feet. Gravel stop covers shall be furnished at each joint. Joints shall be located in a balanced pattern along each run from end to end. Corner sections shall be mitered and welded in a workmanlike manner with joints approximately 2 feet from corner. Joints in gravel stops shall allow for expansion of metal. Plastic cement coating shall be applied between the gravel stop and joint covers such that no asphalt can run through the joints if the asphalt becomes soft under the heat of the sun. E. Flanges of sheet metal items shall be set on continuous sealer tape on top edge envelope ply of roofing. Flanges shall be screwed through sealer tape at 3-inch (max) spacing or securely fastened per Reference Standards. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Flashing and Sheet Metal 07600-6 SECTION 07720 ROOF HATCHES PART 1 - GENERAL 1.01 SUMMARY A. Provide roof hatch system where shown on the Drawings, as specified herein, and as needed for a complete and proper installation. B. Related work: 1. Documents affecting work of this Section include, but are not necessarily limited to, General Provisions, Supplemental Provisions, Special Construction Provisions, and Sections in Division I of these Specifications. 1.02 SUBMITTALS A. All submittals shall be in accordance with the General Provisions, Section 2-5.3. 6. Product data: Contractor shall submit complete information, drawings, and technical data for all material and components, including, but not limited to, the following: 1. Manufacturer's data, catalog cuts, dimensioned drawings, and other data needed to prove compliance with the specified requirements and to enable proper preparation of the roof opening. 1.03 QUALITY ASSURANCE A. Use adequate numbers of skilled workmen thoroughly trained and experienced in the necessary crafts and completely familiar with the specified requirements and methods needed for proper performance of the work of this Section. PART 2 - PRODUCTS 2.01 MATERIALS A. Provide three (3) galvanized sheet metal roof hatches with skylights and one man access hatch. Hatches shall be factory prime-coated for finish painting at the job site. B. Acceptable products: 1. Pump Motor Access Hatch (36" x 48" clear opening with two leafs and skylights): Bilco Model GD-50/XGDX500011 Dur-Red (match configuration and size of Bilco unit), or equal. Man Access Hatch (36" x 30" opening): Bilco Model 5-20, Dur-Red Model LH, or equal. Equal products of other manufacturers when approved in advance by the Owner's Designated Representative. 2. 3. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Roof Hatches 07720-1 PART 3 - EXECUTION 3.01 SURFACE CONDITIONS A. Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not proceed until unsatisfactory conditions are corrected. 3.02 INSTALLATION A. Coordinate as necessary with other trades to assure proper and adequate provision in the work of those trades for interface with the work of this Section. B. Install the work of this Section in strict accordance with the manufacturers' recommendations as approved by the Owner's Designated Representative, anchoring all items firmly into position for long life under hard use. C. Put operating components through at least five complete operating cycles, adjusting as required, and achieving optimum ease of operation. END OF SECTION March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Roof Hatches 07720-2 SECTION 07920 SEALANTS AND CAULKING PART 1 - GENERAL 1.01 1.02 1.03 1.04 SUMMARY A. Throughout the Work, seal and caulk joints where shown on the Drawings and elsewhere as required to provide a positive barrier against passage of moisture and passage of air. B. Related work: 1. Documents affecting work of this Section include, but are not necessarily limited to, General Provisions, Supplemental Provisions, Special Construction Provisions, and Sections in Division I of these Specifications. SUBMllTALS A. All submittals shall be in accordance with the General Provisions, Section 2-5.3. B. Product data: Contractor shall submit complete information and technical data for all materials, including, but not limited to, the following: 1. 2. 3. Materials list of items proposed to be provided under this Section; Manufacturer's specifications and other data needed to prove compliance with the specified requirements; Manufacturer's recommended installation procedures which, when approved by the Owner's Designated Representative, will become the basis for accepting or rejecting actual installation procedures used on the Work. C. Samples: Upon request of the Owner's Designated Representative, submit Samples of each sealant, each backing material, each primer, and each bond breaker proposed to be used. QUALITY ASSURANCE A. Use adequate numbers of skilled workmen thoroughly trained and experienced in the necessary crafts and completely familiar with the specified requirements and methods needed for proper performance of the work of this Section. DELIVERY, STORAGE, AND HANDLING A. Do not keep sealants and caulking on the site beyond the manufacturers shelf life. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Sealants and Caulking 07920-1 PART 2 - PRODUCTS 2.01 SEALANTS (as applicable) A. Provide the following sealants, or equals approved in advance by the Owner’s Designated Representative, where called for on the Drawings or otherwise required for a complete and proper installation. 1. Sealant Type A (at joints subjected to horizontal traffic): a. b. Acceptable Manufacturers: Self-leveling, complying with ASTM C920-79, Grade PI Class 25; (1) (2) Pecora Corporation (800) 233-9754 (3) Equal product as approved by the Owner’s Designated GE Sealants and Adhesives (800) 332-3390 Representative 2. Sealant Type B (at vertical joints and joints subject to extreme movement): a. Polyurethane, non-sag, complying with ASTM C920-79, Type S, b. Acceptable Manufacturers: Grade NS, Class 25, use NT, MI A, and 0; (1) (2) Pecora Corporation (800) 233-9754 (3) Equal product as approved by the Owner’s Designated GE Sealants and Adhesives (800) 332-3390 Representative 3. Sealant Type C (at joints not listed above): a. b. Acceptable Manufacturers: Acrylic latex, complying with ASTM C834-76; (1) (2) Pecora Corporation (800) 233-9754 (3) Equal product as approved by the Owner’s Designated GE Sealants and Adhesives (800) 332-3390 Representative B. For other services, except as may be called for on the Drawings, provide products especially formulated for the proposed use and approved in advance by the Owner’s Designated Representative. The intent of this section of the work is for the Contractor and his sub-contractor to provide the building with an appropriate watertight and flexible sealant system - no exceptions. C. Colors: 1. Colors for each sealant installation will be selected by the Owner’s Designated Representative from standard colors normally available from the specified manufacturer. Should such standard color not be available from an approved substitute manufacturer except at additional charge, provide such colors at no additional cost to the Owner. In concealed installations, and in partially or fully exposed installations where so approved by the Owner’s Designated Representative, use standard gray or black sealant. 2. 3. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Sealants and Caulking 07920-2 2.02 PRIMERS A. Use only those primers which have been tested for durability on the surfaces to be sealed and are specifically recommended for this installation by the manufacturer of the sealant used. 2.03 BACKUP MATERIALS A. Use only those backup materials which are non-absorbent, non-staining, and specifically recommended for this installation by the manufacturer of the sealant used. 2.04 MASKING TAPE A. For masking around joints, provide an appropriate masking tape which will effectively prevent application of sealant on surfaces not scheduled to receive it, and which is removable without damage to substrate. 2.05 OTHER MATERIALS A. Provide other materials, not specifically described but required for a complete and proper installation, as selected by the Contractor subject to the approval of the Owner’s Designated Representative. PART 3 - EXECUTION 3.01 SURFACE CONDITIONS A. Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not proceed until unsatisfactory conditions are corrected. 3.02 PREPARATION A. Concrete and ceramic tile surfaces: 1. 2. 3. 4. Where surfaces have been treated, remove the surface treatment by 5. Install only on surfaces which are dry, sound, and well brushed, wiping free from dust. At open joints, remove dust by mechanically blown compressed air if so required. To remove oil and grease, use sandblasting or wire brushing. sandblasting or wire brushing. Remove laitance and mortar from joint cavities. B. Steel surfaces: 1. Steel surfaces in contact with sealant: a. b. Sandblast as required to achieve acceptable surface for bond. If sandblasting is not practical, or would damage adjacent finish, scrape the metal or wire brush to remove mill scale and rust. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Sealants and Caulking 07920-3 C. Use solvent to remove oil and grease, wiping the surfaces with clean white rags only. Remove protective coatings on steel by sandblasting or by using a solvent which leaves no residue. 2. C. Aluminum surfaces: 1. Aluminum surfaces in contact with sealant: a. Remove temporary protective coatings, dirt, oil, and grease. b. When masking tape is used for protective cover, remove the tape just prior to applying the sealant. Use only such solvents to remove protective coatings as are recommended for that purpose by the manufacturer of the aluminum work, and which are non-staining. 2. 3.03 INSTALLATION OF BACKUP MATERIAL A. When using backup of tube or rod stock, avoid lengthwise stretching of the material, Do not twist or braid hose or rod backup stock. B. Installation tool: 1. For installation of backup material, provide a blunt-surfaced tool of wood or plastic, having shoulders designed to ride on the adjacent finished surface and a protrusion of the required dimensions to assure uniform depth of backup material below the sealant. Do not, under any circumstance, use a screwdriver or similar tool for this purpose. Using the approved tool, smoothly and uniformly place the backup material to the depth indicated on the Drawings or otherwise required, compressing the backup material 25% to 50% and securing a positive fit. 2. 3. 3.04 3.05 3.06 PRIMING A. Use only the primer approved by the Owner’s Designated Representative for the particular installation, applying in strict accordance with the manufacturer’s recommendations as approved by the Owner’s Designated Representative. BOND-BREAKER INSTALLATION A. Provide an approved bond-breaker where recommended by the manufacturer of the sealant, and where directed by the Owner’s Designated Representative, adhering strictly to the manufacturers’ installation recommendations. INSTALLATION OF SEALANTS A. Prior to start of installation in each joint, verify the joint type according to details on the Drawings, or as otherwise directed by the Owner’s Designated Representative, and verify that the required proportion of width of joint to depth of joint has been secured. B. Equipment: September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Sealants and Caulking 07920-4 1. 2. Apply sealant under pressure with power-actuated hand gun or manually- operated hand gun, or by other appropriate means. Use guns with nozzle of proper size, and providing sufficient pressure to completely fill the joints as designed. C. Thoroughly and completely mask joints where the appearance of primer or sealant on adjacent surfaces would be objectionable. D. Install the sealant in strict accordance with the manufacturer's recommendations, thoroughly filling joints to the recommended depth. E. Tool joints to the profile shown on the Drawings, or as otherwise required if such profiles are not shown on the Drawings. 1. 2. Provide uniformly smooth joints with slightly concave surface. Do not use tooling agent unless specifically so recommended in writing by the manufacturer of the sealant. F. Cleaning up: 1. 2. Remove masking tape immediately after joints have been tooled. Clean adjacent surfaces free from sealant as the installation progresses, using solvent or cleaning agent recommended by the manufacturer of the sealant used. Upon completion of the work of this Section, promptly remove from the job site all debris, empty containers, and surplus material derived from this portion of the Work. 3. END OF SECTION September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Sealants and Caulking 07920-5 SECTION 081 00 DOORS, FRAMES, AND HARDWARE TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 1.02 1.03 Description and Scope Contractor shall furnish and install all doors, frames, hardware, and related items, complete and operable, as specified herein and shown on the Drawings. Pump building shall be provided with one single door and one double door as shown on the drawings. Field Measurements Prior to fabrication, Contractor shall verify all conditions affecting the work specified herein, including obtaining accurate opening dimensions and embedded anchorage arrangements. Discrepancies shall be reported to the Owner prior to commencing work. Submittals Complete fabrication, assembly, and installation drawings, together with details and data governing materials used and other accessories furnished, shall be submitted for approval in accordance with the General Provisions, Section 2-5.3. Data shall include, but not be limited to, the following: A. Door and frame details. B. Hardware reinforcement. C. Schedules showing sizes, types, and locations of door louvers and glazing, if any. D. Anchorage details. E. Manufacturer's literature and any engineering calculations that may be required elsewhere in this section. F. Complete detailed hardware list, hardware schedule, and manufacture's literature on each item. G. Hardware schedule shall indicate type, manufacturer's name, catalog number, location, and finish of each item to be furnished. Schedule shall also include a complete template list showing template references and data for each item requiring preparation of metal doors and frames. PART 2 - PRODUCTS 2.01 Manufacturer A. Hollow Metal Doors and Frames Doors and frames shall be as manufactured by Krieger Steel Products Co., Security Metal Products Corp., or approved equal. All doors and frames shall be manufactured by a single manufacturer. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-1 B. Fiberqlass Reinforced Doors and Frames Doors and frames shall be as manufactured FIB-R-DOR, A Division of Advance Fiberglass, Inc., or approved equal. AH doors and frames shall be manufactured by a single manufacturer. C. Rollina Metal Door Assemblies Rolling metal door assemblies shall be as manufactured by Cookson Co., Pacific Rolling Door, Lawrence Roll-Up Doors, Inc., or approved equal. All doors and frames shall be manufactured by a single manufacturer. D. Door Hardware Refer to Hardware Schedule, herein. 2.02 Hollow Metal Door and Frame Fabrication A. General Hollow metal doors and frames shall be manufactured in accordance with the Steel Door I nstitute . B. Doors Doors shall be of hollow metal construction, full flush design, 1-3/4" thick, with no visible seams. Door face sheets shall be formed with seamless 16 gauge steel. Seams at edges shall be continuously and fully welded and ground smooth. Filled joints will not be acceptable. Vertical edges of door shall be reinforced with 14 gauge steel channels the entire height of door. Top and bottom of doors shall have continuous 16 gauge reinforcing channels welded to the face sheets. Doors shall be mortised, reinforced (not less than 8 gauge reinforcement for hinges and 12 gauge for locks and closers), drilled, and tapped in accordance with hardware templates. Reinforcement plates (not less than 14 gauge) shall be provided at all surface applied hardware locations. Reinforcement around openings for louvers and glazing shall be 12 gauge channel reinforcement welded to face sheets. Opening sizes shall be as shown on the Drawings. Louvers shall be mounted in the doors prior to painting. Doors shall be rigid and free from warpage or buckle. Tops of exterior doors shall be provided with flush, water, and weather tight top enclosures. Doors shall be formed and bonded to a rigid fire proof and moisture proof honeycomb core. Doors and frames specified or shown on Drawings as fire rated shall conform to Underwriters Laboratories listings and shall be UL labeled, indicating the type of certification rating . C. Double Doors Double doors shall be provided with a "TI' type steel astragal, unless specified otherwise on the Drawings. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-2 D. Door Frames Door frames shall be of type and sizes as shown, formed of 14 gauge steel. Frames shall have integral stops. All seams and joints shall be continuously and fully welded. All exposed welding shall be ground smooth. Frames shall be mortised, reinforced, drilled, and tapped in the shop to receive mortised template hardware as required. Reinforcement shall be 8 gauge at hinges and 12 gauge at strikes and closers. Provide a minimum of 3 adjustable masonry or steel stud type anchors at each jamb (30" on center, maximum). Provide a minimum of 2 frame head anchors. Spot weld 14 gauge metal clip angles to bottom of each jamb member to provide floor anchorage. E. Factow Prime Coatina Reauirements All interior and exterior doors and frames shall be thoroughly cleaned to remove all rust, scale, grease, and oil, then treated with a chemical compound to assure maximum paint adherence, and prime coated with corrosion-inhibiting primer compatible with finish paint specified on Drawings or in the Basic Coating and Painting Specification for Water and Wastewater Facilities. 2.03 Fiberglass Reinforced Plastic Door and Frame Fabrication A. General Fiberglass reinforced plastic doors and frames shall conform to Steel Door Institute requirements for performance equivalent to hollow metal doors and frames specified herein. 8. Doors Doors shall be of reinforced fiberglass construction, full flush design, 1-3/4" thick, with no visible seams. Door plates shall be molded in one continuous piece, resin reinforced with hand-laid glass fibermat, nominal 1/8" thick, and have a minimum 25 mil .gel-coat. Door plates shall be formed and bonded to a rigid fire proof and moisture proof honeycomb core. All seams at edges shall be a minimum of two layers of resin reinforced glass fibermat (minimum glass fiber to resin ratio of 30 percent), nominal 1/4" thick, and machine tooled. Doors shall be mortised (mortise for lockset, and recess for strike plate in lock stile) drilled and tapped in accordance with the hardware templates. Reinforcement (embed steel reinforcement for hinges in fiberglass matrix; provide for hinge leaf recesses in hinge stile) shall be provided at all surface applied hardware locations. Reinforcement around openings for louvers and glazing shall be type 304 stainless steel channel reinforcement fastened to door plates with stainless steel screws. Opening sizes shall be as shown on the Drawings. Louvers shall be mounted in the doors prior to gel-coating. Doors shall be rigid and free from warpage or buckle. Tops of exterior doors shall be provided with flush, water and weather tight top enclosures. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-3 Doors and frames specified or shown on Drawings as fire rated shall conform to Underwriters Laboratories listings and shall be UL labeled, indicating the type of certification rating. C. Double Doors Double doors shall be provided with a "T" type steel astragal, unless specified otherwise on the Drawings. D. Door Frames Door frames shall be of type and sizes as shown, formed of 14 gauge type 304 stainless steel. Frames shall have integral stops. All seams and joints shall be continuously and fully welded. All exposed welding shall be ground smooth. Frames shall be mortised, reinforced, drilled, and tapped in the shop to receive mortised template hardware as required. Reinforcement shall be type 304 stainless steel, 8 gauge at hinges and 12 gauge at strikes and closers. Provide a minimum of 3 adjustable masonry or steel stud type anchors at each jamb (30" on center, maximum). Provide a minimum of 2 frame head anchors. Spot weld 14 gauge metal clip angles to bottom of each jamb member to provide floor anchorage. E. - Finish All interior and exterior doors shall be provided with smooth gloss surface, minimum Value 88 in accordance with ASTM 0523. Color shall be as selected by Owner. Stainless steel frames shall be uncoated and provided with a uniform brushed finish. 2.04 Rolling Metal Door Assemblies A. General Roll up doors shall be of the metal curtain, flat slat design and shall be chain operated, and weather and dust resistant. Doors shall be provided complete with curtain slats, guides, endlocks, gears, chain, operating mechanism, hood, motors, controls, wiring, hardware brackets, head, bottom and side weather stripping, and all other accessories necessary for a complete and operable system. B. Desian Loadinq Doors and guides shall be designed for a wind load of 30 pounds per square foot. C. Door Curtain Door curtains shall have interlocking flat slats roll-formed in easy curves from galvanized steel sheet. Slats shall be of a gauge size suitable for the design loading and opening dimension, but shall not be lighter than 20 gauge. Galvanized stamped steel endlocks shall be provided on alternate slats. Windlocks shall be provided as required to meet design wind loading. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-4 D. Bottom Bar The bottom bar shall consist of 2 galvanized angles bolted back-to-back on each side of the curtain, complete with tamper-proof slide bolt locks pre-punched for padlocking on inside of door. A replaceable flexible vinyl or neoprene gasket shall be provided as a weather seal and cushion bumper. E. Guides Guides shall be formed of galvanized steel angles, minimum 3/16" thick, properly sized to retain the door curtain. Windlock bar shall be provided as required to meet design wind loading. Guides shall be attached to jambs with 3/8" galvanized steel bolts spaced not more than 30" apart. Guides shall be provided with weather stripping. F. Counterbalance Shaft Assemblv The barrel shaft shall be a steel pipe of sufficient diameter and thickness to support the roll-up curtain without distortion of slats, and to limit deflection of the barrel to not more than 0.03" per foot of span under full load. The barrel shaft shall have a minimum diameter of 4". The spring balance shall consist of one or more helical torsion springs of oil-tempered heat-treated steel designed for proper balance of the door and to ensure that effort to operate door will not exceed 35 pounds. Rotating members shall turn on self-lubricating graphite or grease-sealed ball bearings, with adjustment for counterbalance springs accessible from outside shaft assembly. Brackets to support counterbalance shaft assembly shall be not less than 5/16" thick, cold-rolled steel plate with ball or roller bearings at rotating support points and attached to extension of guide wall angles with 1/2" galvanized steel bolts. Brackets have a bell-mouth guide groove for the door curtain. G. Hood The hood shall be manufactured of 24 gauge galvanized steel sheet. The hood shall fit over the end brackets. Top and bottom edges of hood shall be rolled and reinforced for stiffness, and intermediate supports shall be provided as necessary. Equip hood with a neoprene or vinyl air baffle to close space between hood and door curtain. H. Chain Operation Operation shall be accomplished by endless hand chain, sprocket, and reduction gearing to barrel shaft. Bearings shall be either self lubricating graphite bearings or grease-sealed ball bearings, lubricated for life and self-aligning. Operating chain shall be galvanized extending to 24" above floor. A chain holder shall be provided on wall with provision for padlocking. I. Factow Prime Coatinn Requirements Galvanized surfaces shall be phosphate treated for paint adhesion, and prime coated with corrosion-inhibiting gray primer compatible with finish paint specified on Drawings or in the Basic Coating and Painting Specification for Water and Wastewater Facilities. June 2002 Calavera Pump Station (860-3-CAL) Contract 3889 1 Doors, Frames, & Hardware 081 00-5 All other ferrous metal parts shall be thoroughly cleaned to remove all rust, scale, grease, and oil, then treated with a chemical compound to assure maximum paint adherence, and prime coated with corrosion-inhibiting gray primer compatible with finish paint specified. 2.05 Door Hardware A. General Provide all items of hardware indicated on the Drawings and as herein specified, or where necessary for complete installation and proper operation. Door hardware shall be coordinated with all other related work, including template information for door and frame fabrication. All hardware furnished in connection with doors bearing UL labels or where necessary to meet special requirements will be in strict accordance with conditions established by the authority having jurisdiction and shall be subject to approval of that authority. B. Finish The finish of all hardware shall be 630 (US32D) brush stainless steel, unless otherwise specified in the Hardware Schedule. C. Kevinq All locks and cylinders shall be master keyed to the Owner's requirements. Hardware supplier shall submit a keying schedule for approval by Owner prior to order for locks and keying of cylinders. Contractor shall coordinate between Owner and hardware supplier in developing keying schedule. At the completion of the project, Contractor shall furnish Owner with 5 master keys and 3 keys per cylinder keying combination. During construction, all locks shall be furnished with construction cylinders and construction keys. Contractor shall furnish Owner with 2 construction master keys. D. Hinaes and Pivots Hinges shall be full mortise, template type, unless otherwise specified. All doors over 7'-6" shall have one extra hinge for each 2-1/2' of height. Width of hinges shall be determined by trim conditions. All door hinges shall be provided with non-removable and non-rising pins. E. Locksets and Latchsets All locksets and latchsets shall be mortise type with anti-friction, 2 piece latchbolts, with a minimum 3/4" throw and minimum I" throw deadbolt. Locksets and latchsets at fire rated doors shall meet code requirements. Function shall be appropriate for door use. All locks shall be provided with the same cylinder and keyway for master keying, All locks shall be the product of the same manufacturer as the locksets, unless otherwise specified. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-6 Padlocks shall be heavy duty type, keyed as directed, and shall be of the same manufacturer as the locksets. F. Panic Bars (Exit Devices) Where shown on Drawings or specified herein, doors shall be equipped with UL labeled, touchbar exit devices (panic bars) capable of opening door even when locked. Panic bars shall be provided with mortise lock devices and auxiliary bolt for deadlocking, and shall be constructed of corrosion-resistant hardware. Panic bars and shall be as manufactured by Von Duprin, Inc., Sargent, or approved equal. G. Door Closers All door closers shall be the product of one manufacturer. All door closers shall have full metal covers, adjustable spring power and adjustable backcheck. Closers shall have backcheck regulating screws, with separate screws for closing and latching speeds. Whenever possible, closers shall be installed with arms parallel to the closed door. Closers for out-swinging exterior doors shall be top-jamb mounted and furnished with adapter plates for doors under 7'-6". If necessary, closers may be mounted on drop brackets on doors 7'-6" and over. On double doors, provide a door closer on each leaf. Maximum allowable "door closer" opening force shall be: 5 pounds for interior doors, 8.5 pounds for exterior doors, and 15 pounds for fire doors. H. Door Stops and Holders Stops shall be provided with machine screws and threaded anchors at concrete or masonry, and toggle bolts at plaster and gypsum board. I. Push Plates, Pulls, and KickDlates Push plates shall be 4" x 16" x 0.050" thick, unless otherwise specified. All pulls shall be thru-bolted under the push plates. Kickplates shall be stainless steel, 0.050" thick, beveled on 3 sides, IO" high; except where necessary to clear a louver in which case they shall be 8" high. Width shall be door size, less 2" for single doors and door width, less 1 I' for double doors. J. Thresholds All thresholds not extending beyond face of door frame shall be 1 piece, full width of opening, 1/2" maximum rise. Thresholds extending beyond face of door frame may be two piece and shall have mitered ends for the portion of threshold extending beyond the door frame. All thresholds shall be provided with stainless steel machine screws in threaded expansion anchors at concrete. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-7 K. Hardware Schedule The following hardware schedule is provided as a guide. Contractor shall furnish all hardware necessary for the project. Hardware required for any particular location, but not scheduled, shall be the same as that scheduled for similar locations. Catalog numbers listed in the hardware schedule are from the catalogs of the following manufacturers: BBW C H LCN N Mc P Q RE RU SCH STA VD Z Builders Brass Works Corbin Co. Hager LCN Closers Norton Door Controls McKinney Mfg. Co. Pemko Mfg. Co. Quality Hardware Co. Reese Enterprises, Inc. Russwin Schlage (No substitute) Stanley Von Duprin, Inc. Zero Weatherstripping Listed manufacturers are used to establish the quality and type of hardware to be furnished. Hardware equal in quality and function may be submitted to Owner for approval, provided Contractor demonstrates substitute hardware conforms in function, quality, finish, and workmanship to the products hereinafter specified. Provide product of one manufacturer for each specified hardware item for standardization of appearance, maintenance, and replacement. Hardware Schedule Quantity item Manuf. Description, Catalon No. Finish HW-1 (Ext. Single Door) Each door shall have: 3 1 1 1 1 1 set 1 1 1 Hinges Mc Lockset SCH Holder Q Threshold P Head/Jamb P Bottom P HeadDrip P Closer LCN stop Q T4B3386 (5") L9453P034 433ES 1149A 157A 290AS 216AV 346A (door width +3") 4040 Series (90") June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 US32D US26D US26D US26D ALUM USP USP USP USP Doors, Frames, & Hardware 081 00-8 HW-2 (Ext. Double Doors) Each door pair shall have: 6 1 2 2 2 1 1 1 set 1 2 1 1 Hinges Mc Lockset SCH stop Q Holder Q Flush Bolts Q Strike Q Threshold P Head/Jamb P Astragal Seal P Bottom P HeadDrip P Closer LCN TB2314 (4-1/2") L9453P034 433ES 1149A 1358UL (inactive leaf) 1226 (inactive leaf) 157A 290AS S88D 21 6AV 346A (door width +3") 4040 Series (90") US32D US26D US26D US26D US26D US26D ALUM USP BR USP USP USP PART 3 - EXECUTION 3.01 Hollow MetaVFiberglass Doors and Frames A. B. C. D. E. F. Doors and frames shall be shipped and stored with temporary stiffeners and spreaders to maintain frames in alignment. Storage shall be in a manner that will prevent rusting, damage, or marring of finish. All work shall be shop fabricated to required profiles with edges straight, true, and sharp. Fabricate and fit accurately with hairline joints at corners, surfaces free of warp, wave, buckle, and other defects. Welding "Best Grade Commercial Work", with all exposed beads ground smooth. Door and frame assemblies shall be installed plumb, square, and level, and be securely and rigidly anchored to the adjoining construction. Door and frame assemblies shall be installed in accordance with approved shop drawings and printed recommendations and instructions of the manufacturer. Doors shall be installed with a maximum clearance of 1/8" at head, 3/32" at strike jamb, 1/8" at butt jamb, and as required where thresholds are listed, and shall not exceed the manufacturer's specified limits. All work shall be coordinated with the work of related subcontractors and suppliers to assure a proper installation. Protect installed doors against damage during construction. 3.02 Rolling Metal Door Assemblies A. Rolling metal door assemblies shall be installed in accordance with the manufacturer's printed recommendations and instructions. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-9 B. Rolling metal door assemblies shall be installed plumb, square, and level. Fasteners shall be of sufficient size, length, and spacing for loads imposed. C. Protect installed doors against damage during construction. D. Provide completed installation, secure, and operating freely without binding or stoppage. 3.03 Door Hardware A. Installation 1. All hardware items shall be installed in accordance with manufacturer's written recommendations and instructions. 2. All finish hardware work shall be neat and secure, installed to develop full strength of components and provide proper function. 3. Contractor shall take preventative measures to avoid marring, scratching, or otherwise damaging adjacent finishes during installation. 4. Latchbolts shall be installed to automatically engage in strikes, whether activated by closers or manually. In no case shall additional manual pressure be required to engage latchbolt in strike. 5. Closers and hinges shall be adjusted to operate doors evenly without noise and binding. Closers, closer arms, and hold-open arms shall be attached with sex bolts. 6. Stops and holders shall be installed to allow doors to open as far as possible. 7. Wall mounted hardware shall be installed over solid structural backing or solid blocking in hollow walls. 8. Thresholds shall be installed with ends neatly coped to fit profile of door jamb. Thresholds shall be set in sealant with ends sealed to door jambs, or closed with mitered ends when threshold extends beyond door jamb. 9. All doors shall be provided with weatherstripping or seals unless product weatherstripping or other special seals are specified. IO. Mounting of door hardware shall be in accordance with the published recommendations of the Door and Hardware Institute. B. Protection 1. Contractor shall provide removable protection on exposed surfaces of hardware to prevent damage or staining of hardware during construction. Hardware protection shall be removed just prior to final cleaning and polishing. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-1 0 2. All finish hardware shall be fitted and dismantled before painting work and shall be reinstalled after finish painting work or provided with paint protection prior to painting work. C. Warranty All hardware shall be warranted for a period of 2 years from the date of acceptance of the project. Defects in material and workmanship occurring during the warranty period shall be corrected to the satisfaction of the Owner. D. Special Tools Contractor shall provide 2 sets of installation and adjusting tools. June 2002 Calavera Pump Station (860-3-CAL) Contract 38891 Doors, Frames, & Hardware 081 00-1 1 sEcuwwm PLASTER OVER CONCRETE MASONRY PART I - GENERAL 1.01 General A. Contractor shall provide preparation, grounds, and plaster where indicated on the Drawings, as specified herein, and as needed for a complete and proper installation. B. Related work: Documents affecting work of this Section include, but are not necessarily limited to, General Provisions, Supplementary Provisions, and Special Construction Provisions of these Specifications. I .02 SUBMITTALS A. All submittals shall be in accordance with the General Provisions, Section 2-5.3. B. Product data: Contractor shall submit complete information and technical data for all materials and components, including, but not limited to, the following: 1. Materials list of items proposed to be provided under this Section; 2. Manufacturer's specifications and other data needed to prove compliance with the specified requirements; 3. Samples of the proposed accessories; 4. Manufacturer's recommended installation procedures for accessories which, when approved by the Owner's Designated Representative, will become the basis for accepting or rejecting actual installation procedures used for those accessories on the Work. 1.03 QUALITY ASSURANCE A. Use adequate numbers of skilled workmen thoroughly trained and experienced in the necessary crafts and completely familiar with the specified requirements and methods needed for proper performance of the work of this Section. B. In addition to complying with pertinent codes and regulations of governmental agencies having jurisdiction, comply with materials handling and workmanship provisions of the "Reference Specifications" of the California Lathing and Plastering Contractors Association. June 2004 Plaster Over Concrete Masonry Calavera Pump Station (860-3-CAL) Contract 38891 09202-1 PART 2 - PRODUCTS 2.01 METAL MEMBERS A. Metal plastering accessories: 1. Fabricate from 26 gage or heavier hot-dip galvanized steel, prime-coated unless otherwise specifically approved by the Owner's Designated Representative. 2. Use manufacturer's standard shapes specifically designed for the proposed use. 3. Provide protective coating to permit removal of over-spray upon completion of plastering. 2.02 PLASTER A. Cement: 1. Comply with ASTM C150, type I. 2. Do not use plastic cement of any type. B. Lime: 1. Provide dry hydrated lime complying with ASTM C206. 2. Lime putty (if used): Weigh no more than 83 Ibs per cu ft. C. Sand: Comply with ASTM C144, clean and well graded from coarse to fine. D. Water: Clean and free from deleterious amounts of acid, alkali, and organic materials. 2.03 OTHER MATERIALS A. For plastering over concrete masonry, provide the following products of Thoro System Products, Inc., or provide equal products approved by Owner: 1. "Thoro Surface Bonding" mixed with "Thoro Acyl 60" additive, in the proportions called for below. B. Provide other materials, not specifically described but required for a complete and proper installation, as selected by the Contractor subject to the approval of the Owner. June 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Plaster Over Concrete Masonry 09202-2 PART 3 - EXECUTION 3.01 SURFACE CONDITIONS A. Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not pro- ceed until unsatisfactory conditions are corrected. 3.02 PREPARATION A. Coordination: 1. Carefully coordinate with other trades to assure proper provision in such work for installation of the work of this Section. 2. Install members and components in strict accordance with arrangements shown on the Drawings and the manufacturer's recommendations as approved by the Owner. B. Alignment: 1. Align vertically within a tolerance of one in 1000 2. Align horizontally within a tolerance of one in 500. C. For application of plaster to concrete masonry, brush on two coats of bonding agent as follows: 1. First coat: Apply "Thoro Surface Bonding" at the rate of 2 Ibs per square yard of substrate, mixed with "Thoro Acryl 60" additive at the rate of one part Thoro Surface Bonding to three parts Thoro Acryl60; 2. Second coat: Apply "Thoro Surface Bonding" at the rate of 1 Ib per square yard of substrate, mixed with "Thoro Acryl 60" additive at the rate of one part Thoro Surface Bonding to three parts Thoro Acryl60; 3. Apply plaster base coat to a thickness of approximately 1/2", leaving surface suitable to receive finish coat; 4. Apply finish coat as specified in Paragraph 3.03-B below. 3.03 PLASTERING A. Perform mixing, plastering, and plaster curing in strict accordance with provisions of the referenced standards. June 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Plaster Over Concrete Masonry 09202-3 8. Finish coat: 1. Do not apply finish coat sooner than seven days after installation of the brown coat. 2. Hand trowel the finish coat in a pattern approved by the Owner’s Designated Representative. C. Finish plaster true and even within a tolerance of one in 500, leaving the finished surface free from tool marks and other blemishes. 3.04 CLEANING UP A. Wipe metal accessories clean after application of each coat. B. In addition to other protection, protect adjacent surfaces from the accidental application of plaster. C. In addition to other requirements for cleaning, immediately upon completion of this portion of the Work visually inspect adjacent surfaces and remove all traces of spilled and splashed plaster. END OF SECTION June 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Plaster Over Concrete Masonry 09202-4 SECTION 09870 TAPE COATING SYSTEM WITH MORTAR SHIELD FOR THE EXTERIOR OF STEEL WATER PIPELINES PART 1 - GENERAL 1.1 1.2 1.3 1.4 1.5 DESCRIPTION A. The steel pipe shall be coated with polyethylene tapes in accordance with AWWA C214. Fittings and specials shall be coated with cold-applied polyethylene tapes in accordance with AWWA C209. A reinforced cement mortar shield shall be applied in accordance with AWWA C205. Any modifications to the aforementioned standards are as stated herein. RELATED WORK ELSEWHERE The Contractor shall refer to the following specification section(s) for additional requirements: A. Basic Coating and Painting Specification for Water, Recycled Water, and B. C. Wastewater Facilities: 09900 Petrolatum Wax Tape Coating: 09902 Cement Mortar Lined Steel Pipe: 15061 QUALIFICATIONS OF MANUFACTURERS A. Manufacturer to demonstrate a minimum of five years’ successful application of tape coating system on similar diameter steel water pipelines as specified herein. SUBMllTALS All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. List of tape coating materials indicating manufacturer, product numbers, and thickness of materials related to tape system for joints and repairs. B. Certification of test results for each batch of liquid adhesive and each tape material specified shall be in accordance with AWWA C214. C. Tape application procedure approved by tape manufacturer. COORDINATION WITH TAPE MANUFACTURER A. The pipe manufacturer shall require the tape material manufacturer to furnish qualified factory technical representative to visit the site for technical support at the beginning of the pipe installation as may be necessary to instruct Contractor on appropriate tape application methods in the field or to resolve problems. This visit shall be coordinated to allow City Inspection and Maintenance Staff to participate in the instruction. The Contractor shall allow time for representative to give field taping instructions to his workforce. January 2004 Tape Wrap and Cement Mortar Coating Calavera Pump Station (860-3-CAL) Contract 38891 09870-1 PART 2 - MATERIALS 2.1 2.2 2.3 2.4 POLYETHYLENE TAPE COATlNG A. Provide polyethylene tape coating in accordance with AWWA C214 with a reinforced cement mortar shield in accordance with AWWA C205 and as specified herein. Plant and field applied liquid adhesive, polyethylene tape, and plant and field applied repair tape shall be furnished by a single manufacturer. The physical properties of tape materials shall meet or exceed the requirements of AWWA C214 when tested in accordance with the methods described in Section 5.3, “Coating System Tests”. B. The tape coating systems consist of an exterior polyethylene tape over the bare metal surface of steel pipe with a reinforced cement mortar coating applied over the tape system. Tape coating systems are specified for: 1. Normal plant cold-applied tape 2. 3. Plant cold-applied tape for special sections, connections and fittings, and plant repairs of cold-applied tape Field joint, field coated fittings and repair of field cold-applied tape. LIQUID ADHESIVE A. Liquid adhesive shall consist of a mixture of suitable rubber and synthetic compounds and a solvent in accordance with AWWA C214. The liquid adhesive shall be Polyken #I 039 primer or equivalent. STORAGE PRIMER A. Storage primer on the exposed steel at the tape cutbacks shall be Polyken #924 or equivalent. PLANT APPLIED POLYETHYLENE TAPE SYSTEM, POLYKEN, or equivalent (80 mil) A. Liquid adhesive shall be Polyken #I 039 primer. B. Anti-corrosion inner layer tape shall be Polyken #989 (20 mil), black. C. First mechanical outer layer tape shall be Polyken #955 (30 mil), gray. D. Second mechanical outer layer tape shall be Polyken #956 (30 mil), white. E. Reinforced cement mortar shield 3/4” thick. F. Weld Stripping Tape shall be Polyken #933 (25 mil), if required. January 2004 Tape Wrap and Cement Mortar Coating Calavera Pump Station (860-3-CAL) Contract 38891 09870-2 2.5 PLANT COLDAPPLIED TAPE COATINGS FOR SPECIAL SECTIONS, CONNECTIONS AND FITTINGS, AND PLANT REPAIR COLD-APPLIED POLYETHYLENE TAPE MATERIAL A. Liquid adhesive shall be Polyken #lo39 primer. B. Anti-corrosion inner layer shall be Polyken M32-50 (50 mil), black. C. Mechanical layer outer tape for plant fittings and plant repair cold-applied polyethylene tape shall be Polyken #955 (30 mil), white. D. Reinforced cement mortar shield 3/4" thick. E. Weld stripping tape shall be Polyken #933 (25 mil), if required. 2.6 FIELD JOINT, FIELD COATED FITTINGS, AND FIELD REPAIR COLD-APPLIED POLYETHYLENE TAPE A. Primer shall be Polyken #1029. B. Joint filler tape to be Polyken #939 (125 mil), black. C. Field joint, field fitting, and field repair outer layer tape shall be Polyken #932, (50 mil). D. Mechanical layer outer tape for field joint, field fittings and field repair shall be Polyken #932-50, continue inner layer with 50% overlap. PART 3 - EXECUTION 3.1 POLYETHYLENE TAPE COATING A. Apply polyethylene tape coating to pipe in accordance with AWWA C214. Apply polyethylene tape coating to fittings and specials in accordance with AWWA C209. Apply the reinforced cement mortar shield in accordance with AWWA C205. Any modifications to the aforementioned standards are as stated herein. B. Certificate of Compliance: Prior to shipment of pipe, furnish a certificate of compliance stating that tape materials and work furnished hereunder will comply or have complied with the requirements of these specifications and AWWA C214 and C209. 3.2 ~ STRAIGHT RUN PIPE APPLICATION A. For straight run pipe, plant applied conditions, the polyethylene tapes shall be a four layer system consisting of: (1) liquid adhesive; (2) corrosion prevention tape (inner layer); (3) mechanical protective tape (first outer layer); (4) mechanical protective tape (second outer layer) January 2004 Tape Wrap and Cement Mortar Coating Calavera Pump Station (860-3-CAL) Contract 38891 09870-3 B. Perform the entire coating operation as a one station operation by experienced workers skilled in the application of polyethylene tapes and cement mortar coating under qualified supervisors. Do not allow additional handling following initial set up of pipe section, from application of primer to motar coating. C. All equipment for blasting and application of the tape coating system shall be of such design and condition to comply with all the requirements of AWWA C214 and these specifications. Immediately repair or replace equipment that, in the opinion of the Engineer, does not produce the required results. Include equipment and a repair procedure for correcting defective tape application for use under this specification in the steel pipe fabrication plan. Make available for review a copy of this portion of the fabrication plan, and any updates, at the location of the coating operation, and a repair procedure for correcting defective tape application. D. Remove the exterior weld bead along the entire exterior surface of the pipe. The exterior weld bead-shall be flush with the exterior surface of the pipe with a tolerance of plus 1132-inch. E. Surface preparation shall conform to AWWA C214 and the following. 1. Bare pipe shall be clean of all foreign matter such as mud, mill lacquer, wax, coal tar, asphalt, oil, grease, or any contaminants. Remove welding slag or scale from all welds by wire-brushing, hammering, or other satisfactory means. Remove welding splash globules prior to priming. 2. Prior to blast cleaning, inspect surfaces and, if required, preclean in accordance with the requirements of SSPC SP-1, Solvent Cleaning, to remove oil, grease, and all foreign deposits. Remove visible oil and grease spots by solvent wiping. Use only approved solvents that do not leave any residue. Include in the manufacturer’s fabrication plan the cleaning solvent applications procedure and safety precautions. F. Blast cleaning shall conform to AWWA C214 and the following. 1. Blast the pipe surface using a commercially available shot grit mixture to achieve a prepared surface equal to that which is specified in SSPC SP-6, Commercial Blast Cleaning. 2. For plant mortar lined pipe, perform blast cleaning of said exterior surfaces after the initial curing of the spun mortar lining. Perform the exterior blast cleaning in such a manner as not to endanger the mortar lining in the pipe. Completely remove corrosion and foreign substances from the exterior of the pipe in the cleaning operation, and apply liquid adhesive after completion of blast cleaning. 3. Achieve from abrasive blasting an anchor pattern profile a minimum of 1 .O mil, but not exceeding 3.0 mils. Measure the anchor pattern or profile of the blasted surface using comparator tape as specified herein. January 2004 Calavera Pump Station (860-3-CAL) Tape Wrap and Cement Mortar Coating Contract 38891 09870-4 4. Inspect the blast cleaned exterior pipe surface for adequate surface preparation prior to application of the liquid adhesive. Surface comparator tapes are to be used by the manufacturer in at least eight random areas, along any given 40-foot length of pipe. The results of the surface comparator tapes are to be documented on the quality control sheet for each pipe section. 5. Coat each pipe section with liquid adhesive and tape within the same day of being blast cleaned. Do not allow blasted and/or blasted and primed pipe to sit overnight. All blasted and primed pipe must be coated by the end of the day. No coating will be permitted on pipe sections showing evidence of rust. G. Liquid adhesive application shall conform to AWWA C214 and the following. 1. Prior to liquid adhesive application, clean the pipe surface free of foreign matter such as sand, grease, oil, grit, rust particles, and dirt. . 2. Apply the liquid adhesive in a uniform thin film at the coverage rate recommended by the manufacturer. Meet the recommendations of the manufacturer for the state of dryness of the liquid adhesive prior to the application of the inner layer of tape. 3. Limit the application of liquid adhesive to that length of pipe which can be taped within the same workday. Pipe coated with liquid adhesive that was not taped within the same workday shall be rejected at the discretion of the Engineer. The liquid adhesive shall be removed and the surface shall be reprimed. 4. Protect liquid adhesive coated pipe sections from moisture, dirt, sand, and other potentially contaminating materials 5. Apply storage primer to the exposed steel pipe at tape cutbacks to prevent oxidation of the cleaned metal surface. Apply minimum of 1.5 mils and maximum of 2.5 mils of storage primer to exposed steel per the manufacturer’s recommendations. H. Inner layer tape application: 1. Apply the inner layer tape directly onto the primed surface using approved mechanical dispensing equipment to assure adequate, consistent tension on the tape as recommended by the tape manufacturer. Use rollers to apply pressure on the tape as it comes in contact with the pipe. Make necessary adjustments to mechanical application equipment to assure a uniform, tight coating. Maintain a tight, smooth, mechanically induced, wrinkle-free coating throughout the application process. January 2004 Tape Wrap and Cement Mortar Coating Calavera Pump Station (860-3-CAL) Contract 38891 09870-5 2. The application of tension shall be such that the width of tape will be reduced between 1% to 2 percent of tape width prior to the pull. Provide a pressure readout gauge and chart recorder, suitable to the Engineer, with the tape let-off machine to document the tape tension during application. 3. Apply inner layer tape at a minimum roll temperature of 70°F. Continuously monitor the temperature of the tape within 12 inches of the point of contact with the pipe surface. Use a chart recorder, suitable to the Engineer, to document the temperature of the tape during application. Sections where the tape application tension and temperature is not maintained within manufacturer’s recommendations shall be rejected and the tape removed from the entire pipe section and reapplied. 4. Continuously electronically test the inner tape layer at 6,000 volts immediately following application of the tape by a holiday tester permanently mounted to the tape application station and equipped with an indicator light and audio buzzer, suitable to the Engineer to alert the workmen of the presence of holidays in the coating system. 5. Spirally wrap the inner layer tape over longitudinally or spirally welded pipe. Provide a 1 -inch minimum tape overlap. 6. Splice each new roll by overlapping the new tape over the end of the preceding roll by at least 6 inches. Perform this end lap splice by hand or by a mechanical applicator so that the splice is wrinkle free and maintains the continuity of the inner wrap coating. Maintain the wrapping angle of the new roll parallel to that of the previous roll. 7. Provide tape cutbacks based on the joint type required, cutting the tape edge parallel to the end of the pipe. Perform cutbacks using a cutting device that is guided from the end of the pipe to insure a uniform, straight cutback. I. Mechanical outer layer tape application. 1. Apply the first mechanical outer layer of tape over the inner layer tape using the same type of mechanical equipment used in the application of the inner layer tape. No overlap splice of the other layer coinciding with the overlap splice of the inner layer will be permitted. Provide a minimum 6-inch separation between overlap of splices. Apply two mechanical outer layers of tape as specified herein. The inner layer tape shall be electrically tested, inspected, and approved prior to the application of the first mechanical outer layer tape and the first mechanical outer layer tape shall also be visually inspected and approved prior to the application of the second mechanical outer layer tape. Ensure that both mechanical outer layer tapes are smooth, tight and wrinkle-free. January 2004 Tape Wrap and Cement Mortar Coating Calavera Pump Station (860-3-CAL) Contract 38891 09870-6 2. Apply mechanical outer layer tapes in accordance with the requirements for the inner layer tape, except that the minimum tape roll application temperature shall be 90°F. Monitoring for tension and temperature will be required for the mechanical outer layer tapes. The use of rollers to apply pressure on the tape is not required during application of the mechanical outer layer tapes. Holiday testing of the mechanical outer layer tapes is not required during tape application. Test the complete tape system prior to coating as specified herein. J. Apply a reinforced cement mortar shield over the outer layer of tape in accordance with AWWA C205. Cement mortar shall be 3/4" thick. K. Storage primer application shall conform to AWWA C214 as modified herein: 1. Prior to storage primer application, clean the pipe surface free from foreign matter such as sand, grease, oil, grit, rust particles and dirt. 2. Apply primer only to a dry pipe surface. Whenever the ambient air temperatures are cold enough to cause gelling of the primer, the use of heaters will not be permitted to return the primer back to a fully liquid state. Use new primer at a minimum of 40°F. 3. Apply storage primer to the exposed steel pipe at tape cutbacks to prevent oxidation of the cleaned metal surface. Apply minimum of 1.5 mils and maximum of 2.5 mils of storage primer to exposed steel per the manufacturer's recommendations. Do not place storage primer on the edge of the steel plate. 3.3 FllTlNGS COATED AT THE PLANT A. Coat fittings that cannot be machine coated in accordance with AWWA C209 using materials as specified herein. Weld bead preparation, surface preparation, blast cleaning and liquid adhesive shall be as specified for straight run pipe. Apply an inner layer tape of Polyken #932-50 with a 1 -inch minimum tape overlap on all plant coated fittings. Apply an outer layer of cold-applied polyethylene tape as specified herein with a 55 percent overlap on all plant-coated fittings. Provide a minimum thickness of 110 mils for the total tape coat system for plant-coated fittings. B. Test all completed tape coated fittings in the presence of the Engineer with an electrical flaw detector prior to the application of the cement mortar coating. Applied voltage shall be in the range of 11,000 to 15,000 volts. Repair any holidays found. C. Repair cement mortar coating defects in accordance with the approved repair procedures. D. Apply cement mortar coating in accordance with AWWA C205, over the tape- coated fittings after completion of tape coating, testing and inspections. January 2004 Tape Wrap and Cement Mortar Coating Calavera Pump Station (860-3-CAL) Contract 3889 1 09870-7 3.4 TAPE APPLICATION TO FITTINGS, SPECIALS AND PIPE JOINTS (Field) A. Field cold applied plastic tape coating shall be in accordance with AWWA C209, as modified herein. B. Prior to welding any fieldjoints, wrap an 18-inch strip of heat resistance material over the entire coated pipe section to avoid damage to the plant applied coating by the hot weld spatter. C. Clean the pipe surface free of mud, mill lacquer, wax, tar grease, or any foreign matter. The pipe surface shall be free of any moisture and all foreign matter prior to the application of prime. D. Pack irregularities in joint with elastameric joint filler. E. Apply primer by brush or roller (4 mil wet, 1 mil dry). F. After primer has dried, apply tape to the joint and extend a minimum of 3-inch onto the adjacent tape wrap. Maintain 55 percent overlap on all field joint tape to produce a minimum thickness of 100 mils. G. Apply tape with sufficient tension to conform with the surface. The finish wrap shall produce a smooth, wrinkle-free surface. H. The tape system for pipe joints is shown in Section 2.6. 3.5 INSPECTION OF TAPE COATING Test the final applied tape coating in the presence of the engineer with an electrical holiday detector. Repair all holidays and physical damage. 3.6 MORTAR SHIELD A. Apply mortar coating in accordance with Section 15061 cement. Mortar lined and coated steel pipe and specials, over the tape coated pipe immediately upon completion of tape wrapping, testing, and inspections.. 3.7 PROTECTING COATED PIPE A. The CONTRACTOR shall protect all coated surfaces from damage prior to and during the pipe installation in accordance with these specifications. B. In transporting the coated pipe, it shall rest in saddles shaped to the outside diameter of the coated pipe. The saddles shall be in contact with the bottom of the pipe along an arc of at least 60 degrees. Saddles shall be completely lined with adequate padding. No nails or any other fasteners that may damage the coating will be allowed in the installation of the padding of the saddles. January 2004 Tape Wrap and Cement Mortar Coating Calavera Pump Station (860-3-CAL) Contract 38891 09870-8 C. While laying tape coated steel pipe, the pipe shall not be rolled or skidded when it is in contact with the ground at any point. Immediately before the coated pipe is lowered into the trench the CONTRACTOR shall provide a visual and holiday inspection of the coating on the entire pipe coating system. Coated pipe shall be lowered into the trench using saddled, not choked, belt slings. The use of chains, hooks, or other equipment which might damage the pipe coating will not be permitted. All other pipe handling equipment and methods shall be approved by the ENGINEER. Pipe stored alongside of the trench shall be supported on padded skids, sand bags, or rock-free sand berms. END OF SECTION January 2004 Tape Wrap and Cement Mortar Coating Calavera Pump Station (860-3-CAL) Contract 38891 09870-9 SECTION 09900 BASIC COATING AND PAINTING SPECIFICATION FOR WATER, RECYCLED WATER, AND WASTEWATER FACILITIES PART 1 - GENERAL 1.01 Scope A. The work included in this section consists of furnishing all labor, materials, apparatus, scaffolding and all appurtenant work in connection with coating and painting, as indicated on the drawings and as specified herein. B. In general, the following surfaces are to be coated or painted: 1. Exposed piping and other metal surfaces, interior and exterior. 2. All submerged and intermittently submerged metal surfaces, except stainless steel. 3. All structural and miscellaneous steel, including tanks. 4. The interior of wet wells, manholes, junction structures, headworks, and similar structures. 5. All exterior above ground concrete and masonry. 6. The interior of certain structures as specified in the Painting and/or Coating Schedule. 7. Equipment furnished with and without factory finish surfaces. 8. Doors, frames, woodwork and architectural trim work. C. The following surfaces shall not be coated or painted unless shown or specified herein, or elsewhere in the Contract Documents. 1. Stainless steel. 2. Equipment nameplates, machined surfaces and grease fittings. 3. Non-ferrous and galvanized ferrous metal, including: (a) floor gratings, plates and frames, (b) handrailing, (c) stair treads, stringers and supports, (d) ladders and supports, (e) chain link fencing and appurtenances, (f) conduits. D. In no case shall any concrete, wood, metal or any other surface requiring protection be left uncoated or unpainted, even though not specifically defined herein. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 1.02 Reference Specifications and Standards Without limiting the general aspects of other requirements of these specifications, all surface preparation, coating and painting of surfaces shall conform to the applicable requirements of the National Association of Corrosion Engineers (NACE), the Steel Structures Painting Council (SSPC), the American Concrete Institute, the Forest Products Research Society, and the manufacturer's printed recommendations. In the event of a conflict between codes, reference standards, drawings, and these specifications, the most stringent requirements shall govern. All conflicts shall be brought to the attention of the Owner for clarification and direction prior to ordering or providing any materials or labor. 1.03 Painting Subcontractor Where protective coatings are to be performed by a subcontractor, said subcontractor must possess a valid state license as required for performance of the painting and coating work called for in this specification and shall have a minimum of five years practical experience and successful history in the application of specified products to surfaces and facilities of water and wastewater treatment facilities. Upon request, he shall substantiate this requirement by furnishing a list of references. 1.04 Shop Drawing Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. For each coating system to be used, the Contractor shall submit for Owner's review and approval the following data: 1. Paint manufacturer's data sheet for each product used, including statements on the suitability of the material for the intended use. 2. Paint manufacturer's instructions and recommendations on surface preparation and application. 3. Samples of colors and finishes available for each product. Where custom mixed colors are specified (e.g. to match colors of existing coated surfaces), the submitted color samples shall be made using color formulations prepared to match the color samples furnished or specified by the Owner. The color formula shall be provided with each color sample. 4. Compatibility of shop and field applied coatings (where applicable). 5. Material safety data sheet for each product used. 6. Submit written certification that all paintkoatings conform to applicable local Air Quality Management District rules and regulations for products and applications. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-2 1.05 Quality Assurance A. Surface PreDaration Surface preparation will be based upon comparison with "Pictorial Surface Preparation Standards for Painting Steel Surfaces", SSPC-Vis 1 ASTM Designation D220; "Standard Methods of Evaluating Degree of Rusting on Painted Steel Surfaces", SSPC-Vis 2 ASTM Designation D610; Visual Standard for Surfaces of New Steel Airblast Cleaned with Sand Abrasive", NACE Standard TM-01-70; and as described below. Anchor profile for prepared surfaces shall be measured by use of a non-destructive instrument such as a Keane-Tator Surface Profile Comparator. To facilitate inspection, the Contractor shall on the first day of sandblasting operations, sandblast metal panels to the standard specified. Plates shall be 1/8" (3.75 mm) plate stock and shall measure a minimum of 8-1/2" x 11" (216 mm x 280 mm). After mutually agreeing a specific panel meets the requirement of the specification, it shall be initialed by the Contractor and Inspector and securely sealed in clear plastic with desiccant to prevent rusting. Panels shall be prepared for each type sandblasting specified and shall be utilized by the Inspector throughout the duration of sandblasting operations. B. Coatinu and Paintinu Application No coating or paint shall be applied: when the surrounding air temperature or the temperature of the surface to be coated or painted is below 40°F (4.4"C); to wet or damp surfaces or in rain, snow, fog, or mist; when the temperature is less than 5°F (2.8"C) above the dew point; when it is expected the air temperature will drop below 40°F (4.4"C) or less than 5°F (2.8"C) above the dew point within 8 hours after application of coating or paint. Dewpoint shall be measured by use of an instrument such as a Sling Psychrometer in conjunction with U.S. Department of Commerce Weather Bureau Psychrometric Tables. If above conditions are prevalent, coating or painting shall be delayed or postponed until conditions are favorable. The day's coating or painting shall be completed in time to permit the film sufficient drying time prior to damage by atmospheric conditions. C. Inspection Concrete, non-ferrous metal, plastic and wood surfaces shall be visually inspected to insure proper and complete coverage has been attained. A destructive testing instrument, such as a Tooke Gage, shall be used if deemed necessary. Thickness of coatings and paint on ferrous metal surfaces shall be checked with a non-destructive, magnetic type dry film thickness gauge. Coating integrity of Systems A and C surfaces shall be tested with an approved inspection device. Holiday detectors shall not exceed the voltage recommended by the manufacturer of the coating system. For film thicknesses between 10 and 20 mils (0.25 mm and 0.50 mm) a non-sudsing type wetting agent such as Kodak Photo-Flo, shall be added to the water prior to wetting the detector November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-3 sponge. All pinholes shall be marked, repaired in accordance with the manufacturer's printed recommendations and retested. No pinholes or other irregularities will be permitted in the final coating. In cases of dispute concerning film thickness or "holidays", the Owner's calibrated instruments and measurements shall predominate. Wide film thickness discrepancies shall be measured and verified with a micrometer or other approved measuring instrument. Contractor shall give the Owner a minimum of 3 working days advance notice of the start of any field surface preparation work or coating application work, and a minimum of 7 working days advance notice of the start of any shop surface preparation work or coating application work. D. Inspection Devices The Contractor shall furnish, until final acceptance of coating and painting, inspection devices in good working condition for detection of holidays and measurement of dry-film thickness of coating and paint. The Contractor shall also furnish US. Department of Commerce, National Bureau of Standards certified thickness calibration plates to test the accuracy of dry-film thickness gauge and certified instrumentation to test the accuracy of holiday detectors. Dry-film thickness gauges shall be made available for the Owner's use at all times until final acceptance of application. Holiday detection devices shall be operated by the Contractor in the presence of the Owner. Acceptable devices for ferrous metal surfaces include, but are not limited to K-D "Bird-Dog" holiday detector for coatings to 20 mils (0.50 mm) dry film thickness, Tinker-Rasor Models AP and AP-W holiday detectors for coatings in excess of 20 mils (0.50 mm) dry-film thickness, and "Owner" units for dry-film thickness gauging. Non- ferrous metal surfaces shall be checked with an instrument such as an Elcometer "Eddy Current" Tester. Inspection devices shall be operated in accordance with the manufacturer's instructions. E. Warrantv Inspection Warranty inspection shall be conducted during the eleventh month of the Contract warranty period. The Contractor and a representative of the coating material manufacturer shall attend this inspection. All defective work shall be repaired in accordance with this specification and to the satisfaction of the Owner. 1.06 Safety and Health Requirements A. General Surface preparation and application of coatings shall be performed by the Contractor in compliance with all applicable federal, state, and local occupational safety, health, and air pollution control regulations. The Contractor shall obtain and comply with all safety precautions recommended by the paint manufacturer November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-4 in printed instructions or special bulletins. The Contractor shall provide and require use of personnel protective lifesaving equipment for persons working in or about the project site. Head and Face Protection and Respiratorv Devices Equipment shall include protective helmets which shall be worn by all persons while in the vicinity of the work. In addition, workers engaged in or near the work during sandblasting shall wear eye and face protection devices and air-purifying, half-mask or mouthpiece respirator with appropriate filter. Ventilation Where ventilation is used to control hazardous exposure, all equipment shall be explosion-proof. Ventilation shall reduce the concentration of air contaminant to the degree a hazard does not exist. Sound Levels Whenever the occupational noise exposure exceeds the maximum allowable sound levels, the Contractor shall provide and require the use of approved ear protective devices. Illumination Adequate illumination shall be provided while work is in progress, including explosion-proof lights and electrical equipment. Whenever required by the Owner, the Contractor shall provide additional lighting and necessary supports to illuminate all areas to be inspected. The level of illumination for inspection purposes shall be determined by the Owner. Temporarv Ladders and Scaff oldinq All temporary ladders and scaffolding shall conform to applicable safety requirements. They shall be erected where requested by the Owner to facilitate inspection and be moved by the Contractor to locations requested by the Owner. 1.07 Extra Stock Upon completion of all coating and painting work, Contractor shall deliver to the Owner a minimum of two 1 gallon cans of each type and color of finish paint and coating used on the project and two 1 gallon cans of each primer. Each container shall be unopened and properly labeled for identification and have a manufacture date within two months of the date of delivery to the Owner. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-5 PART 2 - PRODUCTS 2.01 General A. Products specified are those which have been evaluated for the specific service and are listed to establish a standard of quality. Requests for product substitution are subject to the requirements of section "Contractor Submittals Technical Specifications". 6. All materials shall be brought to job site in original sealed containers. Contractor shall provide coating material name, formula or specification number, batch number, color and date of manufacture to the Owner. Coating materials shall not be used until the Owner has inspected contents and checked information on containers or label. Materials exceeding storage life recommended by the manufacturer shall be rejected. C. All coatings and paints shall be stored in enclosed structures to protect them from weather and excessive heat or cold. Flammable coatings or paints must be stored to conform with city, county, state, and federal safety codes for flammable coating or paint materials. Water based coatings or paints shall be protected from freezing. D. Contractor shall use products of same manufacturer for all coating systems unless approved in writing by the Owner. E. It is the intent of this specification that all coatings used meet local, state, and federal air pollution control regulations. These regulations change frequently. If a listed coating does not meet local, state, and federal air pollution control regulations at the time the work is actually performed, the Contractor shall provide the manufacturer's compliant, recommended substitute coating at no additional cost to the Owner. 2.02 Service Condition A Ferrous metals subject to corrosive moisture or atmosphere and condensation such as outside of tanks, out-of-doors piping, valves, and equipment, bridges over process units, etc. shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be field sandblasted in conformance with Steel Structures Painting Council Specifications SSPC-SP10 and National Association of Corrosion Engineers Surface Finish NACE No. 2 (Near-White Blast Cleaning) to achieve a 1.5-2.5 mil (40-60 micron) blast profile. B. Application Application shall be in strict accordance with manufacturer's recommendations. The minimum and maximum required times between coats shall be per the manufacturer's product data sheet. Written requests for shop surface November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-6 preparation and application of the prime coat shall be reviewed and approved by Owner on a case-by-case basis. If approved by Owner, shop applied prime coat surface shall be field scarified by brush-blasting prior to application of intermediate coat. C. Coatinn Svstem Except as otherwise noted, the prime coat shall have a minimum dry film thickness (MDFT) of 4.0 mils. The intermediate coat shall have a MDFT of 4.0 mils and the finish coat shall have a MDFT of 2.0 mils. The total dry film thickness of the complete system shall be 10.0 mils, minimum. Carboline System Primer - Carboline 893 Intermediate - Carboline 890 Finish - Carbothane D134HS Ameron System Primer - Amercoat 385 Intermediate - Amercoat 385 Finish - Amercoat 450 HS Tnemec System Primer - Series 69 Hi-Build Epoxoline II Intermediate - Series 69 Hi-Build Epoxoline II Finish - Series 1074 Endurashield II 2.03 Service Condition B Ferrous metals not subject to corrosive moisture or atmosphere and condensation; normal indoor or outdoor exposure such as metal doors, other architectural items; piping, valves, and pumps indoors, etc. shall receive the following surface preparation and coating: A. Surface PreDaration All surfaces shall be field sandblasted in conformance with SSPC-SP6 and NACE No. 3 (Commercial Blast Cleaning). Application shall be in strict accordance with manufacturer's recommendations. The minimum and maximum times required between coats shall be per the manufacturer's product data sheet. Written requests for shop surface preparation and application of the prime coat shall be reviewed and approved by Owner on a case-by-case basis. If approved by Owner, shop applied prime coat surface shall be scarified by brush-blasting prior to application of finish coat. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-7 C. Coatinq System Except as otherwise noted, the prime coat shall have a MDFT of 4.0 mils. The finish coat (one or more) shall have a MDFT of 3.0 mils. The total dry film thickness of the complete system shall be 7.0 mils, minimum. Carboline System Primer - Carboline 893 Finish - Carbothane D134 HS Ameron System Primer - Amercoat 385 Finish - Amercoat 450 HS Tnemec System Primer - Series 69 Hi-Build Epoxoline II Finish - Series 1074 Endurashield II 2.04 Service Condition C Ferrous metals submerged or intermittently submerged in sewage or similar corrosive liquid, shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be field sandblasted in conformance with SSPC-SP10 and NACE No. 2 (Near-White Blast Cleaning) to achieve a 2-4 mil (50-100 micron) blast profile. B. Application Application shall be in strict accordance with manufacturer's recommendations. If recoating is required to correct pinholes, holidays or insufficient coating thickness; surfaces shall be scarified by brush-blasting prior to recoat. C. Coatinq System Except as otherwise noted, one coat shall be applied at a MDFT of 16.0 mils. Carboline System Bitumastic 300M (coal tar epoxy) Ameron System Amercoat 78HB (coal tar epoxy) Tnemec System Series 46H-413 Hi-Build Tneme-Tar (coal tar epoxy) November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-8 2.05 Service Condition D Buried metal surfaces shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be cleaned in conformance with SSPC-SP3 (Power Tool Cleaning) or SSPC-SP6 and NACE No. 3 (Commercial Blast Cleaning). B. Application Application shall be in strict accordance with manufacturer's recommendations. The minimum time required between coats and prior to backfilling shall be per the manufacturer's product data sheet. C. Coatinq Svstem Except as otherwise noted, two or more coats shall be applied to a minimum total dry film thickness of 30 mils. Carboline System Bitumastic No. 50 (coal tar) Ameron System Base Coat - Amerlastic 281 (15 mils MDFT) Top Coat - Amerlastic 282 (1 5 mils MDFT) Tnemec System Series 46-465HB Tnemecol (coal tar) 2.06 Service Condition E Ferrous metals subject to high temperature exposure (resistant to 1 OOOOF, continuous) shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be field sandblasted in conformance with SSPC-SP10 and NACE No. 2 (Near-White Blast Clearling) to achieve a 1.0 mil (25 micron) blast profile. B. Application Application shall be in strict accordance with manufacturer's recommendations. The maximum dry film thickness of this system shall not exceed the limits established by the manufacturer. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-9 C. Coatinq Svstem Except as otherwise noted, two coats shall be applied at 1.0 mil per coat to a total 2.0 mil dry film thickness for the system. Carboline System Primer - Carboline 4631 Finish - Carboline 4631 Ameron System Primer - Amercoat 892HS Finish - Amercoat 892HS Tnemec System Primer - Series 39 Silicone Aluminum Finish - Series 39 Silicone Aluminum 2.07 Service Condition F Non-ferrous or galvanized ferrous metals, specifically identified in the Contract Documents as requiring coating, shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be cleaned in conformance with Steel Structures Painting Council Specifications SSPC-SP1 (solvent cleaning). 6. ADplication Application shall be in strict accordance with manufacturer's recommendations. C. Coatinq Svstem Except as otherwise noted, one pre-treatment coat shall be applied to a minimum dry film thickness of 0.5 mils and shall be self priming on non-ferrous metals and galvanized surfaces. The primer and finish coats shall be the system recommended for the specific Service Condition. Carboline System Pre-Treatment Coat - Carbozinc 11 Ameron System Pre-Treatment Coat - Galvaprep (Parker Amchem) November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 0 2.08 Service Condition G Metals finished with asphalt, coal tar, or other bleeding type finish, specifically identified in the Contract Documents as not requiring removal prior to field coating, shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be cleaned in conformance with Steel Structures Painting Council Specification SSPC-SP1 (Solvent Cleaning). B. Apdication Application shall be in strict accordance with manufacturer's recommendations. C. Coatinn Svstem Except as otherwise noted, one barrier coat shall be applied to a MDFT of 3.0 mils. Finish coats shall be the system recommended for the specific Service Condition. Carboline System Barrier Coat - Carboline 893 Ameron System Barrier Coat - Amerlock 400 Tnemec System Barrier Coat - Series 69 Hi-Build Epoxoline II 2.09 Service Condition H - Not Used 2.10 Service Condition I Concrete subject to continuous or intermittent submergence in sewage, scum, sludge or other corrosive liquid where specified shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be thoroughly cleaned by sandblasting or other approved methods, removing all traces of previous materials. Remove all loose concrete by chipping, etc. to leave only sound firmly bonded concrete. All cracks and voids shall be filled with the specified epoxy filler and surfacer. Final surface shall be smooth and free of voids, cavities, dirt, dust, oils, grease, laitance or other contaminants. B. Application Application shall be in strict accordance with manufacturer's recommendations. The minimum and maximum required times between coats shall be per the manufacturer's product data sheet. If recoating is required to correct pinholes or November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 1 insufficient system coating thickness, surfaces shall be brush-blasted prior to recoat. C. Coatina System The prime coat shall be applied at a coverage rate not to exceed 200 S.F. per gallon. Finish coats shall be two or more coats to a total dry film thickness of 16.0 mils (minimum) for the system. Carboline System Filler - Carboline 195 Surfacer Primer - Bitumastic 300M Thinned 30% with 2000 Thinner Finish - Bitumastic 300M (undiluted) Ameron System Tnemec System Filler - NU-KLAD 114A Primer - Amercoat 385 Finish - Amercoat 351 Filler - Series 63-1500 Epoxy Filler and Surfacer Primer - Series 46H-413HB Tneme-Tar Thinned 30% with Tnemec #2 Thinner Finish - Series 46H-413HB (undiluted) 2.1 1 Service Condition J Concrete surfaces subject to corrosive spillage and mechanical wear shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be thoroughly cleaned by sandblasting or other approved methods, removing all traces of previous materials. Remove all loose concrete by chipping, etc. to leave only sound firmly bonded concrete. All cracks and voids shall be filled with the specified filler and surfacer. Final surface shall be smooth and free of voids, cavities, dirt, dust, oils, grease, laitance or other contaminants. B. Application Application shall be in strict accordance with manufacturer's recommendations. The minimum and maximum required times between coats shall be per the manufacturer's product data sheet. If recoating is required to correct pinholes of insufficient system coating thickness, surfaces shall be brush-blasted prior to recoat. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 2 C. Coatinq Svstem Total dry film thickness of the complete system shall be 24.0 mils, minimum. Ameron System Filler - NU-KLAD 114A Primer - Amercoat 385 (6 mils MDFT) Finish - Amercoat 351 (9 mils MDFT, each coat) Tnemec System Filler - Series 120-5003 Vinester F&S Primer - Series 120-5002 Beige Vinester (12 mils MDFT) Finish - Series 120-5001 Grey Vinester (12 mils MDFT) 2.12 Service Condition K Interior and exterior concrete surfaces exposed to view, not subject to immersion and not subject to pedestrian traffic, and concrete block and masonry without integral color or architectural treatment, shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be thoroughly cleaned by sandblasting or other approved methods, removing all traces of previous materials. Remove all loose concrete, mortar splatter and protrusions by chipping, etc. to leave only sound firmly bonded concrete, concrete block, or masonry. All cracks and voids shall be filled with an approved concrete and masonry patching compound. Final surface shall be smooth and free of voids, cavities, dirt, dust, oils, grease, laitance or other contaminants. B. Application Application shall be in strict accordance with manufacturer's recommendations. A minimum of 12 hours is required before additional coats may be applied to the prime coat and two hours for the finish coats. C. Coatinq Svstem Prime coat shall be applied at a rate of 75-100 square feet per gallon. A minimum of two finish coats shall be applied at a coverage rate not to exceed 150 square feet per gallon per coat. Carboline System Primer - Sanitile 100 Finish - Sanitile 155 Ameron System Primer - Amerlastic 172 Finish - Amerlastic 290 LT (Smooth) or Amerlastic 290 TC (Textured) November 2003 Calavera -Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 3 Tnemec System Primer - Series 130 Envirofill Finish - Series 180 (Smooth) or 181 (Textured) 2.13 Service Condition L Concrete floors subject to corrosive moisture and pedestrian traffic where specified shall receive the following surface preparation and coating: A. Surface PreDaration All surfaces shall be thoroughly cleaned by sandblasting or other approved methods; removing all traces of previous materials. Remove all loose concrete by chipping, etc. to leave only sound firmly bonded concrete. Cracks and voids shall be repaired or filled with the specified filler and surfacer. Final surfaces shall be smooth and free of voids, cavities, dirt, dust, oils, grease laitance or other contaminants. B. Awlication Application shall be in strict accordance with manufacturer's recommendation. Where a non-skid finish is specified broadcast #50 dry washed silica sand onto primer coat while still wet and follow with finish coat after required drying time. C. Coatincr Svstem Prime coat shall be thinned 15-20% with manufacturer recommended thinner and applied at a coverage rate not to exceed 250 square feet per gallon. Finish coat shall be applied at a coverage rate not to exceed 200 square feet per gallon. Total dry film thickness of the complete system shall be a minimum of 10 mils. Carboline System Filler - Carboline 195 Surfacer Primer - Carboline 890 Finish - Carboline 890 Ameron System Filler - NU-KLAD 114A Primer - Amerlock 400 Finish - Amerlock 400 Tnemec System Filler - Series 63-1 500 Filler and Surfacer Primer - Series 104 H.S. Epoxy Finish - Series 104 H.S. Epoxy 2.14 Service Condition M Concrete and concrete block masonry furnished with an approved architectural finish (e.g. integral color or architectural treatment) shall receive the following surface preparation and clear water repellent sealing system: November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 4 A. Surface PreDaration All surfaces shall be cleaned of all dirt, dust, grease, and other foreign matter before sealing. B. Application Application shall be in strict accordance with manufacturer's recommendations. C. Coating System Apply one coat at a coverage rate not to exceed 100 square feet per gallon. Rainguard System Super Monopole System Monochem Aquaseal 2.15 Service Condition N Interior and exterior architectural woodwork shall receive the following surface preparation and coating: A. Surface Preparation Sand new and bare wood to remove any surface contamination and surface cells. For previously coated surfaces sand loose paint to a tight, adherent surface. Cracks, nail holes, and other defects shall be filled with putty or plastic wood after priming. All knots shall be sealed with an approved knot sealer. Prior to coating, all surfaces shall have a moisture content below level recommended by coating manufacturer and be thoroughly cleaned and free of all foreign matter. B. Application Application shall be in strict accordance with manufacturer's recommendations. C. Coatinq Svstem Prime coat shall be applied at a coverage rate not to exceed 280 square feet per gallon. The finish coat shall be applied at a coverage rate not to exceed 280 square feet per gallon. Carboline System Primer - Carbocrylic 120 (satin) Finish - Carbocrylic 3359 (semi-gloss) Ameron System Primer - Amercoat 220 (satin or gloss) Finish - Amercoat 220 (satin or gloss) Tnemec System Primer - Series 6 (flat) or 7 (semi-gloss) Finish - Series 6 (flat) or 7 (semi-gloss) November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 5 2.16 Service Condition 0 Exposed plastic and fiberglass surfaces, specifically identified in the Contract Documents as requiring coating, shall receive the following surface preparation and coating (coating to be used for this category shall be certified by the plastic and fiberglass manufacturer to be completely acceptable and non-injurious to the material): A. Surface Preoaration Surface preparation shall consist of hand sanding to remove gloss. All remaining dust shall be removed with vacuum brushing or tack rag. Sanded surfaces shall not be washed with either solvent or water. B. Awlication Application shall be in strict accordance with manufacturer's recommendations. C. Coatina Svstem Except as otherwise noted, two coats shall be applied at 4.0 mils per coat to a total 8.0 mil MDFT for the system. Carboline System Carbothane D134 HS Ameron System Amercoat 450 HS Tnemec System Series 1074 Endurashield II 2.17 Service Condition P Manufactured items furnished with shop-applied coat of primer requiring field touch-up or with a shop applied primer which is not compatible with the required coating system shall receive the following surface preparation and coating system: A. Surface Preparation All surfaces shall be cleaned in conformance with Steel Structures Painting Council Specification SSPC-SP2 (Hand Tool Cleaning), including hand sanding and feathering of damaged areas. If determined by the Owner that damage is too extensive for touch-up, item shall be recleaned and coated or painted as directed by Owner. B. Coatina Svstem Prime and finish coats shall be the system recommended for the specific Service Condition. Prime coat shall be compatible with the required system. If not (as determined by the Owner) the prime coat shall either be removed by sandblasting or coated with a suitable primer which is compatible with the shop primer utilized and the coating system required. Costs incurred for repair or November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 6 replacement of shop-applied primers shall be the sole responsibility of the Contractor. 2.18 Service Condition Q Manufactured items furnished with shop-applied primer and finish coats requiring field touch-up shall receive the following surface preparation and coating system: A. Surface Preparation All surfaces shall be cleaned in conformance with Steel Structures Painting Council Specification SSPC-SP2 (Hand Tool Cleaning), including hand sanding and feathering of damaged areas. If determined by the Owner that damage is too extensive for touch-up, item shall be recleaned and coated or painted as directed by Owner. B. Coatinq Svstem Prime and finish coats shall be the system recommended for the specific Service Condition. Costs incurred for repair or replacement of shop-applied coatings or finishes shall be the sole responsibility of the Contractor. 2.19 Service Condition R Ferrous metal tanks, vessels, or equipment containing raw water or potable water shall receive the following surface preparation and coating: A. Surface Preparation All interior surfaces, including miscellaneous accessories and components, submerged or unsubmerged, shall be field sandblasted in conformance with SSPC-SP10 and NACE No. 2 (Near-White Blast Cleaning) to achieve a 2-4 mil (50-1 00 micron) blast profile. All exterior surfaces, including miscellaneous accessories and components, shall be field sandblasted in conformance with SSPC-SP6 and NACE No. 3 (Commercial Blast Cleaning). B. Aimlication Application shall be in strict accordance with manufacturer's recommendations. The minimum and maximum required times between coats shall be per the manufacturer's product data sheet. Written requests for shop surface preparation and application of the prime coat shall be reviewed and approved by Engineer on a case-by-case basis. If approved by Engineer, shop applied prime coat surface shall be field scarified by brush-blasting prior to application of finish coat. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 7 C. Coatinq Svstem Interior Surfaces: Interior coating system shall be certified by the National Sanitation Foundation to be in accordance with ANSVNSF Standard 61 for potable water contact. Except as otherwise noted, the prime coat shall have a MDFT of 6.0 mils. The finish coat shall have a MDFT of 6.0 mils. The total dry film thickness of the complete system shall be 12.0 mils, minimum. Carboline System Primer - Super Hi-Gard 891 Finish - Super Hi-Gard 891 Tnemec System Primer - Series 139 Pota-Pox II Finish - Series 139 Pota-Pox II Exterior Surfaces: Except as otherwise noted, the prime coat shall have a MDFT of 6.0 mils. The finish coat (one or more) shall have a MDFT of 3.0 mils. The total dry film thickness of the complete system shall be 9.0 mils, minimum. Carboline System Primer - Super Hi-Gard 891 Finish - Carbothane D134 HS Tnemec System Primer - Series 139 Pota-Pox II Finish - Series 1074 Endurashield II 2.20 Service Condition S Concrete subject to continuous or intermittent submergence in sewage, scum, or sludge shall receive the following surface preparation and coating: A. Surface Preparation All surfaces shall be thoroughly cleaned by sandblasting, removing all traces of previous materials. Remove all loose concrete by chipping, etc. to leave only sound firmly bonded concrete. All cracks and voids shall be filled with a non-sag epoxy resin adhesive. Surfaces to be coated shall be roughened by blast cleaning or equivalent mechanical means to achieve the coating manufacturer's minimum designated degree of roughness. Final surface shall be rough and free of voids, cavities, dirt, dust, oils, grease, laitance or other contaminants. B. ApDlication Application shall be in strict accordance with manufacturer's written recommendations. The minimum and maximum coating thickness per lift shall be in accordance with the manufacturer's requirements. Coating manufacturer shall provide the services of a technical field representative to review and November 2003 Caiavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 8 2.21 approve the surface preparation and to assist the coating applicator during the initial phase of coating. C. Coatina System The finished coating thickness shall be a minimum of 1/2 inch. Lafarge Calcium Aluminates System Primer/Finish - Sewpercoat Sika System Primer - Armatec 1 10 Finish - Sikadur 45 Epocem Miscellaneous Coatings A. Aluminum Metal Isolation All aluminum bearing on, or embedded in, concrete shall be coated with a wash primer (0.5 mils) followed by one coat (8 mils) of heavy bodied bituminous paint, Kop-Coat Biturnastic Super Service Black or Tnemec 46-465. PART 3 - EXECUTION 3.01 General A. All surface preparation, coating and painting shall conform to applicable standards of the National Association of Corrosion Engineers, the Steel Structures Painting Council, the American Concrete Institute, the Forest Products Research Society, and the Manufacturer's printed instructions. Material applied prior to approval of surface preparation by the Owner shall be removed and reapplied to the satisfaction of the Owner at the expense of the Contractor. B. All work shall be performed by skilled craftsmen qualified to perform the required work in a manner comparable with the best standards of practice. Continuity of personnel shall be maintained and transfers of key personnel shall be coordinated with the Owner. C. Unless otherwise specified, dust, dirt, oil, grease or any foreign matter that will affect the adhesion or durability of the finish must be removed by washing with clean rags dipped in an approved cleaning solvent and wiped dry with clean rags. D. Coating and painting systems include surface preparations, prime coatings and finish coatings. Surface preparation for a specific Service Condition shall be as specified for that coating or painting system. Unless otherwise specified, prime coatings shall be field applied. Where prime coatings are shop applied, they shall be thoroughly cleaned and touched up in the field as specified. If shop coatings are deficient or damaged too extensively for adequate repair, they shall be removed and coated and painted as directed by the Owner. Contractor shall instruct suppliers to provide prime coats compatible with the finish coats November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-1 9 specified. Any off site work which does not conform to this specification is subject to rejection by the Owner. E. The Contractor's coating and painting equipment shall be designed for application of materials specified and shall be maintained in first class working condition. Compressors shall have suitable traps and filters to remove water and oils from the air. Contractor's equipment shall be subject to approval by the Owner. 3.02 Surface Preparation, Ferrous Metal A. General The latest revision of the following surface preparation specifications of the Steel Structures Painting Council and the National Association of Corrosion Engineers shall form a part of this specification: 1. Solvent Cleaninu (SSPC-SPI). Removal of oil, grease, soil and other contaminants by use of solvents, emulsions, cleaning compounds, steam cleaning or similar materials and methods which involve a solvent or cleaning action. 2. Hand Tool Cleaninu (SSPC-SP2). Removal of loose rust, loose mill scale and other detrimental foreign matter to degree specified by hand chipping, scraping, sanding and wire brushing. 3. t. Removal of loose rust, loose mill scale and other detrimental foreign matter to degree specified by power wire brushing, power impact tools or power sanders. 4. White Metal Blast Cleaninu CSSPC-SP5). Blast cleaning to a gray-white uniform metallic color until each element of surface area is free of all visible residues. 5. Commercial Blast Cleanina (SSPC-SP6 and NACE No. 3). Blast cleaning until at least two-thirds of each element of surface area is free of all visible residues. 6. Brush-off Blast Cleanina (SSPC-SP7 and NACE No. 4). Blast cleaning to remove loose rust, loose mill scale and other detrimental foreign matter to degree specified. 7. Near White Blast Cleaninu (SSPC-SP10 and NACE No. 2). Blast cleaning to nearly white metal cleanliness, until at least 95% of each element of surface area is free of all visible residues. B. Slag and weld metal accumulation and spatters not removed by the fabricator, erector, or installer shall be removed by chipping and grinding. All rough welds shall be ground smooth and sharp edges shall be ground to approximately 1/8" radius. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-20 C. D. E. F. G. H. I. J. K. L. Field blast cleaning for all surfaces shall be dry sandblasting unless otherwise directed. The Contractor shall comply with all applicable local, state, and federal, air pollution control regulations for blast cleaning. All oil, grease, welding fluxes and other surface contaminants shall be removed by solvent cleaning per SSPC-SP1 prior to blast cleaning. Maximum particle size of abrasives used in blast cleaning shall be that which will produce a surface profile in accordance with these specifications and the recommendations of the manufacturer of the specified coating system to be applied. Sand used in blast cleaning operations shall be washed, graded and free of contaminants that would interfere with adhesion of coating or paint and shall not be reused. Shop applied temporary coatings or shop applied coatings of unknown composition shall be completely removed before the specified coatings are applied. During blast cleaning operations, caution shall be exercised to insure that existing coatings or paint are not exposed to abrasion from blast-cleaning. The Contractor shall keep the area of his work in a clean condition and shall not permit blasting materials to accumulate as to constitute a nuisance or hazard to the prosecution of the work or the operation of the existing facilities. Surfaces shall be cleaned of all dust and residual particles of the cleaning operation by dry air blast cleaning, vacuuming or another approved method prior to application of specified coatings or paint. No coatings or paint shall be applied over damp or moist surfaces. All welds shall be neutralized with a suitable chemical compatible with the specified coating materials. 3.03 Surface Preparation, Galvanized Ferrous Metal Prior to application of specified pretreatment coating, galvanized ferrous metal shall be alkaline cleaned per SSPC-SPI to remove oil, grease, and other contaminants detrimental to adhesion of the protective coating system to be used. 3.04 Surface Preparation, Ferrous Metal with Existing Coatings A. All grease, oil, heavy chalk, dirt, or other contaminants shall be removed by solvent or detergent cleaning prior to abrasive blast cleaning. The generic type of the existing coatings shall be determined by laboratory testing. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-21 B. The Contractor shall provide the degree of cleaning specified in the coating system schedule for the entire surface to be coated. If the degree of cleaning is not specified in the schedule, deteriorated coatings shall be removed by abrasive blast cleaning to SSPC-SP6, Commercial Blast Cleaning. Areas of tightly adhering coatings shall be cleaned to SSPC-SP7, Brush-off Blast Cleaning, with the remaining thickness of existing coating not to exceed 3 mils. C. If coatings to be applied are not compatible with existing coatings the Contractor shall apply intermediate coatings per the paint manufacturer's recommendation for the specified coating system or shall completely remove the existing coating prior to abrasive blast cleaning. A small trial application shall be conducted for compatibility prior to painting large areas. D. Coatings of unknown composition shall be completely removed prior to application of new coatings. 3.05 Surface Preparation, Concrete and Masonry A. Surface preparation shall not begin until at least 30 days after the concrete or masonry has been placed. B. All oil, grease, and form release and curing compounds shall be removed by detergent cleaning per SSPC-SP1 before abrasive blast cleaning. C. Concrete and masonry surfaces and deteriorated concrete surfaces to be coated shall be abrasive blast cleaned to remove existing coatings, laitance, deteriorated concrete, and to roughen the surface. The abrasive used should be dry and clean with the maximum particle size that will pass through a 16 mesh screen. Cracks and voids shall be repaired or filled with the specified filler and surfacer. Final surface shall be sound, firmly bonded, smooth and free of voids, cavities, dirt, dust, oils, grease, laitance, or other contaminants. D. Residual abrasive, dust and loose particles shall be removed from the surface by vacuuming or blowing off with dry high pressure air. E. Unless required for proper adhesion, surfaces shall be dry prior to coating. The presence of moisture shall be determined with an approved moisture detection device. 3.06 Surface Preparation, Wood and Composition Materials All surfaces shall be cleaned of dirt, oil, or other foreign substances with mineral spirits, scrapers, sandpaper, or wire brushes. Finished surfaces exposed to view shall, if necessary, be made smooth by planing or sandpapering. Small, dry, seasoned knots shall be surface scraped, sandpapered, and thoroughly cleaned, and shall be given a thin coat of WP-578 Western Pine Association knot sealer before application of the priming coat. Large, open unseasoned knots, and all beads or streaks of pitch shall be scraped off, or if the pitch is still soft, it shall be removed with mineral spirits or turpentine and the resinous area shall be thinly coated with knot sealer. After priming, all holes and imperfections shall be filled with putty or plastic wood (colored to match the November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-22 finish coat), allowed to dry, and sandpapered smooth. cleaned of all loose or flaking paint and sandpapered to a tight, adherent surface. Existing surfaces shall be 3.07 Coating and Painting Application, General A. Coating and painting application shall conform to the requirements of the Steel Structures Painting Council Paint Application Specifications SSPC-PA1 , latest revision, for "Shop, Field and Maintenance Painting", and recommended practices of the National Association of Corrosion Engineers, the American Concrete Institute, the Forest Products Research Society and the Manufacturer of the coating and paint materials. B. Application of the first coat shall follow immediately after surface preparation and cleaning and within an eight hour working day. Any cleaned areas not receiving first coat within an eight hour period shall be recleaned prior to application of first coat. Cleaned surfaces and all coats of the specified system shall be inspected prior to application of each succeeding coat. Contractor shall schedule such inspection with Owner in advance. C. Prior to assembly, all surfaces made inaccessible after assembly, shall be prepared as specified herein and shall receive the coating or painting system specified. D. Thinning shall be permitted only as recommended by the Manufacturer and approved by the Owner. E. Coating materials shall be protected from exposure to cold weather, and shall be thoroughly stirred, strained, and kept at a uniform consistency during application. F. Each application of coating or paint shall be applied evenly, free of brush marks, sags, runs, and variations in color, texture and finish, with no evidence of poor workmanship. Care shall be exercised to avoid lapping on glass or hardware. Coatings and paints shall be sharply cut to lines. Finished surfaces shall be free from defects or blemishes. G. Protective coverings or drop cloths shall be used to protect floors, fixtures and equipment. The working parts of all mechanical and electrical equipment shall be protected from damage during surface preparation and coating operations. Openings in motors shall be masked to prevent entry of coating or other materials. Care shall be exercised to prevent coatings or paints from being spattered onto surfaces which are not to be coated or painted. Spray painting shall be conducted under carefully controlled conditions. The Contractor shall be fully responsible for and shall promptly repair any and all damage to adjacent facilities or adjoining property occurring from blast cleaning or coating operations. H. When two or more coats of coating or paint are specified, each coat shall be of a slightly different shade to facilitate inspection of surface coverage of each coat. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-23 I. J. K. L. M. N. Specified film thicknesses per coat for the Service Conditions are minimum required. Contractor shall apply additional coats as necessary to achieve the specified thickness. All material shall be applied as specified. All welds and irregular surfaces shall receive a brush coat of the specified product prior to application of the first complete coat. Cleaning and coating shall be coordinated so that dust and other contaminants from the cleaning process will not fall on wet, newly-coated surfaces. Drying time between coats and surface curing shall be as recommended by the coating manufacturer depending upon field conditions of temperature and humidity. Times shall be submitted with the shop drawings based on 70°F and relative humidity of 50%. In the case of enclosed areas, the forced air ventilation system shall operate continuously to provide air circulation and exhausting of solvent vapors. 3.08 Shop Coating A. All items of equipment, or parts of equipment which are not submerged in service, shall be shop primed and then finish coated in the field, after installation, with the specified or approved color. The methods, materials, application equipment and all other details of shop painting shall comply with these specifications. 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. B. All items of equipment, or parts and surfaces of equipment which are submerged or inside an enclosed hydraulic structure when in service, with the exception of pumps and valves, shall have all surface preparation and coating work performed in the field. C. For certain pieces of equipment it may be undesirable or impractical to apply finish coatings in the field. Such equipment may include engine generator sets, equipment such as electrical control panels, switchgear or main control boards, submerged parts of pumps, ferrous metal passages in valves, or other items where it is not possible to obtain the specified quality in the field. Such equipment shall be shop primed and finish coated and touched up in the field with the identical material after installation. The Contractor shall require the manufacturer of each such piece of equipment to certify as part of its shop drawings that the surface preparation is in accordance with these specifications. Copies of applicable coating manufacturer's material data sheets shall be submitted with equipment shop drawings. D. For certain small pieces of equipment the manufacturer may have a standard coating system which is suitable for the intended service conditions. In such cases, the final determination of suitability will be made during review of the shop November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-24 3.09 3.1 0 3.1 1 drawing submittals. Equipment of this type generally includes only indoor equipment such as instruments, small compressors, and chemical metering pumps. E. Shop painted surfaces shall be protected during shipment and handling. Primed surfaces shall not be exposed to the weather for more than 6 months before topcoated, or less time if recommended by the coating manufacturer. F. Damage to shop-applied coatings shall be repaired in accordance with these specifications and the coating manufacturer's printed instructions. G. The Contractor shall make certain that the shop primers and field topcoats are compatible and meet the requirements of these specifications. Protective Coating and Painting Schedule The protective coating and painting schedule provided herein or on the drawings shall indicate the coating system to be used. The schedule shall not be construed as a complete list of all surfaces to be coated but rather as a guide as to the application of the various coating systems. All surfaces shall be coated and painted except those specifically excluded herein or on the drawings. Color Scheme All colors and shades of colors of all coats of paint and protective coating material shall be as selected by the Owner, except as noted below under "Pipe Color Coating". The Contractor shall submit a current chart of the manufacturer's available colors to the Owner at least forty-five days prior to the start of coating and painting operations. Pipe Color Coding and Labelling All exposed piping shall be color coded and labeled to conform to all OSHA requirements and "Scheme for the Identification of Piping Systems'' (ANSI A1 3.1). "State (1 0) Standards" color scheme shall be used to further identify specific commodity. As a guideline the following color coding schedule is provided. Color codes shall be confirmed with Owner prior to commencing work. A. Color Code Schedule Item Color Code Aeration Air Aftercooler Return Aftercooler Supply Air Scour Alum AWT Bypass Safety Green Safety Red Safety Red Safety Green Safety Yellow/Red Bands Safety Red Belt Press Return Water Gray November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-25 (continued) Item Color Code Caustic Soda Chemical Drain Chlorine Gas Chlorine Liquid Chlorine Solution Chlorine Vacuum Cold Sludge Digested Sludge Digested Sludge Exchange Drain Engine Cooling Water Engine Exhaust Filter Backwash Filter Backwash Return Filter Effluent Filter Influent Fire Water Flotation Thickener Overflow Flotation Thickener Return Foul Air Froth Spray Fuel Oil Fuel Oil Return Fuel Oil Supply Gravity Thickener Overflow Ground Water Drainage Grit Grit Chamber Influent Grit Washer Overflow Heat Recovery Return Heat Recovery Supply Heated Sludge Holding Tank Overflow High Pressure Digester Gas High Temperature Wash Water Hydrogen Peroxide Industrial Water Influent Force Main November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Safety Orange Safety Orange Safety Orange Safety Orange Safety Orange Safety Orange Brown Brown Brown Gray Safety Red Safety Red Safety Red Safety Red Safety Red Safety Red Safety Red Brown Gray White Safety Red Black Black Black Brown Gray Brown Brown Gray Safety Blue/Orange Bands Safety Blue/Orange Bands BrownNellow Bands Brown Light Yellow Safety Blue/Orange Bands Safety Orange Safety Red Brown Coating and Painting 09900-26 (continued) Item Color Code Jacket Water Return Jacket Water Supply Liquid Propane Gas Low Pressure Digester Gas Lube Oil Return Lube Oil Supply Lube Oil Waste Methanol Natural Gas Plant Air Plant Effluent Polymer Potable Water Primary Influent Primary Skimmings Primary Sludge Pumped Drainage Water Raw Influent Recycled Water Return Activated Sludge Return Water Sample Sanitary Drain Seal Water Secondary Effluent Secondary Skimmings Secondary Sludge Skimmings Sludge Heater Bypass Sludge Return Sludge Transfer Spray Wash Storm Drain Sulfer Dioxide Gas Sulfer Dioxide Liquid Sulfer Dioxide Solution Sulfer Dioxide Vacuum Tank Drain Tertiary Effluent November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Safety Red Safety Red Light Yellow Light Yellow Black Black Black Safety Yellor.:/R Light Yellow d Bands Safety GreenNellow Band Safety Red Safety Yellow/Blue Bands Safety Blue Brown Brown Brown Gray Brown Safety Purple Brown Safety Red Safety Red Gray Safety Red Safety Red Brown Brown Brown Brown Brown Brown Safety Red Gray Safety Orange Safety Orange Safety Orange Safety Orange Brown Safety Red Coating and Painting 09900-27 (continued) I tem Color Code Thickened Digested Sludge Brown Thickened Sludge Brown Thickened Waste Activated Sludge Brown Thickener Dilution Water Safety Red Vent Ventilation Air Wash Water Waste Activated Sludge Waste Sludge White White Safety Red Brown Brown 6. Label Codinq Pipe labels (or markers) shall be pressure-sensitive, self-adhesive, vinyl film pipe markers as manufactured by Seton Name Plate Corporation, or equal. Background colors, letter colors, letter heights and spacing shall conform with ANSI A13.1. Pipe designation labels and direction-of-flow arrows shall be placed at 10 foot intervals (maximum) and at every change in direction. Pipe designation wordings shall be selected by the Owner and may not correspond to standard wordings available from the manufacturer. 3.12 Cleanup Upon completion of the work, all staging, scaffolding, and containers shall be removed from the site or destroyed in a manner approved the Owner. Coating or paint spots and oil or stains upon adjacent surfaces shall be removed and the job site cleaned. All damage to surfaces resulting from the work of these specifications shall be cleaned, repaired or refinished to the satisfaction of the Owner and at no additional cost to the Owner. November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Coating and Painting 09900-28 SECTION 09902 PETROLATUM WAX TAPE COATING PART1 - GENERAL 1.1 1.2 1.3 SCOPE This section covers the work necessary to furnish and install petrolatum wax tape coating on pipe, pipe flanges, fittings or other buried pipeline appurtenances, complete, as indicated on the drawings and specified herein. SUBMllTALS DURING CONSTRUCTION Submit manufacturer's technical product data, details, installation instructions and general product recommendations. All submittals shall be in accordance with the General Provisions, Section 2-5.3. PRODUCT IDENTIFICATION The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired only. Products of other manufacturers will be considered in accordance with the Contract Documents. PART 2 - MATERIALS 2.1 2.3 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. PRIMER Exposed surfaces shall be prime coated with a blend of petrolatum, plasticizer, and corrosion inhibitor having a paste-like consistency. The material shall have the following properties: Pour Point 400-100" F Flash Point 350" F minimum Approximate Coverage Color Brown 1 gal/lOO square feet The primer shall be Trenton Wax-Tape Primer or equivalent. January 2004 Petrolatum Wax Tape Coating Calavera Pump Station (860-3-CAL) Contract 38891 09902-1 2.3 WAX TAPE Two types of petrolatum wax tape shall be available from the manufacturer: one type for buried installations and another type for above-ground installations. 2.3.1 BURIED INSTALLATIONS The covering material shall be a plastic-fiber felt tape, saturated with a blend of petrolatum, plasticizers, and corrosion inhibitors that is easily formable over irregular surfaces. The tape shall have the following properties: Color: Brown Thickness 70-90 mils Dielectric Strength I70 volts/mil Tape Width 6 inches Saturant Pour Point 115" - 125°F Wax tape shall be Wax-Tape #1 as manufactured by The Trenton Corporation (Ann Arbor, Michigan), or approved equal. 2.4 OUTER COVERING The primed and wax-tape wrapped surface shall be wrapped with a plastic tape covering consisting of three (3) layers of 50 gauge, clear, polyvinylidene chloride, high cling membranes wound together as a single sheet. The material shall have the following properties: Width Thickness Dielectric Strength Water Absorption Color 6 inches 1.5 mils 2000 volts/mil Negligible Clear The outer covering shall be Trenton Poly-Ply or approved equal. 2.5 OTHER PETROLATUM WAX TAPE SYSTEM COMPONENTS Any components not listed above, but required for a complete petrolatum wax tape coating system as recommended for this application by the manufacturer shall be provided at no additional cost to Owner. PART 3 - EXECUTION 3.1 GENERAL The petrolatum wax tape system shall be installed in conformance with the manufacturer's recommendations. END OF SECTION January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Petrolatum Wax Tape Coating 09902-2 SECTION 10520 FIRE EXTINGUISHERS AND BRACKETS PART 1 - GENERAL 1.01 SUMMARY A. Provide fire extinguishers and brackets where shown on the Drawings, as specified herein, and as needed for a complete and proper installation. B. Related work: 1. Documents affecting work of this Section include, but are not necessarily limited to, General Provisions, Supplemental Provisions, Special Construction Provisions, and Sections in Division I of these Specifications. 1.02 SUBMllTALS A. All submittals shall be in accordance with the General Provisions, Section 2-5.3. B. Product data: Contractor shall submit complete information, drawings, and technical data for all equipment, material, and components, including, but not limited to, the following: 1. 2. 3. 4. Materials list of items proposed to be provided under this Section; Manufacturer's specifications and other data needed to prove compliance with the specified requirements; Dimensioned drawings as needed to depict the space required for these items, and their interface with the work of other trades. Manufacturer's recommended installation procedures which, when approved by the Owner's Designated representative, will become the basis for accepting or rejecting actual installation procedures used on the Work. 1.03 QUALITY ASSURANCE A. Use adequate numbers of skilled workmen thoroughly trained and experienced in the necessary crafts and completely familiar with the specified requirements and methods needed for proper performance of the work of this Section. PART 2 - PRODUCTS 2.01 BRACKET AND FIRE EXTINGUISHER A. At each fire extinguisher location, provide a 4A:60B:C type ABC Dry Chemical Fire extinguisher with appropriate hanging bracket. Fire extinguishers shall be as manufactured by Amerex, Ansul, or equal. B. Service, charge, and tag each fire extinguisher not more than five calendar days prior to the Date of Substantial Completion of the Work as that Date is established November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Fire Extinguishers and Brackets 10520-1 by the Owner. PART 3 - EXECUTION 3.01 3.02 SURFACE CONDITIONS A. Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not proceed until unsatisfactory conditions are corrected. IN STALL ATlON A. Coordinate as required with other trades to assure proper and adequate provision in the work of those trades for interface with the work of this Section. B. Install the work of this Section in strict accordance with the original design, the approved Shop Drawings, pertinent requirements of governmental agencies having jurisdiction, and the manufacturer's recommended installation procedures as approved by the Owner, anchoring all components firmly into position for long life under hard use. C. Locate additional bracket-mounted extinguishers where directed by the Owner and the Fire Department official. END OF SECTION November 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Fire Extinguishers and Brackets 10520-2 SECTION 11 005 GENERAL MECHANICAL AND EQUIPMENT TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 Description A. These General Mechanical and Equipment Specifications, which apply to all systems and equipment unless specified otherwise in the equipment Technical Specifications or on the Drawings, are hereby made a part of each and all of the separate Sections of this Specification. Contractor shall direct the attention of all subcontractors and suppliers of mechanical and related appurtenances to the provisions of the Contract Documents and this Section. 8. The Contractor shall provide all tools, supplies, materials, equipment, and all labor necessary for the furnishing, construction, installation, testing, and operation of all equipment and appurtenant work, complete and operable, all in accordance with the requirements of the Contract Documents. 1.02 Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. Shop Drawings. The Contractor shall furnish complete shop drawings for all equipment specified in the various sections of the Specifications and the Construction Drawings, together with all piping, valves, and controls for review by the Owner. 6. Lateral Desian Data. Submit with the shop drawings, details of constructions, and method of attachment for all manufactured products showing compliance with Paragraph 3.04, "Lateral Design and Restraint". Where specified in the Special Requirements or Special Construction Provisions for certain equipment, calculations and details signed by a Professional Engineer who has demonstrated proficiency in Structural Engineering or Civil Engineering and is registered in the State of California shall be submitted. The calculations shall be performed specifically for this project, during the time frame of the project and be dated by the Engineer performing them. C. Tools. The Contractor shall supply one complete set of special wrenches or other special tools necessary for the assembly, adjustment, and dismantling of the equipment. All tools shall be of best quality hardened steel forgings with bright, finished heads and with work faces dressed to fit nuts. The set of tools shall be neatly mounted in a labeled tool box of suitable design provided with a hinged cover. D. ODeration and Maintenance Manuals. Prepare and submit manuals covering all mechanical equipment and machinery and its electrical components in accordance with Special Construction Provisions. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-1 E. Manufacturer's Certified Reports. Each equipment manufacturer, or his authorized representative, shall submit a written report stating that equipment is ready for start-up and interim operation, and a subsequent written report certifying that the equipment has been properly installed, lubricated, aligned, started-up, tested, adjusted, and operated over the equipment range (full to minimum load, speed, range); the equipment is free from any undue stress imposed by connecting piping or anchor bolts, and is ready for operation by the Owner: equipment is safe to operate and that the equipment is fully covered under the terms of the guarantee. Note that interim operation of equipment may be necessary to provide required treatment or suitable plant operation. F. Contractor's Certification ReDorts. Contractor shall submit a written certification along with the manufacturer's certification for start-up and interim operation that he has examined subject equipment and confirms that it is ready for start-up and interim operation and is safe to operate. Contractor shall submit written certification for relocated, modified, temporarily installed Owner's equipment or Contractor furnished equipment that has been installed for interim operation by the Owner stating that said equipment has been started-up, is ready for operation and is safe to operate. G. Liftinn Recommendations. Each manufacturer shall provide details for proper lifting of equipment and materials during unloading, handling, and installation. Means of lifting equipment shall not impose any undue stress to the equipment. Contractor shall strictly adhere to said manufacturers recommendations. H. Storage Requirements. Each manufacturer shall provide details and storage of equipment and materials for protection under the specific conditions of the project site, such as rain, snow, freezing, windy, wind blown sand, high temperatures, direct sunlight, etc. 1.03 Quality A. Factorv Inspection. The Owner or its representative may inspect fabricated equipment at the factory without cost to Contractor. The Contractor shall notify the Owner in sufficient time so that factory inspection can be arranged. Factory inspection will be made after manufacturer has performed satisfactory checks, adjustments, tests and operations. Approval of equipment at the factory only allows the manufacturer to ship the equipment to the site, and does not constitute final acceptance by the Owner. B. Standard of Quality. Items of equipment are specified by performance and by name of a manufacturer for the purpose of establishing a standard of quality and acceptable experience. Where "or equal" or "approved equal" is specified Substitute equipment will be acceptable if it can be demonstrated to the Owner that the substitute is in strict accordance with the Specifications and equal in quality to those models specifically named. Substitutions shall be submitted in accordance with Contractor Submittals Technical Specifications. Manufacturers specified have been determined by the Owner to meet or exceed the minimum September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-2 acceptable standard for the designated equipment; however, manufacturer's standard model may require optional equipment, upgrade or modification to meet the intent and requirements of the specifications. All mechanical equipment furnished under this Specification shall be new and of current design. C. Manufacturer's Experience. Unless specifically named in the detailed Specifications, a manufacturer shall have furnished equipment of the type and size specified which has demonstrated successful operation and is in regular use. D. Field Inspection, Start-up, and Adiustment. The Contractor shall demonstrate that all equipment meets the specified performance requirements. Contractor shall provide the services of an experienced, competent, and authorized service representative of the manufacturer of each item of major equipment who shall visit the site of Work to perform the following tasks: 1. Assist the Contractor in the installation of the equipment. 2. To inspect, check, adjust if necessary and approve the equipment installation. 3. To start-up and field-test the equipment for proper operation, efficiency, and capacity and to assure that equipment is ready and safe to operate. 4. To perform necessary field adjustment during the test period until the equipment installation and operation are satisfactory to the Owner. 5. To instruct the Owner's personnel in the operation and maintenance of the equipment. Instruction shall include step-by-step trouble shooting procedures with all necessary test equipment. E. Costs. The costs of all inspection, start-up, testing, adjustment, and instruction work performed by said factory-trained representatives shall be borne by the Contractor. When available, the Owner's operating personnel will provide assistance in the field testing. 1.04 Equipment A. General. All equipment furnished shall be complete, ready for installation and operation. All bolts, nuts, washers, mounting plates, bed plates, bases, anchor bolts and other miscellaneous items necessary to form a complete, installed, operational system shall be furnished whether specifically specified or not. B. Conditions of Service.All equipment shall be capable of operating over the full range specified under the project site environmental conditions including altitude, temperature, relative humidity, freezing, or windy condition as shown on the Drawings or specified in the Special Requirements. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment I 1005-3 C. Adaptation of Equipment. No responsibility for alteration of a planned structure to accommodate substitute equipment will be assumed by the Owner. Equipment which requires alteration of the structures will be considered only if the Contractor assumes all responsibility for making and coordinating all necessary alterations. All revisions to structures, mechanical, electrical, or other work made necessary by such substitution shall be approved by the Owner and the cost of said revisions, including cost of redesign, shall be made at the Contractor's expense. D. Motors. Ratings specified and/or shown for the proposed equipment are in accordance with the best information available to the Owner. In the event any equipment item proposed by the Contractor should require motors with larger horsepower rating than indicated on Electrical Drawings, it shall be the Contractor's responsibility to provide the proper control equipment, required modifications to motor control centers, starting equipment, feeder and branch circuits, and accessories as required to make the installation comply with the electrical code and to prevent excessive voltage drop without added cost to the Owner. E. Match Equipment and Driver. Equipment shall be matched such that the motor rating meets or exceeds the driven equipment requirements (over its full operating range) and the motor controller, switchgear, variable speed drive, etc. meets or exceeds the motor requirements. Where the motor controller or variable speed drive will induce additional heat or otherwise cause derating of the motor, the motor shall be oversized accordingly. F. Existina Equipment. Where equipment to be furnished is installed in an existing enclosure or adjacent to existing equipment, the Contractor shall field check the dimensions of existing equipment, location of conduits, etc., and shall familiarize himself with all existing conditions and difficulties to be encountered in performing such work. 1.05 Guarantee and Warranties The Contractor shall guarantee all equipment in accordance with the conditions of the Contract Documents and as specified in the Contract Appendix or Special Provisions. In addition to the general guarantee requirements, equipment guarantee shall cover faulty or inadequate design; improper assembly or erection; defective workmanship or materials; and leakage, breakage, or other failure. For equipment bearing a manufacturer's warranty in excess of one (1) year, furnish a copy of the warranty to Owner with Owner named as beneficiary. PART 2 - PRODUCTS 2.01 General Requirements A. Materials and Workmanship. All equipment furnished shall be new and guaranteed free from defects in materials, design, and workmanship. It shall be the manufacturer's responsibility to ascertain the conditions and service under which the equipment will operate and to warrant that operation under those September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-4 conditions shall be successful. All parts of the equipment shall be amply proportioned for all stresses that may occur during fabrication, erection, and intermittent or continuous operation. B. Standards. All equipment shall be designed, fabricated, and assembled in accordance with the best modern engineering and shop practice. Individual parts shall be manufactured to standard sizes and gages so that repair parts, furnished at any time, can be installed in the field. Like parts of duplicate units shall be interchangeable. Equipment shall not have been in service at any time prior to delivery, except as required by tests. Materials shall be suitable for service conditions. Iron castings shall be tough, close-grained gray iron free from blowholes, flaws, or excessive shrinkage and shall conform to ASTM A48. Except where otherwise specified, structural and miscellaneous fabricated steel used in items of equipment shall conform to the Standards of the American Institute of Steel Construction. All structural members shall be considered as subject to shock or vibratory loads. Unless otherwise specified, all steel which will be submerged, all or in part, during normal operation of the equipment shall have a minimum nominal thickness of 1/6inch. Provide equipment and materials suitable for the service conditions and meeting standard specifications such as ANSI, ASME, AWWA, ASTM, NEMA, UBC and UL. The location of the fabricator and his shop schedule shall be furnished to the Owner prior to the beginning of fabrication so that the Owner can schedule shop inspection. C. Structural Steel Fabrications. Conform to "Code of Standard Practice for Steel Buildings and Bridges" and "Specification for the Design, Fabrication and Erection of Structural Steel for Buildings" of the AlSC unless otherwise indicated or specified. Design all fabrications for dynamic and vibratory loadings. Use structural steel shapes conforming to ASTM A36, A440, A500, A501, A570, A618, or equal, as applicable. Galvanize specified items in accordance with ASTM A123, A153, or A386 as applicable; use galvanized bolts and fasteners with galvanized assemblies. D. Weldinq. Unless otherwise specified or shown, all welding shall conform to the following: 1. All welding shall be by the metal-arc method or gas-shielded arc method as described in the American Welding Society's "Welding Handbook" as supplemented by other pertinent standards of the AWS. Except as modified herein, welding process qualification and operator qualification shall comply with the applicable requirements of the "Code for Arc and Gas Welding in Building Construction" of the AWS. 2. Latest revision of ANSVAWWA D100 and AWWA C206. 3. Each weld shall be uniform in width and size throughout its entire length. Each layer shall be smooth, free from slag, cracks, pinholes, and undercut and shall be completely fused to adjacent weld beads and base metal. Cover pass shall be completely free of coarse ripples, irregular surfaces, non-uniform bead pattern, high crown, deep ridges or valleys between beads, and shall blend smoothly and gradually into surface of September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-5 base metal. Butt welds shall be slightly convex, of uniform height, and shall have full penetration. Fillet welds shall be of size indicated, with full throat, and with each leg of equal length. Repair, chipping, or grinding of welds shall not gouge, groove, or reduce base metal thickness. 4. All composite fabricated steel assemblies which are to be erected or installed inside a hydraulic structure, including any fixed or movable structural components of mechanical equipment, shall have continuous seal welds to prevent entrance of air or moisture. 5. In assembly and during welding, the component parts shall be adequately clamped, supported, and restrained to minimize distortion and for control of dimensions. Weld reinforcement shall be as specified by the AWS code. Upon completion of welding, all weld splatter, flux, slag, and burrs left by attachments shall be removed. Welds shall be repaired to produce a workmanlike appearance, with uniform weld contours and dimensions. All sharp corners of material to be painted or coated shall be ground to a minimum of 1/32-inch on the flat. E. Protective Coatinqs. All equipment shall be painted or coated in accordance with Basic Coating and Painting Specifications for Water and Wastewater Facilities. F. Protection of Eauioment. All equipment including valves shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage. All equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Pumps, motors, drives, or electrical equipment, and other equipment having anti-friction or sleeve bearings shall be stored in weather tight storage facilities prior to installation. For extended storage periods, plastic equipment wrappers should be avoided, to prevent accumulation of condensate in gears and bearings. G. Electrical Equipment. Maintain electrical equipment, controls, and keep insulation dry at all times. Keep heaters in equipment connected and operating until equipment is placed in operation. 2.02 Lubrication A. Lubrication Svstems. Lubrication of equipment shall ensure constant presence of lubricant on all wearing surfaces. Lubricant fill and drain openings shall be readily accessible. Easy means for checking the lubricant level shall be provided. Prior to testing and/or operation, the equipment shall receive the prescribed amount and type of lubricant as required by the equipment manufacturer. Equipment lubrication systems shall be systems that require attention no more often than weekly during continuous operation, shall not require attention during start-up or shut down, and shall not waste lubricants. B. Lubrication. Contractor shall have all moving parts of the furnished equipment lubricated prior to shipment to insure protection against corrosion during shipment, storage, and installation. Lubricants furnished by Contractor shall September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-6 conform to the manufacturer's printed recommendations. Safeguard(s) shall be provided where necessary to prevent operation of the equipment without proper lubrication. Contractor shall provide Alemite lubrication fittings at all locations on the equipment which require grease lubrication. All lubrication fittings shall be readily accessible. The grease passages and ports shall be designed so that grease is forced into the normally loaded sides of the bearings. Contractor shall lubricate all equipment prior to start-up. Contractor shall furnish grease lubricants for testing and initial lubrication, and for protection of wearing surfaces of equipment he furnishes during shipment and storage. Where lubricants can come in contact with potable water, the lubricant shall not have any toxic or deleterious effect on potable water and shall be of material approved by the FDA in accordance with Federal Regulation No. 121.253, Category AA. Contractor shall furnish one Year's supply of lubrication oils, grease, and other necessary lubricants including applicators and grease guns required for lubrication. All lubricants shall be as specified by the equipment manufacturer. Contractor shall limit the various types of materials by consolidating, with the equipment manufacturer's approval, the required lubricants into the least number of different lubricants. Contractor shall coordinate with Owner to match, where possible, lubricants normally used by Owner. 2.03 Equipment Supports A. Equipment Bases and Bedplates. Mount equipment assemblies on a single heavy cast iron or welded steel bedplate unless otherwise shown or specified. Provide bases and bedplates with machined support pads, tapered dowels for alignment or mating of adjacent items, adequate openings to facilitate grouting, and openings for electrical conduits. Continuously weld seams and contact edges between steel plates and shapes, and grind welds smooth. Do not support machinery or piping on bedplates other than that which is factory installed. Provide jacking screws in equipment bases and bedplates to aid in leveling prior to grouting. All mechanical equipment, tanks, control cabinets, motor control centers, etc. shall be mounted on raised concrete bases, unless otherwise shown or specified, Provide plates of minimum thickness of 1/4-inch. Pump bedplates shall include a drip lip and associated piping and appurtenances for directing gland leakage to a single disposal point. B. Anchors and Sleeves. Each equipment manufacturer shall be responsible to design and specify the required anchor equipment including bolts, nuts, washers, and sleeves for securing equipment bases and bedplates to concrete bases. Loads shall be those induced by the equipment and lateral loads as specified herein. Design calculations are specifically required for certain equipment by the Special Requirements or Special Construction Provisions. Where specified or where specialty anchoring equipment is necessary for the equipment being furnished the anchoring equipment shall be furnished by the manufacturer. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-7 2.04 2.05 2.06 Sleeves shall be at least 1-1/2 times anchor bolt diameter. Anchor bolts shall be as specified on Drawings or, if not specified, shall be Type 316 stainless steel and of adequate length to allow for 1-1/2 inch of grout under baseplates and adequate anchorage into structural concrete unless otherwise shown or specified. Couplings A. Flexible couplings shall be provided between the driver and the driven equipment to accommodate angular misalignment, parallel misalignment, end float, and to cushion shock loads. B. The Contractor shall have the equipment manufacturer select or recommend the size and type of coupling required to suit each specific application. C. Taperlock bushings may be used to provide for easy installation and removal on shafts of various diameters. D. Where universal type couplings are shown they shall be of the needle bearing type construction, equipped with commercial type grease fittings. Shafting A. General. All shafting shall be continuous between bearings and shall be sized to transmit the maximum power output of the driver. Keyways shall be accurately cut in line. Shafting shall not be turned down at the ends to accommodate bearings or sprockets whose bore is less than the diameter of the shaft. All shafts shall rotate in the end bearings and shall be turned and polished, straight, and true. B. Materials. Shafting materials shall be appropriate for the type of service and torque transmitted. Environmental elements such as corrosive gases, moisture, and fluids shall be taken into consideration. Materials shall be as shown or specified unless furnished as part of an equipment assembly. Bearings A. General. Bearings shall conform to the standards of the Anti-Friction Bearing Manufacturers Association, Inc. (AFBMA). Bearings shall be as specified by the specific equipment specification and as generally specified herein. Bearing application, fitting practice, mounting, lubrication, sealing, static rating, housing strength, and other important factors shall be considered in bearing selection. All re-lubricatable type bearings shall be equipped with a hydraulic grease fitting in an accessible location and shall have sufficient grease capacity in the bearing chamber. All lubricated-for-life bearings shall be factoty-lubricated with the September 2003 Calavera Pump Station (860-3-CAL) Contract 3889 1 Mechanical and Equipment 1 1005-8 manufacturer's recommended grease to insure maximum bearing life and best performance. Bearing housings shall be of cast iron or steel and bearing mounting arrangement shall be as specified or shown, or as recommended in the published standards of the manufacturer. Split-type housings may be used to facilitate installation, inspection and disassembly. Sleeve-type bearings shall have a Babbit or bronze liner. B. Bearing Life. Except where otherwise specified or shown, all bearings shall have an L-10 minimum rated life expectancy corresponding to the type of service, as follows: Tvpe of Service Design Life hears) L-IO Design Life (hours) (whichever comes first) 1. 16-hour shift or less 10 40,000 2. Continuous 10 60,000 2.07 Gears and Gear Drives A. Unless otherwise specified, gears shall be machine'cut, of the helical or spiral- bevel type, designed and manufactured in accordance with AGMA Standards, with a minimum service factor of 1.7, a minimum L-10 bearing life of 60,000 hours and a minimum efficiency of 94 percent. Worm gears shall not be used, unless specifically approved by the Owner. B. All gear speed reducers or increasers shall be of the enclosed type, oil- or grease-lubricated and fully sealed, self-cooling, with a breather to allow air to escape but keep dust and dirt out. The casing shall be of cast iron or heavy duty steel construction with lifting lugs and an inspection cover for each gear train. An oil level sight glass and an oil flow indicator shall be provided, arranged for easy reading. Where the Contractor elects to furnish equipment requiring external cooling by water or radiator he shall be responsible to furnish and install the cooling facilities necessary for proper operation. C. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation. D. Material selections shall be left to the discretion of the manufacturer, provided the above AGMA values are met. Input and output shafts shall be adequately designed for the service and load requirements. Gears shall be computer- matched for minimum tolerance variation. The output shaft shall have 2 positive seals to prevent oil leakage. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-9 2.08 2.09 2.1 0 E. Oil level and drain location relative to the mounting arrangement shall be easily accessible. Oil coolers or heat exchangers with all required appurtenances shall be furnished when necessary. F. Where gear drive input or output shafts have to connect to couplings or sprockets supplied by others, the Contractor shall have the gear drive manufacturer supply matching key taped to the shaft for shipment. Safety Guards All equipment furnished by Contractor shall comply with the applicable requirements of the Safety Orders of the Division of Industrial Safety of the State of California. Copies of the Safety Orders as available at the Printing Division, Documents Section, State of California, Sacramento, California, 9581 4. Cover belt or chain drives, fan blades, couplings, exposed shafts, other moving or rotating parts and hot surfaces (exhaust pipes) on all sides with safety guards. Safety guards shall be free of all sharp edges and corners. Use corrosion-resistant materials at least equivalent to hot-dip galvanized steel. Safety guards shall be fabricated from 16 USS gage, or heavier, galvanized or aluminum-clad steel or l/Z-inch mesh galvanized expanded metal. Design guards for easy installation and removal. Provide necessary supports, accessories, and fasteners, of hot-dip galvanized steel or stainless steel. Design guards in outdoor locations to prevent entrance of rain and dripping water. Manufacturer's Nameplates Manufacturer shall provide Type 316 stainless steel nameplates of ample size with embossed or preprinted lettering, fastened to the equipment in a prominent place with 316 S.S. pins. On nameplates, display manufacturer, serial number, date of manufacture, model number and essential operating characteristics. Inscribe data plates with specific or directed information. Equipment Identification Nameplates In addition to manufacturer's nameplates specified in equipment Technical Specifications and herein, Contractor shall provide project specific equipment identification nameplates. Equipment mounted out-of-doors shall be furnished with nameplates constructed of Type 31 6 stainless steel with 3/8" high embossed lettering and shall be fastened to the equipment in a prominent place with 316 stainless steel pins. Equipment mounted indoors shall be furnished with nameplates constructed of laminated engraving plastic. Nameplates shall be fastened to the equipment in a prominent place with 316 stainless steel pins. Colors, lettering, styles, and sizes shall be as selected by Owner. Nameplates shall display the project specific identification of each equipment item. Proposed nameplate wording shall be submitted to Owner for approval. PART 3 - EXECUTION September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-1 0 3.01 Coordination Contractor shall coordinate the installation of equipment and assure compliance with Drawings. Said Drawings show in a diagrammatic form the arrangements desired for the principle apparatus, piping, and similar appurtenances, and shall be followed as closely as possible. Contractor shall take all measurements for his Work at the installation sites, verify all subcontractor and equipment drawings and be responsible for the proper installation. Specific equipment furnished may require certain modifications for installation. Contractor shall have all pertinent equipment shop drawings submitted and accepted by Owner prior to performing work impacted by said equipment. Contractor shall coordinate, monitor, schedule the fabrication, and verify compliance with Contract Documents of equipment assembled of several components under the unit responsibility of one manufacturer or equipment supplier. Contractor shall submit the following information to the Owner in writing on a monthly basis: A. Shipment dates of the various components to the unit responsibility manufacturers. B. Scheduled dates of factory tests by unit responsibility manufacturers. C. Schedule shipment dates to site of unit responsibility items. D. Scheduled arrival date, installation date and start-up date. 3.02 Installation A. Inspection. Contractor shall inspect each item of equipment for damage, defects, completeness, and correct operation before installing and inspect previously installed related Work to verify that it is ready for installation of equipment. Contractor shall inspect the completed installation. B. Preparation. Prior to installing equipment, Contractor shall ensure that installation areas are clean and that concrete or masonry operations are completed. Contractor shall maintain the areas in a broom-clean condition during installation operations. Equipment shall be cleaned, conditioned, and serviced in accordance with Instruction Manuals and the Contract Documents before installing. C. Certification. Upon completion of equipment installation certifications from the manufacturer and the Contractor in accordance with Part 1.02 shall be submitted. D. Eauipment Installation. Contractor shall employ skilled craftsmen experienced in installation of the types of equipment specified and use specialized tools and equipment, such as precision machinist levels, dial indicators, gages, and micrometers, as applicable. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-1 1 E. Anchor Bolts. Equipment shall be attached to concrete base using cast in place anchor bolts. Contractor shall set anchor bolts correctly before structural concrete is placed. Use of templates or setting drawings is required. An acceptable anchorage system is a cast in place sleeve anchor which allows adjustment as manufactured by DECO Manufacturing Co. or equal. Deferred bolting devices shall not be permitted, unless otherwise shown on Drawings. F. Base and Bedplate Grouting. Prior to placing grout, initial fitting and alignment of connected piping shall be completed. Once equipment is leveled and aligned to the manufacturer's tolerances, base or bedplates can be grouted by filling the entire space between the base or bedplate and concrete foundation. Exposed grout, shall be troweled to a smooth dense finish, edges beveled to 45 degrees and damp cured with burlap for three days. When grout is fully hardened, Contractor shall remove jacking screws and tighten nuts on anchor bolts. Equipment alignment and level shall be checked for conformance with manufacturer's tolerances and corrective work performed as necessary. 3.03 Equipment Shop and Field Performance Testing A. General. Equipment shall be shop tested and field tested as specified in the specific Technical Specifications. B. Field Testinq. Unless otherwise specified field testing of equipment shall be performed to demonstrate compliance with Contract Documents. Equipment operation, over the entire specified range, shall be free of vibration, noise, or cavitation. Contractor shall furnish test instruments required to confirm performance. Testing shall include the following: 1. Vibration shall be checked and recorded over the operating range and shall be equal to or less than the amplitude limits recommended by the manufacturer or as otherwise specified. As a minimum, pumping units shall meet or exceed the vibration requirements of the Hydraulic Institute Standards. 2. Equipment performance shall be documented by obtaining concurrent readings showing motor voltage and amperage, and equipment output. Readings shall be documented for at least three operating conditions. Each power lead to the motor shall be checked for proper current balance. 3. In the event any equipment fails to meet the performance requirements, it shall be modified and retested. 3.04 Lateral Design and Restraint All manufactured equipment supplied under this Contract shall be designed, constructed and attached to resist stresses produced by seismic forces and wind forces as specified. . Equipment that does not vibrate during normal operation shall be rigidly attached. Equipment that vibrates during normal operation shall be attached by means of isolators with mechanical stops that limit movement in all directions unless it can be September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 1 1005-1 2 demonstrated by calculations that such stops are not required. Equipment or portions of equipment that move during normal operation shall be restrained with mechanical devices that prevent displacement unless it can be demonstrated by calculations that such restraints are not required. A. Calculations shall be submitted where required by the Special Requirements or Special Construction Provisions. B. Minimum Lateral Forces. The minimum lateral seismic and wind forces shall be those prescribed for Essential Facilities by the Uniform Building Code and applicable supplements as published by the International Conference of Building Officials, 5360 South Workman Mill Road, Whittier, CA 90601. Higher lateral forces shall be utilized where specified. C. Contractor shall make submittals of shop drawings, details and data requested herein in accordance with Contractor Submittals Technical Specifications. END OF SECTION September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Mechanical and Equipment 11 005-1 3 SECTION 1 131 0 CLOSE COUPLED VERTICAL TURBINE PUMPING UNIT TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 1.02 Specific Project Description Contractor shall furnish and install Close Coupled Vertical Turbine Pumping Units as specified herein and shown on the Drawings. Pumping units shall be suitable for installation in suction cans and shall include pump, motor, column, shafting and.discharge head. Motor shall be suitable for variable frequency drive operation. Pumping units shall be suitable to operate in variable speed mode using variable frequency drives and to pump filtered recycled water. Specific Project Pumping Unit Requirements A. General All vertical turbine pumps shall be furnished with fabricated steel discharge heads as shown on the Drawings. Pumps shall be provided with single mechanical seals, John Crane Type 21, or equal. Pump manufacturer shall supply a complete seal water system as part of the discharge head including all necessary piping and drain line to the pump can. Pump impellers shall be enclosed design. Pumping unit data per 1.03 need not be submitted with bid, but shall be submitted as Contractor's Submittals. Factory performance test as specified shall be performed. B. Performance Contractor shall furnish and install three (3) vertical turbine pumping units as specified herein and shown on the Drawings. Pumping Unit Requirements: 1. Pumping units shall provide the following performance at a speed of 1,770 RPM: Total Dynamic Flow (gpm) Head (feet) 440 287'* 15' 620* 250'* 800 195l-1- 15' *(design condition shall have a minimum efficiency of 82.5% and maximum NPSHR of 10'). 2. Pumping units will operate from 70% to 100% speed. March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 1 131 0-1 3. Pumping units shall be suitable for variable speed operation using variable frequency driver (VFD). 4. Motors shall be vertical hollow shaft, premium efficiency, 1800 RPM (maximum), 60 horsepower (maximum), 460 volt, 3 phase, 60 hertz. Motors shall be inverter duty rated suitable for VFD operation. No point on the pump performance curve at maximum speed shall exceed motor horsepower. 5. Each pump shall be provided with a fabricated steel discharge head with 8" ANSI 300 Ib. flanged discharge connection and ANSI 150 Ib flanged base. Discharge head shall be designed for a working pressure of 250 psi and a test pressure of 300 psi. 6. Discharge head base flange shall be provided with one welded 1/2" threaded half coupling (3000 Ib) for suction can air release. 7. Pump suction can shall be welded steel with a cement mortar lining. Suction can shall be designed for a working pressure of 150 psi and a test pressure of 225 psi. 8. Column pipe shall be 8" diameter standard weight welded steel pipe. 9. A stainless steel basket strainer shall be provided for each pumping unit. Basket strainer shall be attached to pump with stainless steel fasteners. 10. Pumps shall be as manufactured by Peabody Floway, American Turbine Pump Company, Goulds, or equal. 11. Preliminary pump selections are as follows: Peabody Floway 1 OJKH (6-stage), American Turbine Pump Company 12-M-70 (4-stage) Goulds 1 1 CLC @stage) 1.03 Pumping Unit Data to be Submitted by Bidder Unless specified otherwise in section 1 -02 herein bidder shall submit (with his bid) a certified pumping unit component drawing for each different pumping unit to be furnished and it shall show dimensions of pumping unit and its components including bowl assembly, column assembly, tube and shaft assembly, discharge head assembly, motor, and related appurtenances. Bidders shall submit (with his bid) a certified pump performance curve together with design calculations for each different pump to be furnished. Each curve shall show head versus capacity, pump bowl efficiency versus capacity, brake horsepower versus capacity, overall (wire to water) efficiency versus capacity, all for full operating range specified. Each certified pump curve shall be continuous from zero capacity to maximum pumping unit capacity on the abscissa. It shall be furnished full size on 8-1/2 inches (ordinate) x 11 inches (abscissa) paper. Bidder shall indicate certified values on each curve for the following characteristics at all specified design points since consideration will be given March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 11310-2 thereto in selecting units to be furnished. A. Discharge capacity in gallon per minute. B. Total discharge head in feet (bowl head). C. Pump bowl efficiency. D. Brake horsepower (including losses in pump, shaft, column, and head). E. Wire to water efficiency (including losses in motor, pump, shaft, column, and head). F. Down thrust and momentary up thrust. G. Net positive suction head (close coupled booster application only). Bidder shall submit (with his bid) a guaranteed motor performance curve together with other performance data for each different motor to be furnished. Each curve shall denote horsepower, service factor, efficiency, locked rotor current, and temperature rise and each curve shall show efficiency, power factor, speed, kilowatt input, current, and line voltage under operating range between full load and half load. 1.04 Contractor Submittals Complete submittals (shop drawings) showing performances, fabrication, assembly, and installation, together with detailed specifications and data covering performance and materials of construction, power drive assembly, parts, devices, wiring diagrams, and other accessories forming a part of the pumping units shall be submitted in accordance with the General Provisions, Section 2-5.3. Submittals shall include, but shall not be limited to, the following: A. Submit the following minimum information for each pumping unit specified herein for the Owner's review and approval: 1. Items as specified in Section 1.03 2. Type and model number with reference to pumping units suitability for service for pumps specific intended use. 3. Assembly drawing, nomenclature and material list. 4. Type, manufacturer, model numbers, location and spacing of bearings. 5. Impeller diameter, eye area, sphere size, and identification number. 6. Maximum rotative speed. 7. Complete Performance curves indicating total dynamic head, flow rate, brake horsepower, shutoff head, net positive suction head required, RPM, and efficiency. March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 1 131 0-3 a. 9. 10. 11. 12. 13. 14. 15. 16. 1.05 Quality The manufacturer shall indicate by arrows to points on the H/Q curves the limits recommended for stable operation, between which pumps are to be operated to prevent surging, cavitation, and vibration. The stable operating range shall be as large as possible and shall be based on actual hydraulic and mechanical characteristics of the units. Complete performance curves for 1 OO%, 90%, 8O%, 75%, 50%, and 33% speed showing limits of recommended operation. Provide certified performance curves prior to shipment. Suitability for suction can pressure ranges specified. Motor data, including the manufacturer, size, type designation, minimum guaranteed efficiency and power factor at full load, 3/4 load, and 1/2 load, locked motor current in amps, full load current in amps, the motor speed in rpm, mounting details, and other data as required in the Contract Documents. Written certification of motor inverter duty rating for pumping units specified for operation with variable frequency drives. Outline dimensions and weights of pumping unit components and as assembled. Materials of pump construction including bowls, bowl lining, shafts bearings, impellers and castings. Written certification of pumping units capability to withstand specified pressures. Protective coating of pumping unit. Installation instructions. Operation and maintenance manuals. Suction can fabrication drawings. A. All pumping equipment furnished under this Section shall be of a design and manufacture that has been used in similar applications. Manufacturer shall demonstrate to the satisfaction of the Owner that pumps of similar construction are in service and functioning properly. Manufacturers as specified herein manufacture pumping units with acceptable quality or experience. Manufacturers must, however, meet the performance requirements stated herein for the actual pumps specified. Listing of said manufacturers does not imply that said performance requirements can be met for each pumping unit specified. Contractor shall be responsible to verify that manufacturers supplying equipment meet the size and capacity requirement specified herein. B. Pump manufacturer shall verify applicability of pumping equipment with respect to March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 1 131 0-4 NPSHA, suction piping, can and discharge geometry to assure prevention of cavitation, vibration, surging, overheating, corrosion, and vortexing. C. Pumping unit Supplier shall be an authorized distributor approved by Owner. Said distributor shall have adequate service facilities within a 60 mile radius of Owner's office and shall have a service organization, machine shop facilities, and parts inventory such that servicing or replacement of pumping units can be provided with minimum delay. PART 2 - PRODUCTS 2.01. General Booster vertical turbine pumps shall be close coupled open line shaft (water lubricated) type with an aboveground flanged discharge and either enclosed or semi-open impellers. All parts of the pump exposed to water shall be of stainless steel, brass, heavy cast iron, or equivalent corrosion resistant material. Unless otherwise specified herein, all applicable provisions of AWWA E 101 (Part A), latest, are hereby made a part of these Specifications. Pumps shall be manufactured by Floway, Goulds, Fairbanks Morse, lngersoll Dresser, or equal. 2.02. Pump and Components A. Pump Bowls Bowls shall be of close-grained, gray cast iron, ASTM A48, Class 30 or better, precision cast, free from blow holes, sand pockets, and other detrimental defects. Water passageways in said bowls shall be smooth so as to allow freedom from cavitation and permit maximum efficiency. Each bowl shall have end and/or side seal to prevent slippage of water between bowl and impeller. Bowls shall be lined with vitreous porcelain enamel, or equal, to produce long effective life (said lining shall not be applied for the purpose of short time gain in efficiency). Lining identical to that furnished hereunder shall have been used in the field under similar conditions with satisfactory results for at least a five-year period. Bowls shall be of such size to fit the suction can with proper clearance (velocity of water between bowls and can of five (5) feet per second maximum at specified capacity). Bowls shall be capable of withstanding 1-1/2 times the pump shutoff head pressure (zero discharge) or twice the rated capacity pressure, whichever is greater. Bowl material shall have a minimum tensile strength of 30,000 psi. B. Pump Impellers Impellers shall be of the enclosed or semi-open type, constructed of SAE 40 bronze. They shall be balanced hydraulically and dynamically to prevent vibration and shall be smoothly finished on all surfaces for minimum friction. Impellers shall be March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 1 131 0-5 accurately fitted and securely locked to the pump shaft. Vertical adjustment of impellers shall be possible by adjusting top shaft nut. C. Pump Shaft Pump shaft shall be constructed of AISI-410 or 416 stainless steel and shall be accurately machined to provide smooth operation. It shall easily withstand torsional loads and other stresses encountered within the pump. Pump shaft shall have adequate bearing support at every bowl section and at top and bottom case section, and shall be equipped with a suitable steel coupling for connection to the line shaft. D. Pump Bearinas Pump Bearings shall be sleeve type constructed or SAE 40,64,67, or 660 bronze, or approved equal. Bearing area, bearing cooling, and bearing lubrication shall be ample for long, trouble-free operating life. E. Discharae Case Discharge case shall securelyfasten the pump bowl assembly to the column piping. It shall be heavily reinforced with streamlined fluid passages and it shall contain sleeve bearings for the pump shaft. F. Suction Case Suction case shall securelyfasten the suction bell to the bowl assembly. It shall be heavily reinforced with streamlined fluid passages and it shall contain a sleeve bearing for the pump shaft which is effectively plugged at the bottom to form a grease container. A sand collar shall prevent sand from entering the suction case bearing. G. Suction Bell Unless specified otherwise, a suction bell of the same material and diameter as the bowl assembly shall be provided. The suction bell inlet shall be set two (2) suction bell diameters, 18 inches minimum, from bottom of suction can. H. Column Pipinq Column piping shall be threaded pipe conforming to the following diameters and weights per foot unless specified otherwise. Nominal Size Outside Diameter Weight Per Foot /Inches) (Inches) (Pounds) 6 6.625 18.97 8 8.625 24.70 10 10.750 34.24 12 12.750 43.77 14 14.000 54.57 16 - . ,16.000 62.58 March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 1 131 0-6 Column pipe sections shall be connected with threaded steel sleeve type couplings. Ends of each pipe section shall be faced normal to section axis and machined with threads to permit ends to butt to ensure proper alignment when assembled. Coating of the column piping, either interior or exterior, is not required. I. Line Shaft Line shaft shall be comprised of AIS1 C-1045 material, or approved equal. Line shaft shall be 18 inches minimum length. 2.03. Discharge Head Discharge head shall be constructed of fabricated steel as shown on the Drawings as specified in Section 1.02 herein and shall be capable of withstanding all loads imposed during normal operation. Discharge head shall be furnished with a shaft stuffing box, as approved by Owner, unless specified otherwise. Where pumping unit is installed in a suction can, the discharge head shall be equipped with flanged base matching the can and suitable for suction can pressure specified. Unless specified otherwise, flange base shall be 150 Ib ANSI B16.5 or AWWA C207, Class E. Discharge head shall be suitably enclosed to prevent the entrance of dust and foreign material. Drain plugs shall be provided at the bottom. Discharge head shall have a standard flanged outlet of the size specified except where otherwise permitted. If the discharge flange is not the size specified, an adapter consisting of a smooth eccentric increaser (with bottoms level) or reducer (with tops level) shall be provided. Said adapter shall be flanged to mate the discharge head at one end and as specified at the other. Unless specified otherwise, discharge head base flange shall be bored for two (2) 1/2 inch diameter Class 3000 forged steel couplings. Steel couplings shall be welded to the base flange and provided with threaded plugs. Discharge head assembly shall be capable of withstanding 1-1/2 times the pump shutoff head pressure (zero discharge) or twice the rated capacity pressure, whichever is greater. Motor base, column flange face, and discharge flange face shall be accurately machined, faced, and drilled to NEMA and ASA standards. Upon assembly, motor and discharge head shall form an integral unit. 2.04 Nameplate Nameplate, easy to read and corrosion resistant, shall be provided with each pump and said nameplate shall contain complete pump information including manufacturer, serial number, model number, capacity in gallons per minute, total dynamic head in feet, and pump speed, all at specified design point. Said nameplate shall be mounted on pump head. March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Con tract 3889 1 1 131 0-7 2.05 Suction Cans A. General Booster pump suction cans used in conjunction with close coupled line shaft vertical turbine pumping units shall have diameter, length, lining, coating, wall thickness, orientation of suction inlet, drilling of top flange, and dimensions all as specified herein and as shown on the drawings. Unless otherwise specified, suction cans shall be provided with all booster pumping units. B. Suction Can Reauirements Can shall be sized so that velocity of water passing bowl(s) within can shall be 3 feet per second maximum at specified capacity. Can shall be of sufficient length to provide for column piping of 18 inches minimum length and 18 inches minimum clearance between bottom of pump bowl assembly (suction bell or strainer, whichever is specified) and bottom of can. Can inlet shall be 36 inches minimum and 60 inches maximum from bottom of can. Cans shall be manufactured or 1/4 inch minimum steel plate. Cans shall be provided with suitable baffles, if necessary, to prevent excessive turbulence. Can shall be cement mortar lined, 3/8 inch thick for can diameters 18 inches and less and 112 inch thick for can diameters over 18 inches. Can shall be cement mortar coated, 518 inch thick for can diameters 18 inches and less and 3/4 inch thick for can diameters over 18 inches. Can shall be provided with top flange matching the discharge head and shall be suitable for suction pressure specified. 2.06 Vertical Hollow Shaft Electric Motor A. General Vertical hollow shaft electric motors shall be Design 6, high thrust, squirrel cage, induction type having NEMA weather protected Type I enclosures unless specified otherwise. Motors shall be built to form an integral part of pump head assembly and shall be suitable electrically and mechanically to efficiently and effectively drive pumps specified. Motors shall operate in accordance with these Specifications. Motors shall be manufactured by General Electric Corporation, US. Electrical Motors Division Emerson Electric Co., or Westinghouse Electric Corporation, or approved equal. Unless specified otherwise all materials, workmanship, and tests shall conform with the applicable specifications of the National Electrical Manufacturers Association (NEMA), Institute of Electrical and Electronic Engineers (IEEE), and American Standards Association (ASA), and the Anti-Friction Bearing Manufacturers March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 11310-8 Association (AFBMA). B. Power Unless specified otherwise, motors shall be nameplate rated, 3 phase, 60 hertz, 460 volts. C. Speed Unless specified otherwise, motors shall be 4 pole and shall have no load speed of 1800 rpm. D. Starting Characteristics Motors rated 200 hp and smaller shall be full voltage line start and motors rated 250 hp and larger shall be part winding increment start, unless specified otherwise. E. Efficiency All motors shall be rated premium efficiency, unless specified otherwise. Rated efficiencies shall be based on NEMA Standard MG1-12.536. Guaranteed efficiencies shall be determined in accordance with IEEE #12, Test Method B and E, latest revision. F. Service Factor Rated service factor shall be 1 .I 5 or greater. G. Insulation System All motors shall be provided with Class 'IF" or better insulation systems except that motor lead insulation may be Class "8" or better. Impregnating materials shall be rated Class "F" (155 degrees C) minimum. Completed windings, when tested in accordance with IEEE #57, latest revision, shall show a thermal rating of not less than 150 degrees C for 30,000 hour's life. Windings shall be held firmly in stator slots to prevent coil shift. Sharp edges and burrs shall be removed from stator slots prior to winding or inserting coils. Slot liners and coil end phase insulation, in addition to the coating, shall be provided. Stator windings shall be of high conductivity copper magnet wire. Completed stator windings shall be provided with a properly cured, uniform impregnation for mechanical rigidity, moisture resistance, and protection against winding failures from accumulation of foreign conductive matter. The completed insulation system shall be capable of withstanding phase-to-ground rms voltage of 600 volts continuous and 2,300 volts instantaneous (surge or transient). H. Temperature Rise Rated temperature rise above 40 degrees C ambient temperature measured by resistance at service factor load of 1.1 5 shall not exceed 90 degrees C. March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 1 131 0-9 1. Inrush Current Motors rated between 10 hp and 50 hp shall be rated NEMA locked rotor Code H or better and motors rated 50 hp and larger shall be rated NEMA locked rotor Code G or better except where NEMA locked rotor Code H is specifically permitted. J. Load Conditions Actual motor loads shall not exceed the nameplate rating (horsepower) unless specified otherwise. K. Motor Balance Motors shall be dynamically balanced to a maximum of .001 inches peak to peak amplitude, especially at upper bearing housing. L. Bearinqs Motors shall be equipped with anti-friction type thrust and guide bearings. Angular contact ball thrust bearings shall be used in preference to spherical roller thrust bearings wherever possible. Angular contact ball thrust bearing shall be self cooled wherever possible. Water cooled angular contact ball thrust bearings shall be used only when approved by Owner. Spherical roller thrust bearings shall be water cooled. Bearings shall be of sufficient capacity to carry all static and dynamic up and down thrust loads, both momentary and continuous, imposed by the pump. Bearings shall provide minimum 5 year B10 life (40,000 hours) based on continuous design thrust load or minimum 1 year BIO life (8770 hours) based on maximum pump shut-off thrust load, whichever is greater. Bearings shall also provide for minimum momentary upthrust equal to 30% of rated downthrust. M. Bushinos Motors shall be equipped with lower end head shaft steady bushings unless specified otherwise. N. Lubrication Svstem Motor thrust bearings shall be oil lubricated; however, motor guide bearings may be grease lubricated. Oil lubrication systems shall provide optimum lubrication of bearings. Said systems shall have sufficient oil storage and oil cooling capacity to limit oil bath temperature rise to 45 degrees C above 40 degrees C ambient temperature unless temperature rise of 50 degrees C is specifically permitted. Oil lubricated motors shall have visual level indicators and accessible fill and drain plugs. Indicators and plugs shall be located 180 degrees from pump discharge unless specified otherwise. Grease lubrication systems shall be regreasable and shall provide for automatic flushing or purging of grease cavity during regreasing. March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 11 31 0-10 0. Thermal Protection Motors shall be equipped with 120 volt thermal sensors, one for each phase, affixed to or embedded in motor windings, set to open control circuit at 135 degrees C. All thermal sensor leads shall terminate in motor terminal box. Control modules and reset switches shall be furnished with the thermal sensors. The thermal sensors shall be Texas Instruments 4BA or 7BA, or approved equal. The control modules shall be Texas Instruments 50AA, or approved equal. P. Space Heaters Motors shall be equipped with 120 volt single phase belt type space heaters capable of raising motor temperature 10 degrees C above ambient temperature to prevent condensation. All space heater leads shall terminate in motor terminal box. Q. Non-Reverse Protection Motors shall be equipped with non-reverse mechanisms which shall limit maximum reversal to within 10 degrees of rotation. R. Terminal Box Motors shall be equipped with extra large heavy duty split type conduit boxes. Unless specified otherwise, motor terminal boxes shall be located 90 degrees from pump discharge. S. Screens Motors shall be equipped with suitable corrosion resistant safety and rodent screens. Said screens shall not interfere with motor cooling or motor heat dissipation. T. Nameplates Nameplates, easy to read and corrosion resistant, shall be provided with each motor and said nameplates shall include the following information: a. Motor Data Nameplate - Manufacturer, serial number, model number, rated horsepower, service factor, frequency, phase, load voltage, full load current, full load speed, design designation, locked rotor-code, insulation class, temperature rise, ambient temperature, thermal sensor setting, NEMA nominal efficiency, guaranteed minimum efficiency, full load power factor, and inverter duty rating (where applicable). b. Connection Data Nameplate - Motor start, motor run characteristics, and motor connection diagram. C. Bearinq Data Nameplate - Manufacturers, bearing types (thrust and guide), bearing numbers, thrust capacity, oil type, minimum operating oil viscosity, maximum operating oil bath temperature, required cooling water flow, and maximum cooling water pressure. March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 11310-1 1 PART 3 - EXECUTION 3.01. Pumping Unit Factory Performance Test Each completed pumping unit (pump bowl assembly and vertical hollow shaft motor to be furnished) shall be given a certified factory performance test by pump manufacturer prior to shipment from factory. Test procedures and apparatus shall conform to the applicable requirements of the Hydraulic Institute Standards, except as modified herein. Pumping unit shall be tested at all design points for verification of certified performance curve furnished by manufacturer and approved by Owner. Manufacturer shall guarantee pumping unit performance at specified operating conditions, including flow, total dynamic head, and efficiency. The certified test logs and performance curves shall be signed by an officer of the manufacturer. Tests shall be performed using suitable equipment for measuring bowl capacity, bowl head, power (input, brake, and water), and speed, all as approved by Owner. Equipment shall include a power meter for measuring input power (wire), a dynamometer for determination of pump brake horsepower, and a water meter for measuring output power (water). Contractor shall submit three copies of each certified factory performance test for acceptance by Owner. Owner reserves the right to have a representative present during any tests and to witness same. Owner shall be notified at least two (2) weeks in advance of factory performance testing. 3.02. Pumping Unit Installation Contractor shall bear full responsibility for the satisfactory installation and initial operation of all pumping units furnished under these Specifications and shall provide sufficient personal supervision over all installation and start-up procedures accordingly, unless otherwise specified. Contractor shall also provide all test equipment necessary to determine initial operating performance. During installation, Contractor shall disinfect all portions of the pump bowl assembly and column piping with a chlorine solution and method acceptable to Owner. 3.03. Pumping Unit Field Performance lest (Acceptance Test) After equipment has been completely installed, field tests will be performed which shall be witnessed by Contractor. Each pumping unit furnished hereunder shall be operated for a period of two weeks during which time acceptance tests may be conducted. Head capacity, overall efficiency, and input and output horsepower shall be determined for at least three different operating conditions in the operating range of the pumping unit, including the specified design point, for comparison with the certified pump curves and the factory performance test results, both as approved by Owner. Pumping units (pump and motor) shall perform in the field substantially in accordance with the certified pump curves and the factory performance test results as adjusted for field conditions. If, in the opinion of Owner, the equipment furnished does not perform in accordance with these Specifications, Contractor shall promptly make all necessary repairs or corrections so that the equipment fully complies with these Specifications. Contractor shall remove, restore, and replace the equipment if required. Factory and field performance tests shall be rerun if necessary. Pump manufacturer's field service engineer shall assist March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 11310-12 Owner in the proper conduct of the above field acceptance tests. 3.04. Pumping Unit Vibration Completed pumping unit (pump and motor) shall receive a final field trim balance, as may be required, and vibration of unit shall not exceed 0.0025 inches, peak to peak amplitude when operating. Contractor shall field measure vibration with a suitable calibrated instrument and all measurements shall be witnessed by Owner. Vibration shall be measured at motor thrust bearing housing and at any other locations on pumping unit as directed by Owner. March 2004 Close Coupled Vertical Turbine Pumping Unit Calavera Pump Station (860-3-CAL) Contract 38891 1 1 31 0-1 3 SECTION 131 10 CATHODIC PROTECTION BY SACRIFICIAL ANODES PART 1- GENERAL Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. 1.1 SCOPE Furnish all labor, materials, tools and incidentals to install the sacrificial anode cathodic protection system. Cathodic protection installation, inspection, and testing are required for a complete and workable system. 1.2 DEFINITIONS A. CONTRACTOR. The qualified construction firm selected by the Owner to have prime responsibility for the completion of work. B. OWNER. The Owner, as referred to in these specifications, is the City of Carlsbad. C. ENGINEER. The Engineer is the Owner's representative who is assigned to be the direct contact between the Owner and the Contractor. D. CORROSION ENGINEER. Retained by the Contractor, who is trained and experienced in cathodic protection installations and design and who is either a Registered Corrosion Engineer or a NACE Certified Cathodic Protection Specialist. 1.3 SPECIFICATIONS AND STANDARDS A. American Society for Testing and Materials (ASTM): C94-86 Ready-Mixed Concrete D-2220 D-I248 B3 B8 Concentric-Lay Stranded Copper Conductors Polyvinyl chloride Insulation for Wire and Cable Polyethylene Plastics Molding and Extrusion Materials Soft or Annealed Copper Wire 8. Federal Specifications (FS) Military Specification (Mil. Spec): MIL-C-18480B Coating Compound, Bituminous, Solvent, Coal Tar Base C. Underwriter's Laboratories, Inc. (UL) Publications: 83-80 Thermoplastic-Insulated Wires 486-76 Wire Connectors and Soldering Lugs for Use with Copper Conductors D. National Association of Corrosion Engineers (NACE): RPOI 69-96 Recommended Practice, Control of External Corrosion on Underground or Submerged Metallic Piping Systems January 2004 Cathodic Protection by Sacrificial Anodes Calavera Pump Station (860-3-CAL) Contract 38891 131 10-1 E. National Association of Corrosion Engineers (NACE): RP0286 Electrical Isolation of Cathodically Protected Pipelines 1.4 SUBMllTALS The following information shall be submitted for approval of the ENGINEER in accordance with Section 1300 of these specifications. A. Cataloa Cuts: 1. High potential magnesium anodes 2. At-grade concrete test box with cast iron lid 3. Shunts 4. Wire and cable 5. Exothermic weld kits 6. Weld caps 7. Weld coating 8. Plastic warning tape 9. Insulating flange kits 10. Wax tape coating system B. As-Built Drawings. The CONTRACTOR shall maintain As-Built drawings showing exact locations of anodes, test stations, insulators, and wire trenching runs. Location changes from the design shall be clearly marked in red on a blue line copy of the design drawings. The As-Built drawings shall be submitted to the ENGINEER at the end of the project. The project is not considered complete until As-Built drawings are submitted. C. Test Results. 1. Insulator tests 2. Continuity tests 3. Anode testing and cathodic protection performance PART 2 - MATERIALS 2.1 GENERAL Materials and equipment shall be new and the standard product of manufacturers regularly engaged in the manufacturing of such products. All materials and equipment shall bear evidence of safe operation approval from a nationally recognized testing laboratory. 2.2 HIGH POTENTIAL MAGNESIUM ANODES A. CaDacitv. High potential magnesium anodes shall have a theoretical energy content of 1000 ampere-hours per pound and have a minimum useful output of 500 ampere-hours per pound. January 2004 Cathodic Protection by Sacrificial Anodes Calavera Pump Station (860-3-CAL) Contract 38891 131 10-2 B. Chemical Composition (High Potential Magnesium). Aluminum Manganese Zinc Copper Nickel Iron Silicon Other Magnesium 0.01 percent (max) 0.5 to 1.3 percent 0.002 percent (max) 0.02 percent (max) 0.001 percent (max) 0.03 percent (max) 0.002 percent (max) 0.05 percent each (max) balance C. Open Circuit Potential. The open circuit potential of all anodes, buried in the soil, shall be between 1.55 and 1.75 volts dc versus a copper-copper sulfate reference electrode. D. lnaot Size And Weiqht. Anodes shall be 48-pound pre-packaged, high potential ingots with a trapezoidal cross section. Ingot length shall be 32 inches long. The total packaged weight shall be 105 Ibs. E. Anode Construction. Anodes shall be cast magnesium with a galvanized steel core rod recessed on one end to provide access to the rod for connection of the lead wire. Silver braze the lead wire to the rod and make the connection mechanically secure. Insulate the connection to a 600-volt rating by filling the recess with epoxy and covering any exposed bare steel core or wire with heat shrinkable tubing. The insulating tubing shall extend over the lead wire insulation by not less than 1/2 inch. F. Anode Pre-Packaqed Backfill Material. The anodes shall be completely encased and centered within a permeable cloth bag in a special low resistivity backfill mix with the following composition: Gypsum 75% Powdered bentonite 20% Anhydrous sodium sulfate 5% G. Backfill grains shall be such that 100 percent is capable of passing through a screen of 100 mesh. Backfill shall be firmly packed around the anode such that the ingot is approximately in the center of the backfill. The resistivity of the backfill shall be no greater than 50 ohm-cm when tested wet in a soil box. Total prepackaged weight shall be approximately 105 pounds. 2.3 AT-GRADE TEST STATIONS A. Test Box. At-grade test boxes shall be round, pre-cast concrete with a cast iron lid. The dimensions shall be 14-1/4 inches O.D. by 9 inches I.D. by 12 inches high, similar to Christy G5 Utility Box with a cast iron supporting ring and lid. The lid shall be cast with the legend "CMWD Test Station". B. Identification Taus. All test leads shall be identified with an Avery label (model 5361 ), self-adhesive covered with polyolefin clear heat shrink tubing (3mfp301). The January 2004 Cathodic Protection by Sacrificial Anodes Calavera Pump Station (860-3-CAL) Contract 38891 131 10-3 label shall include: name of facility - size - pipe material; type of insulation; station number. C. Concrete Pad. Test boxes mounted in unpaved areas shall be mounted in a reinforced 24-inch square by 4-inch thick concrete pad constructed of ASTM C94 ready-mix concrete. Rebar shall be No. 4 steel. 2.4 WIRE AND CABLE All wires shall be stranded copper with HMWPE or THWN insulation suitable for direct burial in corrosive soil and water, conforming to UL 83 and ASTM standards 83 or B8. HMWPE insulation shall conform to ASTM D1248 type 1, class c, grade 5. THWN insulation shall conform to ASTM D- 2220. A. Test Leads. No. 8 AWG HMWPE. B. Anode Lead Wire. Anode lead wires shall be No. 12 AWG THWN. C. Mechanical Joint Bond Wire. No. 2 AWG HMWPE. D. All wire and copper connectors shall conform to UL 486-76. E. Wire Solicinq. NO wire splicing is permitted. 2.5 EXOTHERMIC WELD KIT Wire-to-metal connections shall be made by the exothermic "cadweld" welding process. Weld alloy shall be for steel pipe. It is the CONTRACTOR'S responsibility to determine the manufacturer's recommended weld charge size for metallic surfaces. A. Weld Caps. Royston Roybond Primer 747 and Royston Handy Cap 2 or equal. B. Weld Coating. Cold-applied fast-drying mastic consisting of bituminous resin and solvents per Mil. Spec. Mil-C-184808 such as Koppers bitumastic 50 or 505, Tnemec 40-h-413, tape-coat TC mastic or 3M Scotch Clad 244. The minimum coating thickness shall be 25 mils (0.025 inch). 2.6 INSULATING FLANGE KITS A. Gaskets: ANSI B-16.21 , Type E, NEMA GI 0 glass with a rectangular O-ring seal for operation between 20-deg. F and 150-deg. F. Gaskets shall be suitable for the temperature and pressure rating of the piping system in which they are installed. B. Insulating Sleeves: 1/32-inch thick tube, full length, G10 glass material per NEMA LI-1 for operation between 20-deg. F and 150-deg. F. For installation at threaded valve flanges, half-length sleeves shall be used. C. lnsulatinq Washers: 1/8-inch thick, full length, G10 glass per NEMA LI-1 for operation between 20-deg. F and 150-deg. F. January 2004 Cathodic Protection by Sacrificial Anodes Calavera Pump Station (860-3-CAL) Contract 38891 131 10-4 D. Steel Washers: 1/8-inch cadmium plated steel placed between the nut and insulating washer. E. Coatinq: All buried insulating flanges shall be wax taped coated per AWWA C217. See section for "External Coating for Buried Surfaces" below. EXTERNAL COATING FOR BURIED SURFACES A. All buried insulating flange kits, AND buried pipe sections and fitting surfaces that are not epoxy or polyurethane coated shall be wrapped with a three-layer petrolatum wax tape coating system per AWWA C217. B. Primer: All surfaces shall be prime coated with a blend of petrolatum, plasticizer, inert fillers, and corrosion inhibitors having a paste-like consistency. C. Wax Tape: Covering material shall be a synthetic felt tape, saturated with a blend of petrolatum, plasticizers, and corrosion inhibitors that is formable over irregular surfaces. D. Plastic Outer WraD: The primed and wax taped surface shall be covered with a plastic outer wrap consisting of three layers of 50-guage (1 O-mil) polyvinylidene chloride or PVC, high cling membrane wound together. PLASTIC WARNING TAPE A. Plastic warning tape for all cable trenches shall be a minimum of 4 mils thick and 6 inches wide, inert plastic film designed for prolonged use underground, and printed with "Caution: Cathodic Protection Cable Below". PART 3 - CATHODIC PROTECTION INSTALLATION 3.1 GENERAL A. Standard. Cathodic protection installation shall conform to NACE RPOl69-96 "Recommended Practice, Control of External Corrosion on Underground or Submerged Metallic Piping Systems. B. CONTRACTOR Qualifications. All work shall be performed by qualified, experienced personnel working under continuous, competent supervision. Qualified CONTRACTORS must demonstrate at least five years of experience with cathodic protection installations. C. Test Results. The CONTRACTOR shall submit a CORROSION ENGINEER'S report including all test data, conclusions, repairs, and cathodic protection system performance. D. Notification For Testinq. The CONTRACTOR shall notify the ENGINEER at least five days in advance of the anodes and test station installations. The ENGINEER or the OW NER's representative shall, at their discretion, witness the installation of anodes and cathodic protection facilities. Testing shall be as described in this January 2004 Cathodic Protection by Sacrificial Anodes Calavera Pump Station (860-3-CAL) Contract 38891 131 10-5 specification section. 3.2 MAGNESIUM ANODES A. B. C. D. E. F. G. InsDection. All lead wires shall be inspected to ensure that the lead wire is securely connected to the anode core and that no damage has occurred to the lead wire. Lead wire failures shall require replacement of the complete anode and lead wire. Pre-Packaaed Anode Inspection. Each anode shall be inspected to ensure that the backfill material completely surrounds the anode and that the cloth bag containing the anode and backfill material is intact. If the prepackaged anodes are supplied in a waterproof container or covering, that container or covering shall be removed before installation. The CONTRACTOR shall notify the ENGINEER at least five (5) days in advance of installing the anodes. Location. Anodes are to be installed in augured holes as shown in the drawings. Anode positions can be adjusted slightly to avoid interference with existing structures. Alternate anode positions must be approved by the ENGINEER. Handlinq. Care shall be taken to ensure that the anode is never lifted, supported, transported, or handled by the lead wire. All anodes shall be lowered into the hole using a sling or a rope. Anode Hole Size and Depth. Anodes shall be placed vertically at the bottom of a 12 feet deep augured hole, 12 inches in diameter (minimum). Soakina Requirements, Pre-Packaaed Anodes. Once the prepackaged anodes are in the hole, 15 gallons of water shall be poured into the hole so that the anodes are completely covered with water. Allow the anodes to soak for a minimum of 30 minutes before any soil backfill is added. Soil Backfill. After the pre-packaged anodes are soaked, the hole is backfilled with stone-free, native soil. No voids shall exist around the anode bags and the anode lead wire shall not be damaged. The backfill shall be tamped and compacted in 18- inch lifts taking care not to damage the anode lead wire. 3.3 AT-GRADE TEST STATIONS A. Location. At-grade corrosion monitoring test boxes shall be located at the edge and directly behind the curb. All test box locations shall be approved by the ENGINEER. B. Test Box Bottom. Test boxes shall be set in native soil. C. Test Lead Attachment. Test leads shall be attached to the pipe using the exothermic weld process. An 18-inch length of slack wire shall be coiled at each weld at the pipe and inside each test box. D. Concrete Pad. A 24-inch square by4-inch thick reinforced concrete pad is required around each at-grade test station. Test boxes and concrete pad shall be flush with the top of the curb. January 2004 Cathodic Protection by Sacrificial Anodes Calavera Pump Station (860-3-CAL) Contract 38891 13110-6 3.4 WIRE AND CABLE A. Test Lead Trench. Horizontal test or anode lead runs shall be placed in a 36-inch trench. Wire Handlinq. Wire leads shall not be stretched or kinked. Care shall be taken when installing wire and backfilling. If wire insulation is damaged during installation, it shall be rejected and replaced completely at the CONTRACTOR'S expense. All rejected wire shall be removed from the job site at the close of each workday. Plastic Warnina Tape. Plastic warning tape shall be installed in all wire trenches and 12 inches below finished grade. Splicinq. Wire splices are not permitted. B. C. D. 3.5 WIRE-TO-PIPE CONNECTIONS A. B. C. D. E. F. G. H. All connections of copper wires to the pipe shall be made by the exothermic weld method. Weld Charge Size. It is the CONTRACTOR'S responsibility to ensure that the manufacturer's recommended weld charge size is used. Preparation Of Wire. Do not deform cable. Remove only enough insulation from the cable to allow for the exothermic weld. Preparation Of Metal. Remove all coating, dirt, grime and grease from the metal structure by wire brushing. Clean the structure to a bright, shiny surface free of all serious pits and flaws by using a file. The surface area of thestructure must be absolutely dry. Wire Position. The wire is to be held at a 30-degree angle to the surface when welding. Only one wire shall be attached with each weld. Testina of All Completed Welds. After the weld has cooled, the weld shall be tested by striking the weld with a 2-lb hammer while pulling firmly on the wire. All unsound welds shall be cleaned, re-welded, and re-tested. All weld slag shall be removed. Coatinq Of Welds. The area to be coated shall be clean and completely dry. Apply a primer specifically intended for use with an elastomeric weld cap. Apply the weld cap and a bituminous mastic coating material to all exposed areas around the cap in accordance ,with the manufacturer's recommendations. The coating shall overlap the structure coating by a minimum of 3 inches. Mortar Repair. Coating voids shall be filled with cement grout. 3.6 BOND WIRES A. Mechanical Joint Bond Wires. Two (2) No. 2 HMWPE bond wires are required across each non-insulating, in-line valve; a third No. 6 HMWPE bond wire is required Cathodic Protection by Sacrificial Anodes January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 13110-7 from the valve to one outside flange as shown in the drawings. The bond wires shall be attached using the exothermic weld process. Bond wires shall have some slack wire at each weld to allow for creep when backfilling. 3.7 INSULATING FLANGE KITS A. General: Insulating flange kits shall be pre-assembled and installed as recommended by the manufacturer, and per NACE RPO 286. Moisture, soil, and other foreign matter must be fully removed and prevented from contacting any portion of mating surfaces. If foreign matter contacts any portion of these surfaces, then the entire flange shall be disassembled, cleaned, and dried before reassembly. B. Installation: Align and install insulating joints according to the manufacturer's recommendations to avoid damaging insulating materials. The manufacturer's bolt tightening sequence and torque specifications shall be followed. C. Paint Piclments: No electrically conductive pigments or paints shall be used either internally or externally on the bolts, washers, or flanges. D. Inspection: All buried insulating flanges shall be inspected, tested, and approved by the ENGINEER as described in Part 4 of this specification and prior to the application of wax tape coating. 3.8 EXTERNAL COATING A. All buried insulating flanges shall be covered with a 3-layer wax tape coating system per AWWA C217. Additionally, all in-line valves, flanges, couplings, and adapters that are not coated with a bonded dielectric coating shall be wax tape coated per AWWA C217. B. Primer: Surfaces must be cleaned of all dirt, grime, and dust by using a wire brush and clean cloth. The surface shall be dry. Apply the primer by hand or brush. A thin coating of primer shall be applied to all surfaces and worked into all crevices. The primer shall be applied generously around bolts, nuts, and threads, and shall fully cover all exposed areas. The primer should overlap the pipe coating by a minimum of 3-inches. C. Petrolatum Saturated Tape: The wax tape can be applied immediately after the primer. Short lengths of tape shall be cut and carefully molded around each individual bolt, nut, and stud end. For long bolts (such as in couplings), short lengths of tape shall be cut and circumferentially wrapped around each individual bolt. After the bolts are covered, the tape shall be circumferentially wrapped around the flange with sufficient tension to provide continuous adhesion without stretching the tape. The tape shall be formed, by hand, into all voids and spaces. There shall be no voids or gaps under the tape. The tape shall be applied with a l-inch minimum overlap. ' D. Outer Coverinq: A plastic outer cover shall be applied over the petrolatum-saturated tape. The plastic shall be a minimum of 50-guage (1 O-mils) and shall have two layers applied. January 2004 Cathodic Protection by Sacrificial Anodes Calavera Pump Station (860-3-CAL) Contract 38891 1 31 10-8 PART 4 - TESTING AND INSPECTION The CONTRACTOR’S CORROSION ENGINEER shall submit his proposed test procedures to the ENGINEER at least five (5) days in advance of the time that the cathodic protection system testing is scheduled. The ENGINEER shall witness all testing at his discretion. All test data shall be submitted to the ENGINEER within seven (7) days of the completion of the testing. All testing shall be done under the supervision of a qualified CORROSION ENGINEER who is retained by the CONTRACTOR. All deficiencies found to be due to faulty materials or workmanship shall be repaired or replaced by the CONTRACTOR and at his expense. The City of Carlsbad shall be notified at least three (3) days in advance to witness the performance testing. 4.1 TEST LEADS. It is the CONTRACTOR’S responsibility to test all test leads A. Test Method. All completed wire connection welds shall be tested by striking the weld with a 2-lb hammer while pulling firmly on the wire. Welds failing this test shall have the surface re-prepared, have the wire re-welded to the pipe and re-tested. Wire welds shall be spot tested by the Engineer. After backfilling the pipe, all test lead pairs shall be tested using a standard ohmmeter. B. Acceptance. The resistance between each pair of test leads shall not exceed 150% of the total wire resistance as determined from published wire data. 4.2 Anode Lead Wire. The CONTRACTOR is responsible for inspecting anode lead wires. Lead wires shall be spot inspected by the ENGINEER. A. Test Method. A visual inspection and by running his hand along the full length of the lead while installing. B. Acceptance. All leads shall be free of cuts nicks or abrasions in the wire insulation. Damaged leads shall be rejected. 4.3 TEST LEAD TRENCHING. The ENGINEER, at his or her discretion, shall inspect wire trenches and backfill material and methods. A. Test Method. The depth, trench bottom, padding, and backfill material shall be visually inspected prior to backfilling. 6. AcceDtance. Conformance with specifications. January 2004 Calavera Pump Station (860-3-CAL) Cathodic Protection by Sacrificial Anodes 13110-9 Contract 38891 4.4 PIPELINE CONTINUITY THROUGH IN-LINE VALVES. The CONTRACTOR’S CORROSION ENGINEER shall measure the linear resistance of sections of pipe in which in-line valves or other mechanical joints have been installed. All testing shall be done by the CORROSION ENGINEER in the presence of the ENGINEER. A. Test Method. Resistance shall be measured by the linear resistance method. A direct current shall be impressed from one end of the test section to the other (typically test station to test station). A voltage drop is measured for several different current levels. The measured resistance (R) is calculated using the equation R=dV/I, where dV is the voltage drop between the test span and I is the current. The resistance shall be measured for at least four (4) different current levels. B. AcceDtance. Acceptance is a comparison between the measured resistance (from the field test data) and the theoretical resistance. The theoretical resistance must consider the pipe (length and wall thickness) and the resistance of the bond wires. The measured resistance shall not exceed the theoretical resistance by more than 130%. The CONTRACTOR’S CORROSION ENGINEER shall submit, within seven (7) days of the completion of the testing and in a report format, to the ENGINEER all calculations of the theo’retical resistance and measured pipe resistance for each section tested. 4.5 INSULATING FLANGE KITS A. Responsibility: Insulating flanges shall be inspected and tested by the CONTRACTOR’S CORROSION ENGINEER and in the presence of the ENGINEER, prior to backfilling. Testing of the buried insulating flange kit prior to backfill will result in non-acceptance of the insulator. B. Test Method: The assembled flange shall be tested using a Gas Electronics Model 601 Insulation Checker specifically design for testing insulating flanges. The testing shall be done by a qualified CORROSION ENGINEER accepted by the ENGINEER and shall be done in accordance with NACE RPO 286. C. AcceDtance: The installation of the insulating flange kit shall be considered complete when the testing device indicates no shorts or partial shorts are present. The CONTRACTOR shall provide assistance in finding any and all shorts or shorted bolts. All disassembly and reassembly necessary for acceptance shall be done at the CONTRACTOR’S expense. 4.6 CATHODIC PROTECTION PERFORMANCE The cathodic protection system shall be activated and tested by the CONTRACTOR’S CORROSION ENGINEER in the presence of the ENGINEER. A. Test Method. The installed cathodic protection system testing shall include: native pipe-to-soil potentials, protected pipe-to-soil potentials, open-circuit anode potentials, and anode current output measurements. January 2004 Cathodic Protection by Sacrificial Anodes Calavera Pump Station (860-3-CAL) Contract 38891 131 10-10 B. Acceptance. Shall be based on achieving the -850 mV criterion as outlined in NACE RPO169-96. All data shall be submitted, in a typed 8-1/2 X 11 inch report to the City's ENGINEER and the City's CORROSION ENGINEER for approval. C. Compliance With Specifications. Deficiencies or omissions in materials or workmanship found by these tests shall be rectified at the CONTRACTOR'S expense. Deficiencies shall include but are not limited to: broken leads, improper or unclean trenches, lack of 18-inchor slack wire in test boxes; improperly mounted test boxes; improper installation and testing of insulators; and other deficiencies associated with the workmanship, installation, and non-functioning equipment. **END OF SECTION** January 2004 Calavera Pump Station (860-3-CAL) Cathodic Protection by Sacrificial Anodes 131 10-1 1 Contract 38891 SECTION 13221 SURGE ARRESTOR TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 General Description Contractor shall provide all labor, equipment, and materials necessary to construct a surge arrestor system as shown on the Drawings and specified herein. Surge arrestor system shall include a 1,800 gallon horizontal surge tank, compressed air system, and appurtenances. 1.02 References Publications listed below form part of this Specification to extent referenced in the text by basic designation only. The latest edition of publication governs unless otherwise noted. A. ASME American Society of Mechanical Engineers B. ASTM American Society for Testing and Materials C. NEC National Electric Code D. NEMA National Electrical Manufacturers Association E. UBC Uniform Building Code 1.03 Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. Product Data and Shop Drawinas 1. As a minimum, submittals shall include product data and shop drawings for the following: horizontal surge tank, surge tank appurtenances, compressed air system, including air compressor, air receiver, compressor control panel, and appurtenances. 2. Product data shall include catalog cut sheets reflecting characteristics, performance specifications, and selected options for proposed equipment and appurtenances. 3. Shop drawings shall be provided for all mechanical and electrical equipment items showing layout of equipment; orientation, details, and dimensions of all appurtenances; and anchor bolt locations, sizes, and minimum embedment requirements. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Surge Arrestor 13221 -1 4. Equipment anchorage calculations for the horizontal surge tank and air compressor/air receiver. Equipment anchorage calculations shall be prepared in accordance with the Uniform Building Code (latest edition) for Seismic Zone 4 essential facilities. Calculations shall be prepared by a registered professional civil or structural engineer in the State of California. Design of horizontal surge tank, support saddles, and anchorage system shall be based on the flooded weight of the tank (full of water). 5. Shop drawings shall also include compressor control panel wiring diagrams and interconnection diagrams. Wire numbers, terminal numbers, and legend symbols shall be shown. B. Operations and Maintenance Manuals 1. Operation and Maintenance (O&M) Manuals shall be provided in accordance with the requirements of the Special Construction Provisions. 2. Documentation shall be specific to the surge arrestor system constructed and shall cover all aspects of equipment operation and maintenance. Support data for any equipment shall be provided by those supplying the equipment. O&M Manuals shall include the following as a minimum: a. Functional description of major equipment items. b. Complete instructions for operating and maintaining equipment and components. c. Calibration and adjustment of equipment for initial start-up or as required for routine maintenance. d. Support data for commercially available components not produced by the prime equipment manufacturer, but supplied in accordance with the Specifications, shall be supported by literature from the prime manufacturer and incorporated as appendices. e. As-built electrical schematic diagrams (control, wiring, and interconnections). PART 2 - PRODUCTS 2.01 Surge Tank A. General Surge tanks shall be horizontal cylindrical vessels with dished heads fabricated of carbon steel and designed and tested in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. All vessel connections 3" in diameter and larger shall be flanged nozzle type connections. Unless specified March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Surge Arrestor 1 322 1 -2 B. C. otherwise, flanges shall be 300 Ib. ANSI 816.5. All vessel connections smaller than 3" in diameter shall be threaded 3,000 Ib. full or half couplings. Surge tanks shall be as manufactured by Fluid Kinetics Corp., Steel Structures, Inc., or equal. The tank shall be of the configuration and size shown on the Drawings. The tank shall have a minimum working pressure rating of 250 psig and test pressure rating of 375 psig (8 hour duration). The tank shall have a permanently attached nameplate bearing the ASME pressure vessel label. Tank shall have a nominal diameter of 4' and a minimum volume of 1,800 gallons. Nozzles and Appurtenances Minimum tank nozzles and appurtenances shall include all items shown on the Drawings and specified herein. Tank nozzles and appurtenances shall be suitable for the tank minimum working pressure rating specified herein or shown on the Drawings. Each tank shall be provided with two lifting lugs, and fabricated steel saddle type supports fully welded to the vessel and suitable for mounting to a reinforced concrete foundation. Support saddles shall be of adequate height to provide the tank invert clearance shown on the Drawings. As a minimum, each tank shall be provided with the following connections: 1. 2. 3. 4. 5. 6. 7. 8. 9. Inlet/Outlet: One (1) 8" diameter, 300 Ib flanged, bottom mounted Air Inlet: One (1) 1" diameter, threaded, top mounted Liquid Level Electrode Holders: Two (2) 3" diameter, 150 Ib flanged, top mounted Access Manways: One (1) 14"x18" elliptical, end mounted. One (1) 24" diameter hinged, top mounted. Drain Outlet: One (1) 4" diameter, flanged, bottom mounted High Pressure Air Relief Outlet: One (1) 1" diameter, threaded, top mounted Sight Glass Outlets: Two (2) 1" diameter, threaded, end mounted Pressure Gauge Outlet: One (1) 1/2" diameter, threaded, end mounted Pipe Support Bracket: One (1) 3" x 3" x 1/4" thick steel angle (3' long) welded along tank springline for pipe support attachment. Refer to Drawings for angle location Drain and air connections shall be provided with isolation valves. Flanged liquid level electrode holder connection shall be provided for conductance-type March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Surge Arrestor 13221 -3 D. electrodes (reference Specification Section 17000 herein). Contractor shall coordinate nozzle size and location with liquid level electrode manufacturer. Each tank shall be provided with a sight glass assembly mounted to the end of the tank. Each sight glass assembly shall be rated for liquid pressures of 500 psi at 100°F and shall include upper and lower isolation valves, glass tube, drain, four (4) guard rods, and automatic ball checks. Sight glass assembly components shall be constructed of stainless steel. Sight glass assemblies shall be as manufactured by John C. Ernst Co., Eugene Ernst Products Co., or equal. Contractor shall coordinate sight glass assembly length and connection size with tank nozzle locations and size. Coatinq Interior of tank shall be coated per Service Condition A of the Basic Coating and Painting Specification for Water, Recycled Water, and Wastewater Facilities, except two intermediate coats shall be provided in lieu of one, and the finish coat shall be eliminated. Exterior of tank shall be coated per Service Condition A of the Basic Coating and Painting Specification for Water, Recycled Water, and Wastewater Facilities. Contractor shall submit color charts to Owner. Colors for interior and exterior of tank shall be selected by the Owner. 2.01 Compressed Air Supply System A. General The compressed air supply system shall be designed to supply air to the surge tank. The system shall be capable of delivering not less than 8 cfm of clean, oil free air, compressed at 250 psig pressure under standard atmospheric conditions of 14.7 psi pressure, 68°F temperature, and 30% relative humidity. The compressed air supply system shall consist of a two-stage air compressor with air filter, pressure regulator, regulators, low oil level shutdown switch, and gauges. All controls and electrical switchgear necessary to automatically start and stop the compressor at the specified air pressures shall be provided as shown on the Drawings. The compressed air supply system shall be as manufactured by Gardner Denver, Ingersoll-Rand, Saylor-Beall, or equal B. Compressor The compressor shall be a single acting reciprocating unit, capable of operating unattended for a period of eight hours at rated speed and capacity. All parts subject to wear or service shall be field serviceable, and the compressor shall require only minimum maintenance. Cover plates for access openings shall be oil-and dust-tight. The compressor shall be air cooled or liquid cooled. The cylinder cooling area shall be adequate to prevent excessive heating. Air March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Surge Arrestor 13221 -4 passages shall be unrestricted. The crankcase or oil pump shall be provided with means for filling and draining oil and for checking the level of the oil except when sealed anti-friction bearings are used. Pressure lubricated compressors shall be provided with an oil pressure gauge mounted on the front of the compressor. The compressor and the motor shall be mounted on a substantial, single, unified frame assembly. Cylinder arrangement shall be vertical or V-type. Pistons shall be of the automotive type, equipped with piston rings of which at least one shall be an oil ring. Each compressor shall be provided with a low oil level shutoff switch and inlet filter/silencer. The filter shall be of the dry type, with replaceable element. The air filterkilencer shall be readily removable for cleaning. C. Air Receiver The air receiver shall be constructed in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Pressure Vessels, and shall carry the official ASME code symbol stamp. The air receiver tank shall be 60 gallon size, vertical, with a minimum working pressure rating of 250 psig. Unless otherwise specified, the volume of the receiver, in cubic feet, or gallons shall be manufacturer's standard size for compressor requested. The receiver tank shall be furnished with a top mounted steel plate support for the compressor and motor, and shall be provided with support legs and vibration isolation pads suitable for anchoring directly to a concrete pad. Each receiver shall be equipped with an ASME spring-loaded safety valve, air pressure gauge, line shutoff valve, and a drain outlet with a solenoid type automatic tank drain valve. The air pressure gauge shall have a pressure range of 0 to 300 psi. The automatic tank drain valve shall automatically remove water from the air receiver at the end of each operating cycle. D. Electric Motor and Drive The electric motor shall be 5 hp, minimum, TEFC with a 1.15 service factor, and suitable for operation on 460 volt, 3 phase, 60 hertz power. The motor shall have a horsepower nameplate rating at least equal to the horsepower required for continuous operation of the compressor at full load. Unless otherwise specified, starter shall be furnished with capacity and electrical characteristics suitable for the motor according to NFPA No. 70. The compressor shall be driven by a single or multi-V-belt with belt guard. Belt guards shall be OSHA approved. E. Electrical Equipment and Controls 1. Construction The compressor control panel (CCP) shall consist of a combination starter for the compressor motor, ON-OFF switch, elapsed time meter, differential air pressure switch, alarm relays and lights, and control March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Surge Arrestor 13221 -5 voltage transformer suitably sized for all control wiring. The CCP shall be provided with a steel support frame and shall be factory mounted to the compressor assembly. All wiring, switches, push-buttons, lights, and panels shall be NEMA 12. All switches, push-buttons, lights, and elapsed time meters shall be mounted to the CCP door. As a minimum, the CCP shall be provided with the following alarm relays and lights: low oil level shutoff. Compressed air system shall only require main power to be fully operational. Electrical power furnished to the CCP shall be 3 phase, 60 hertz, 480 volts, maintained within industry standards. Voltage tolerance shall be plus or minus 10 percent. 2. Operation When the ON-OFF switch is in the "ON" position, the differential pressure switch shall provide start-stop control to automatically start the unit when the air receiver pressure drops to an adjustable minimum setting and to stop the operation when an adjustable maximum pressure setting is reached. Initial start-stop pressure settings shall be 210 (k5) psig and 240 (-5) psig, respectively. Final start-stop pressure settings shall be determined during system start-up and testing. F. Appurtenances As a minimum, each compressed air system shall be provided with the following appurtenances: 1. Air Filter The filter shall be replaceable element, color change type suitable to remove 99.9% of 0.5 micron particles and oil aerosols and shall be sized for compressor rate at 175 psig with a maximum pressure drop of 4 psig over the element life. Unless shown otherwise on the Drawings, the filter shall be piped into the system with bypass piping for changing the element without system shut down. 2. Pressure Regulator Pressure regulator shall suitable for a maximum inlet pressure of 250 psig and shall be capable of outlet pressure adjustment from 50-200 psig. Pressure regulator shall be constructed with an aluminum or brass body and NPT connections (size as shown on the Drawings) and shall be provided with an integral pressure gauge. Pressure regulator shall be as manufactured by Norgren, Parker Hannifin, or equal. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Surge Arrestor 13221 -6 PART 3 - EXECUTION 3.01 Installation and Start-up Surge arrestor system and components shall be installed in accordance with the manufacturer's printed instructions and as shown on the Drawings. Contractor shall arrange for qualified representatives of the manufacturer to inspect the installation and perform start-up of the equipment and to demonstrate required performance to the satisfaction of the Owner. Contractor shall arrange for not less than 2 hours of adequate instruction of Operators selected by the Owner at a time acceptable to the Owner and the manufacturers. Instruction shall cover system operation and routine maintenance and repair. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Surge Arrestor 13221 -7 SECTION 15000 GENERAL PIPING SYSTEM AND APPURTENANCES PART 1 GENERAL 1 .I DESCRIPTION This Section describes the requirements and procedures for piping systems and appurtenances that apply to a number of other complimentary Specification Sections. The items are listed in this Section to avoid repetition in Sections elsewhere. This Section includes, but is not limited to: Temporary above ground piping (high line), wet taps, flexible pipe couplings, grooved and shouldered end couplings, joint restraint system, field touch up, bolts, nuts, polyethylene wrap, warninghdentification tape, tracer wire, gate well and extension stems, meter boxes, abandonment and removal of existing facilities, and salvage. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. A. American National Standards Institute (ANSI) B. American Society for Testing and Materials (ASTM) 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings 1.4 SUBMllTALS All submittals shall be in accordance with the General Provisions, Section 2-5.3. Submit manufacturers’ catalog data showing dimensions, materials of construction by ASTM reference and grade and coatings.. 1.5 LINING CONTAMINATION PREVENTION Volatile organic compounds present in the linings of items in contact with potable water or recycled water shall not exceed concentrations allowed by the latest requirements of the State Office of Drinking Water and Department of Health Services. Some products and materials may also require proof of NSF certification on the lining materials to be used. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 1 5000- 1 1.6 1.7 1.8 1.9 1.10 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) High line piping, where shown on the Approved Plans or required by the District Engineer, shall be furnished, installed, disinfected, connected, maintained, and removed by the Contractor. Bacteriological sampling and testing shall be performed by a State of California Certified testing laboratory. The Contractor shall provide a submittal to the District showing pipe layout, materials, sizing, flow calculations, schedule and duration of use, and disinfection for all high line piping. The submittal shall be reviewed and approved by the Engineer prior to ordering or delivery of any materials. PIPE TAPPING (WET TAP) All pipe tap (wet tap) connections to existing pipelines, whether for mainline extensions or service laterals, shall be performed by the Contractor under the inspection of the District. The Contractor shall provide materials and labor to excavate, pour thrust block, backfill, compact, and repair pavement as indicated in this Section. JOINT RESTRAINT SYSTEM Joint Restraint Systems may be used for PVC or ductile-iron pipe only with prior approval of the District Engineer. Joint restraint systems shall be used in the place of, or in conjunction with, concrete thrust blocks as directed. Contractor shall submit shop drawings, calculations, and catalog data for joint restraint systems. Splined gaskets, also known as joint restraint gaskets, may be used for PVC or ductile- iron pipe located within casings, or for PVC pipe casings, only. POLYETHYLENE ENCASEMENT Polyethylene encasement shall be used for all ferrous metal materials not otherwise protectively coated. A. Polyethylene wrap shall be used for the protection of buried ductile-iron fittings and valves. B. Polyethylene sleeves shall be used for the protection of buried ductile iron pipe. C. Polyethylene wrap or sleeves may also be installed around buried PVC pipe for recycled water identification. WARN I NG/I D ENTl FIC ATlON TAPE Warninghdentification tape shall be used to identify location of underground utilities and to act as a warning against accidental dig-ins of buried utilities. Warninghdentification tape shall be used on all underground water and recycled water mains, potable and recycled water irrigation systems, sewer mains, and all related appurtenances. WarningAdentification tape shall also be used on cathodic protection wiring systems and tracer wire brought into and out of access ports. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-2 GATE WELLS 1.11 1.12 1 .I3 1.14 1.15 Gate Wells shall be used for buried valves 50mm (4") and larger, unless otherwise indicated on the Standard Drawings. Gate well box and lid shall be used on all gate wells. VALVE STEM EXTENSION Valve Stem Extensions shall be installed when the valve operating nut is more than 1.5m (5') below grade. Stem extensions shall be of sufficient length to bring the operating nut to a point between 300mm (12") and 450mm (18") below the gate well lid. METER BOXES A. B. Meter boxes shall be used for 25mm (1") and 50mm (2") water meters. Meter boxes shall be sized for the specific meter size or size as indicated on the Standard Drawings. RECYCLED WATER IDENTIFICATION Facilities installed for the use of recycled water shall be identified with purple color coating, identification labels, or signs. CURB IDENTIFICATION MARK FOR SERVICES The Contractor shall mark the location of all potable water, recycled water and sewer laterals at the curb crossing by stamping the face of the curb in 50mm (2") high letters as described below: A. Potable water laterals shall be stamped with a letter "W". B. Recycled water laterals shall be stamped with a letter WW". C. Sewer laterals be stamped with a letter "S". PART 2 MATERIALS 2.1 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) High line piping layout, materials and appurtenances shall be as indicated on the approved submittal. 2.2 FLEXIBLE PIPE COUPLINGS Flexible pipe couplings shall be in accordance with the Approved Materials List and as described below: A. Steel Couplings shall have middle rings made of steel conforming to ASTM A 36/A 36M, A 53 (Type E or S), or A 512 having a minimum yield strength of 207 MPa (30,000 psi). Follower rings shall be ductile-iron per ASTM A 536, or steel per ASTM A 108, Grade 1018 or ASTM A 510, Grade 1018. Minimum middle ring length shall be 175 mm (7") for pipe sized 150 mm (6") through 600 mm (24"). January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-3 2.3 2.4 2.5 2.6 B. Sleeve bolts shall be made of stainless steel per ASTM A193 and shall have a minimum yield strength of 276 MPa (40,000 psi), an ultimate yield strength of 414 MPa (60,000 psi), and shall conform to AWWA C111. GROOVED END OR SHOULDERED COUPLINGS FOR DUCTILE IRON OR STEEL PIPE Groove end or shouldered couplings shall be in accordance with the Approved Materials List and as described below: A. Use square-cut shouldered or grooved ends per AWWA C606. Grooved-end couplings shall be malleable iron per ASTM A 47, or ductile iron per ASTM A 536. Gaskets shall be per ASTM D 2000. B. Bolts in exposed service shall conform to ASTM A 183, 69 MPa (10,000 psi) tensile strength. JOINT RESTRAINT SYSTEM Joint Restraint Systems shall be ductile-iron and shall consist of a split-ring restraint with machined (not cast) serrations - on the inside diameter, a back-up ring, and connecting bolts, and shall be selected from the Approved Materials List. Splined gaskets, also known as joint restraint gaskets, shall be a rubber-ring type with stainless steel locking segments vulcanized into the gasket. FIELD TOUCH-UP APPLICATIONS All surfaces of metallic appurtenances in contact with potable water and not protected from corrosion by another system shall be shop-coated by the manufacturer. Appurtenances with damaged coatings shall be repaired or replaced as directed by the Engineer. Touch-up of damaged surfaces, when allowed by the Engineer, shall be performed in accordance with the manufacturer’s recommendations. BOLTS AND NUTS Bolts and nuts shall be as indicated below. A. Cadmium-plated or zinc-plated bolts and nuts shall be used for the installation of pipelines up to 500mm (20“) diameter and shall be carbon steel conforming to ASTM A307, Grade A, unless otherwise indicated on the approved drawings. Bolts shall be standard ANSI B1.l, Class A coarse threads. Nuts shall be standard ANSI B1.1, Class 2H coarse threads. B. Stainless steel bolts and nuts shall be used for the installation of pipelines 600mm (24”) diameter and larger and for submerged flanges. Bolts and nuts shall be Type 316 stainless steel conforming to ASTM A193, Grade B8M for bolts, and Grade 8M for nuts. Use lubricant for stainless steel belts and nuts. Lubricant shall be Husky Lube “0” Seal by Husk-IT Corporation or equal. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-4 C. All bolt heads and nuts shall be hexagonal, except where special shapes are required. Bolts shall be of such length that not less than 6.4mm (1/4") or more than 12.7mm (1/2") shall project past the nut in tightened position. D. Provide a washer under each nut and under each bolthead. Use washers of the same materials as the nuts. 2.7 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be as indicated below and shall be selected from the Approved Materials List. Polyethylene materials shall be kept out of direct sunlight exposure. A. Polyethylene sleeves shall be a minimum 0.305mm (0.012" or 12 mil) thick polyethylene plastic in accordance with AWWA C105. B. Polyethylene wrap shall be a minimum 0.203mm (0.008" or 8 mil) thick polyethylene plastic in accordance with AWWA C105. C. Polyethylene wrap and sleeves shall be clear for use with potable water and purple for use with recycled water. D. Polyethylene or vinyl adhesive tape a minimum of 50mm (2") wide or plastic tie straps shall be used to secure polyethylene encasement. 2.8 WARNING/IDENTIFICATION TAPE Warning/identification tape shall be as indicated below and in accordance with the Approved Materials List. A. Tape shall be an inert plastic film or metallic formulated for prolonged underground use that will not degrade when exposed to alkalies, acids and other destructive substances commonly found in soil. B. Tape shall be puncture-resistant and shall have an elongation of two times its original length before parting. C. Tape shall be colored to identify the type of utility intended for identification. Printed message and tape color shall be as follows: Printed Messaqe Tape Color Caution: Waterline Buried Below Blue Caution: Recycled Waterline Buried Below Purple Caution: Cathodic Protection Cable Buried Below Red Caution: Electric Line Buried Below Red Ink used to print messages shall be permanently fixed to tape and shall be black in color with message printed continuously throughout. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-5 D. Tape shall be minimum 0.1 02mm (0.004" or 4 mil) thick x 150mm (6") wide with a printed message on one side. Tape used with the installation of onsite potable and recycled water irrigation systems shall be a minimum of 75mm (3") wide. 2.9 INSULATING UNIONS & COUPLINGS A. For insulating unions, use a molded nylong sealing sleeve mounted in a three- piece malcable-iron body (ASTM A47 or Al97). Use thread ends when connecting to steel piping, and copper solder joint when connecting to copper piping. Minimum working pressure shall be 150 psi. B. Threaded insulating couplings shall provide dielectric protection from electrolytic corrosion at points where piping of dissimilar metals is joined. 2.10 GATE WELLS Valve gate wells shall be as indicated below in accordance with the Approved Materials List. A. Valve gate well size and material shall be as follows: I Larger than 100mm (4") 200mm (8") diameter (3-900 PVC 1. PVC gate wells for use in recycled water system applications shall be white. 2. PVC gate wells for use in potable water system applications shall be white or blue. B. Gate well box lids shall be as indicated below in accordance with the Approved Materials List. 1. Gate well lids shall be circular ductiie-iron, and shall include a skirt for a close fit inside the upper portion of the gate well. Lids shall be cast with the AGENCY NAME (CMWD) and the word WATER for use on potable water systems, and recycled water for recycled water systems. 2. Lids shall be Brooks 4lT for potable water and Brooks 3RT for recycled water with long skirt, or approved equal. 3. Normally closed potable water valves and recycled water valves shall use box lids by Brooks 3RT with long skirt or approved equal. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-6 4. Lid sizes shall be as follows: 250mm x 500mm (1 2" x 20") 425mm x 750mm (1 7" x 30") 2.1 1 VALVE STEM EXTENSIONS 25mm (1") water services 50mm (2") water services Stem extensions shall be complete with operating nut, location ring, and lower socket to fit valve-operating nut. The configuration of the extension stem nut shall match that of the valve it operates. A. Stem extensions shall be square fiberglass tubing glued together to make a continuous one-piece unit used to a maximum length of 2.4m, eight feet (8'). B. Steel stem extensions shall be used where the maximum length of the extension exceeds 2.4m (8') or at the request of the District Engineer. Steel stem extensions may be round or square hot-dipped galvanized steel tubing of solid design (no pinned couplings permitted) with guides. 2.12 METER BOXES Meter boxes shall be polymer-type boxes with lids selected from the Approved Materials List. A. Meter box sizes shall be as follows: B. Meter box lids for use in potable water system applications shall be gray. C. Meter box lids for use in recycled water system applications shall be purple. 2.13 RECYCLED WATER IDENTIFICATION Materials used to identify pipe and appurtenances used for recycled water, not manufactured in purple color, shall be as described in Carlsbad Reclamation Rules & Regulation for Construction of Reclaimed Water Mains. PART 3 EXECUTION 3.1 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) A. All high line piping, fittings, and service connections shall be furnished, installed, and maintained by the Contractor, and the Contractor shall make connections to a water source designated by the District Engineer. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-7 3.2 B. C. D. E. F. G. H. All pipe, valves, fittings, hose and connections furnished by the Contractor shall be of good quality, clean, and suitable for conveying potable water in the opinion of the District Engineer. The high line pipe shall be installed in such a manner that it will not present a hazard to traffic and will not interfere with access to homes and driveways along its route. Valves shall be installed at 60m (200') intervals or as directed by the District Engineer. The use of pressure reducing valves (PRV) may be required as directed by the District Engineer. The Contractor shall be responsible for disinfecting all high lines, connections, and flushing. Following disinfection and acceptance of the high line as a potable water system, the Contractor shall maintain continuous service through the high line piping to all consumers normally served both directly and indirectly by the pipeline. Upon completion of the work, the Contractor shall remove the high line piping and appurtenances. If progress in making repairs to the high line is inadequate, the District Engineer, may order necessary corrective measures. Corrective measures may consist of directing District personnel or another contractor to complete the work. All costs for corrective measures shall be borne by the Contractor. CONNECTION TO EXISTING FACILITIES (WET TAPS AND CUT-IN INSTALLATIONS) The Contractor shall furnish the tapping sleeve or tee, valves and all other materials as called for in the Standard Specifications in accordance with the Approved Materials List. The Contractor shall provide all equipment and labor required for the excavation and installation of the connection including, but not limited to, backfill and pavement replacement. In certain circumstances the Contractor may be required to provide a water truck, high line, and fittings as part of the equipment for making the connections. In addition, the Contractor shall assist the District in alleviating any hardship incurred during a shutdown for connections. Emergency standby equipment or materials may be required of the Contractor by the District Engineer. Wet taps or cut-in tee and valve installations shall be performed as follows: A. Prior to construction, Contractor shall pothole the existing pipe at the location of the proposed connection. The District shall inspect the pothole prior to Contractor's repair of trench. Refer to the Greenbook for protection of existing facilities. Contractor shall record the following information on as-built drawings: 1. Pipe size, outside diameter. 2. 3. 4. Elevation, grade, and alignment. Pipe type such as ACP, PVC, Ductile-Iron or Steel. Pipe class andor pressure rating. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-8 5. Location of collars, pipe bells, fittings or couplings, if found. Note: collars, bells, fittings, or couplings shall not be within 18-inches of the outer dimension of the tapping saddle. Potential conflicts with existing utilities. 6. B. To facilitate the proposed connection and allow for slight adjustments in alignment, the Contractor shall leave a minimum 3.0m (IO') gap between the new pipe installation and the proposed connection point at the existing water main. The Contractor shall leave a gap longer than 3.0m (10') if conditions warrant, or if directed by the Engineer. The new pipeline shall have successfully passed pressure testing in accordance with Section 15044 and disinfection and bacteriological testing in accordance with Section 15041 prior to proceeding with the connection to the existing pipeline. C. D. After the City Engineer has given approval to proceed with the connection, the Contractor shall schedule with the District for the wet tap or cut-in installation. 1. Shutdowns will be scheduled at the convenience of the District. Shutdowns may be scheduled for nights or weekends if required. 2. The Contractor shall give the District a minimum of 5 working days notice prior to any proposed excavation or shutdown of existing mains or services. Scheduling shall be subject to approval by the District Engineer. 3. The District may postpone or reschedule any shutdown operation if, for any reason, the District Engineer believes that the Contractor is improperly prepared with competent personnel, equipment, or materials to proceed with the connection. 4. If progress in completing the connection within the time specified is inadequate, the District may order necessary corrective measures. Corrective measures may consist of District personnel or another contractor completing the work. All costs for corrective measures shall be borne by the Contractor. E. Contractor may proceed with excavation only after potholing has been completed, materials have been approved and delivered, and wet tap or cut-in installation has been scheduled with approval of a Connection Permit. 1. The Contractor shall saw-cut pavement, excavate and provide and install shoring and steel plating, when necessary, one day prior to the wet tap or cut-in installation. 2. The Contractor shall provide lights, barricades and traffic control in accordance with the agency of jurisdiction and as deemed necessary for the excavation by the Engineer. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-9 3.3 3. The Contractor shall de-water existing mains, in full compliance with NPDES standards, where cut-in installations are required and shall be in the presence of the Engineer and in accordance with Section 15041. Only District personnel are authorized to operate existing valves. The Contractor shall be responsible for any and all damage resulting from unauthorized operation of existing District facilities. 4. The Contractor under the inspection of the City shall perform the following work for wet taps and cut-in installations: a. Wet taps: Disinfect and install and tapping saddle and tapping valve and perform tapping operations. b. Cut-ins: Cut and remove portions of existing mains, and disinfect and install tees, valves, couplings, and appurtenances required to complete the closure. The Contractor shall discard pipe and appurtenances removed from service in accordance with this Section. 5. After the Contractor has performed tapping or cut-in operations, and the Engineer has given approval to proceed, the Contractor shall complete the installation as shown on the Approved Plans in accordance with the Standard Specifications including, but not limited to: a. Disinfecting and installing the pipe section(s) necessary to make the closure to the new system. b. Installing and setting the valve gate well(s) in accordance with the Standard Drawings. C. Installing thrust and anchor blocks in accordance with CMWD Standard Drawing W 15 and W 19. d. Completing all backfill and compaction of the trench in accordance with CMWD Reclamation Rules & Regulations. e. Repairing or replacing pavement as necessary. FLEXIBLE PIPE COUPLINGS Flexible pipe couplings shall be installed in accordance with the manufacturers recommendations and as described below: A. Use plain-end pipe with flexible couplings per AWWA C200. Provide joint harnesses per AWWA MI1 for aboveground applications or where indicated on the Approved Plans. B. Flexible couplings may be used only where indicated on the drawings. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-1 0 C. Clean oil, scale, rust, and dirt from the pipe ends and touch-up the epoxy coating and allow time for curing before installing the coupling. Clean the gaskets before installing. D. Follow the manufacturer's recommendation for installation and bolt torque using a properly calibrated torque wrench. E. Lubricate the bolt threads with graphite prior to installation. 3.4 GROOVED-END OR SHOULDERED COUPLINGS FOR DUCTILE IRON OR STEEL PIPE Grooved-end or shouldered couplings shall be installed in accordance with the manufacturer's recommendations and as described below: A. Grooved-end or shouldered joint couplings shall be installed per AWWA C606 and the manufacturer's recommendations. B. Clean loose scale, rust, oil, grease, and dirt from the pipe or fitting groove and touch-up the epoxy coating as necessary, allowing time for curing before installing the coupling. C. Clean the gasket before installation. Apply a lubricant selected from the Approved Materials List to the gasket exterior including lips, pipe ends, and housing interiors. D. Fasten the coupling alternately and evenly until the coupling halves are seated. Follow the manufacturer's recommendation for bolt torque using a properly calibrated torque wrench. 3.5 JOINT RESTRAINT SYSTEM Joint Restraint Systems shall be installed in accordance with the manufacturers recommendations and as described below: A. Length of pipe to be restrained on each side of bends, tees, reducers and other fittings shall be determined by the Private Engineer or manufacturer of the restraint device. B. Split ring restraint shall be installed on the spigot end of pipe, connected to a back-up ring which seats behind the bell of the adjoining pipe or fitting. C. Restraint devices can be installed prior to lowering pipe into the trench. D. Splined gaskets, also known as joint restraint gaskets, shall be installed in accordance with the manufacturer's recommendations. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-1 1 3.6 BOLTS AND NUTS A. All bolts and nuts shall be new and unused. B. Bolts and nuts shall be cleaned, if needed, by wire brushing and lubricated prior to assembly. C. Tighten nuts uniformly and progressively. D. Buried bolts and nuts shall receive a heavy coat of protective non-oxide grease coating selected from the Approved Materials List prior to being wrapped with polyethylene. E. All stainless steel bolts shall be coated with an anti-seize compound selected from the Approved Materials List. F. Bolts and nuts shall not be reused once tightened. Used bolts and nuts shall be discarded and removed from the job. 3.7 POLYETHYLENE ENCASEMENT A. Polyethylene encasement shall completely encase and cover all metal surfaces. Pipe: AI1 ductile-iron pipe shall be encased with polyethylene sleeves in accordance with Method A described in AWWA C105, or with polyethylene wrap in accordance with Method C described in AWWA C105. Fittings: Fittings such as tees, bends and reducers shall be encased with polyethylene wrap in accordance with AWWA C105. Valves: Valves shall have only the stem and operating nut exposed and the wrap shall be attached so that valve operation will not disturb the wrapping or break the seal. B. Polyethylene sleeves shall be secured with polyethylene or vinyl adhesive tape or plastic tie straps at the ends and quarter points along the sleeve in a manner that will hold the sleeve securely in place during backfill. Polyethylene wrap shall be secured with polyethylene or vinyl adhesive tape in a manner that will hold the wrap securely in place during backfill. 3.8 WARN INGA DENTI FlCATlON TAPE WarningAdentification Tape shall be installed as described below in accordance with the Standard Drawings. A. Tape shall be placed at the top of the pipe zone 300mm (12") above and centered over the utility intended for identification. Tape used with onsite potable and recycled water irrigation systems shall be installed at 150mm (6") above the pipe. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-1 2 3.9 3.1 0 3.1 1 B. Tape shall be installed with the printed side up and run continuously along the entire length of the utility intended for identification. Tape shall be installed on the main piping and all appurtenant laterals, including blowoffs, air valve assemblies, fire hydrants, and services. Tape splices shall overlap a minimum of 600mm (24") for continuous coverage. C. Tape shall be installed prior to placement of the Trench Zone Backfill. GATE WELLS AND VALVE STEM EXTENSIONS Gate wells shall be installed as shown on the Standard Drawings and as described below: A. Gate wells shall be installed as shown on the Standard Drawings and as described below: B. The top exterior portion of the gate well lid and ring shall be coated in accordance with CMWD Reclamation Rules & Regulations. C. Valve Stem Extensions shall be installed when the valve operating nut is more than 1.5m (5') below grade. Stem extensions shall be of sufficient length to bring the operating nut to a point between 300mm (12") and 450mm (18") below the gate well lid. Valve stem extensions shall be installed in accordance with the Standard Drawings. METER BOX INSTALLATION Meter boxes shall be installed at the elevations and locations shown on the Approved Plans and in accordance with the Standard Drawings. Near the completion of the project, a final meter box adjustment to finish grade may be required. Water meters shall not be installed until final adjustments are made to the meter box and approved by the District. ABANDONMENT OR REMOVAL FROM SERVICE OF EXISTING FACILITIES Before excavating for new mains that are to replace existing pipes or services, the Contractor shall make provisions for the continuation and maintenance of service to customers as directed by the District Engineer. Abandonment or removal from service of existing mains, appurtenances or water services shown on the Approved Plans or as called for by the District Engineer shall be as directed by the District Engineer. Abandonment or removal from service of existing mains, appurtenances or water services shown on the Approved Plans or as called for by the District Engineer shall be as indicated below and in accordance with the Standard Drawings: A. Abandonment in place: 1. Existing pipe lOOmm (4") and smaller shall have a short section of pipe removed and pipe ends encased in concrete. January 2004 General Piping System and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15000-1 3 2. Existing pipe 150mm (67 through 350mm (14") shall be cut and plugged with concrete or shall be pressure-grouted at intervals of 60m (200') as recommended by the Engineer. 3. Existing pipe 400mm (16") and larger shall be entirely filled by pressure- grouting or by blown sand as determined by the Engineer. 4. Existing pipe ends shall be filled with concrete in accordance with the Standard Drawings. 5. All valves shall be removed and remaining fitting blind flanged. 6. Gate wells shall be removed and replaced with compacted backfill. 7. Water service corporation stops shall be closed. Meter boxes and curb stops shall be removed. Service lateral to be cut back a minimum of 24" below the finished grade. 8. Water services to be abandoned that are connected to pipelines that will remain in service shall be abandoned in-place. 9. Sewer laterals shall be cut and plugged with concrete or capped at the main as directed by the Engineer for the specific circumstance and material type identified. 10. Sewer access holes shall have the cover and frame, concrete ring, grade rings and cone section removed. Inlet and outlet piping shall be plugged with concrete, manhole void shall be filled with sand, and a 300mm (12") thick, reinforced concrete slab shall be poured over the top of remaining manhole. The Contractor shall backfill hole to ground surface with compacted select fill. B. Removal by excavation: 1. Existing pipe and appurtenances shall be removed from the ground as indicated on the Approved Plans or as directed by the District Engineer. 2. Contractor shall provide measures that allow for the removal of existing sewer mains and appurtenances with no leakage of raw sewage. Transportation of sewer mains and appurtenances removed from service shall be in waterproof trucks to prevent raw sewage from leaking on public streets. January 2004 Calavera Pump Station (860-3-CAL) General Piping System and Appurtenances Contract 38891 15000-1 4 3. Removal of asbestos-cement pipe (ACP) and sewer mains and appurtenances shall be in accordance with all applicable State and Federal requirements. Legal disposal is the responsibility of the Contractor. Obtain approval from the agency having disposal jurisdiction with respect to disposal sites. 4. Backfill, compaction, and surface repair of all excavations for removal of pipe and appurtenances shall be made in accordance with the Approved Plans, the Standard Specifications, and the Standard Drawings. 3.12 SALVAGE When the Contractor is required to remove existing pipe and appurtenances, or portions thereof, from the ground, such material may, at the discretion of the Engineer, be considered salvage. All materials identified as salvage are considered property of the District. A. The Contractor shall remove and temporarily stockpile all materials identified as salvage in a safe location that will not disrupt traffic or shall deliver salvage to the District's Field Operations Yard as directed by the District Engineer. 6. The Contractor shall legally dispose of all other materials in an appropriate manner. Disposal is the responsibility of the Contractor. Obtain concurrence from the agency having disposal jurisdiction with respect to disposal sites and transportation methods. 3.13 RECONNECTIONS A. The Contractor may encounter unused service laterals or appurtenant piping connected to an existing pipeline being replaced. Laterals and appurtenance piping that will not be connected to the new pipeline shall be abandoned as described in section 3.1 1. B. Existing service laterals or appurtenances to be connected to new pipelines shall be as shown on the Approved Plans or as directed by the District Engineer in accordance with the Standard Drawings. END OF SECTION January 2004 Calavera Pump Station (860-3-CAL) General Piping System and Appurtenances Contract 38891 15000-1 5 SECTION 15041 DISINFECTION OF PIPING PART 1 GENERAL 1.1 1.2 1.3 1.4 1.5 DESCRIPTION This section describes requirements for disinfection by chlorination of potable and recycled water mains, services, pipe appurtenances and connections. REFERENCED STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. A. American Water Works Association (AWWA) B300 Standard for Hypochlorites B301 Standard for Liquid Chlorine C651 Disinfecting Water Mains RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Specifications 15000, 1 5044, 15056, 15057, 15061, and 15064 SERVICE APPLICATION A. All water mains and appurtenances taken out of service for inspection, repairs, or other activity that might lead to contamination shall be disinfected before they are returned to service. B. All new water mains and temporary high lines shall be disinfected prior to connection to the District's existing system. C. All components incorporated into a connection to the District's existing system shall be disinfected prior to installation. SUBMITTALS All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. A written disinfection and dechlorination plan signed by a certified chlorinator shall be submitted to the Engineer for review and approval prior to starting disinfection or dechlorination operations. Plan for disinfection method and procedure shall include equipment used to inject the chlorine solution, gauges or scales to measure the rate at which chlorine is injected, qualifications of personnel, testing location and schedule, source of water and water disposal locations. Personnel performing the disinfection shall demonstrate a minimum of five years experience in the chlorination and dechlorination of pipelines. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Disinfection of Piping 15041 -1 B. Qualification of certified testing laboratory. 1.6 1.7 1.8 C. Four copies of bacteriological test results to the Engineer upon completion of each test. D. Emergency Response Plan. DELIVERY, STORAGE AND HANDLING Chlorination and dechlorination shall be performed by competent individuals knowledgeable and experienced in the operation of the necessary application and safety equipment in accordance with applicable Federal, State and Local laws and regulations. The transport, storage and handling of these materials shall be performed in accordance with Code of Federal Regulations (CFR) 1910.120 Hazardous Waste Operations and Emergency Response, CFR 49.172 Hazardous Materials Regulations, and the General Industry Safety Orders of the California Code of Regulations, Title 8, Section 5194. CONCURRENT DISINFECTION AND HYDROSTATIC TESTING The specified disinfection of the pipelines may be performed concurrently with the hydrostatic testing in accordance with Section 15044. In the event repairs are necessary, as indicated by the hydrostatic test, additional disinfection may be required by the Engineer in accordance with this specification. CONNECTION TO EXISTING MAINS Prior to connection to existing mains, disinfection and bacteriological testing shall be performed in accordance with this specification, and hydrostatic testing shall be performed per Section 15044. A District Connection Permit is required authorizing connection to an existing system and shall be given only on the basis of acceptable hydrostatic, disinfection and bacteriological test results. Connection to existing mains shall be performed in accordance with Section 15000. PART 2 MATERIALS 2.1 CHLORINE (GAS) A. Liquid chlorine contains 1 OO-percent available chlorine and is packaged in steel containers in net weights of 68.lkg (150 Ib.) or 907.2kg (1 ton). B. Liquid chlorine shall be used with appropriate gas flow chlorinators, heaters, and injectors to provide a controlled, high-concentration solution feed to the water. The chlorinators and injectors shall be the vacuum-operated type. 2.2 SODIUM HYPOCHLORITE (LIQUID) Sodium hypochlorite is available in liquid form in glass or plastic containers, ranging in size from 0.95 L (1 Qt.) to 18.93 L (5 Gal.). The solution contains approximately 10% to 15% available chlorine. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Disinfection of Piping 15041 -2 2.3 TABLET OR GRANULAR HYPOCHLORITE Tablet or granular hypochlorite may be used if a solution container is utilized to provide a continuous feed method. PART 3 EXECUTION 3.1 GENERAL A. Disinfection of pipelines shall not proceed until all appurtenances and any necessary sample ports have been installed and the Engineer provides authorization. B. Every effort shall be made to keep the water main and its appurtenances clean and dry during the installation process. C. All piping, valves, fittings, and appuflenances which become contaminated during installation shall be cleaned, rinsed with potable water, and then sprayed or swabbed with a 5 percent sodium hypochlorite disinfecting solution prior to installation. D. Water mains under construction that become flooded by storm water, runoff, or groundwater shall be cleaned by draining and flushing with metered potable water until clear water is evident. Upon completion, the entire main shall be disinfected using a method approved by the Engineer. 3.2 METHODS A. Chlorine (Gas) 1. Only vacuum-operated equipment shall be used. Direct-feed chlorinators, which operate solely from gas pressure in the chlorine cylinder, shall not be permitted. The equipment shall incorporate a backflow prevention device at the point of connection to the potable water source used to fill the line being tested. 2. The chlorinating agent shall be applied at the beginning of the system to be chlorinated and shall be injected through a corporation stop, a hydrant, or other approved connection to ensure treatment of the entire system being disinfected. 3. Only a certified, licensed chlorination and testing contractor shall perform gas chlorination work. The chlorination contractor must also possess a Grade II Treatment Plant Operator Certification from the State of California. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Disinfection of Piping 15041 -3 B. Sodium Hypochlorite Solution (Liquid) 1. Sodium hypochlorite solution shall be used for cleaning and swabbing piping and appurtenances immediately prior to installation and for disinfecting all components of connections to the District's existing system. 2. Sodium hypochlorite solution may be used for the initial disinfection of newly installed water mains. The solution shall be applied at a terminus of the system to be chlorinated using an injector which can adjust the amount of solution being injected into the piping system. The solution shall be injected in the appropriate concentration to achieve the specified concentration range of chlorine throughout the entire piping system. Where pumping equipment is used in conjunction with an injector, an integral backflow prevention device shall be used and connected to the potable water supply. 3. Water trucks, pumping equipment, piping, appurtenances and all other equipment in contact with potable water shall be disinfected prior to use. 4. Sodium hypochlorite solution may also be used to increase the total chlorine residual if the concentration from the initial chlorination of the system is found to be low. The solution shall be added to the system in sufficient amounts at appropriate locations to ensure that the disinfecting solution is present at a concentration within the specified range throughout the piping system. 3.3 PROCEDURE FOR DISINFECTING WATER MAINS AND APPURTENANCES A. The pipeline shall be filled at a rate not to exceed 1,135 liters per minute (300 GPM) or a velocity of 0.3m per second (1 foot per second), whichever is less. B. Disinfection shall result in a total chlorine concentration of not less than 25-mgA. This concentration shall be evenly distributed throughout the system to be disinfected, using a continuous feed method of chlorination. C. All valves shall be operated with the disinfection solution present in the pipeline. All appurtenances such as air-vacuum relief valves, blowoffs, hydrants, backflow prevention devices, and water service laterals shall be flushed with the treated water a sufficient length of time to ensure a chlorine concentration within the specified range in all components of each appurtenance. (Note the limitations for discharge of chlorinated water outlined below.) D. The Engineer will verify the presence of the disinfection solution throughout the system by sampling and testing for acceptable chlorine concentrations at the various appurtenances and/or at the test ports provided by the Contractor. Areas of the system found to be below the specified chlorine concentration level shall receive additional flushing as noted above and/or additional disinfection solution as necessary. (Note the limitations for discharge of chlorinated water outlined below.) Addition of disinfection solution after the initial charging of the line shall be made by either the liquid chlorine (gas) method, or the sodium hypochlorite method as directed by the Engineer. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Disinfection of Piping 15041 -4 E. The chlorinated water shall be retained in the system for a minimum of 24 hours. The District Engineer will test the total chlorine residual. The system shall contain a total chlorine residual of not less than 80% of the initial total chlorine residual before the 24-hour soaking period began. If the total chlorine residual has decreased more than 20%, the system shall be soaked for an additional 24-hour period. If the total chlorine residual has not deceased after this additional 24-hour period, the system shall be flushed in accordance with the procedure detailed herein. If the total chlorine residual has decreased, the system shall be flushed in accordance with the procedure detailed herein, and shall be re-disinfected. F. Following a successful retention period as determined by the District Engineer, the chlorinated water shall be flushed from the system at its extremities and at each appurtenance, using potable water from a source designated by the District Engineer. The minimum water velocity during flushing shall be 0.9 meters per second (3 feet per second) or as directed by the Engineer. Flushing shall continue until the replacement water in the new system is equal in chlorine residual to the potable source of supply as verified by the District. (Note the limitations for discharge of chlorinated water outlined below.) G. The Contractor shall contract with a State certified sampling laboratory to perform sampling, transport samples and perform bacteriological sampling and testing as specified herein. 3.4 DISCHARGE OF CHLORINATED WATER A. Indiscriminate onsite disposal or discharge to sewer systems, storm drains, drainage courses or surface waters of chlorinated water is prohibited. B. All discharge of chlorinated water shall require the neutralizing of the chlorine residual by means of a reducing agent in accord with AWWA C651 and the requirements of this specification. C. The reducing agent shall be applied to the water as it exits the piping system. The Contractor shall monitor the chlorine residual during the discharge operations. Total residual chlorine limits in these locations, and for the discharge of chlorinated water from the testing of pipelines to surface waters of the San Diego Region are as follows: Total Residual Chlorine Effluent Limitations 30-Day Average - 0.002 mg/l Average Daily Maximum - 0.008 mg/l Instantaneous Maximum - 0.02 mg/l The various methods of dechlorination available can remove residual chlorine to concentrations below standard analytical methods of detection, 0.02 mg/l, which will assure compliance with the effluent limit. The Developer will perform all necessary tests and keep records to ensure that the total residual chlorine effluent limitations listed above are met. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Disinfection of Piping 15041 -5 D. In locations where no hazard to the environment is evident based on the joint examination described above, the chlorinated water may be broadcast for dust control on the surface of the immediate site. Care shall be exercised in broadcasting the water to prevent runoff. 3.5 BACTERIOLOGICAL TESTING The Contractor shall employ a State certified laboratory to perform bacteriological sampling and testing of all new system installations. The testing methodology employed by the District shall be as set forth in "Standard Methods for the Examination of Water and Waste Water" (current edition). Testing requirements are as set forth in the California Domestic Water Quality and Monitoring Regulations and commensurate with current requirements for surface water testing. The testing laboratory will analyze the samples for the presence of coliform bacteria and heterotrophic-type bacteria (heterotrophic plate count). The evaluation criteria employed by the District for a passing test sample is as follows: A. Coliform bacteria: no positive sample, and B. Heterotrophic plate count (HPC): 500 colony forming unitdm1 or less. 3.06 REDISINFECTION If the initial disinfection fails to produce satisfactory bacteriological test results, the pipeline system shall be re-flushed and re-sampled. If the second set of samples does not produce satisfactory results, the pipeline system shall be re-chlorinated, flushed, and re-stamped. The chlorination, flushing, and sampling procedure shall continue until satisfactory results are obtained. Re-disinfection and retesting shall be at the Contractor's expense. 3.07 DISINFECTING TIE-INS AND CONNECTIONS Pipes, fittings, valves and all other components incorporated into connections with the District's existing system shall be spray disinfected or swabbed with a liquid chlorine solution in accordance with AWWA C651 and as specified herein. Upon connection to the main, the line shall be flushed as directed by the District Engineer. Disinfection by this method is generally limited to assemblies of 6m (20') or less in length. Alternate methods such as "predisinfection" prior to installation in accordance with AWWA C651 may be required at the discretion of the District Engineer. END OF SECTION January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Disinfection of Piping 15041 -6 SECTION 15044 HYDROSTATIC TESTING OF PRESSURE PIPELINES PART 1 GENERAL 1 .I DESCRIPTION This section describes the requirements and procedures for pressure and leakage testing of all pressure mains. 1.2 RELATED WORK SPECIFIED ELSEWHERE CMW D Standard Drawings CMWD Standard Specifications 15000, 15041, 15056, 15057, 15061, and 15064 1.3 REQUIREMENTS PRIOR TO TESTING A. Provide testing procedure submittal including testing pressure, testing schedule, test bulkhead locations, and water supply details. B. All piping, valves, fire hydrants, services, and related appurtenances shall be installed prior to testing. C. The pipe trench shall have trench zone backfill placed and compacted with a minimum of 0.76m (2.5') of material over the pipe. D. All concrete anchor blocks shall be allowed to cure a sufficient time to develop a minimum strength of 13.79 MPa (2,000 psi) before testing. E. Pressure tests on exposed and aboveground piping shall be conducted only after the entire piping system has been installed and attached to pipe supports, hangers or anchors as shown on the Approved Plans. F. Steel pipelines shall not be tested before the mortar lining and coating on all pipe lengths within the line have been in place for a minimum of fourteen (14) days. Cement-mortar lined pipe shall not be filled with water until a minimum of eight hours has elapsed after the last joint has been mortared. 1.4 CONCURRENT HYDROSTATIC TESTING AND DISINFECTION OF PIPELINES Hydrostatic testing of pipelines shall be performed prior to or concurrently with the disinfection operations in accordance with Section 15041. In the event repairs are necessary, as indicated by the hydrostatic test, the District may require additional disinfection in accordance with Section 15041. January 2004 Hydrostatic Testing of Pressure Pipelines Calavera Pump Station (860-3-CAL) Contract 38891 1 5044- 1 1.5 CONNECTION TO EXISTING MAINS Hydrostatic testing shall be performed prior to connections to existing mains. A District Connection Permit authorizing connection to the existing system shall be given only on the basis of acceptable hydrostatic, disinfection and bacteriological test results. Connection to existing mains shall be performed in accordance with Section 15000. PART 2 MATERIALS 2.1 WATER A. Potable water shall be used for hydrostatic testing of potable and recycled water mains. B. Potable water shall be supplied by a District-approved source. Make-up water for testing shall also be potable water. C. A chlorinated water solution, in accordance with Section 15041 , shall be used to charge the line and for make-up water when hydrostatic testing and disinfection operations are combined. D. Meet all applicable state and local requirements for disposal of testing water. 2.2 CONNECTIONS A. Testing water shall be supplied through a metered connection equipped with a backflow prevention device in accordance with Section 151 12 at the point of connection to the potable water source used. B. The Contractor shall provide any temporary piping needed to deliver potable water to the piping that is to be tested. Temporary piping shall be in accordance with Section 15000. PART 3 EXECUTION 3.1 GENERAL A. All water systems shall be pre-tested to insure passage of test prior to scheduling official test with inspector. B. The Contractor shall provide the District with a minimum of 48 hours' notice prior to the requested date and time for hydrostatic tests. C. The Contractor shall furnish all labor, materials, tools, and equipment for testing. D. Temporary blocking during the tests will be permitted only at temporary plugs, caps or where otherwise directed by the District. January 2004 Hydrostatic Testing of Pressure Pipelines Calavera Pump Station (860-3-CAL) Contract 38891 15044-2 E. All valves and appurtenances shall be operated during the test period. The test shall be conducted with valves in the open position. The Contractor is not permitted to operate any valves on the District’s system. F. At the onset of testing, all valves, air vacuum assemblies, blowoffs, and services shall be monitored for possible leakage and repairs made, if necessary, before the test proceeds. The appurtenances shall be monitored through the duration of the testing. G. For pipe with porous lining, such as cement mortar, the pipe shall be filled with water and placed under a slight pressure for a minimum of forty-eight (48) hours prior to the actual hydrostatic test. H. Testing shall be made before connecting the new line with the existing District pipes and mains. I. The pipeline should be filled at a rate such that the velocity of flow is less than 1 fps. J. Maximum length of pipe to be included in any one (1) test shall not exceed 2,500 linear feet or a vertical elevation difference of 58 feet. FIELD TEST PROCEDURE A. Before, applying the specified test pressure, care shall be taken to release all air within the pipe and appurtenances to be tested. Air shall be released through services, fire hydrants, air release valves, or other approved locations. B. The leakage shall be considered as the total amount of water pumped into the pipeline during the test period. C. Apply and maintain the test pressure by means of a hydraulic force pump. D. Maintain the test pressure for the following duration by restoring it whenever it falls an amount of 5 psi: Pipe Diameter 18 and less 4 20 to 36 8 Greater than 36 24 Hours (inches) - January 2004 Hydrostatic Testing of Pressure Pipelines Calavera Pump Station (860-3-CAL) Contract 38891 15044-3 E. After the test pressure is reached, use a meter to measure the additional water added to maintain the pressure. This amount of water is the loss due to leakage in the piping system. The allowable leakage for various sizes of PVC and DIP with rubber gaskets are shown in the following table: TYPE OF PIPE: CLASSES: 150 & 200 P.V.C. & D.I.P. Pipe Sizes (inches) 6 8 lo” 12” 14” 16 1 8” Allowable Leakage Gals/4 hrdl000’ of pipe 50 Gals .66 Gals .83 Gals. .99 Gals. 1.16 Gals. 1.32 Gals. 1.53 Gals. F. The allowable leakage for welded steel pipe shall be zero gallons. G. The allowable leakage for piping having threaded, brazed, or welded (including solvent welded) joints shall be zero gallons. H. Repair and retest any pipes showing leakage rates greater than that allowed in the above criteria. 3.3 TEST PRESSURE Pipe sizes in excess of 16” diameter shall be tested at a pressure based on hydraulic gradient elevation (H.G.L) as shown on the drawings. If no test H.G.L. is shown, the pipeline at the low point in test section shall be pumped to a hydrostatic test pressure of 75 p.s.i. in excess of the working pressure. Pressure shall be maintained for a duration shown in section 3.2 and shall be repumped when it falls an amount of 5 p.s.i. The test pump gauge and meter shall be connected to the water main at a location other than the highest point in the line, in order to allow release of air from the high point. Means shall be provided for accurately measuring the quantity of water pumped through a meter and pumped into the pipe immediately, during and after the test period in order to maintain or restore the initial test pressure. All pipe, fittings, valves, services and appurtenances shall be subjected to the hydrostatic test and irrespective of the measured quantity of leakage, all detectable leaks shall be repaired by the Contractor at the contractor’s expense and no cost to Carlsbad Municipal Water district. If a tested system is damaged or a leak occurs after official test the entire system or portion of system will be retested as directed by Inspector. END OF SECTION January 2004 Hydrostatic Testing of Pressure Pipelines Calavera Pump Station (860-3-CAL) Contract 38891 15044-4 SECTION 15057 COPPER TUBING, BRASS AND BRONZE PIPE FllTlNGS PART 1 GENERAL 1.1 1.2 1.3 1.4 1.5 1.6 DESCRIPTION This section includes materials and installation of copper tubing, brass and bronze pipe fittings and appurtenances. REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. ANSI B1.20.1 Pipe treads, general purpose ANSI B16.18 Case copper alloy solder joint pressure fittings RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 0991 0, 15000,15041,15044,15056,15061 and 15064 SERVICE LATERAL WET TAP CONNECTIONS All wet tap connections to existing pipelines shall be performed in accordance with Specification 15000, Section 1.7. RECYCLED WATER IDENTIFICATION Copper Tubing, Brass, and Bronze Pipe Fittings for recycled water shall be identified with purple polyethylene sleeve, identification labels or signs in accordance with Section 15151. W ARNl NG/I DENTI FIC ATlON TAPE Warning/ldentification Tape shall be used for all copper tubing, except that which is bored or jacked, in accordance with Section 15000. PART 2 MATERIALS 2.1 COPPER TUBING Copper tubing shall conform to the requirements of ASTM B 88 Type K or ASTM B 88 M (Metric) Type A seamless copper water tube. Copper tubing up to 25mm (1”) diameter shall be soft; 50mm (2”) may be soft or rigid. Components shall be selected from the Approved Materials List in accordance with the Standard Drawings. January 2004 Copper Tubing, Brass and Bronze Pipe Fittings Calavera Pump Station (860-3-CAL) Contract 38891 15057-1 2.2 BRASS PIPE, NIPPLES, AND FImNGS Threaded nipples, brass pipe and fittings shall conform to ASTM 843, regular wall thickness. Threads shall conform to ANSI 81.20.1. Fittings shall be flared or silver soldered per the CMWD standard drawings. 2.3 BRONZE APPURTENANCES A. B. C. D. Corporation stops, curb stops, meter and angle meter stops, meter flange adapters, and bronze-bodied service saddles shall be selected from the Approved Materials List in accordance with the Standard Drawings. Fittings shall be flared type or silver soldered. All items specified herein shall be manufactured of bronze conforming to ASTM B 62. Service saddles shall be the double strap type. Service saddles shall be used on all service and appurtenance connections on PVC piping. For piping materials other than PVC, service and appurtenance connections shall be performed in accordance with the Approved Drawings. 2.4 BOLTS AND NUTS FOR FLANGES Bolts and nuts shall be in accordance with Specification 15000 and the Approved Materials List. 2.5 WARNlNGnDENTlFlCATlON TAPE WarningAdentification Tape materials shall be in accordance with Section 1 5000 and shall be selected from the Approved Materials List. PART 3 EXECUTION 3.1 COPPER TUBING AND FITTINGS A. Trenching, bedding, backfilling and compacting shall be performed in accordance with CMWD Rules and Regulations and the Standard Drawings. Provide a minimum cover of 760mm (30") below finished street grade. 6. Cut tubing true and square and remove burrs. C. Bends in soft copper tubing shall be long sweep. Shape bends with shaping tools. Form bends without flattening, buckling, or thinning the tubing wall at any point. D. Assemble copper tubing and fittings per the manufacturer's recommendation in accordance with the Standard Drawings. January 2004 Copper Tubing, Brass and Bronze Pipe Fittings Calavera Pump Station (860-3-CAL) Contract 38891 15057-2 E. Install warninghdentification tape in accordance with Section 15000 and the Standard Drawings. F. All fittings shall be soldered or flared, as shown on the Approved Plans and Standard Drawings. 3.2 SERVICE SADDLES A. Service saddles shall be located a minimum of 600mm (24") from any pipe joint or fittings. B. Service saddles for connections shall be located a minimum of 600mm (24") from other saddles. Additionally, multiple service saddles for connections that are installed on the same side of a single pipe length shall be alternately staggered between 100 and 300 to prevent a weak plane in the pipe. C. The surface of the pipe shall be clean and all loose material shall be removed to provide a hard, clean surface. D. The service saddle shall be tightened in accordance with the manufacturer's recommendations to ensure a tight seal, using care to prevent damage or distortion of the service saddle or corporation stop due to over-tightening. E. The tap into the pipe shall be made in accordance with the pipe manufacturer's recommendation. Tapping tools and shell cutters with internal teeth or double slots that will retain the coupon shall be used. 3.3 DISINFECTION AND BACTERIOLOGICAL TESTING Disinfection, bacteriological testing, and flushing shall be performed in accordance with Section 15041. 3.4 HYDROSTATIC TESTING Field hydrostatic testing shall be performed in accordance with Section 15044. END OF SECTION January 2004 Copper Tubing, Brass and Bronze Pipe Fittings Calavera Pump Station (860-3-CAL) Contract 38891 15057-3 SECTION 15061 CEMENT-MORTAR LINED AND COATED STEEL PIPE AND SPECIALS PART 1 GENERAL 1.1 DESCRIPTION This section includes materials, design, fabrication, and installation of cement-mortar lined and coated steel pipe and specials. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. AWWA C200 AWWA C205 AWWA C206 AWWA C207 AWWA C208 AWWA C209 AWWA C210 AWWA C213 AWS ASME AWWA C214 Steel Water Pipe 6-Inches and Larger Cement-Mortar Protective Lining and Coating Field Welding of Steel Water Pipe Steel Pipe Flanges Dimensions for Fabricated Fittings Cold Applied Tape Coating for the Exterior of Special Sections, Connection and Fittings for Steel Water Pipelines Coal-Tar Epoxy Coating System for Interior and Exterior of Steel Water Pipelines Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines Standard Qualification Procedure for Manual Welding Operators Boiler and Pressure Vessel Code Tape Coatings Systems for the Exterior of Steel Water Pipeline 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 02223, 0991 0, 131 IO, 15000, 15041, 15044, 15074, 151 00, 151 02, 151 08, 151 12 and 15300. 1.4 SERVICE APPLICATION Cement-mortar lined and coated steel pipe and specials shall be used only for specific purposes as shown on the Approved Plans. Generally, cement-mortar lined and coated steel pipe shall be used for transmission mains of 24" or larger. 1.5 SPECIALS A special is defined as any piece of pipe other than a normal full length of straight pipe. This includes, but is not limited to, elbows, short pieces, reducers, tees, crosses, spools, sections with outlets, beveled sections and access holes. January 2004 Calavera Pump Station (860-3-CAL) Cement-Mortar Lined and Coated Steel Pipe and Specials 15061 -1 Contract 38891 SU BM llTALS 1.6 1.7 1.8 The Contractor shall furnish submittals in accordance with Section 2-5.3, Submittals Shop Drawing. Submittals are required for the following: A. Submit Shop Drawings, material lists, manufacturer's literature and catalog cuts of, but not limited to, the following: Shop Drawings Fabrication Details La you t Schedule Manufacturer's tests Protective Coatings Mill Reports or Plant Test Reports Dimensional Checks Welding Rods for Field Welding Shop Drawings shall be submitted and approved prior to manufacture of pipe. The layout schedule shall indicate the order of installation, the length and location of each pipe section and special, the station and elevation of the pipe invert at all changes in grade, and all data on curves and bends for both horizontal and vertical alignment. B. Submit data used by the Contractor in manufacture and quality control. C. Test reports showing the physical properties of the rubber used in the gaskets shall be submitted. PAYMENT A. Payment for the Work in this section shall be included as part of the lump-sum or unit-price bid amount for which such Work is appurtenant thereto. B. Payment by the linear foot shall be for each diameter and for each pipe strength designation measured horizontally over the pipe centerline. QUALITY ASSURANCE A. Cement-mortar lined and coated steel pipe shall be inspected at the supplier's manufacturing plant by the District Engineer. Developer shall be responsible for District Engineer's expenses, including travel, time, meals and overnight accommodations. Overnight accommodations and air travel may be required, at the discretion of the Engineer, if the manufacturing plant is more than 100 miles from the District Engineer's office. B. In addition to the shop hydrostatic testing performed on pipe cylinders required per AWWA C200, all welds of specials and attachments (Le., joint rings and nozzles) shall be tested by a dye-penetrant process. Certification of such testing shall be submitted to the District. C. Field welders shall be certified under Section IX, Part A of the ASME Boiler and Pressure Vessel Code or in accordance with AWWA C206, Section 3. Welders shall present a copy of their certification to the District prior to performing any field welding. Certifications shall be dated within three (3) years of the job to be performed. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -2 1.9 D. Plainly mark each length of straight pipe and each special at the bell end to identify the proper location of the pipe item by reference to the layout schedule. E. The top of all pipe and specials shall be clearly identified by marking the top with "T.O.P." for easy identification in the field. DELIVERY, STORAGE, AND HANDLING Delivery, storage, and handling of the pipe and specials shall be as follows: A. Pipe and fittings shall be carefully handled and shall be protected against damage to linings and coatings due to impact shocks. Pipe shall not be placed directly on rough ground but shall be supported in a manner which will protect the pipe against injury whenever stored at the site or elsewhere. Pipe shall be handled and stored per these requirements and in accordance with the Manufacturer's recommendations. B. Temporary internal bracing shall be installed in all pipe 600mm (24") and larger prior to shipment to the job site. Temporary internal bracing shall be 1OOmm x 1OOmm (4" x 4") wooden struts installed in both the horizontal and vertical directions. Each set of struts shall be nailed together as a unit. Wooden wedges may be used to maintain the proper tight fit of the internal bracing. The bracing shall be located 300mm (12") in from each end of the pipe section for all pipe, and additionally at the mid-point for piping 800mm (30") and larger. Maintain internal bracing as specified under Pipe Installation. C. Transport pipe to the job site on padded bunks with nylon tie-down straps or padded bonding to protect the pipe. D. Pipes and specials shall only be handled with appropriate spreader bars and wide nylon slings. Chains or wire rope slings shall not be used. Under no circumstances shall pipe or specials be pushed or dragged along the ground. All pipe sections over 6m (20') in length shall be lifted at the quarter points from each end. E. Store pipe on earth berms or timber cradles adjacent to the trench in the numerical order of installation. Place the supports at about one-quarter point from the pipe ends. F. Maintain plastic end caps on all pipe and specials in good condition until the pipe is ready to be installed in the trench. Periodically open the plastic end caps and spray potable water inside the pipe for moisture control. PART 2 MATERIALS 2.1 PIPE DESIGN REQUIREMENTS Pipe lining and coating shall be the product of one company in the business of designing and manufacturing cement-mortar lined, tape wrapped and mortar coated steel pipe. January 2004 Calavera Pump Station (860-3-CAL) Cement-Mortar Lined and Coated Steel Pipe and Specials Contract 38891 15061 -3 Use of subcontractors or subcontracts to apply the lining and coating of the steel pipe is not allowed. The pipe shall consist of the following components: A welded steel cylinder with joints formed integrally with the steel cylinder or with steel joint rings welded to the ends; A centrifugally-cast cement-mortar lining; A self-centering bell and spigot joint with a circular preformed elastomeric gasket, so designed that the joint will be watertight under all conditions of service; Tape wrapping of the cylinder over a dielectric coating; A dense, concentric, steel reinforced exterior cement-mortar coating. The Plans indicate the elevations and alignment of the pipeline, the nominal inside diameter of the lined pipe, and the minimum steel cylinder thickness or design pressure (adjusted to satisfy transient conditions). Design soil cover shall be as stated on the Plans or Specifications or, if none is stated, the amount of cover shall be scaled from the Plans. Minimum thickness of the steel cylinder shall be as shown on the Plans or, if not shown on the Plans, as determined by the following formula, except that steel thickness shall not be less than 10 gauge (0.1 345-inch). t = Pd Where P = Design pressure, in psi plus 50 psi minimum 2s S = Steel stress at design pressure, Le., 16,500 psi t = Steel cylinder thickness, in inches d = OD of steel cylinder, in inches STEEL CYLINDERS Materials used in fabricating steel cylinders shall be hot rolled carbon steel sheets conforming to the requirements of ASTM A53, Grade B, ASTM A570 Grade 36 or Grade 33, or steel plates conforming to the requirements of ASTM A36. The method of testing shall conform to the requirements of ASTM A570. Full penetration welds will be required. Welds may be straight or spiral seam. The circumferential stress in the steel shall not exceed 16,500 psi at the design pressure. CEMENT Cement for mortar lining and coating shall be Portland Cement Type II and conform to ASTM C150, unless otherwise specified. Admixtures containing chlorides shall not be used. STEEL BAR OR WIRE REINFORCEMENT Circumferential steel bar or wire reinforcement shall conform to ASTM A615, Grade 40, "Specifications for Billet-Steel Bars for Concrete Reinforcement". Wire fabric reinforcing for cement-mortar coatings and linings of fittings shall conform to ASTM A185, "Specifications for Welded Steel Wire Fabric," or ASTM A497, "Specifications for Welded Deformed Steel Wire Fabric." Spiral-wire reinforcement for cement-mortar coatings shall conform to ASTM A82. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -4 2.5 2.6 2.7 2.8 2.9 STEEL FOR JOINT RINGS Steel for bell rings shall conform to ASTM A575 "Specification for Merchant Quality Hot Rolled Carbon Steel Bars." Steel for spigot rings shall conform to ASTM A576, "Specification for Special Quality Hot-Rolled Carbon Steel Bars." DIMENSIONS The steel pipe sizes shown on the Plans or otherwise referred to shall be the nominal inside diameter. Unless otherwise specified, the nominal diameter shown on the Plans shall be considered to be the inside diameter after lining. MANUFACTURER'S TESTS Each steel cylinder with joint rings attached and cylinders for specials shall be hydrostatically tested to a circumferential stress of at least 22,000 psi, but not more than 25,000 psi. If leaks develop during testing, the cylinder shall be repaired by welding and retested until all leaks are eliminated. The seams in short radius bends and special fittings shall be tested by the air-soap method using air at a pressure of 5 psi or by the dye-check method. However, if the fitting is fabricated from cylinders which have been previously hydrostatically tested, no further test will be required on seams so tested. Hydrostatic testing of fittings to 150% of the design pressure may replace the tests described above. Any defects revealed by any of the alternate test methods shall be repaired by welding and the fitting retested until all defects have been eliminated. FABRICATION DETAILS Each special and each length of straight pipe shall be plainly marked at the bell end to identify the design pressure and the proper location of the pipe or special by reference to layout schedule. Exposed portion of joint rings shall be protected from corrosion by the manufacturer's standard coating. The pipe shall be fitted with devices shown on the Plans to permit continuous electrical bonding of the various joints following field installation. PROTECTIVE COATINGS AND LININGS All exposed metal surfaces shall be painted or coated as specified in Section 09870 and 09900, Painting and Coating, except where other coatings are specified elsewhere and in this section. All steel pipe and fittings shall be cement-mortar lined in accordance with AWWA C205 and C602. Linings shall be in accordance with table below. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -5 All steel pipe and fittings for underground service shall be cement-mortar lined, taped wrapped and cement-mortar coated in accordance with AWWA C205, C214 and (3602 and Section 09870 unless otherwise specified on the Plans. For the following nominal inside diameters, the lining thickness and minimum cement-mortar coating thickness shall be as follows: LINING Nominal Pipe Size Thickness Tolerance (inches) (inches) (inches) 4- 10 1 i4 - 1 /32+ 1 /32 12-18 318 -1 /16+1/8 20 - 44 - 1 I1 6+ 1 /8 45 - 58 314 -1/16+1/8 60 and over 314 -1/16+1/8 1 I2 COATING Thickness Tolerance (inches) (inches) 1 I2 +1/8 518 +1/8 314 +1/8 1 +1/8 1 114 +1/8 2.10 STEEL PIPE AND SPECIALS Steel pipe and specials shall conform to the requirements of the AWWA C200 and C205, and AWWA M11 , except as modified herein. A. Steel for fabricated cylinders shall conform to ASTM A 36lA 36M, ASTM A 283/ A 283M, Grade D, or ASTM A 57OlA 570M, Grade 36. Other steel grades may be used only upon approval of the District Engineer. B. Cement-mortar coating shall be reinforced in accordance with AWWA C205. C. Cement mortar grout for field joints shall consist of a mixture of 1-112 to 2 parts sand to 1 part Type II or Type V Portland Cement with enough clean, potable water to permit packing and troweling without crumbling. The sand shall be washed, well-graded sand such that all will pass a No. 8 sieve. The quantity of water to be used in the preparation of grout shall be the minimum required to produce a mixture sufficiently workable for the purpose intended. Grout shall attain a minimum compressive strength of 12.4 MPa (1,800 psi) in 28 days. D. In certain circumstances, rapid-setting mortar may be required. Acceleration admixtures may be used in the mix as permitted by the District Engineer. Calcium chloride shall not be used in the mix. 2.11 PAINTING AND COATING A. Paint and coating products for exterior surfaces of all pipe and appurtenances not otherwise mortar-coated shall be in accordance with Section 0991 0 and the Approved Materials List. B. Paint and coating products for areas in contact with potable water such plain ends of pipe, grooved and shouldered ends of pipe and exposed inside surfaces or threaded outlets and blind flanges shall be in accordance with Section 15000 and selected from the Approved Materials List. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -6 2.12 BOLTS AND NUTS FOR FLANGES Bolts and nuts shall be in accordance with Section 15000 and the Approved Materials List. 2.13 GASKETS A. Rubber-ring gaskets shall comply with AWWA C200 according to the applicable joint type and pressure rating of the piping system. B. Flange gaskets shall comply with AWWA C207. Flange gaskets shall be 3.1 8mm (1/8") thick acrylic or aramid fibers bound with nitrile for all sizes of pipe. Gaskets shall be full-face type with pre-punched holes or ring-type extending to the inner edge of the bolt circumference of the flange. C. In the event of encountering organic solvents or petroleum products during the course of the work, alternate gasket materials or joint treatment will be required as directed by the District Engineer. 2.14 CEMENT-MORTAR CURING The pipe shall be cured by water curing, steam curing or a combination of both. Water curing and steam curing may be used interchangeably on a time ratio basis of four hours water curing to one hour of steam curing. Where steam curing is used, the pipe shall be kept in steam maintained at a temperature of 100 F to 150 F for the specified period and, where water curing is used, the pipe shall be kept continually moist by spraying or other means for the specified periods. The pipe shall not be allowed to dry either on the inside or outside surfaces during the curing period. Where water curing is used, the pipe shall be kept continuously moist for seven days at a temperature of not less than 40 F before being moved to the trench site. Cement-mortar lining and coating of special pipe and fittings may be cured in accordance with the above provisions or by prompt application of a white-pigmented sealing compound conforming to ASTM C309. Sealing compound shall not be applied at joint ends where compound will interfere with the bond of joint mortar. 2.15 SPECIAL PIPE AND FITTINGS The manufacturer shall furnish all fittings and special pieces required for closures, curves, bends, branches, manholes, outlets, connections for mainline valves, and other appurtenances required by the Plans. Special fittings shall be fabricated of welded steel sheet or plate, lined and coated with cement-mortar of the same type as the adjoining pipe and applied as specified for lining and coating of specials in AWWA C205 and as modified herein. Butt welding shall be used, unless otherwise indicated on the Plans. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -7 Minimum centerline radius of an elbow or bend shall be as follows. The maximum deflection at a mitered girth seam shall be 22-112 degrees. Pipe Size (Inches) Minimum Centerline Radius 30 - 48 51 -60 Over 60 2-112 times ID 1 O-feet 2 times ID The circumferential stress in the sheet or plate shall not exceed 13,500 psi at the design pressure. The minimum thickness of sheet or plate shall be as follows: FittinQ Diameter Range llnches) 18 and under 20 - 24 26 - 36 38 - 45 48 - 54 57 - 60 63 - 72 75 - 84 Outlets at special fittings shall b Minimum Thickness of Sheet or Plate 10 gauge 311 6" or 7 gauge 114" 51 1 6" 318" 711 6" 1 /2" 518" reinforc d with collars or crotch plates. If Aar reinforcement is used, the outlet diameter shall not exceed 69% of the ID of the fitting. The diameter of outlets reinforced with crotch plates may equal the fitting diameter. The effective shoulder width "W" of collars from the inside surface of the steel outlet to the outside edge of the collar measured on the surface of the cylinder shall be not less than one-third or more than one-half the ID of steel outlet. The thickness of the collar shall be not less than "T" as determined by: Pw x ID cvl. x ID outlet T= 36,000 x W where Pw is the design pressure in pounds per square inch, and all other dimensions are in inches. Collars may be oval in shape or rectangular with well-rounded corners. Outlets 3-inches in diameter and smaller may be installed without collars. The design of crotch plates shall be based upon the paper by Swanson, Chapton, Wilkinson, King, and Nelson, originally published in June 1955 issue of the Journal of the American Water Works Association and in conformance with AWWA M-11 . 2.16 TAPE WRAP AND MORTAR SHIELD Tape wrap and mortar shield for concrete mortar lined steel pipe shall be in accordance with Section 09870. January 2004 Calavera Pump Station (860-3-CAL) Cement-Mortar Lined and Coated Steel Pipe and Specials Contract 38891 15061 -8 2.17 HANDLING AND SHIPMENT Pipe and special fittings shall be handled carefully, and blocking and holddowns used during shipment shall prevent movement or shifting. Both ends of pipe and fittings on trucks or rail cars shall be bulkheaded or covered in order to prevent excessive drying of the interior lining. PART 3 EXECUTION 3.1 GENERAL At all times when the work of installing pipe is not in progress, including worker break times, the ends of the pipe shall be closed with a vermin-proof and child-proof cap or plug. Do not permit trench water to enter the pipe. Do not place tools, clothing, or other materials in the pipe. The Contractor shall maintain the interior of the pipe in a sanitary condition free from foreign materials. 3.2 DEWATERING The Contractor shall provide, and maintain at all times during construction, ample means and devices to promptly remove and dispose of all water from any source entering trench excavations or other parts of the work. Any damage caused by flooding of the trench shall be the Contractor's responsibility. Contractor shall obtain a Discharge Permit as required by the Regional Water Quality Control Board. Dewatering shall be performed by methods that will maintain a dry excavation, preservation of the final lines and grades and protection of all utilities. If flooding of the trench does occur, the Contractor shall immediately dewater and restore the trench. Damaged or altered pipeline appurtenances shall be repaired or replaced as directed by the Engineer. 3.3 PIPE INSTALLATION When the work requires and the size of the pipe allows entry of personnel into the pipe, the Contractor shall comply with all Federal and State regulations for confined space entry. Work inside pipelines shall not be undertaken until all the tests and safety provisions of the Code of Federal Regulations 1910.146, and the General Industry Safety Orders of the California Code of Regulations, Title 8, Section 5159 for confined space entry have been performed and the area is verified as safe to enter. Generally, the aforementioned safety provisions apply to pipe 600mm (24") and larger. Note that for pipe less than 600mm (24") diameter, more stringent safety procedures apply. The Contractor shall furnish and install all pipe, specials, fittings, closure pieces, valves, supports, bolts, nuts, gaskets, jointing materials, and all other appurtenances as shown on the Approved Plans and as required to provide a complete and workable installation. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -9 Pipe installations shall be as shown on the Approved Plans and Shop Drawings in accordance with the following: A. No pipe shall be installed where the linings or coatings show cracks that may be harmful as determined by the District Engineer. Such damaged linings and coatings shall be repaired or new, undamaged pipe sections shall be provided. B. Pipe damaged prior to Substantial Completion shall be repaired or replaced by the Contractor. C. The Contractor shall inspect each pipe and fitting to ensure that there are no damaged portions of the pipe. The Contractor shall remove or smooth out any burrs, gouges, weld splatter, or other small defects prior to laying the pipe. D. Before placement of pipe in the trench, each pipe or fitting shall be thoroughly cleaned of any foreign substance which may have collected thereon and shall be kept clean at all times thereafter. For this purpose, the openings of all pipes and fittings in the trench shall be closed during any interruption to the work as noted above. E. Pipe shall be laid directly on the bedding material. No blocking will be permitted, and the bedding shall be such that it forms a continuous, solid bearing for the full length of the pipe. Excavations shall be made as needed to facilitate removal of handling devices after the pipe is laid. Bell holes shall be formed at the ends of the pipe to prevent point loading at the bells or couplings and to permit visual inspection of the joint. Excavation shall be made as needed outside the normal trench section at field joints to permit adequate access to the joints for field connection operations and for application of coatings on field joints. F. Installation Tolerances: Each section of pipe shall be laid in the order and position shown on the approved layout schedule to the proper lines and grades in accordance with the following: 1. Each section of pipe having a nominal diameter less than 1200mm (48") shall be laid not to vary more than 0.3 ft. horizontally or 0.1 ft. vertically from the alignment and elevations shown on the Approved Plans. 2. Each section of pipe having nominal diameter 1200mm (48") and larger shall be laid not to vary more than five percent (5%) of the pipe diameter horizontally or two and one half percent (2.5%) of the pipe diameter vertically. 3. In addition to the horizontal and vertical tolerances above, lay the pipe so that no high or low points occur along the pipeline other than those shown on the approved layout schedule. G. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the District Engineer may change the alignment and/or the grades. Such change shall be made by the deflection of joints, by the use of bevel adapters, or by the use of additional fittings. However, in no case shall the deflection in the joint exceed seventy five percent (75%) of the maximum January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -1 0 deflection recommended by the pipe manufacturer. No joint shall be deflected any amount that will be detrimental to the strength and water tightness of the finished joint. In all cases the joint opening, before finishing with the protective mortar inside the pipe, shall be the controlling factor. H. Pipes shall be laid uphill on grades exceeding 10 percent. Pipe that is laid on a downhill grade shall be blocked and held in place until the following pipe section has been installed to provide sufficient support to prevent movement. I. Temporary internal pipe bracing shall be left in place in pipe sizes larger than 600mm (24") until pipe zone compaction has been completed. Bracing in pipe smaller than 600mm (24") may be removed immediately after the pipe has been laid into the trench. The Contractor shall employ a laboratory to monitor pipe deflection by measuring pipe inside diameter before bracing is removed and 24 hours after struts are removed. Pipe deflection shall not exceed 3 percent in 24 hours after the bracing has been removed. After the backfill has been placed, the struts shall be removed. J. Cold Weather Protection: No pipe shall be installed upon a foundation onto which frost has penetrated or at any time that there is a danger of the formation of ice or penetration of frost at the bottom of the excavation. No pipe shall be laid unless it can be established that the trench will be backfilled prior to formation of ice and frost. K. Pipe and Special Protection: The openings of all pipe and specials where the pipe and specials have been mortar-lined in the shop shall be protected with suitable bulkheads to maintain a moist atmosphere and to prevent unauthorized access by persons, animals, water, or any undesirable substance. The bulkheads shall be designed to prevent drying out of the interior of the pipe. The Contractor shall introduce water into the pipe to keep the mortar moist where moisture has been lost due to damaged bulkheads. 3.4 RUBBER-RING JOINTS: SHALL ONLY BE USED AS SHOWN ON PLANS For pipe sizes smaller than 24-inches, the bell end shall be buttered with cement mortar in a manner and quantity that will completely fill the recess between the respective linings of the two joined sections of pipe. The spigot end shall then be entered into the bell end of the adjacent pipe section the distance shown on the Shop Drawings. Immediately after joining, the pipe interior shall be swabbed to remove all excess mortar by drawing a swab or squeegee through the pipe. The pipe interior shall be inspected by a closed circuit television camera, to assure quality of internal mortar. For pipe sizes 24-inches and larger, the joint recess shall be pointed from the inside with cement mortar after the backfill has been placed and compacted and the pipe permitted to take any normal settlement. The mortar shall be mixed of one part cement to one and one-half parts of sand and pointing accomplished in two or more lifts and finished off flush by troweling. Pipe shall be inspected visually by work persons within the pipe, to assure internal mortar quality. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -1 1 Each pipe joint shall be bonded to provide electrical continuity along the entire pipeline. The bond shall be made by the proper welding of pipe joints together as indicated on the Plans. The outside joint recess shall be grouted with cement mortar after a diaper has first been placed around the joint and tightened securely to prevent leakage while the mortar is being poured. The diaper shall be made of moisture resisting paper or heavy duty sail cloth of sufficiently close weave to prevent cement loss from the mortar. The diapers shall be hemmed on each edge and shall contain a metal strap within each hem sufficiently longer than the circumference of the pipe to allow a secure attachment of the diaper to the pipe. The diaper width will depend upon pipe size and design and shall be the width recommended by the manufacturer. Following installation of the diapers, the joints shall be poured and rodded from one side only until the mortar comes up to the top of the diaper on the opposite side. Approximately one hour subsequent to the pouring of the joint, the joint shall be rechecked and, if any settlement, leakage or shrinkage has taken place, the joint shall be refilled with mortar. Outside joints may be grouted before or after the placement of bedding and backfill materials if those materials are to be mechanically compacted. If bedding and backfill materials are to be hydrauiically densified, grout shall be poured and allowed to set before applying water. In any case, joints shall be grouted before backfill is placed over the top of the pipe. 3.5 BUTT-STRAP CLOSURE JOINTS Butt-Strap Closure Joints: Butt-strap closure joints shall be completed in the trench after the pipe has been laid to the alignment and grade shown on the Plans. They should be field welded by full-circumferential fillet welds or one of the edges may be shop welded and the other field welded. Welding shall be done in the same manner as specified for welded joints. The interior of the joints shall be filled with stiff plastic mortar and finished off smoothly with the inside of the pipe. Clean the inside steel surfaces by wire brushing or power brushing. Wire mesh, 2" x 4" x No. 13 gauge, clean, and free from rust, shall be applied to the interior of the joints so that the wires on the 2-inch spacing run circumferentially around the pipe. The wires on the 4-inch spacing shall be crimped in such a manner that the mesh will be held 3/8-inch from the metal joint surface. The mesh shall be lapped a minimum of 8-inches and shall be securely wired in position. Pack the cement mortar into the recess of the joint and steel trowel finish to match the adjoining pipes. The joint exterior shall be coated with mortar to a minimum thickness of 1%-inches. Immediately prior to applying mortar to the interior or exterior of the joints, a cement wash shall be applied to the metal to be coated. 3.6 FIELD WELDED JOINTS A. Welded joints shall be completed after the pipe is in final position. Welded joints shall be a lap-welded slip joint as shown on the Plans. The minimum overlap of the assembled bell and 9 pigot section of lap joint shall be shown on the plans. Any recess between the bell and spigot shall be caulked with a rod to facilitate the welding. Pipe of 30-inches in diameter or more may be welded from the January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -1 2 B. C. D. E. F. G. H. I. J. K. January 2004 inside. Joints shall be welded on the inside and outside where indicated on the Plans as “Double Welded Joints.” Field Welding shall be in accordance with AWWA C206 and AWS D1.l, except as modified herein. Welders assigned to the Work shall be qualified under the AWS standard qualification procedure, within the past three (3) years. Joints to be welded shall be cleaned, preferably prior to placing the pipe in the trench, of all loose scale, heavy rust, paint, cement, and grease. At least a 1/2-inch recess shall be provided between adjacent mortar-covered surfaces to place the weld. In all hand welding, the metal shall be deposited in successive layers and the minimum number of passes shall be 2. Preheat the joints to be welded where required in accordance with Table 1 of AWWA C206. All joints shall be visually inspected and shall undergo dye testing and hydrostatic testing in accordance with AWWA C-206. After the joints have been welded, the interior joint shall be grouted with cement mortar. Welded joints shall be completed in the trench per AWWA C206. Both the bell and spigot ends shall be cleaned of foreign matter prior to welding. Welding electrodes shall be as recommended by the pipe manufacturer. Typically, electrodes shall be E6010 for root passes and E7018 for additional passes. Do not deposit more than 3.2mm (1/8”) of throat thickness per pass. Weld material shall be deposited in successive layers. Complete and clean each pass around the entire circumference of the pipe before commencing the next pass. The minimum number of passes in the completed weld shall be as follows: Steel Cylinder Thickness mm (inches) Number of Passes Field Weld Minimum 6.35 or less (0.2500 or %”) 2 Greater than 6.35 (0.2500 or %Ir) 3 To minimize longitudinal stresses due to temperature variations, it is necessary to leave unwelded one joint per each 120m (400’) of pipeline. This joint shall be left unwelded until all the joints on both sides of it are welded, and it shall be welded at the coolest time of the working day. The District Engineer shall decide if and when this procedure is warranted. Tack-welding the joint may be permitted to hold the pipe in place. If the joint is to be circumferentially welded, sufficient time shall elapse to allow for an initial set of interior joint lining prior to proceeding with joint welding. Rapid-setting mortar may be used in accordance with this Section. In some cases, the District Engineer may require hand holes. Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -1 3 3.7 3.0 3.9 3.1 0 L. Field welders shall be certified in accordance with ASME Section 9 (pipe welders) or AWS D1.l (plate welders). Welders shall present a copy of their certification to the District Engineer prior to performing any field welding. M. Prior to butt-strap welding, the pipe and pipe joint shall be properly positioned in the trench using line-up clamps so that, in the finished joint, the abutting pipe sections shall not be misaligned by more than 1.59mm (lh6"). N. The pipe ends shall be cut straight on joints where butt straps are used for realignment, adjustment, or deflection, and fillet welds shall be made as indicated. 0. Inspection of Field Welded Joints: 1. The District shall arrange for the welds to be inspected. Inspection of welds shall take place as soon as possible following the completion of the welds. 2. The Contractor shall coordinate and supply ventilation, lighting, and other equipment deemed necessary for inspection. The Contractor shall be responsible for providing safe entry into and out of the trench, safety of inspection personnel, traffic control and other safety precautions deemed necessary for the inspections. PREVENTING FOREIGN MATTER FROM ENTERING THE PIPE At all times when pipe laying is not in progress, the open end of the pipe shall be closed with a tight-fitting cap or plug to prevent the entrance of foreign matter into the pipe. These provisions shall apply during the noon hour as well as overnight. In no event shall the pipeline be used as a drain for removing water which has infiltrated into the trench. The Contractor shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the Owner's Representative. HANDLING OF PIPE Refer to Section 09870 regarding handling of the concrete mortar lined and tape wrapped and mortar coated steel pipe. INTERIOR JOINT FINISH - PIPE LESS THAN 600mm (24") Complete interior mortar joints for pipe sizes less than 600mm (24") by drawing through a tight-fitting swab or squeegee. Coat the face of the cement mortar lining at the bell with a sufficient amount of stiff cement mortar to fill the gap. Immediately after joining the pipes, draw the swab through the pipe to remove all excess mortar and expel it from the open pipe end. Do not move the pipe after the swab has been pulled past the joint. See requirements under "Field Welded Joints" for these joints requiring welding. INTERIOR JOINT FINISH - PIPE 600mm (24") AND LARGER A. Complete interior mortar joints for pipe sizes 600mm (24") and larger by the trowel method. Prior to applying interior mortar at the joints all backfill in the area January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -1 4 shall be completed. After cleaning the interior joint, pack cement mortar into each joint. Finish the surface with a steel trowel to a smooth finish and equal thickness to match the adjoining pipe mortar. B. Where more than a 100mm (4") joint strip of mortar is required, place galvanized welded wire mesh reinforcement in 50mm x 1OOmm (2" x 4") pattern of No. 13 gauge over the exposed steel. Install the mesh so that the wires on the 50mm (2") spacing direction run circumferentially around the pipe. Crimp the wires on the 100mm (4") spacing to support the mesh 9.5mm (3/8") from the metal surface. Steel-trowel finish the interior mortar to match adjoining mortar-lined pipe sections. 3.1 1 EXTERIOR JOINT FINISH A. The outside annular space between pipe sections shall be completely filled with grout formed by the use of polyethylene foam-lined fabric bands. The grout space shall be flushed with water prior to filling so that the surfaces of the joint to be in contact with the grout will be thoroughly moistened when the grout is poured. The joint shall be filled with grout by pouring from one side only. Grout shall be rodded with a wire or other flexible rod or vibrated so that the grout completely fills the joint recess by moving down one side of the pipe, around the bottom of the pipe and up the opposite side. Pouring and rodding the grout shall be continued to allow completion of the filling of the entire joint recess in one operation. Care shall be taken to leave no unfilled space. Grouting of the outside joint spaces shall be kept as close behind the laying of the pipe as possible except that in no case shall grouting be closer than three joints of the pipe being laid. B. The grout bands or heavy-duty diapers shall be polyethylene foam-lined fabric with steel strapping of sufficient strength to hold the fresh mortar, resist nodding of the mortar, and allow excess water to escape. The foam plastic shall be 100 percent closed cell, chemically inert, insoluble in water and resistant to acids, alkalis and solvents. Foam Plastic shall be Dow Chemical Company, Ethafoam 222, or equal. The fabric backing shall be cut and sewn into 224mm (9") wide strips with slots for the steel strapping on the outer edges. The polyethylene foam shall be cut into strips 150mm (6") wide and slit to a thickness of 6.35mm (1/4") that will expose a hollow or open-cell surface on one side. The foam liner shall be attached to the fabric backing with the open or hollow cells facing towards the pipe. The foam strip shall cover the full interior circumference of the grout band with sufficient length to permit a 200mm (8") overlap of the foam at or near the top of the pipe joint. Splices to provide continuity of the material will be permitted. The polyethylene foam material shall be protected from direct sunlight. The polyethylene foam-lined grout band shall be centered over the joint space with approximately equal widths extending over each pipe end and securely attached to the pipe with the steel straps. After filling the exterior joint space with grout, the flaps shall be closed and overlapped in a manner that fully encloses the grout with polyethylene foam. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 1 5061 - 1 5 C. Following grouting, the joint shall then be wrapped with two layers of polyethylene encasement in accordance with Section 15000. 3.12 BUT STRAP JOINTS Butt strap closure joints shall be installed where shown on the Approved Plans in accordance with AWWA C206. A. B. C. D. E. F. G. Butt straps shall be field welded to the outside plain end of the pipe along both edges with a full circumferential weld. A minimum of two weld passes shall be used. The interior of the joints shall be filled with a rapid-set mortar and finished off smoothly to match the pipe interior diameter. Clean the butt strap with a wire brush and apply a cement and water wash coat prior to applying cement mortar. Galvanized wire mesh, 50mm x 1OOmm (2" x 4") x No. 13 gauge shall be installed to the exterior of the joint prior to applying the mortar coating. Coat the exterior of the closure assemblies with mortar to cover all steel with a minimum of 32mm (1-1/4"). Seal weld the steel plug to the hand hole after the interior of the joint has been inspected and approved by the District Engineer. Following grouting, the joint shall then be wrapped with two layers of polyethylene encasement in accordance with Section 1 5000. 3.13 FLANGED CONNECTIONS Flanged connections shall be installed where indicated on the Approved Plans. A. Bolt holes shall straddle the horizontal and vertical centerlines. 6. The bolts, nuts and flange faces shall be thoroughly cleaned by wire brush prior to assembly. C. Bolts and nuts shall be lubricated with a District-approved anti-seize compound. D. Nuts shall be tightened in an alternating "star" pattern to the manufacturer's recommended torque. E. Slip-on type flanges intended for field fit-up and welding shall be welded inside and outside in accordance with AWWA C207. F. Coat the exterior of exposed flanges, bolts and nuts in accordance with Section 0991 0. January 2004 Cement-Mortar Lined and Coated Steel Pipe and Specials Calavera Pump Station (860-3-CAL) Contract 38891 15061 -1 6 3.1 4 3.1 5 3.1 6 3.17 3.1 8 3.1 9 3.20 3.21 FLANGED COUPLING ADAPTERS Flanged coupling adapters shall be installed in accordance with the manufacturer's recommendations. Bolts shall be tightened with a torque wrench in the presence of the District Engineer to the torque recommended by the manufacturer. JOINT BONDING/CATHODIC PROTECTION INSULATION Bonding of joints to provide continuity, flange insulation kits, internal epoxy linings, and other cathodic protection items and materials shall be installed where shown on the Approved Plans in accordance with the Standard Drawings and Section 131 IO. WAX TAPE Wax tape shall be installed as shown on the Approved Plans or as directed by the District Engineer in accordance with Section 131 10 and the Standard Drawings. CONCRETE Where required, concrete thrust and anchor blocks shall be installed in accordance with CMWD Reclamation Rules & Regulations and as shown on the Approved Plans. Prior to filling the pipeline with water, refer to CMWD Reclamation Rules & Regulations for the minimum concrete curing time required. WARNINGADENTIFICATION TAPE Warningldentification Tape shall be installed in accordance with Section 15000 and the Standard Drawings. DISINFECTION AND BACTERIOLOGICAL TESTING Disinfection, bacteriological testing, and flushing shall be performed in accordance with Section 15041. HYDROSTATIC TESTING Field hydrostatic testing shall be performed in accordance with Section 15044. FIELD PAINTING AND COATING A. Exterior surfaces of all pipe and appurtenances not otherwise mortar-coated shall be field painted in accordance with Section 0991 0. B. Areas in contact with potable water such plain ends of pipe, grooved and shouldered ends of pipe and exposed inside surfaces of threaded outlets and blind flanges shall be coated in accordance with Section 15000. END OF SECTION January 2004 Calavera Pump Station (860-3-CAL) Cement-Mortar Lined and Coated Steel Pipe and Specials 15061 -1 7 Contract 38891 SECTION 15092 MISCELLANEOUS COUPLINGS, PIPE AND APPURTENANCES PART 1 GENERAL 1.1 1.2 1.3 1.4 DESCRIPTION All valves, couplings, and appurtenances shall conform to requirements of the standard dimensions and pressure classification of the immediately adjacent pipe, valve or appurtenance as specified. RELATED WORK DESCRIBED ELSEWHERE The Contractor shall refer to the following Specification section(s) for additional requirements: A. Painting and Coating: 09900 B. Petrolatum Wax Tape Coating: 09902 SUBMITTALS Contractor shall furnish submittals in accordance with the requirements of Section 2-5.3, Shop Drawing Submittals. The following submittals are required: A. Submit Shop Drawings for all miscellaneous couplings, pipe and appurtenances. Shop Drawings shall include listing of materials of construction, with ASTM reference and grade, including lining and paint coating intended for use, with lining and coating manufacturers' and paint numbers listed. PAYMENT Payment for the Work in this section shall be included as part of the lump-sum or unit- price bid amount for which such Work is appurtenant thereto. PART 2 - MATERIALS 2.1 GASKETS, NUTS, AND BOLTS Gaskets for flanged joints shall be fullface, asbestos composition sheet packing, graphited on both sides, "drop-in" type, boltholes prepunched, conforming to the requirements of ANSI B16.21 and shall be as manufactured by Crane Co., Garlock or approved equal. Bolts and studs for aboveground installations shall be cadmium plated and shall conform to ASTM A307, Grade B, "Steel Machine Bolts and Nuts and Tap Holes," when a ring gasket is used and shall conform to either ASTM A261, "Heat-Treated Carbon Steel Bolting Material" or ASTM A1 93, "Alloy-Steel Bolting Material for High Temperature Service," when a full-face gasket is used. Bolts and nuts shall be heavy hexagon series. Nuts shall conform to ASTM A194, "Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service" either in Grade 1, 2 or 2H. The fit shall be ANSI B1.1, "Unified Screw Threads," Class 2, except that Class 3 fit shall be used in holes tapped for studs. Threads may be made by either cutting or cold forming. Between 1/4-inch and 3/8-inch shall project through the nut when drawn tight. Washers shall be Drovided for each nut and shall be the same material as each nut. All buried flanges, including bolts, nuts and washers, shall be encased in wax tape per Section 09902. January 2004 Miscellaneous Couplings, Pipe and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15092-1 2.2 2.3 2.4 2.5 All bolt threads shall be lubricated with non-oxide grease. Flanged faces shall be wire brushed and cleaned prior to joining each flange. POLYETHYLENE ENCASEMENT Unless otherwise specified on the Plans, all couplings and appurtenances for underground installation shall be encased in wax tape per Section 09902. PAINTING AND COATING All miscellaneous couplings, pipe and appurtenances referenced in this section shall be painted and coated, interior and exterior, in accordance with Section 09900, Painting and Coating. FLEXIBLE COUPLINGS Joints for which flexible couplings are required, shall be made with Baker, Smith-Blair, or approved equal. Gaskets shall be plain rubber gaskets. Threads on bolts of compression collars shall be lubricated with non-oxide grease before assembling the coupling. For cast-iron, ductile-iron or asbestos cement pipe sizes 2-inches through 16-inches, use Baker Series 228, Smith-Blair Series 413, or approved equal. Transition couplings shall be Baker Series 21 2, Smith-Blair Series 413, or approved equal. Flanged coupling adapters for cast iron or ductile iron pipe sizes 4-inches through 12-inches shall be Baker Series 601, Smith-Blair Series 912, or approved equal. Flanged coupling adaptors for cast or ductile iron pipe greater than 12-inches shall be Baker Series 602 or Smith-Blair Series 91 3. PIPE UNIONS Screw unions may be employed on pipelines 2-1/2-inches in diameter and smaller. Pipes and fittings made of non-ferrous metals shall be isolated from ferrous metals by nylon insulating pipe bushings, unions or couplings manufactured by Smith-Blair, Pipe Seal and Insulator Co. or approved equal. PART 3 - EXECUTION (Not Applicable) END OF SECTION January 2004 Miscellaneous Couplings, Pipe and Appurtenances Calavera Pump Station (860-3-CAL) Contract 38891 15092-2 SECTION 15099 PROCESS VALVES, REGULATORS AND MISCELLANEOUS VALVES PART 1 GENERAL 1.1 1.2 1.3 1.4 1.5 DESCRIPTION This section includes materials, testing and installation of manually operated process valves such as check valves, pressure control valves, pressure reducing valves and ball valves. REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. American Water Works Association AWWA C508 Standards for Swing Check Valve ASTM B62 Standards for Ball Vales RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Specification Sections 0991 0, 15000, 15041, 15044, 15057, 15074, 151 08, 151 12 and 15152 SERVICE APPLICATIONS Check valves, pressure control valves, pressure reducing valves, bronze gate valves and ball valves are primarily used in the installation of potable and recycled water main appurtenances and where called for on the Approved Plans and indicated on the Standard Drawings. SUBMllTALS The following items shall be submitted to the District for review and approval prior to ordering or delivery of valves per Section 2-5.3 Submittals. A. The valve manufacturers catalog data showing the size to be used, valve dimensions, pressure rating and materials of construction. B. Manufacturers catalog data and proof of NSF certification on the lining materials to be used. C. Installation procedures including field adjustments as required. January 2004 Calavera Pump Station (860-3-CAL) Process Valves, Regulators and Miscellaneous Valves 15099-1 Contract 38891 1.6 1.7 1.8 1.9 1.10 SIZING OF VALVES Valves shall be the same size as the appurtenance in which they are to be installed with unless otherwise called for on the Approved Plans or indicated on the Standard Drawings. VALVE ENDS Valve ends shall be compatible with the piping system or appurtenance in which they are to be installed or as called for on the Approved Plans or indicated on the Standard Drawings. DELIVERY, STORAGE AND HANDLING Valves shall be delivered and stored in accordance with the manufacturer's recommendations. Valves shall remain in factory packaging until ready for installation. Valves shall not be stored in contact with bare ground. POLYETHYLENE WRAP Polyethylene wrap shall be used for the buried installation of valves in accordance with Section 15000. GATE WELLS AND EXTENSION STEMS Valve boxes and extension stems shall be installed in accordance with Section 15000 and the Standard Drawings. PART 2 MATERIALS 2.1 RUBBER-FLAPPER SWING CHECK VALVE A. Swing check valves and appurtenant components shall be in accordance with AWWA C508 and selected from the Approved Materials List. A submittal will be required as described in this Section. B. Rubber-flapper swing check valves shall have a heavily constructed ductile-iron body and cover. The body shall be long pattern design (not wafer), with integrally cast-on end flanges. The flapper shall be Buna-N having an "0" ring seating edge and be internally reinforced with steel. C. Flapper shall be captured between the body and the body cover in a manner to permit the flapper to flex from closed to full open position during flow through the valve. Flapper shall be easily removed without need to remove valve from line. Check valves shall have full pipe size flow area. Seating surface shall be on a 45' angle requiring the flapper to travel only 35" from closed to full open position, for minimum head loss and non-slam closure. January 2004 Calavera Pump Station (860-3-CAL) Process Valves, Regulators and Miscellaneous Valves Contract 38891 15099-2 2.2 2.3 2.4 2.5 2.6 D. Buna-N flapper shall be high-strength coated fabric, coated both sides with 70 DURO, which creates an elastic spring effect, molded internally, to assist the flapper to close against a slight head to prevent slamming. When essential to create backflow through the check valve, as directed by the District Engineer, an external backflow device shall be furnished. E. F. Valve ends shall be flanged ductile-iron in accordance with Section 15056 unless otherwise called for on the Approved Plans or directed by the District Engineer. Check valves shall be tested by the manufacturer and the test results shall be approved by the District Engineer prior to shipment to the project. Check valves must unseat at a head no greater than 600mm (24"). SMALL DIAMETER ISOLATING VALVES Provide all small diameter valves and cocks for shut-off process connections, instrumentation and other miscellaneous uses in accordance with the Approved Plans. These valves shall be of the same material and pressure rating as the adjacent process piping. Shutoff valves shall be compatible with instrumentation and other equipment in accordance with the manufacturer's recommendations. CORPORATION STOPS Corporation stops shall be in the ball type with a bronze body and T-Head operator. Valve ends shall be compatible with the piping system in which they are being installed or as called for on the Approved Plans or indicated on the Standard Drawings. Corporation stops shall be rated for a minimum pressure of 1,379 KPa (200 psi). Corporation stops shall be selected from the Approved Materials List. ANGLE METER STOPS Angle meter stops shall be the ball type with a bronze body and 90" lock wing. Valve ends shall be flare style inlet and swivel meter nut for 25mm (1") and meter flange for 50mm (2") outlets. Angle meter stops shall be rated for a minimum pressure of 1,379 KPa (200 psi). Angle meter stops shall be selected from the Approved Materials List. CUSTOMER METER SHUT-OFF VALVE Customer meter shut-off valves shall be the ball type with a bronze body and lever handle operator. Valve ends shall be swivel meter nut for 25mm (1") inlets and meter flange for 50mm (2") inlets. Customer meter shut-off valves shall be rated for a minimum pressure of 1,379 KPa (200 psi). The District Engineer may require the use of a customer meter shut-off valve equipped with a 90" lock wing. BALL VALVES Ball valves 50mm (2") and smaller shall be of bronze construction conforming to ASTM 862 and equipped with a T-Head or lever handle operator as required. Valve ends shall be compatible with the piping system in which they are being installed or as indicated on the Approved Plans or Standard Drawings. Ball valves shall be rated for a minimum pressure of 1,379 KPa (200 psi). Ball valves shall be selected from the Approved Materials List. January 2004 Process Valves, Regulators and Miscellaneous Valves Calavera Pump Station (860-3-CAL) Contract 38891 15099-3 2.7 BACKFLOW PREVENTERS Backflow preventers shall be in accordance with Section 151 12 and selected from the Approved Materials List. 2.8 POLYTHYLENE WRAP Polyethylene wrap shall be in accordance with Section 15000 and selected from the Approved Materials List. 2.9 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be in accordance wit Section 15000 and selected from the Approved Materials List. PART 3 EXECUTION 3.1 INSTALLATION A. Valves shall be set in true alignment straddling the centerline of pipe with the valve operator in the vertical position unless otherwise noted on the Approved Plans or shown on the Standard Drawings. B. Valves shall be installed in accordance with the manufacturer's recommendations and the applicable section of these specifications for the piping material and joint type being used. C. Aboveground valves shall be rigidly held in place using supports and hangers in accordance with the Approved Plans and Standard Drawings. The stem orientation of valves in elevated piping shall be as approved by the District Engineer for accessibility, except that no valves shall be installed with stems aligned below horizontal. Saddle type valve supports shall be provided. Supports shall be of rugged construction providing at least one hundred twenty degrees (120') under support for the valve body. Valve supports shall be constructed of steel, and shall be anchored to the foundations using stainless steel anchor bolts. 3.2 POLYETHYLENE WRAP Installation of polyethylene wrap for buried valves shall be in accordance with Section 15000. 3.3 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be in accordance with Section 15000 and the Standard Drawings. January 2004 Calavera Pump Station (860-3-CAL) Process Valves, Regulators and Miscellaneous Valves Contract 38891 15099-4 3.4 DISINFECTION OF ME VALVES Disinfection and flushing shall be in accordance with Section 15041, as part of the progress of disinfecting the main pipeline. The valves shall be operated during the disinfection period to completely disinfect all internal parts. 3.5 HYDROSTATIC TESTING Valves shall be hydrostatically tested in conjunction with the pipelines in which they are installed in accordance with Section 15044. END OF SECTION January 2004 Process Valves, Regulators and Miscellaneous Valves Calavera Pump Station (860-3-CAL) Contract 38891 15099-5 SECTION 15100 RESILIENT WEDGE GATE VALVES (RWGV's) PART 1 GENERAL 1.1 DESCRIPTION This section includes materials, testing, and installation of manually operated resilient wedge gate valves (RWGV's). 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 0991 0, 15000, 15041, 15044, 15056, 15057, 15061, 15064, 15074, 15108 and 15112 1.4 SERVICE APPLICATION A. Resilient wedge gate valves (RWGV's) shall be installed on potable and recycled water mains and appurtenances in accordance with the Approved Plans and the Standard Drawings. B. Resilient wedge gate valves shall be used for openklosed operations, throttling service and frequent operation after long periods of non-actuation. C. In general, resilient wedge gate valves shall be used when valves are required on pipelines and appurtenances 1 OOm (4") through 400mm (1 6"). D. Valves for pipelines sized 450mm (18") and larger generally require the use of butterfly valves (BFV) in accordance with Section 151 02. 1.5 SUBMllTALS The following items shall be submitted for review and approval per Section 2-5.3, prior to ordering or delivery of resilient wedge gate valves. A. An affidavit from the valve manufacturer stating that valves have successfully passed hydrostatic tests in accordance with AWWA C509 and manufacturer's own coatings tests. B. The valve manufacturer's catalog data showing the size to be used, valve dimensions, pressure rating and materials of construction. C. Manufacturer's catalog data and proof of NSF certification for the lining materials to be used. January 2004 Resilient Wedge Gate Valves (RWGV's) Calavera Pump Station (860-3-CAL) Contract 38891 151 00-1 1.6 1.7 1.8 1.9 ' 1.10 1.11 SIZING OF VALVES Valves shall be the same size as the line in which they are installed unless otherwise noted on the Approved Plans. VALVE ENDS Valve ends shall be compatible with the piping system in which they are being installed in accordance with the Approved Plans or directed by the District Engineer. Ductile-iron flanges shall be in accordance with Section 15056. VALVE TESTING Resilient wedge gate valves shall be hydrostatically tested and valve coatings shall be holiday detected prior to shipment to the field in accordance with the testing procedures shown in Appendix A. Valves delivered to the site prior to successful hydrostatic testing and holiday detection shall be subject to rejection. DELIVERY, STORAGE AND HANDLING Valves shall be delivered and stored in accordance with AWWA C550. The port openings shall be covered with plastic, cardboard or wood while in transit and during storage in the field. These covers shall remain in place until valves are ready to be installed. Valves shall not be stored in contact with bare ground. Valves shall not be stacked. "NOT USED" POLYETHYLENE WRAP Polyethylene wrap shall be used for the buried installation of resilient wedge gate valves in accordance with Section 15000. PART 2 MATERIALS 2.1 RESILIENT WEDGE GATE VALVES (RWGV's) A. Resilient wedge gate valves and appurtenant components and materials shall be selected from the Approved Materials List. RWGVs shall be ductile-iron in accordance with AWWA C509 and C515 except as modified herein. Each valve shall have a smooth unobstructed waterway free from any sediment pockets. All RWGV's shall be leak-tight at their rated pressure. B. C. D. January 2004 Resilient Wedge Gate Valves (RWGV's) Caiavera Pump Station (860-3-CAL) Contract 38891 1 5 1 00-2 E. RWGVs shall have a non-rising low-zinc bronze or stainless steel stem, opened by turning left (counterclockwise). F. Stem seals shall be the O-ring type incorporating a minimum of two rings as required by AWWA (2509. G. Low-friction torque-reduction thrust washers or bearings shall be provided on the stem collar. H. Wedge (gate) shall be fully encapsulated with a bonded-in-place Nitrile elastomer covering. Minimum thickness of the rubber seating area shall be 6.35mm (1/4"). I. Valves for buried applications shall be provided with a 50mm (2") square operating nut, and valves located above ground or in structures shall be equipped with a hand wheel in accordance with AWWA C509 unless otherwise indicated on the Approved Plans. J. RWGV interior and exterior surfaces (except for the encapsulated disc) shall be coated as described below. K. All bolts and nuts used in the construction of RWGVs shall be Type 31 6 stainless steel. 2.2 EPOXY LINING AND COATING Epoxy linings and coatings for valves shall be provided in accordance with AWWA C210, C213, and C550, with the following modifications: A. Epoxy lining and coating of valve surfaces shall be performed by the manufacturer in a facility with qualified personnel, where the environment can be controlled. Epoxy lining and coating of valves in the field is prohibited. B. Repairs made to manufactures applied coatings shall be performed in a facility with qualified personnel, where the environment can be controlled. The facility shall be approved by the valve manufacturer. C. Surface preparation shall be as detailed in SSPC-SP5, White-Metal Blast Cleaning. D. Liquid epoxy lining and coating materials shall be listed in the NSF Listing for Drinking Water Additives, Standard 61, certified for use in contact with potable water. E. The minimum dry film thickness for epoxy linings shall be 0.203mm (0.008" or 8 mils). Liquid epoxy lining shall be applied in two (2) coats in accordance AWWA c210. F. Powder epoxy coating materials shall contain one hundred percent (1 00%) solids, in accordance with AWWA C213. January 2004 Resilient Wedge Gate Valves (RWGV's) Calavera Pump Station (860-3-CAL) Contract 38891 151 00-3 2.3 2.4 2.5 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be in accordance with Section 15000 and selected from the Approved Materials List. CONCRETE Concrete used for anchor or thrust blocks shall be Class 500-C-3250. POLYETHYLENE WRAP Polyethylene wrap shall be in accordance with Section 15000 and selected from the Approved Materials List. PART 3 EXECUTION 3.1 3.2 3.3 3.4 3.5 INSTALLATION A. Install valves with the bolt holes straddling the vertical centerline of pipe and the operating nut in the vertical position unless otherwise noted on the Approved Plans. B. Valves shall be installed in accordance with the manufacturer's recommendations and the applicable section of these specifications for the piping material and joint type being used. C. Joints shall be cleaned and installed in accordance with Section 15056. POLYETHYLENE WRAP Installation of polyethylene wrap for buried valves shall be in accordance with Section 15000. CONCRETE Concrete thrust, anchor, and support blocks shall be installed in accordance the Standard Drawings. The concrete shall be placed so that valves and valve operators will be accessible for repairs or replacement. GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be installed in accordance with Section 15000 and the Standard Drawings. DISINFECTION OF VALVES Disinfection and flushing of valves shall be in accordance with Section 15041, as part of the process of disinfecting the main pipeline. The valves shall be operated during the disinfection period to completely disinfect all internal parts. January 2004 Calavera Pump Station (860-3-CAL) Resilient Wedge Gate Valves (RWGV's) 151 00-4 Contract 3889 1 3.6 HYDROSTATIC TESTING Valves shall be hydrostatically tested in conjunction with the pipeline in which they are installed in accordance with Section 15044. 3.7 FIELD PAINTING AND COATING The exterior of valves installed above ground or exposed in vaults or enclosures shall be field painted in accordance with Section 09910. END OF SECTION January 2004 Resilient Wedge Gate Valves (RWGV’s) Calavera Pump Station (860-3-CAL) Contract 38891 151 00-5 SECTION 15108 AIR RELEASE VALVE, AIR AND VACUUM VALVE, AND COMBINATION AIR VALVE ASSEMBLIES PART 1 GENERAL 1 .I 1.2 1.3 1.4 DESCRIPTION This section includes the materials and installation instructions for above ground air release valve, air and vacuum valve, and combination air valve assemblies. The term "air valve" is used generically in this specification to refer to requirements common to all of the specified air release valves, air and vacuum valves, and combination air valves. Otherwise, the various types of air valves are addressed by the individual designations commonly used in AWWA and industry standards. REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. American Water Works Association (AWWA) C512 Standards for Combination Air Valve Assemblies RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 0991 0, 15000, 15041, 15044, 15056, 15057, 15061, 15064, 15100,16640 SERVICE APPLICATION A. Combination air valves are generally installed on all potable and recycled water mains at high points and where shown on the Approved Plans and in accordance with the Standard Drawings. B. Unless otherwise directed by the District Engineer, combination air valves will be required as indicated below: 1. 25mm (1 ") combination air valve assemblies shall be installed on pipeline sizes 150mm (6") and 200mm (8"). 2. 50mm (2") combination air valve assemblies shall be installed on pipeline sizes 250mm (IO") and 300m (12"). 3. Multiple (2") 50mm (4") combination air valve assemblies shall be installed on pipeline sizes 400mm (16") and 500mm (20"). 4. 150mm (6") combination air valve assemblies shall be installed on pipeline sizes 600mm (24") through 900mm (36"). January 2004 Air Release Valve, Air & Vacuum Valve, &Combination Air Valve Assemblies Calavera Pump Station (860-3-CAL) Contract 38891 151 08-1 1.5 1.6 1.7 C. Air release valves and air and vacuum valves shall be installed in accordance with the Approved Plans or as directed by the District Engineer. DELIVERY, STORAGE, AND HANDLING Valves shall be delivered and stored in accordance with AWWA C550. The port openings shall be covered with plastic, cardboard, or wood while in transit and during storage in the field. These covers shall remain in place until the valve is ready to be installed. Valves shall not be stored in contact with bare ground. Valves shall not be stacked. "NOT USED" WARNINGADENTIFICATION TAPE WarningAdentification tape shall be installed for air valve assemblies in accordance with Section 15000. PART 2 MATERIALS 2.1 COMBINATION AIR VALVES A. Combination air valves and appurtenant components and materials suitable for the system pressure shall be selected from the Approved Materials List. B. Combination air valves shall comply with AWWA C512 except as modified herein. C. 25m (1") and 50mm (2") combination air valves shall be the single-body type incorporating stainless steel internal components and National Pipe Threaded (NPT) inlet and outlet configurations. D. 1OOmm (4") and 150mm (6") Combination Air Valves shall be the single-body type. Valves shall incorporate stainless steel internal components, protective hood and flanged inlet. E. Internal protective epoxy coatings shall be provided in accordance with AWWA C550. 1. Liquid epoxy lining and coating materials shall be listed in the NSF Listing for Drinking Water Additives, Standard 61, certified for use in contact with potable water. 2. The minimum dry film thickness for epoxy linings shall be 0.203m (0.008" or 8 mils). Liquid epoxy lining shall be applied in two (2) coats in accordance with AWWA C210. January 2004 Air Release Valve, Air & Vacuum Valve, &Combination Air Valve Assemblies Calavera Pump Station (860-3-CAL) Contract 38891 151 08-2 2.3 2.4 2.5 2.6 2.7 ENCLOSURES Air Valve Enclosures shall be selected from the Approved Materials List. CONCRETE Concrete used for anchor or thrust blocks and equipment pads shall be in accordance with Section 03000. BREAK-AWAY BOLTS Combination air valves, air release valves and air and vacuum valves located above ground sized 1OOmm (4") and larger shall be installed with break-away bolts in accordance with the Standard Drawings and selected from the Approved Materials List. WAR Nl NGA DENTlFl CATION TAPE WarningAdentification Tape shall be in accordance with Section 1 5000 and selected from the Approved Materials List. FIELD PAINTING AND COATING Field painting and coating materials shall be in accordance with Section 09910 and 0991 5 and selected from the Approved Materials List. PART 3 EXECUTION 3.1 3.2 3.3 INSTALLATION A. Air valve assemblies shall be provided as shown on the Approved Plans. Additional air valve assemblies may be required in areas of potential air entrapment, at the discretion of the District Engineer. B. Air valve assemblies shall be installed relative to street improvements in accordance with the Standard Drawings. Connections for the air valve assemblies shall be made within a section of the main line no closer than 600mm (24") to a bell, coupling, joint or fitting. C. CONCRETE Concrete thrust or anchor blocks and equipment pads shall be installed in accordance with the Standard Drawings. WARNINGADENTIFICATION TAPE Warninghdentification Tape shall be installed in accordance with Section 15000 and the Standard Drawings. January 2004 Air Release Valve, Air & Vacuum Valve, &Combination Air Valve Assemblies Calavera Pump Station (860-3-CAL) Contract 38891 151 08-3 3.4 DISINFECTION Air valve assemblies shall be disinfected in accordance with Section 15041 in conjunction with disinfecting the main to which it is connected. The assembly valves shall be operated and the assembly flushed to completely disinfect all internal parts. 3.5 HYDROSTATIC TESTING Air valve assemblies shall be hydrostatically tested in accordance with Section 15044 in conjunction with the pipeline to which they are connected. 3.6 FIELD PAINTING AND COATINGS A. Field repairs to the enclosure shall not be permitted. Enclosures requiring repairs to the coating shall be returned to the supplier or coating vendor for repairs or recoating in accordance with Section 0991 5. END OF SECTION January 2004 Air Release Valve, Air & Vacuum Valve, &Combination Air Valve Assemblies Calavera Pump Station (860-3-CAL) Contract 38891 151 08-4 SECTION 151 12 BACKFLOW PREVENTERS PART 1 GENERAL 1.01 1.02 1.3 1.4 DESCRIPTION This section includes materials, installation, and testing of reduced-pressure backflow prevention devices and check valve and double check valve assemblies. REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. State of California Department of Health Services Division of Drinking Water and Environmental Management, Approved Backflow Prevention Assemblies for Service Isolation. RELATED WORK SPECIFIED ELSEWHERE Agencies of Jurisdiction Rules and regulations regarding "Cross Connection Control and Backflow Prevention" CMWD Standard Drawings CMWD Standard Specifications 0991 0, 15000, 15041, 15044, 15056, 15057, 15061, 15064 and 151 00 SERVICE APPLICATION A. Reduced-pressure backflow prevention assemblies shall be provided on all commercial, industrial irrigation and multi-family water services. B. Reduced-pressure backflow prevention assemblies shall be provided on all irrigation services by potable and recycled water. C. Reduced-pressure backflow prevention assemblies shall be provided on potable water services where recycled water, well water or any other water supply is served to the same property. D. Reduce pressure backflow preventers assemblies shall be provided at all points of connections to District sources at construction sites. E. Double check detector assemblies shall be provided on all fire services. F. The District shall be the final authority as to the location, installation, and type of backflow prevention device required. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Backflow Preventers 15112-1 1.5 1.6 1.7 1.8 GENERAL DESIGN CONSIDERATIONS A. The Design and construction of the backflow prevention assembly shall meet the requirements called for in this specification except that any modifications specifically shown on the Approved Plans shall take precedence over these general standards. B. The nominal size of the backflow prevention device shall be equal to or greater than the size of the purchased meter. For example, a 25mm (1") meter shall have a 25mm (1 ") or larger backflow device. C. The assembly shall include same size valves located on either side of the backflow prevention assemblies. Four test cocks shall be appropriately located on the assembly for testing and certification. D. The nominal size of double check detector assemblies shall be as shown on the Approved Plans or as directed by the Fire Department. E. Enclosures and concrete slabs shall be provided only as shown on the Approved Plans. DELIVERY, STORAGE AND HANDLING Backflow prevention assemblies shall be delivered and stored in accordance with AWWA C210, AWWA C213, and AWWA C550. The port openings shall be covered with plastic, cardboard, or wood while in transit and during storage in the field. These covers shall remain in place until the backflow assembly is ready to be installed. Backflow assemblies shall not be stored in contact with bare ground. Backflow assemblies shall not be stacked. RECYCLED WATER IDENTIFICATION Backflow prevention assemblies and enclosures for recycled water shall be identified with purple-colored coating, identification labels, or signs in accordance with Section 15151. WARNING/IDENTIFICATION TAPE WarningAdentification Tape shall be installed for backflow prevention assemblies in accordance with Section 15000. PART 2 MATERIALS 2.1 BACKFLOW PREVENTION ASSEMBLIES Backflow prevention assemblies shall be among those listed on the list of "Approved Backflow Prevention Assemblies for Service Isolation" as issued by the State of California Department of Health Services, Division of Drinking Water and Environmental Management. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Backflow Preventers 15112-2 2.2 CONCRETE Concrete used for slabs and anchor or thrust blocks shall be in accordance with Standard specifications for Public Works Construction. 2.3 WARN IN G/I D E NTI FIC AT1 0 N TAP E WarningAdentification Tape shall be in accordance with Section 15000 and the Approved Materials List. PART 3 EXECUTION 3.1 3.2 3.3 3.4 3.5 INSTALLATION A. Installation shall comply with the latest edition of the Uniform Plumbing Code, applicable local agency and District requirements. B. Backflow prevention assemblies shall be installed in accordance with the Standard Drawings. Water service and fire service shut-off valves will be secured closed during installation until an approved backflow prevention device is installed and tested in compliance with this specification. When static pressure exceeds 1.03MPa (1 5Opsi), or when recommended by the backflow device manufacturer, a pressure-reducing valve shall be installed as shown on the Standard Drawings. C. D. WARNlNGfiDENTlFlCATlON TAPE WarningAdentification Tape shall be installed in accordance with Section 15000 and the Standard Drawings. CONCRETE Concrete thrust or anchor blocks and slabs shall be installed in accordance with Standard Drawings. ENCLOSURES Enclosures shall be installed where shown on the Approved Plans in accordance with the Standard Drawings. DISINFECTION Disinfection and flushing shall be performed in accordance with Section 15041, as part of the process of disinfecting the main pipeline. The backflow assemblies shall be operated during the disinfection period to completely disinfect all internal parts. January 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Backflow Preventers 15112-3 3.6 HYDROSTATIC TESTING Backflow assemblies shall be hydrostatically tested in conjunction with the pipeline to which they are connected in accordance with Section 15044. 3.7 TESTING The District will inspect and initially test each backflow prevention assembly after inspection of its proper installation is complete. Required maintenance of the backflow prevention device and appurtenances and annual testing of the device shall be the owner's responsibility. END OF SECTION January 2004 Calavera Pump Station (860-3-GAL) Contract 38891 Backflow P reventers 15112-4 SECTION 151 51 RECYCLED WATER FACILITIES (OFFSITE) PART 1 GENERAL 1.01 1.02 DESCR I PTl ON This section includes special provisions, materials, and identification of offsite recycled water systems. REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. (TO BE ADDED LATER) 1.03 1.04 1.05 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 02202, 02223, 03000, 0991 0, 15000, 15041, 15044, 15056, 15057, 15061, 15064, 15074, 15100, 15102,15108, and 15112 APPROVED USE All potential applications of recycled water shall be reviewed and approved by the District prior to installation of facilities. The facilities shall be constructed in accordance with the procedures and requirements of the District. No connections to recycled water main(s) shall be installed unless shown on the Approved Plans or permission has otherwise been granted in writing by the District. OFFSITE AND ONSITE CRITERIA Recycled water facilities are separated into two categories: A. "Offsite" (pre-meter, public) recycled water facilities consist of those facilities which are on the upstream side of the meter. These facilities are, or will be, owned, operated and maintained by the District. The Specification Section will detail the requirements for construction of Offsite Recycled Water Facilities. B. "Onsite" (post-meter, private) recycled water facilities consist of those facilities which are on the downstream side of the water meter. These are facilities which will be owned, operated and maintained by the customer. Refer to Section 151 52 for the detailed requirements of onsite irrigation and plumbing systems. January 2004 Recycled Water Facilities (Offsite) Calavera Pump Station (860-3-CAL) Contract 38891 151 51 -1 1.06 DESIGN CRITERIA A. 6. C. D. E. F. G. H. I. J. A licensed Civil Engineer registered in the State of California shall be responsible for the design of offsite recycled water facilities, including the preparation of plans and specifications. Plans for offsite potable and recycled water systems in the same street or easement shall show both potable and recycled water mains on the same sheets of plans. The minimum depth of cover for recycled water mains shall be in accordance with Section 02223 or as shown on the Approved Plans. In general, where both recycled and potable water mains are to be installed in the same street or easement, the top of pipe of the recycled water main shall be 300mm (12") below the top of the potable water main. A horizontal separation of 3.05m (lo'), and a vertical separation of 300mm (12") shall be maintained between recycled water lines and potable water lines, and between recycled lines and sanitary sewers. Recycled water lines shall be designed to cross under potable water mains and above sanitary sewers. In the event that it is not possible to maintain the required separation and relative positions between recycled water lines, potable water lines, and sanitary sewers, special construction shall be required in accordance with the Standard Drawings and as directed by the District Engineer. The minimum size distribution main shall be 150mm (6"). The District shall be the final authority concerning the size and pressure rating of the distribution main. Offsite recycled water mains shall typically be located on the opposite side of the street or easement from the potable water main. Offsite recycled water mains shall be designed with service laterals perpendicular to the main. Service laterals shall be a minimum of 50mm (2") in size. Larger sized laterals may be required. A service lateral shall be designed for each lot or area to be served with recycled water. A service lateral shall not be designed to serve opposite sides of a street or easement and shall not be located in street medians or center islands. Offsite recycled water systems shall not be designed with fire hydrants, wharf heads, or other appurtenances which would allow recycled water to be used for other than the approved uses unless the appurtenances are expressly approved by the District. Offsite recycled water mains shall not be designed with temporary connections unless expressly approved by the District. When permitted, temporary connections shall be located, sized, and designed according to the requirements of the District. January 2004 Calavera Pump Station (860-3-CAL) Recycled Water Facilities (Offsite) Contract 3889 1 151 51 -2 1.07 PROVISIONS FOR FUTURE USE OF RECYCLED WATER In those areas where the District has determined that recycled water will be supplied to the subject area in the future but is not currently available, recycled facilities shall be installed as detailed in this Section. Provisions for future connection to the permanent recycled water system shall be included in the initial installation of the system as directed by the District. In the interim, the new recycled system will be supplied with potable water via a temporary connection performed by the Contractor as directed by the District. This temporary service connection shall be provided in accordance with the Standard Drawings and shall incorporate a master backflow prevention device located and installed in accordance with Section 151 12. Connections between offsite recycled water mains and potable water mains shall only be permitted when the recycled water main is to temporarily convey potable water. No connection of any other kind shall be permitted between the potable water and recycled water mains. In the future, the Owner shall be responsible to remove the temporary service and transfer the main to a permanent connection to the recycled system when it becomes available. PART 2 MATERIALS 2.01 OFFSITE RECYCLED WATER FACILITIES A. Materials for offsite recycled water systems shall generally consist of those specified for potable water systems as detailed within these Standard Specifications, the Standard Drawings, the Approved Materials List, and as mod if ied he rein , B. Recycled water mains sized 150mm (6") and larger shall be PVC in accordance with Section 15064. PVC pipe for recycled water system applications and related gate well casings shall be manufactured in the purple color. Pipe markings shall include the designation "RECYCLED WATER" in addition to the standard factory labeling required by AWWA. C. Devices and appurtenances such as air valve assemblies, backflow preventers, blowoff assemblies, butterfly valves, gate valves, services and other items shall be provided in accordance with the various applicable Sections of these Standard Specifications, the Standard Drawings and the Approved Materials List. Color coding and other identification shall be provided as indicated below. D. Miscellaneous materials such as gate wells, meter boxes, warning tape, tracer wire, copper tubing, ductile iron fittings, brass and bronze fittings and devices, and all related items shall be provided in accordance with the various applicable Sections of these Standard Specifications, the Standard Drawings and the Approved Materials List. Color coding and other identification shall be provided as indicated below. E. WarningAdentification Tape shall be as specified in Section 15000 in accordance with the Approved Materials List. January 2004 Recycled Water Facilities (Offsite) Calavera Pump Station (860-3-CAL) Contract 38891 151 51 -3 F. G. H. PART 3 Paint products for protection and identification shall be provided as specified below and in accordance with Sections 09910,09915 and the Approved Materials List. Warning signs and labels shall be post mounted aluminum or vinyl, self adhesive with peel off paper backing, bearing the warning "RECYCLED WATER - DO NOT DRINK" or the equivalent, in English and Spanish, along with the international "Do Not Drink" symbol. Warning labels and signs shall have a purple background with contrasting lettering and markings. Utility identification tape shall be 0.102mm (0.00411 or 4 mils) PVC, pressure- sensitive adhesive-backed tape in rolls of various widths. The tape shall be color- coded purple and shall bear the designation "RECYCLED WATER" or the equivalent, in contrasting permanent lettering at approximately 300mm (1 2") intervals. Identification tape will generally be used in the 50mm (2") width to identify buried materials and components as detailed below. EXECUTION 3.01 OFFSITE RECYCLED WATER FACILITIES In general, offsite recycled water facilities shall be installed in accordance with the requirements for potable water materials and facilities within these Specifications, the Standard Drawings and the Approved Plans. 3.02 FIELD IDENTIFICATION - PIPING AND APPURTENANCES Recycled water mains and appurtenances shall be identified with purple-colored coding and identification labels and signs as specified herein. A. PVC pipe and related gate well casings shall be colored purple as manufactured. If purple-colored PVC pipe in the specified size or class is not readily available from suppliers, standard colored PVC pipe may be used and sleeved with a 0.203mm (0.008'' or 8 mils) purple-colored, high-density polyethylene encasement sleeve which totally encloses the pipe. B. Buried items that are not available from the manufacturer in the purple color shall be identified in the field by means of utility identification tape applied to the surface of the items. Valves, ductile iron fittings and similar items shall receive a band of the tape applied circumferentially at the ends of the fittings adjacent to connections to the adjoining piping sections, and to the operator portions of gate and butterfly valves. The identification tape shall also be used to secure the polyethylene wrap specified for the various piping materials and appurtenances. Copper tubing and appurtenant bronze fittings shall be identified by means of utility identification tape applied continuously along the upper surface of the entire length of the line. C. Meter and blowoff boxes shall be colored purple as manufactured. January 2004 Recycled Water Facilities (Offsite) Calavera Pump Station (860-3-CAL) Contract 38891 15151 -4 D. Accessible items that are not available from the manufacturer in the purple color, such as those located at grade, above ground and within meter boxes and vaults shall be identified in the field by means of a paint coating in the purple color. Meters, blowoff piping and blowoff box covers or blowoff manhole covers, valve box lids, air valves and enclosures, piping, valves, backflow devices and all other items either accessible or exposed to view, shall be identified by means of the purple coating or integral purple color. The coating system shall be suitable for the substrate material and the degree of protection required for the various items, in accordance with Section 0991 0 and the Approved Materials List. E. Tracer wire shall be installed in accordance with Section 15000 and the Standard Drawings. F. Warning/ldentification tape shall be installed in accordance with Section 15000 and the Standard Drawings. 3.03 LABELS AND SIGNAGE Labels shall be installed on recycled facilities exposed to view including above ground piping and appurtenances, meter and blowoff box covers, and where indicated on the Standard Drawings and the Approved Plans. Signs shall be installed where necessary and as indicated on the Approved Plans. 3.04 DISINFECTION AND BACTERIOLOGICAL TESTING In the event the recycled water mains are installed with provisions for future use for transporting recycled water, but will initially transport potable water (see item above), disinfection, flushing and bacteriological testing shall be performed in accordance with Section 15041. 3.05 HYDROSTATIC TESTING Potable water shall be used for filling, flushing, and hydrostatic testing. Field hydrostatic testing shall be performed in accordance with Section 15044. 3.06 BACKFLOW PREVENTION During the course of flushing and disinfection and hydrostatic testing of the recycled water mains, an appropriate backflow prevention device shall be installed on the potable source piping to isolate the potable from the non-potable system in accordance with Section 15044 and 151 12. END OF SECTION January 2004 Recycled Water Facilities (Offsite) Calavera Pump Station (860-3-CAL) Contract 38891 15151-5 SECTION 15800 HEATING AND VENTILATION EQUIPMENT TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 1.02 1.03 1.04 Specific Project Description The Contractor shall furnish, install, and test the ventilation equipment for the pump building including, intake louvers and exhaust ventilators, and accessories as specified herein and shown on the Drawings. Specific Project Louver Requirements Exterior Intake Louvers for Equipment Buildinq Equipment building intake louvers shall be the fixed louver type suitable for mounting in the building masonry wall. Specific Project Exhaust Ventilator Requirements Contractor shall furnish and install exhaust ventilators as manufactured by Loren Cook, or equal as follows and shown on the Drawings: Minimum Ventilator CFM Q Minimum Maximum Location No. Tvpe 318” S.P. HP Sound Power Remarks Equipment Building EF1 Roof 2,950 314 75 dB (1) (2) EF2 Roof 2,950 314 75 dB (1) (2) (1) 460 volt, three phase, two speed, two winding motor. Low speed shall be one-half of (2) Each ventilator shall be operated by timer and thermostat control. Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. high speed. Data to be Submitted bv Contractor Contractor shatl submit complete information, drawings, and technical data for all equipment and components, including, but not limited to, the following: materials, fabrication, assembly, detailed specifications, performance curves, and installation instructions and dimensions. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Heating & Ventilation 15800-1 B. ODeration and Maintenance Manual Contractor shall submit a detailed operation and maintenance manual for each item of equipment. PART 2 - PRODUCTS 2.01 Wall Louvers A. General Louvers shall be intake or exhaust as shown on the drawings of the fixed (unless othewise specified), flat blade, 45" type, having a width of 4" and sized to fit the opening specified. Louvers shall be suitable for mounting in stud wall, with gypsum board and stucco, concrete walls, or masonry walls 'as shown on the Drawings. Louvers shall be anchored into walls (from inside of building) at corners, top and side, and bottom and side with wood lag screws or expansion anchors as applicable. Additional anchors shall be provided such that maximum anchorage space shall be 24" O.C. Louvers shall be weatherproof with edges caulked with exterior grade caulking compound. B. Wall Mounted Stationarv (Fixed) Louvers Fixed blade (stationary) intake or exhaust louvers shall be flat blade type of formed steel with blades at 45" angle. Frame shall be minimum 18 gauge galvanized steel and blades shall be minimum 20 gauge galvanized steel. Each louver shall be provided with a removable 1/4" galvanized 19 gauge mesh insect screen with galvanized steel frame. Screen shall be attached with screws. Screen shall be located on interior side of wall. Stationary wall louvers shall be Model L811 as manufactured by Ruskin Manufacturing, Model 609A as manufactured by Airolite, or equal. C. Wall Mounted Adiustable Louver Adjustable blade intake or exhaust louvers shall be of formed steel construction with frame and blade minimum 18 gauge galvanized steel. Blades shall be positioned at 45" when fully opened. Crank handle shall be provided for adjusting and shall be provided with an extension where wall thickness necessitates. Insect screen as specified per Item 2.01 .B, herein, shall be provided. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Heating & Ventilation 15800-2 Adjustable wall louvers shall be Model L745 as manufactured by Ruskin Manufacturing, Model 645 as manufactured by Airolite, or equal. Where shown on the Drawings or specified herein, adjustable louvers shall be recessed in the wall and be provided with a vandal protection type louver on exterior. D. Wall Mounted Automatic Gravitv Tvpe Louvers Intake and exhaust automatic gravity type louvers shall be suitable for high velocity and high static pressure and shall automatically open upon operation of the ventilation system or radiator cooling exhaust fan. Louver shall be intake or exhaust as shown on the Drawings and dictated by the ventilation system. Louvers shall consist of 16 gauge galvanized formed steel frame and 14 gauge aluminum tied blades with felt tip edges. Automatic gravity type louvers shall be as manufactured by Louvers & Dampers, Inc., or equal. Intake and exhaust openings shall be provided with weather protection fixed louvers on exterior face and the gravity louvers on the interior face unless otherwise specified. Where specified, intake and exhaust automatic louvers shall be provided with a fixed vandal protection type louver as shown on the Drawings. E. Wall Mounted Acoustical Louver Formed steel acoustical wall louvers shall be provided where specified or shown on the Drawings. Construction shall be similar to fixed wall louvers. Noise side of louver shall include acoustical insulation covered with 22 gauge (minimum) perforated galvanized steel. Minimum noise reduction of 16 dB at octave band No. 4 shall be provided. Insect screen as specified per Item 2.01 .B, herein, shall be provided. Acoustic louver shall be 8" thick Model ACL 845 as manufactured by Ruskin Manufacturing, Model 91 08 as manufactured by Airolite, or equal. F. Wall Mounted Vandal Protection Tvpe Louvers Where specified herein or shown on the Drawings, fixed louvers of the vandal protection type shall be provided for air supply or exhaust. Louvers shall be as shown on the Drawings. Louvers shall be provided with insect screen as specified in Part 2.01 .B, herein. 2.02 Roof Mounted Exhaust Ventilators, Low Profile Type with Hood Roof exhaust ventilators shall be of low profile design with extruded aluminum hood of the centrifugal, belt-driven type. Construction of the fan housing shall be of heavy gauge aluminum. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Heating & Ventilation 15800-3 The fan wheel shall be all-aluminum of the centrifugal blower type featuring backward inclined blades and a tapered inlet shroud. Wheels shall be statically and dynamically balanced. Motors shall be of the heavy duty, permanently lubricated, sealed ball bearing type. Drives shall be sized for 165% of motor horsepower capabilities and of the cast iron type, keyed to the fan and motor shafts. Variable pitch drives shall be standard. Fan shaft shall be of steel construction, turned, ground, and polished to precise tolerances in relationship to the hub and bearings. Drive belts shall be of the oil-resistant, non-static, non-sparking type with life expectancy of over 24,000 hours. Bearings shall be flanged and of the permanently lubricated, permanently sealed, ball bearing type capable of over 200,000 hours bearing life. The entire drive assembly and wheel shall be removable, as a complete unit, from the support structure without disassembling the external fan housing. The complete drive assembly shall be mounted on rubber vibration isolation. Direct drive units shall be of identical construction as belt drive units, except for drives, belts, and fan shaft bearings. Fans shall be licensed to bear the AMCA ratings seal for air and sound performance. Fans shall be Model HLC as manufactured by Loren Cook, Model LD/LB as manufactured by Greenheck, or equal. Roof exhausters shall be mounted on pre-fabricated curbs as shown on the Drawings. 2.03 Ductwork and Miscellaneous Accessories A. Construction Ducts shall be sheet metal constructed with airtight joints and seams in accordance with ASHRAE standards and SMACNA Duct Construction Manual. All joints shall be taped with pressureless tape and adhesive, except welded or soldered joints. Ductwork materials shall be galvanized steel or aluminum, unless otherwise specified. Minimum duct gauges required are as follows: Maximum Size Galvanized Steel Aluminum of Ducts (In.) U.S. Standard Gaucle B and S Gauqe 12 and less 13 through 30 31 through54 55 through 84 26 24 22 20 24 22 20 18 B. SUPDOrtS Supports for horizontal ducts shall be galvanized steel angles with hanger rods. Supports for vertical ducts shall be band iron strap or angle bracket type. Inlet ducts shall be amply braced to withstand maximum negative pressure. C. Flexible Connectors Flexible duct connections shall be made with banded or flanged 8 02. canvas or reinforced plastic, or equal at each point where a blower unit is connected to a March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Heating & Ventilation 15800-4 duct. A minimum clearance of 3" between the duct and source of vibration shall be maintained. PART 3 - EXECUTION 3.01 General Contractor shall examine all equipment upon arrival at jobsite and determine that it is the specified equipment, or approved replacement, and that it is in good condition. Contractor shall connect all necessary electrical power including furnishing of all necessary materials in addition to that included in the specified equipment. Wiring materials and installation shall be in accordance with the Basic Electrical Specifications and controls in accordance with System Description Technical Specifications. 3.02 Start-up and Instruction Contractor shall arrange for qualified representatives of the manufacturer to inspect the installation and perform start-up of the equipment and to demonstrate required performance to the satisfaction of the Owner. Contractor shall balance the ventilation systems by adjusting louvers or grills to obtain even air flow across a room. Contractor shall furnish calibrated (certification required) air velocity meters for such balancing. Contractor shall arrange for not less than 1 hour of adequate instruction of operators selected by the Owner at a time acceptable to the Owner and the manufacturers. Instruction shall be for operation and routine maintenance and repair of ventilation equipment. END OF SECTION March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Heating & Ventilation 15800-5 SECTION 16040 SHORT CIRCUIT/COORDINATION STUDY TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 Scope The Contractor shall provide short circuit and protective device evaluation and coordination study to verify protective devices selected and selective tripping coordination for proposed facilities. The evaluations and study shall include all portions of the proposed electrical distribution system from the normal power source or sources down to and including the smallest adjustable trip circuit breaker in the distribution system. Normal system connections and those which result in maximum fault conditions shall be adequately covered in the study. The study shall be performed, stamped and signed by a registered electrical engineer in the State of California. Credentials of the individual(s) performing the study and background of the firm shall be submitted to the Owner for approval prior to start of the work. A minimum of five (5) years experience in power system analysis is required for the individual in charge of the project. The firm performing the study shall provide assistance during start up as required. The Engineer performing the system studies shall furnish the Contractor with a listing of the required data immediately after award of the contract and the Contractor shall expedite collection of the data to assure completion of the studies prior to final approval of the distribution equipment shop drawings and/or release of the equipment for manufacture. PART 2 - PRODUCTS 2.01 Short Circuit and Protective Device Evaluation and Coordination Study A. The short circuit study shall be performed in accordance with the latest applicable I EEE and ANSI standards. Provide calculation methods and assumptions, the base per unit quantities selected, one-line diagrams, source impedance data including power company system characteristics, typical calculations, tabulations of calculation quantities and results, conclusions, and recommendations. Calculate short circuit interrupting and momentary (when applicable) duties for an assumed 3-phase bolted fault at each supply switchgear lineup, unit substation primary and secondary terminals, low-voltage switchgear lineup, switchboard, motor control center, distribution panelboard, pertinent branch circuit panelboard, and other significant locations throughout the system. Provide a ground fault current study for the same system areas, including the associated zero sequence impedance data. Include in tabulations fault impedance, X to R ratios, asymmetry factors, motor contribution, short circuit kVA, and symmetrical and asymmetrical fault currents. November 1997 Short CircuitlCoordination Study Calavera Pump Station (860-3-CAL) Contract 38891 16040-1 B. In the protective device evaluation and coordination study include utility company device characteristics, system medium-voltage equipment relay and device characteristics, low-voltage equipment circuit breaker trip device characteristics, pertinent transformer characteristics, pertinent motor and generator characteristics, and characteristics of other system load protective devices. Include at least all devices down to largest branch circuit and largest feeder circuit breaker in each motor control center, and main breaker in branch panelboards. Provide time-current curves graphically indicating the coordination proposed for the system. Include with each curve sheet a complete title and one-line diagram with legend identifying the specific portion of the system covered by that particular curve sheet. Include a detailed description of each protective device identifying its type, function, manufacturer, and time-current characteristics. Tabulate recommended device tap, time dial, pickup, instantaneous, and time delay settings. Include all adjustable settings for ground fault protective devices. Include manufacturing tolerance and damage bands in plotted fuse characteristics. Show transformer full load and 150, 400, or 600 percent currents, transformer magnetizing inrush, ANSI transformer withstand parameters, and significant symmetrical and asymmetrical fault currents. Terminate device characteristic curves at a point reflecting the maximum symmetrical or asymmetrical fault current to which the device is exposed. C. When emergency generator is provided, include phase and ground coordination of the generator protective devices. Show the generator decrement curve and damage curve along with the operating characteristic of the protective devices. Obtain the information from the generator manufacturer and include the generator actual impedance value, time constants and current boost data in the study. Do not use typical values for the generator. D. For motor control circuits, show the MCC full-load current plus symmetrical and asymmetrical of the largest motor starting current and time to ensure protective devices will not trip during major or group start operation. 2.02 Study Report A. The results of the power system study shall be summarized in a final report. Six (6) bound copies of the final report shall be submitted to Owner. B. The report shall include the following sections: 1. Descriptions, purpose, basis and scope of the study. 2. Tabulations of circuit breaker, fuse and other protective device ratings versus calculated short circuit duties, and commentary regarding same. November 1997 Calavera Pump Station (860-3-CAL) Contract 38891 Short CircuitKoordination Study 16040-2 3. Protective device time versus current coordination curves, tabulations of relay and circuit breaker trip settings, fuse selection, and commentary regarding same. 4. Fault current calculations including a definition of terms and guide for interpretation of computer printout. 2.03 Modifications Required by Study The Contractor shall coordinate the study results with the manufacturer and supplier of the electrical equipment to incorporate the recommendations and modifications therein, prior to fabrication. PART 3 - EXECUTION 3.01 Utility Company Approval A. Where required, copies of the final report shall be submitted to the utility company for their review and approval. Approved copies of the report shall be submitted to the Owner. 3.02 Field Settings A. The Contractor shall perform field adjustments of the protective devices as required to place the equipment in final operating condition. The settings shall be in accordance with the approved short circuit study, protective device evaluation study, and protective device coordination study. B. Necessary field settings of devices and adjustments and minor modifications to equipment to accomplish conformance with the approved short circuit and protective device coordination study shall be carried out by the Contractor at no additional cost to the Owner. November 1997 Calavera Pump Station (860-3-CAL) Contract 38891 Short CircuitKoordination Study 16040-3 SECTION 16050 BASIC ELECTRICAL SPECIFICATIONS PART 1 - GENERAL 1.01 Description The Contractor shall furnish all labor, equipment, and materials to provide a complete and operable electrical system, all accordance with the requirements of the Contract Documents. 1.02 Reference Codes and Standards All electrical equipment and materials, including the design, construction, and installation thereof, shall comply with the following codes and standards (latest editions), as applicable. Where two codes or standards are at variance, the most stringent requirements shall govern: A. B. C. D. E. F. G. H. I. National Electric Code (NEC). Basic Electrical Regulations, Title 24, State Building Standards, California Administrative Code. Low Voltage Electrical Safety Orders, Title 8, Division of Industrial Safety, State of California. City and County Electrical Codes. American National Standards Institute (ANSI). National Electrical Manufacturers Association (NEMA). National Fire Protection Association (NFPA). Underwriters Laboratories, Inc. (UL). Occupational Safety and Health Act (OSHA) Safety and Health Standards (29CFR1910 and 29CFR1926), State Building Standards, and applicable local codes and regulations. All equipment and material furnished by the Contractor shall be listed by and shall bear the label of Underwriters Laboratories, Inc. (UL) or of an independent testing laboratory acceptable to the local agency with jurisdiction over the electrical work. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 1 6050- 1 1.03 Submittals A. Shop Drawings All submittals shall be in accordance with the General Provisions, Section 2-5.3. Contractor shall submit complete information, drawings, and technical data for all equipment and components, including, but not limited to, the following: 1. Catalog data including catalog cut sheets, bulletins, brochures, etc. Applicable sizes, model numbers, and options shall be clearly marked and delineated. 2. Connection diagrams, terminal diagrams, and internal wiring diagrams. 3. Equipment and material temperature limitations. 4. Drawings for all grounding work not specifically shown. 5. Nameplates for all electrical panels, including nameplate material, lettering height, and proposed inscriptions. B. Operation and Maintenance Manuals Contractor shall submit detailed Operation and Maintenance Manuals for each item of equipment in accordance with the Special Construction Provisions. C. Record Drawings Contractor shall maintain and keep current a complete record set of construction drawings showing every change from the Contract Drawings and Specifications and the exact locations, sizes, and types of equipment and material installed. Record drawings shall show all conduit runs (sizes and number), circuits, and conductors (sizes and numbers). Record drawings shall show depths and routing of all concealed and below grade electrical installations. Record drawings shall be available to the Owner during construction and shall be delivered to the Owner upon project completion. 1.04 Delivery, Storage, and Handling A. Delivew Deliver electrical materials and equipment in manufacturer's original cartons and containers with seals intact. Deliver conductors on sealed reels. Deliver large multi-component equipment in sections to facilitate field handling and installation. B. Storaae Unless designed for outdoor exposure, store electrical equipment and material of the ground and under cover. Equipment and material shall be protected from weather, corrosion, contamination, and deterioration. Dents, marred finishes, October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-2 and other damage shall be repaired to its original condition or replaced as directed by the Owner. C. Handlinq All equipment and material shall be handled in accordance with the manufacturer's recommendations. Large or heavy items shall be lifted at the points designed by the manufacturer. Equipment and material shall be handled and installed as necessary to prevent damage. 1.05 Public Utilities A. Contractor shall obtain electrical service requirements from public utility furnishing electrical power to the project. Contractor shall coordinate installation of power service with public utility. Contractor shall obtain, at his expense, all permits, licenses, and inspections required for electrical construction work by public utilities having jurisdiction. B. Contractor shall furnish and install all service conduit, fittings, transformer pad(s), manholes, vaults, grounding, and conductors not furnished by the serving utility. PART 2 - PRODUCTS 2.01 General All equipment and materials shall be new, shall be listed by UL, and shall bear the UL label, where UL requirements apply. All equipment and material shall be of industrial grade and be capable of long term, reliable, and trouble-free service. Similar equipment and material items shall be products of the same manufacturer. 2.02 Grounding A. Grounding and grounding components shall comply with the applicable requirement of the NEC, Article 250. B. Grounding cable shall be stranded copper and shall be sized in accordance with Code requirements when sizes are not shown on the Drawings. Contractor shall submit shop drawings for all grounding work not shown on the Drawings. C. Grounding rods shall conform to ANSI/UL 467 and shall be copper-clad steel, 3/4-inch (minimum) in diameter and 10 feet (minimum) in length. Rods shall be driven in the ground at least 9' -6" deep. Provide the number of rods required to obtain proper ground resistance, as applicable to all manholes, padmount switches, transformers, service entrances, etc. D. Ground rod mechanical connector bodies shall be manufactured from high strength, high conductivity cast copper alloy material. Bolts, nuts, washers and October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-3 lockwashers shall be made of silicon bronze and supplied as a part of the connector body and shall be of the two bolt type. Split bolt connector types are not allowed. The connectors shall meet or exceed the requirements of UL 467 and be clearly marked with manufacturer and conductor size. E. Ground rod compression connectors shall be manufactured from pure wrought copper. The conductivity of this material shall be no less than 99% by IACS standards. The connectors shall meet or exceed the performance requirements of IEEE 837, latest revision. The connectors shall be clearly marked with the manufacturer and conductor size. The installation of the connectors shall be made with a compression, tool and die system, as recommended by the manufacturer of the connectors. Each connector shall be factory filled with an oxide-inhibiting compound. 2.03 Manholes and Pull Boxes A. Manholes and Pull-Boxes shall be of precast concrete, designed for H-20 traffic loading. Concrete sections shall modular with tongue and groove joints. A continuous waterproof gasket shall be provided at all section and slab joints. Manhole and Pull-Box minimum inside dimensions shall be as shown on the Drawings. Manholes and Pull-Boxes shall be equipped with galvanized steel pulling irons opposite each ductbank entrance. Manholes and Pull-Boxes shall be provided with a sump opening and one (1) one-inch ground rod opening in the base section. Sump opening shall be provided with cast iron perforated cover. Manhole and Pull-Boxes shall be placed on a 12" thick crushed rock base. B. Manhole covers shall be cast iron, 30" round (minimum), designed for H-20 traffic loading, and supported on the necking section. Pull-Box covers shall be hot dipped galvanized, checkered plate steel suitable for H-20 traffic loading (unless noted otherwise), and bolted down to cast-in-place hot dipped galvanized steel frames with stainless steel hardware. Manhole and Pull-Box covers shall be marked "High Voltage Electric", unless noted otherwise. C. Manholes and Pull-Boxes shall be provided with cable supports as required to support cable at 3-fOOt (minimum) intervals. Cable supports shall be fabricated from hot dipped galvanized or fiberglass strut channel and attached to slotted galvanized steel channel cast-in-place inserts. Provide glazed porcelain insulators with channel clamps for support channels. Strap cable to insulators with plastic tie wraps. All phase and ground cables in each circuit shall be kept together and contained on/in the porcelain cable supports. No phase cable shall be run separate from the other two phases and ground. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-4 D. Manholes and Pull-Boxes shall be provided with knockouts for connections to all underground conduit and ductbanks. Ductbank entrances shall be grouted flush with non-shrink grout. Ducts and conduits shall be terminated with flush-end bells. E. One ground rod shall be provided for each manhole and pull-box, unless otherwise noted. Provide #4/0 bare stranded copper ground wire completely around the inside perimeter of each manholes and pull-box and anchor to walls. Connect the ground wire to the ground rod. Bond the bare copper ground wire to any splice shield wires, ground wires, cable racks, cover frames, sump frames and other metal items in the manholes. All separate ground wires accompanying circuits shall be grounded in each manhole passed through. F. Manholes and Pull-Boxes shall be manufactured by Brooks, Quikset, or equal. 2.04 Conduit A. General Each length of conduit shall bear the UL label and be a minimum size of 3/4", unless noted otherwise. Exposed elbows shall be standard radius sweeps meeting the requirements of the NEC. Buried or concealed elbows shall be long radius sweeps. B. Riaid Steel Conduit 1. Rigid steel conduit shall be Schedule 40 steel, pipe size, finished inside and out by hot-dipped galvanizing, and shall conform with ANSI C80.1 and UL. All rigid steel conduit in direct contact with the ground or concrete shall be protected by double wrapping with 20 mil PVC tape. 2. Couplings shall be galvanized steel. 3. Insulating Bushings: threaded malleable iron with thermoplastic liner. 4. Insulated Grounding Bushings: threaded malleable iron body with insulated thermoplastic liner throat and "lay-in" ground lug with compression screw. 5. Insulated Metallic Bushings: threaded malleable iron body with plastic insulated throat. 6. Running threads are not acceptable. C. PVC Coated Riaid Steel Conduit 1. Conduit shall be Schedule 40 steel, pipe size, finished inside and out by hot-dipped galvanizing, and shall conform with ANSI C80.1 and UL. A PVC coating of 40 mils (minimum) thickness shall be bonded to the outer galvanized surface of the conduit and a urethane coating shall be applied October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-5 D. to the interior surface of the conduit. The bond between the PVC coating and the conduit surface shall be greater than the tensile strength of the plastic. A PVC jacketed coupling shall be furnished with each length of conduit. PVC coated rigid steel conduit and fittings shall be manufactured by Robroy, Occidental, or equal. 2. Conduit fittings shall be PVC coated and furnished by the same manufacturer as the conduit to provide a complete and compatible protective system. PVC coated fittings and couplings shall have specially formed sleeves to tightly seal to conduit PVC coating. The sleeves shall extend beyond the fitting or coupling a distance equal to the conduit outside diameter or two inches, whichever is greater. Riqid Non-Metallic Conduit 1. Conduit shall be UL listed, sunlight resistant, Schedule 40 polyvinyl- chloride (PVC) conduit, rated for 90' C conductors, and manufactured to NEMA TC-2 standards. 2. Couplings and connectors shall be of the same manufacturer as the conduit and shall be joined as recommended by the manufacturer. All PVC conduits shall be terminated with approved connectors or end bells. E. Electrical Metallic Tubina (EMT) 1. Conduit shall be formed of cold rolled strip steel, electroplated, and shall meet ANSI and UL requirements. 2. Couplings shall be electroplated steel, UL listed rain and concrete tight. 3. Connectors shall be gland compression type with insulated plastic throat. F. Liquid-Tiqht Flexible Metallic Conduit 1. Conduit shall be liquid tight and shall have an interlocking flexible galvanized steel core with permanently bonded continuous exterior gray PVC jacket. Exterior jacket shall be moisture and oil-proof, and UV protected. A copper bonding conductor shall be included between the segments. Interior surfaces shall be smooth and offer minimum drag to pulling conductors. Liquid-tight flexible metallic conduit shall be as manufactured by Anaconda, Electroflex, or equal. 2. Connectors shall be the screw clamp or screw-in (Jake) variety with cast malleable iron bodies and threaded male hubs with insulated throats or insulated bushings. Liquid-tight fittings shall be of cadmium plated cast malleable iron, with insulated throat, with provisions for grounding. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-6 2.05 Non-Metallic Cable Tray A. General Non-metallic cable tray shall be ladder-type conforming to applicable sections of NEMA FG-1 and ASTM E-84. Non-metallic cable tray system shall be constructed of fire-retardant polyester resin. All composite material shall be provided with an ultra-violet light inhibiting chemical additive and meet ASTM E- 84, maximum 25 flame spread (Class l rating). Cable tray load class shall be selected based upon the weight of specified cables/conductors shown on the Drawings with a 25% additional weight allowance for future cables/conductors while maintaining a minimum safety factor of 1.5. The non-metallic cable tray system shall be as manufactured by Enduro Composite Systems, Inc., or equal. B. Construction Unless specified otherwise, cable tray shall conform to the following dimensional requirements: Nominal Width = 12" minimum Cable Loading Depth = 4" minimum Fitting Radius = 12" minimum Rung Spacing = 6" Cable tray side rail members shall turn inward. Rungs and side members shall be connected by both mechanical and chemical (adhesive) means. All bonded connections shall be sanded to maximize adhesion and structural integrity. The cable tray interior shall be clear of all projections or sharp objects. All straight sections and fittings shall be pre-drilled to accept connector plates. All cut ends and drilled holes (factory and field) shall be sealed with resin coating. All fittings shall be designed and installed so as to have the same load carrying capacity as straight sections. Unless specified otherwise, all fittings shall be concentric curved molded type, not mitered. C. Connections, Accessories, and Supports Connector plates shall be fiberglass and designed to transfer cable tray loads to the support system. Fasteners for connector plates shall be Type 316 stainless steel or FRP studs and hex nuts as required. Where specified on the Drawings, cable trays shall be provided with fiberglass flat covers. Cable tray support systems shall be constructed of polyester or vinyl ester resin strut channels (single or double channel as necessary) and appurtenances. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-7 2.06 2.07 Support spacing shall be in accordance with the cable tray manufacturer's printed recommendations for the specified loads. Cable tray manufacturer shall provide all clamps, support assemblies, and appurtenances necessary for the installation of a complete cable tray system. Non-Metallic Wireway A. General Non-metallic wireway shall be solid bottom type construction with minimum wall thickness of 0.1875 inches. Covers and cover splice plates shall be snap-on type construction requiring no installation fasteners. The wireway system shall conform to the applicable sections of NEC Article 362. The non-metallic wireway system shall be as manufactured by Enduro Composite Systems, Inc., or equal. B. Construction Wireways, covers, and connector plates shall be pultruded utilizing polyester resin with UV light inhibiting additives and exterior nexus veil coverage. All composite material shall meet ASTM E84, maximum 25 flame spread rating. All cut ends and drilled holes (factory and field) shall be sealed with resin coating. C. Connections, Accessories, and Sumorts Connector plates shall be fiberglass and designed to transfer wireway loads to the support system. Fasteners for connector plates shall be Type 31 6 stainless steel or FRP studs and hex nuts as required. Wireways shall be provided with fiberglass flat snap-on/snap-off covers. Wireway support systems shall be constructed of polyester or vinyl ester resin strut channels (single or double channel as necessary) and appurtenances. Support spacing shall be in accordance with the wireway manufacturer's printed recommendations for the specified loads. Conductors and Cable A. General Cables and wires shall be new, stranded conductors, solid copper, not smaller than #12 AWG (except shielded control wire) unless otherwise shown on Drawings. Insulation shall bear manufacturer's trademark, insulation October 2003 Calavera Pump Station (860-3-CAL) Contract 3889 1 Electric 16050-8 designation, voltage rating, and conductor size at regular intervals. Each type of cable or wire shall be the product of a single manufacturer. B. Conductors Conductors for power service, power feeders, power circuits, and lighting feeders, lighting circuits, and control circuits shall be stranded copper, rated 600 volt, with 75' C THWN insulation, UL approved, for installation underground, in concrete, in masonry, or in wet locations. Minimum conductor size shall be # 12 AWG. C. Shielded Cable Shielded cable shall consist of minimum 3 #16 AWG, stranded, tinned-copper conductors, individually insulated with 25 mils of polyethylene and 100% aluminum foil tape. Unless otherwise shown on the drawings, shielded cable shall be used for all 4-20 ma signals. Cable shall be manufactured by Belden, or equal. D. Color Codinq System conductors shall be factory color coded by integral pigmentation with a separate color for each phase and neutral, or by an approved colored marking tape at all terminations and in all junction boxes, pull-boxes, and manholes. Each voltage system shall have a color coded system that shall be maintained throughout the project. Approved colored marking tape is as follows: Svstem 120V, 1 Phase, 2 wire 208V, 3 Phase, 4 wire 480V, 3 Phase, 4 wire All October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Service Color Line Black Neutral White Black Phase A Phase B Red Phase C Blue Neutral White Phase A Brown Phase B Orange Phase C Yellow Neutral White Ground Green & Bare Copper Electric 16050-9 2.08 Switches and Relays A. Toclale Switches Local single pole switches shall be flush tumbler type AC rated, quiet type, heavy duty, 20 amp minimum, rated 120/277 volt, back or side wired with binding screws. Switches shall conform to NEMA WD-1 specifications. Two pole three way and other switches shall be similar. Switches shall be as manufactured by Hubbell, Bryant, or equal. B. Relays Control relays shall be rated 120VAC with minimum 10A contacts, unless otherwise noted on the Drawings. All control relays and relay timers shall be DIN rail mounted, with instantaneous reversible contacts, 8 or 11 pin base type only. 2.09 Receptacles A. General Purpose General purpose receptacles shall be duplex, 3-wire grounding type, rated 125 /250 volt, AC, 20 amp minimum, NEMA 5-20R, back or side wired with binding screws, as manufactured by Hubbell, Bryant, G.E, or equal. B. Ground Fault Interrupter (GFI) GFI receptacles shall be NEMA 5-20R configured and shall mount in a standard device box. Units shall trip at 5 milliamperes of ground current and shall comply with NEMA WD-1-1.10 and UL 943. GFI receptacles shall be capable of individual protection as well as downstream protection. 2.10 Device Boxes, Junction Boxes, and Fittings A. Device Boxes (General Purpose - Indoors or Outdoors) Unless otherwise noted on the Drawings, device boxes shall malleable iron constructed with zinc or cadmium plating and enamel finish, minimum single gang size, deep box type, with treaded hubs and solid gasketed cover. Device boxes shall be properly sized for required circuitry or splicing. Surface mounted boxes shall be furnished with mounting lugs. Where located outdoors, device boxes shall be waterproof. Device boxes shall be Crouse-Hinds FD, Appleton FD, or equal. B. Junction Boxes (General Purpose - Indoors or Outdoors) Unless otherwise noted on the Drawings, junction boxes shall be malleable iron constructed, rain tight, dust tight, minimum size 4"x4"x3", drilled and tapped or field installed with slip holes (alternate hub plates are acceptable). Junction boxes shall be properly sized for the number and sizes of conductors and conduit entering the box and required splicing. Provide feet where necessary for October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 0 surface mounting. Junction boxes shall be Crouse-Hinds WAB, Appleton RS, or equal. C. Device Boxes (Wet or Corrosive Locations) Where specified on the Drawings, device boxes shall be constructed of 316 stainless steel, minimum single gang size, deep box type, with gasket and 316 stainless steel solid cover. Device boxes shall be properly sized for required circuitry or splicing. Surface mounted boxes shall be furnished with mounting lugs or feet. Device boxes shall be NEMA 4X as manufactured by BEL Products, Inc., Cushing Manufacturing Co., or equal. D. Junction Boxes (Wet or Corrosive Locations) Where specified on the Drawings, junction boxes shall be constructed of 316 stainless steel, with gasket and 316 stainless steel solid cover. Junction box minimum size shall be 4"x4"x3". Junction boxes shall be properly sized for required circuitry or splicing. Provide feet where necessary for surface mounting. Junction boxes shall be NEMA 4X as manufactured by BEL Products, Inc., Cushing Manufacturing Co., or equal. E. Fittinqs Conduit fittings shall be provided where shown on the Drawings or required to facilitate installation of the electrical conduit and equipment. 1. Metallic fittings shall be constructed of malleable iron with zinc or cadmium plating and enamel finish, with gasket and cast cover. Fittings shall be Condulet Type as manufactured by Crouse-Hinds, Appleton, or equal. 2. Non-metallic fittings shall be compatible with the non-metallic conduit used and shall be of the same manufacturer. 3. Fittings shall be of the shapes, sizes, and types required to facilitate installation or removal or conductors and cables from the conduit, cable tray, and wireway systems. 4. Connectors, couplings, locknuts, bushings, and caps used with Rigid Steel conduit shall be threaded and thoroughly galvanized. Bushings shall be insulated. 5. Metallic conduit unions shall be "Erickson" couplings, or approved equal. Running threads are not acceptable. 6. Connectors for liquid-tight flexible metallic conduit shall be liquid tight with insulating bushings and provision for ground continuity. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 1 2.1 1 Disconnect Switches A. Switch Interior Dead-front construction with hinged arc suppressor and switch blades which are fully visible in the "OFF" position and with door open. B. Switch Mechanism Switches shall be quick-make and quick-break with arc quenching and ambient temperature compensated overload devices. Switch operating handle and mechanism shall be provided with a dual cover interlock to prevent unauthorized opening of the switch door in the "ON" position or closing the switch mechanism while the door is open. Switch operating handle shall be capable of being padlocked in the "OFF position. Switches shall be manufactured by General Electric, Westinghouse, Square D, or equal. C. Ratinas Switches shall be horsepower rated for the operating voltage and with fused or non-fused arrangements as shown on the Drawings. D. Enclosures Unless otherwise noted on the Drawings, for interior locations enclosures shall be NEMA 12 panels with hinged covers and padlockable hasps. Switches in exterior locations shall be provided with gasketed NEMA 3R enclosures with hinged covers and padlockable hasps. 2.1 2 Low-Voltage Cable Splices Low-voltage cable splices and terminations shall be rated at not less than 600 Volts. Splices in conductors No. 10 AWG and smaller shall be made with an insulated, solderless, pressure type connector, conforming to the applicable requirements of UL 486A. Splices in conductors No. 8 AWG and larger shall be made with noninsulated, solderless, pressure type connector, conforming to the applicable requirements of UL 486A and UL 486B. Splices shall then be covered with an insulation and jacket material equivalent to the conductor insulation and jacket. Splices below grade or in wet locations shall be sealed type conforming to ANSI C119.1 or shall be waterproofed by a sealant- filled, thick wall, heat shrinkable, thermosetting tubing or by pouring a thermosetting resin into a mold that surrounds the joined conductors. 2.1 3 Miscellaneous Equipment and Material A. Concrete Anchors Type 304 (or better) stainless steel expansion anchors (wedge or sleeve) shall be used to for mounting all electrical conduit, boxes, and equipment. NO type of explosive anchor will be permitted. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 2 D. Conduit Straps Where specified on the Drawings, conduit straps shall be malleable iron constructed, one-hold type strap with cast clam-backs and spacers as required. E. Channel (Unistrut) Supports Unless otherwise specified, support channel (Unistrut) shall be single strut type, 1-1/2" x 1-1/2", 12 gauge hot dipped galvanized steel with 17/32" diameter bolt holes on 1 -1/2" centers. F. Nameplates Nameplates shall be provided for all electrical panels, enclosures, stations, and equipment furnished by the Contractor. Nameplates shall be engraved laminated plastic, with 1/4" high white lettering on black background. Nameplates shall indicate equipment and its function. Nameplates shall be securely fastened with stainless steel drive screws or escutcheon pins. G. Panelboard Labelinq Panelboard circuits shall be labeled clearly indicating which piece of equipment, outlet, lighting, receptacle, etc. is powered by the respective circuit. Labeling shall be arranged in numerical order. H. Conductor and Terminal Markers Conductor and terminal markers shall be self-adhering, pre-printed cloth or vinyl. PART 3 - EXECUTION 3.01 General A. Prefabricated Material and Equipment Installation of all prefabricated items and equipment shall conform to the requirements of the manufacturer's specifications and installation instructions. When code requirements apply to installation of materials and equipment, the more stringent requirements, code, or manufacturer's specifications and installation instructions shall govern the work. B. Power Supplies to Mechanical Equipment 1. An electric power supply, including conduit, any necessary junction or outlet boxes, and conductors and connections shall be furnished and installed by Contractor for each item of mechanical equipment. 2. Circuit breakers or fused disconnect protection shall be provided for each separate item of mechanical equipment shown on the Drawings, or specified in the Basic or Technical Specifications. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 3 3. Power supplies to individual items of equipment shall be terminated in a suitable outlet or junction box adjacent to the respective item of equipment, or a junction box provided by the manufacturer of the equipment. Sufficient lengths of conductor at each location shall be provided to permit connection to equipment without damaging the conductors. 3.02 Conduit Installation A. General 1. Contractor shall install conduit and electrical equipment in locations that will cause minimal interference with the maintenance and removal of mechanical equipment. Conduits and connections are shown schematically on the Drawings. Contractor shall run conduit in a neat manner parallel or perpendicular to walls and slabs, and wherever possible, installed together in parallel runs supported with Unistrut type support system. All conduits shall be installed straight and true with reference to the adjacent work. 2. Unless noted otherwise on the Drawings, conduits shall be concealed in walls or in cast-in-place concrete slabs. Concealed conduits shall be run in as direct a route as possible and with bends of large radii. Floor penetrations shall be made only at specific approved locations; other penetrations are prohibited. Conduits shall be rigidly secured in position by means of approved clamps. 3. Locations of conduit runs shall be planned in advance of the installation and coordinated with the ductwork, plumbing, ceiling, and wall construction in the same areas, and shall not unnecessarily cross other conduits or pipe, nor prevent removal of nor block access to mechanical or electrical equipment. 4. Unless noted otherwise on the Drawings, buried conduit shall be installed with a minimum of 24" cover. All conduit trenches shall be compacted to a minimum of 90% relative compaction. Compaction in the pipe zone shall be accomplished by water jetting imported sand, one sack sand slurry cement, or equal, placed to 6" above top of conduit. Buried conduit shall be installed using approved spacers and cradles, properly supportedanchored and at sufficient intervals to prevent movement during backfill operations (maximum spacing of five feet). Where change in direction is required, long radius elbows shall be installed. Prior to installation of conductors in underground conduits, a testing mandrel not less than six (6) inches long and with a diameter 1/4 inch less than the conduit diameter shall be drawn through after which a stiff bristle brush of the proper size for the conduits shall be drawn through until the conduits are free of all sand and gravel. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 4 B. C. D. E. 5. Unless noted otherwise on the Drawings, conduits cast in, under, or through concrete walls, slabs, or masonry walls shall be Rigid Steel. 6. Unless noted otherwise on the Drawings, buried conduit shall be Rigid Non-Metallic or Rigid Steel. Transition from PVC to Rigid Steel shall be made at the horizontal leg of the buried conduit bend. 7. Unless noted otherwise on the Drawings, exposed or above grade conduit shall be Rigid Steel. 8. Spare conduits shall extend a minimum of 3" above concrete slab or wall, and be provided with threaded cap and polyethylene pull rope with 100- pound (minimum) tensile strength. 9. All conduits shall be tightly sealed during construction by use of conduit plugs or "pennies" set under bushings. All conduit in which moisture or any foreign matter has collected before pulling conductors shall be cleaned and dried to the satisfaction of the Owner. 10. Conduits shall be securely fastened to cabinets, boxes, and gutters using locknuts (one inside and one outside enclosure for rigid conduit, one inside enclosure for EMT) and an insulating bushing or specified insulated connectors. Grounding bushings or bonding jumpers shall be installed on all conduits terminating at concentric knockouts. Riaid Steel Conduit Rigid Steel conduit installations below grade, and cast in, under, or through walls or slabs shall be double wrapped with 20-mil PVC tape. Running threads and threadless couplings will not be acceptable. Where necessary for connecting conduit, UL listed couplings or unions shall be used. All ends and joints shall be reamed smooth after cutting. Electrical Metallic Tubing (EMT) EMT conduit shall only be installed where specifically shown on the Drawings. EMT conduit, where specified, shall be furnished with weatherproof fittings. Liquid-Tiaht Flexible Metallic Conduit Liquid-tight flexible conduit shall be installed in all locations for connections to equipment, including, but not limited to: motors, HVAC equipment, automatic valves, and similar devices. Riqid Non-Metallic Conduit Unless noted otherwise on the Drawings, Schedule 40 PVC conduit may be used underground. PVC conduits shall not be run exposed. October 2003 Calavera Pump Station (860-3-CAL) Contract 3889 1 Electric 16050-1 5 F. supports 1. All raceway systems shall be secured to building structures using specified fasteners, clamps, Unistrut, and hangers spaced according to NEC requirements. 2. Exposed conduit shall be supported with channel supports spaced per NEC requirements (8'-0'' maximum spacing) and within 18" of couplings, bends, boxes, etc., unless otherwise shown on the Drawings. 3. Multiple conduit runs shall be supported using "trapeze" hangers, consisting of approved channels suspended on steel rods from ceiling inserts located not more than eight (8) feet apart. Sizes of channels and rods shall be selected as recommended by the manufacturer for span and loading conditions. G. Termination and Joints 1. Raceways shall be joined using specified couplings or transition couplings where dissimilar raceway systems are joined. 2. Conduit terminations exposed at weatherproof enclosures and cast outlet boxes shall be made watertight using approved connectors and hubs. 3. Expansion couplings shall be installed where any conduit crosses a building separation or expansion joint, including joints in footings and gradebeams. 4. Approved cable-sealing bushings shall be installed on all conduits originating from roof and terminating in switchgear, cabinets, or gutters inside the building. 5. Conduit bodies (Condulets) are not acceptable as enclosures for splices. 6. At all conduit terminations and boxes, conductors shall be protected by a fitting equipped with a plastic bushing having a smoothly rounded insulating surface. 3.02 Conductor and Cable Installation A. General 1. Conductors shall not be installed in conduit runs until all work is completed for each individual conduit run. Care shall be taken in pulling conductors such that insulation is not damaged. UL approved pulling compounds shall be used. 2. Unless noted otherwise on the Drawings, all conductors or cables shall be installed in conduit or electrical enclosures. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 6 3. All cables shall be installed and tested in accordance with manufacturer's requirements and warranty. B. Splicinn and Terminatinq 1. All aspects of splicing and terminating shall be in accordance with cable manufacturers published procedures. 2. All splices in outlet boxes with connectors as specified herein shall be made up with separate tails of correct color. At least six (6) inches of tails packed in box after splice is made up shall be provided. 3. All conductor and cable in panels, control centers and equipment enclosures shall be bundled and clamped. C. Identification 1. All branch-circuits shall be securely tagged, noting the purpose of each. 2. All conductors and conduit shall be numbered and labeled with vinyl wrap-around markers. Where more than two conductors run through a single outlet, each circuit shall be marked with the corresponding circuit number at the panelboard. 3. Conductors size #6 AWG and larger shall be color coded using specified phase color markers and identification tags. 4. All terminal strips shall have each individual terminal identified with specified vinyl markers. 5. Inside of all junction box cover plates shall be identified via felt-tip pen or decal label, denoting the panel and circuit numbers and voltage contained in the box. 6. All receptacles and switches shall be decal labeled on the plate, denoting the panel and circuit number. D. Connections to Circuit Breakers, Switches, and Terminal Strips; Stranded Copper Conductors 1. #12 through 8 AWG: Conductor shall be terminated in locking tongue style, pressure type, compression lugs, unless clamp type connection for stranded conductor is provided with device. 2. #6 AWG and larger: Conductor shall be terminated in one-hole flat- tongue style, compression type lugs, or by connectors supplied by the manufacturer. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 7 E. Joints in Conductors in Drv Locations, Copper Conductors 1. #8 AWG and smaller: Conductors shall be twisted and secured with cap or twist-on, expandable spring type solderless connectors. 2. #6 AWG and larger: Conductor shall be joined with split bolt connectors or compression sleeves. Joints shall be insulated with rubber tape and protected with half-lapped layers of vinyl plastic electrical tape. Insulation may also be provided by UL listed pre-manufactured components such as heat-shrink or cold-shrink devices. F. Joints in Conductors in Moist Locations, Copper Conductors 1. 2. #8 AWG and smaller: Conductor shall be securely joined as specified above, then encapsulated in epoxy (Scotchcast or approved equal). #6 AWG and larger shall be joined as specified above, and suitably water treated. G. Groundinq Enclosures of equipment, raceways and fixtures shall be permanently and effectively grounded. A code-sized, copper, insulated green equipment ground shall be provided for all branch circuit and feeder runs. Equipment ground shall originate at panelboard ground bus and shall be bonded to all switch and receptacle boxes and electrical equipment enclosures. Ground terminals on receptacles shall be connected to the equipment grounding conductor by an insulated copper conductor. H. Sicrnal Wirinq Conductor used for alarm and control signal applications shall be identified at both ends and referenced to appropriate as-built drawings. Control wiring shall be numerically or otherwise coded in accordance with as-built control diagrams 3.03 Installation of Boxes and Wiring Devices A General 1. All outlets shall be surface mounted with walls, ceilings, and floors, except where specified to be finish flush. 2. No unused openings shall be left in any box. Close-up plugs shall be installed as required to seal openings. 3. Exposed outlet boxes and boxes in damp and wet locations shall be provided with gasketed cast metal cover plates, October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 8 B. Box Lavout 1. Outlet boxes shall be installed at the locations and elevations shown on the drawings or specified herein. Adjustments to locations shall be made as required by structural conditions and to suit coordination requirements of other trades. 3.04 Transformer Installation A. Primary shall be connected to minimum value taps during construction period and prior to initial building start-up. B. Voltage readings shall be made and tap connections adjusted to nominal voltage during final construction review and prior to building occupancy. C. Transformers shall be installed on vibration pads designed to suppress the transformer vibrations. Pads shall be selected and arranged in accordance with the weights of the transformers. D. Conduit connections that will prevent transmission of the transformer vibrations to the conduit system shall be installed. E. Transformers installed against a wall shall have readily accessible primary and secondary terminals. 3.05 Protection Conduits, junction boxes, outlet boxes, and other openings shall be kept closed to prevent entry of foreign matter. Fixtures, equipment, and apparatus shall be covered and protected against dirt, paint, water, chemical or mechanical damage, before and during the construction period. Damaged fixtures, apparatus, or equipment shall be restored to original condition prior to final acceptance, including restoration of damaged shop coats of paint. Brightly finished surfaces and similar items shall be protected until in service. No rust or damage will be permitted. 3.06 Workmanship A. Preparation, handling, and installation shall be in accordance with manufacturer's written instructions and technical data particular to the product specified and/or approved, except as otherwise specified. B. Work shall be furnished and placed in coordination and cooperation with other trades. C. Work shall conform to the National Electrical Contractor's Association Standard of Installation for general installation practice. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Electric 16050-1 9 SECTION 16400 DISTRIBUTION SWITCHBOARDS AND MOTOR CONTROL CENTERS TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 1.02 1.03 scope The Contractor shall furnish and install the free standing dead front type low voltage (600 volt) distribution switchboards, motor control centers, and utility service equipment, as specified herein and shown on the Drawings. Quality A. The low-voltage distribution switchboard assembly and all components shall be designed, manufactured, and tested in accordance with standards of NEMA PB- 2 and UL Standard 891. B. The Motor Control Centers (MCC) and all components shall be designed, manufactured and tested in accordance with standards of NEMA, ANSI, and UL 845. C. For the equipment specified herein, the manufacturer shall be IS0 9000, 9001 or 9002 certified. D. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the Owner, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement. E. Manufacturer shall be Cutler-HammerNestinghouse, Allen-Bradley, Square D, or equal. Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. Shop Drawinqs Contractor shall submit complete information, drawings, and technical data for all equipment and components, including, but not limited to, the following: 1. Drawings showing elevations, floor plan, top view, anchorage and conduit entry/exit locations. 2. Single line and unit wiring diagrams depicting internal and remote devices. 3. Nameplate schedule. 4. Starter and component schedule. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Distribution Switchboard 16400-1 1.04 1.05 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Assembly ratings including: a. Short circuit rating. b. Voltage. C. Continuous current. Major component ratings including: a. Voltage. b. Continuous current. C. Interrupting ratings. Cable terminal sizes. Busway connection. Connection details between close-coupled assemblies. Composite floor plan of close-coupled assemblies. Key interlock scheme drawing and sequence of operations. Descriptive bulletins. Product sheets. Lateral design and equipment anchorage details, prepared and stamped by a licensed engineer, registered in the State of California. Installation information prior to shipment. B. The following information shall be submitted for record purposes prior to project completion. 1. 2. Certified production test reports. Final as built drawings and wiring diagrams. C. Operation and maintenance manuals shall include the following information: 1. Instruction books and/or leaflets. 2. 3. Drawings and information required by above. Renewal Parts list showing the important maintenance items which will need to be available for proper maintenance and to provide normal equipment life. Delivery, Storage, and Handling Equipment shall be handled and stored in accordance with manufacturer's written instructions. One (1) copy of these instructions shall be included with the equipment at time of shipment, Where stored out of doors, space heaters and thermostat controls shall be energized. Measurements Contractor shall verify equipment proposed shall fit into the available space, coordinate installation and notify the Owner of any interferences or conflicts in the distribution and MCC system power and control wiring. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Distribution Switchboard 16400-2 PART 2 - PRODUCTS 2.01 Ratings A. The distribution switchboard(s) and MCC's shall be rated to withstand mechanical forces exerted during short circuit conditions when connected directly to a power source having minimum available fault current of 65,000 amperes symmetrical at rated voltage unless shown otherwise on the Drawings. Voltage rating shall be 600 volts, unless indicated otherwise on the Drawings. B. The MCC(s) shall be 600 volt class, suitable for operation on a three-phase, 60- Hertz system. The system operating voltage and number of conductors shall be as indicated on the Drawings. 2.02 Distribution Switchboard Construction A. Refer to Drawings for actual layout and location of equipment and components; current ratings of devices, bus bars, and components; voltage ratings of devices, components and assemblies; interrupting and withstand ratings of devices, buses, and components; and other required details. B. Distribution switchboard(s) shall be as manufactured by Cutler- HammerNVestinghouse, General Electric, Square D, or equal. C. Standard Features 1. Switchboards shall be fully self-supporting structures with 90 inch tall vertical sections (excluding lifting eyes and pull boxes) with the required number of vertical sections bolted together to form a rigid assembly arrangement. The sides and rear shall be covered with removable bolt- on covers. All edges of front covers or hinged front panels shall be formed. Provide adequate ventilation within the enclosure. 2. Switchboards shall be NEMA 1 or NEMA 3R non-walk-in deadfront construction as shown on the Drawings. NEMA 3R construction shall be as listed below. 3. Switchboard frame shall be die formed, 12 gauge steel with reinforced corner gussets. Frame shall be rigidly bolted to support cover plates (code gauge steel), bus bars and installed devices during shipment and installation. 4. All sections may be rolled, moved, or lifted into position. Switchboards shall be capable of being bolted directly to the floor without the use of floor sills. 5. All switchboard sections shall have open bottoms and removable top plates to install conduit. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Distribution Switchboard 16400-3 6. 7. 8. 9. 10. 11. 12. 13. 14. Unless noted otherwise on the Drawings, switchboard sections shall be front-access only. Front-access only switchboard sections shall be front and rear aligned for placement against a wall. Where specified on the Drawings as front and rear access, switchboards shall be front and rear aligned. Switchboards shall be UL listed. Switchboards that are series rated to short circuit requirements shall be appropriately labeled. Tested UL listed combination ratings shall be included in UL recognized Component Directory (DKSY2). All covers shall be fastened by hex head bolts. Provide hinged doors over metering compartments and individually mounted device compartments. All doors shall have concealed hinges and be fastened by hex head bolts. Switchboard protective devices shall be furnished as listed on Drawings and specified herein, including interconnections, instrumentation, and control wiring. Switchboards and devices shall be rated for the voltage and frequency listed on the Drawings. Switchboard current ratings, including all devices, shall be based on a maximum ambient temperature of 25°C per UL Standard 891. With no derating required, temperature rise of switchboards and devices shall not exceed 65°C in a 25°C ambient environment. Switchboard Service Entrance sections shall comply with UL Service Entrance requirements including a UL service entrance label, incoming line isolation barriers, and a removable neutral bond to switchboard ground for solidly grounded wye systems. The group mounted feeder breaker and/or main devices within switchboards shall be circuit breakers only. Mounting for the group mounted devices shall be by bolted connections. No plug-in type connections shall be used for current carrying components. D. The assembly shall be provided with adequate lifting means. 2.03 Distribution Switchboard Bus A. All bus bars shall be silver plated copper. Main horizontal bus bars shall be mounted with all three phases arranged in the same vertical plane. Bus sizing shall be based on NEMA standard temperature rise criteria of 65 degrees C over a 40 degrees C ambient temperature outside the enclosure. Minimum bus rating shall be as specified on the Drawings. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Distribution Switchboard 16400-4 B. A copper ground bus (minimum 1/4 x 2 inch) shall be furnished firmly secured to each vertical section structure and shall extend the entire length of the switchboard. C. All hardware used on conductors shall be high-tensile strength and zinc plated. All bus joints shall be provided with conical spring type washers. 2.04 Distribution Switchboard WiringiTerminations A. Small wiring, necessary fuse blocks and terminal blocks within the switchboard shall be furnished as required. Control components mounted within the assembly, such as fuse blocks, relays, pushbuttons, switches, etc., shall be suitably marked for identification corresponding to appropriate designations on manufacturer's wiring diagrams. B. Mechanical type terminals shall be provided for all line and load terminations suitable for copper or aluminum cable rated for 75 degrees C of the size as indicated on the Drawings. C. Lugs shall be provided in the incoming line section for connection of the main grounding conductor. Additional lugs for connection of other grounding conductors shall be provided as indicated on the Drawings. D. All control wire shall be type SIS, bundled and secured with nylon ties. Insulated locking spade terminals shall be provided for all control connections, except where saddle type terminals are provided integral to a device. All current transformer secondary leads shall first be connected to conveniently accessible short circuit terminal blocks before connecting to any other device. All groups of control wires leaving the switchboard shall be provided with terminal blocks with suitable numbering strips. Provide wire markers at each end of all control wiring. 2.05 Molded Case Circuit Breakers A. Molded case circuit breakers shall provide circuit overcurrent protection with inverse time and instantaneous tripping characteristics. Ground fault protection shall be provided where shown on the Drawings and as specified herein. B. Circuit breakers shall be operated by a toggle-type handle and shall have a quick-make, quick-break over-center switching mechanism that is mechanically trip-free. Automatic tripping of the breaker shall be clearly indicated by the handle position. Contacts shall be nonwelding silver alloy, and arc extinction shall be accomplished by means of DE-ION arc chutes. A push-to-trip button on the front of the circuit breaker shall provide a local manual means to exercise the trip mechanism. C. Circuit breakers shall have a minimum symmetrical interrupting capacity matching the distribution switch board or MCC where installed or as shown on the Drawings. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Distribution Switchboard 16400-5 D. Circuit breakers, 400 ampere frame and below, shall be provided with thermal- magnetic trip units and inverse time-current characteristics unless otherwise shown on the Drawings. E. Circuit breakers, 600 ampere through 2500 ampere frame and circuit breakers used as main to disconnect utility power, shall be provided with microprocessor- based RMS sensing trip units. 1. Each molded case circuit breaker microprocessor-based tripping system shall consist of three current sensors, a trip unit, and a flux-transfer shunt trip. The trip unit shall use microprocessor-based technology to provide the adjustable tirne-current protection functions. True RMS sensing circuit protection shall be achieved by analyzing the secondary current signals received from the circuit breaker current sensors and initiating trip signals to the circuit breaker trip actuators when predetermined trip levels and time delay settings are reached. 2. Interchangeable rating plugs shall establish the continuous trip ratings of each circuit breaker. Rating plugs shall be fixed or adjustable as indicated. Rating plugs shall be interlocked so they are not interchangeable between frames, and interlocked such that a breaker cannot be closed and latched with the rating plug removed. 3. The microprocessor-based trip unit shall have thermal memory capabilities to prevent the breaker from being reset following an overload condition until after a preset time delay. 4. When the adjustable instantaneous setting is omitted, the trip unit shall be provided with an instantaneous override. Internal ground fault protection adjustable pick-up ratings shall not exceed 1200 amperes. Provide neutral ground fault current sensor for four wire loads. 5. .Breakers shall have built-in test points for testing the long time delay, instantaneous, and ground fault functions of the breaker by means of a 120-volt operated test set. Provide one test set capable of testing all breakers 400 ampere frame and above. 6. System coordination shall be provided by the following microprocessor- based time-current curve shaping adjustments: Adjustable long time pick-up and delay Adjustable short time pick-up and delay, with Adjustable instantaneous pick-up Adjustable ground fault pick-up and delay, with selective curve shaping selective curve shaping F. Where shown, provide circuit breakers UL listed for application at 100°/o of their continuous ampere rating in their intended enclosure. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Distribution Switchboard 16400-6 G. Provide shunt trips, bell alarms, and auxiliary switches as shown on the Drawings. 2.06 Bolted Pressure Switches A. Where shown on the Drawings, fusible bolted pressure switches protective devices shall be bolted pressure contact type and shall be UL listed. B. Switches shall be furnished with Class L fuse clips. Switch contact interrupting capacity shall be 12 times the continuous rating of the switch. C. Fuse access door shall be mechanically interlocked with the operating handle and shall have provisions for padlocking the switch in the open position. D. The switch shall utilize a store'd energy dead front operating mechanism compressed and released by the operating handle, to provide quick positive switching action independent of the speed of the operating handle. E. Switches shall electrically tripped unless shown otherwise on the Drawings. Electrically tripped switches shall be designed to be closed only after the opening spring has been charged, ready for electrical opening by solenoid or manual opening by the mechanical push-button. F. Supply electrically tripped switch(es) with the following accessories where indicated on the Drawings: 1. Ground fault protection including Test Panel. 2. Single phase protection to open the switch(es) upon loss of any phase from the source. 3. Blown Fuse Protection to open the switch upon blowing of one or more of the fuses. G. Provide Class L fuses as shown on the Drawings. 2.07 Quick-MakdQuick-Break Fusible Switches A. Protective devices shall be quick-make/quick-break fusible switches as manufactured by Cutler-HammerNVestinghouse, Allen-Bradley, Square D, or equal. Fusible switches, 100 amperes through 600 amperes frames, shall be furnished with rejection Class "R" or "T" type fuse clips unless otherwise specified. Fusible switches, 800 amperes through 1200 amperes, shall be furnished with Class L fuse clips. Switches shall incorporate safety cover interlocks to prevent opening the cover with the switch in the "ON" position or prevent placing the switch in the "ON" position with the cover open. Provide defeater for authorized personnel. Handles shall have provisions for padlocking and shall clearly indicate the "ON" or "OFF" position. Front cover doors shall be padlockable in the closed position. March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Distribution Switchboard 16400-7 B. The 400 through 1200 ampere switches shall be designed to accommodate UL listed shunt trip. Where shown on the Drawings, furnish the following accessories: 1. UL listed 120 volt AC shunt trip. 2. Zero sequence ground protection system including test panel. Ground fault relay shall include separate time and current pick-up adjustments. 2.08 MCC Construction A. MCC(s) shall be as manufactured by Cutler-HammerNVestinghouse, Allen- Bradley, Square D, or equal. Wiring shall be NEMA Class 11, Type B. B. Structures shall be totally enclosed deadfront, freestanding assemblies. They shall be 9Ort inches high and 21k inches deep. Each structure shall be minimum 203t inches wide and wider where shown on the Drawings, or where required to house components shown on the Drawings. Structures shall contain a horizontal wireway at the top, isolated from the horizontal bus and shall be readily accessible through a hinged cover. Adequate space for conduit and wiring to enter the top or bottom shall be provided without structural interference. C. Compartments for mounting control units shall be incrementally arranged such that not more than twelve Size 1 starters can be mounted within each vertical structure. Guide rails shall be provided. D. A vertical wireway with minimum of 35 square inches of cross sectional area shall be adjacent to each vertical unit and shall be covered by a hinged door. Wireways shall contain steel rod cable supports. E. All full voltage starter units through NEMA Size 5 shall be of the drawout type. Drawout provisions shall include a positive guide rail system and stab shrouds to absolutely ensure alignment of stabs with the vertical bus. Drawout units shall have a tin-plated stab assembly for connection to the vertical bus. No wiring to these stabs shall extend into the bus compartment. Interior of all units shall be painted white for increased visibility. Units shall be equipped with side-mounted, positive latch pull-apart type control terminal blocks rated 600 volts. Knockouts shall be provided for the addition of future terminal blocks. In addition, a master terminal block, when Type C wiring is specified, shall be drawout and shall be located in the bottom wireway, readily accessible through a hinged cover. All internal control wire to be 14 gauge minimum. F. All drawout units shall be secured by a spring-loaded quarter turn indicating type fastening device located at the top front of the unit. Each unit compartment shall be provided with an individual front door. G. An operating mechanism shall be mounted on the primary disconnect of each starter unit. It shall be mechanically interlocked with the unit door to prevent access unless the disconnect is in the OFF position. A defeater shall be provided to bypass this interlock. With the door open, an interlock shall be March 2004 Calavera Pump Station (860-3-CAL) Contract 38891 Distribution Switchboard 16400-8 SECTION 16500 VARIABLE FREQUENCY DRIVES TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 Specific Project Description The work included in this Section shall consist of furnishing and installing variable speed drives of the variable frequency drive type (VFD) as shown on the Drawings and as specified herein, including all accessories and controls necessary for a complete and operable system. The equipment furnished under this Section shall be required to operate electric motor(s) driving equipment specified by Section 1 131 0. Contractor shall be responsible to coordinate the work under this Section, with all other electrical equipment and the work specified and shown on the Drawings. Load requirements, torque, horsepower, and speed range of VFDs shall be coordinated with and meet or exceed that of the driven equipment. All equipment specified herein shall be furnished by one (1) manufacturer as a complete assembly . 1.02 Specific Project VFD Requirements A. General Contractor shall furnish and install three (3) VFD units to drive the 60 hp vertical turbine pumping units as shown on the Drawings, and specified herein and per Section 11310. Pumping units shall be new pumps driven by squirrel cage, induction type, premium efficiency, inverter duty hollow shaft vertical electric motors. B. Temperature Ratinq Each VFD unit shall have a minimum rated 60 hp, 77 full load amp output at 40°C ambient temperature. C. TvDe VFD units shall be provided with 6-pulse (or greater) rectifiers with line reactors and passive filters or 18-pulse rectifiers as necessary to comply with the harmonic distortion requirements specified herein. VFD units with 6-pulse or 12- pulse rectifiers and broad band filters or active filters, are not acceptable. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 D. Enclosure and Coolinq Each VFD unit, including harmonic suppression equipment, shall be housed in a gasketed, NEMA 1, floor mounted, 90" high enclosure as shown on the Drawings. Each VFD unit shall be cooled by forced air ventilation. A supply air fan shall be mounted in each enclosure to provide forced air ventilation and to maintain a positive air pressure in the enclosure. Fans and louvers shall be sized by the VFD manufacturer based on: heat generated from the VFD operating at full rated capacity, heat generated from auxiliary components (e.g. transformers, filters, and line reactors), and equipment operating under maximum ambient conditions. A 10°F differential air temperature shall be utilized. Each supply and exhaust air louver shall be furnished with a reusable air filter. Each VFD enclosure shall be isolated from adjacent enclosure to prevent short circuiting of cooling air. Each enclosure shall be furnished with a thermostat for cooling and heating. E. No BvDass Contactors Required VFD units shall not be provided with bypass contactors as specified in Section 2.01 .E.14 herein. F. Door Mounted Devices Each VFD shall be provided with door mounted selector switches, lights, controls, and relays as follows: 1. Padlockable circuit breaker. 2. Power on indicator lamp (light). 3. VFD on-line indicator lamp. 4. Operator Interface (Digital Display/Keypad Unit). Unit shall control, monitor and display VFD functions, operating conditions and faults. 5. Selector switches, indicator lights, and various devices as shown on Drawings (Control/Ladder Diagrams). G. Harmonic Distortion A harmonic study is required and line reactors and filters are to be provided per 2.01 J. H. Warranty Each VFD unit shall be provided with a minimum two-year warranty to be free from defects in material or workmanship. Warranty shall commence upon date October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-2 of project acceptance. During the warranty period, all parts and labor required to repair or replace defective VFD units shall be provided at no cost to the Owner. 1.03 Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. Shop Drawinus Contractor shall submit complete information, drawings, and technical data for all equipment and components, including, but not limited to, the following: October 2003 7) Design capabilities and operating parameters, including a detailed list of all user selectable features and setpoints. Harmonic distortion study demonstrating compliance with specified requirements herein. If specified in the Specific VFD Requirements herein, a preliminary harmonic analysis shall be submitted at bid time. VFD operating efficiency (including control power and cooling power) and output horsepower versus speed for the specific equipment being driven. Motor manufacturer's guarantee that motor insulation and cooling is suitable for continuous operation over specified frequency range and VFD output pulse maximum peak voltage, pulse rise time, and pulse rate. Guarantee that proposed carrier frequency of VFD will not produce a motor audible noise level when operating throughout the VFD speed range of more than 5 dba above that designated in NEMA MG-1 for the same motor operated at constant speed with a 60 Hz sine wave supply voltage. Catalog cut sheets and data for all control devices. Drawing of enclosure, including overall dimensions, anchor hole sizes and locations, and exterior door elevations showing location of all door mounted components, including lights, switches, meters, controllers, and corresponding nameplates. General arrangement drawings of enclosure interior, including location and identification of all internal components. Enclosure space heating and cooling system and design calculations covering entire speed range of variable frequency drive. Where building or panel cooling systems are shown on the Drawings, provide calculations for maximum heat output of VFD and associated components. System schematic diagrams, block diagrams, interconnection diagrams and ladder diagrams. Detailed specifications and data covering all necessary components, including, but not limited to, fuses, circuit breakers, switches, bypass Variable Freauencv Drives Calavera Pump Station (860-3-CAL) Contract 38891 i 6500-3 contactors, line reactors, filters, cooling equipment, status lights, and push buttons. 10) Manufacturer's warranty guaranteeing the operation of the VFD against failure due to defects for two (2) years from date of project acceptance. During this period, parts and labor shall be supplied at no cost to the Owner. 6. Operation and Maintenance Manuals Operation and maintenance manuals shall be provided in accordance with the requirements of the Special Construction Provisions. As a minimum, operation and maintenance manuals shall include: design capabilities, operating parameters, recommended ranges, system schematic diagrams, block diagrams, interconnection diagrams, ladder diagrams, complete wiring diagrams, enclosure drawings, safety provisions and precautions, standard publications on all major items furnished, parts list with specification packets on the entire unit, list of recommended spare parts, and installation diagrams. Manuals shall be completely indexed and include step-by-step procedures for the operation and maintenance of the VFD as installed. The maintenance portion of the manual shall include preventive maintenance and troubleshooting for the entire system. Contractor shall provide approved operations and maintenance manuals to Owner at least 30 days prior to VFD startup and testing. 1.04 Quality Contractor shall provide a complete, reliable, fully tested, adjustable speed drive system suitable for manned or unmanned operation. The VFDs shall be as manufactured by Toshiba, A.B.B., Eaton/Cutler/Hammer, Allen Bradley, or equal. Third party distributor or packager modifications to a standard product will only be permitted with written approval from the VFD manufacturer, and statement confirming that the installed VFD equipment will be fully covered by manufacturer's warranty. In addition, VFD manufacturer (factory) shall review and approve all shop drawings prepared by third party distributors prior to submittal of said shop drawings to Owner. PART 2 - PRODUCTS 2.01 Variable Frequency Drive (VFD) A. General The VFD units shall be integrated, solid state systems, designed to control the speed of electric motor drivers for the driven equipment specified. VFD units shall be as specified herein, including all requirements and modifications listed in Section 1.02, Specific Project VFD Requirements. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-4 B. Environmental Conditions Unless otherwise specified, the VFD units shall be capable of operation under any combination of the following conditions without mechanical or electrical damage. Ambient Temperature: Altitude: 4 to 40 degrees C (40" to 100" degrees F) 500 ft above sea level Relative Humidity: 100% C. Ratinq VFD shall be sized based on the maximum motor horsepower and required starting and operating torque of the selected equipment to be driven or the minimum output as shown on the Drawings or specified herein, whichever is greater. Unless otherwise specified, VFD shall be capable of continuous operation at any speed between 20% (minimum) and 100% (maximum) of the driven equipment full rated speed. D. Basic Descrbtion The VFD units shall convert 460 volt (-5% to +l O%), three-phase, 60 hertz (*3%) utility power to adjustable voltage (0 - 460V) and frequency (0 - 60 hz) three- phase, AC power for stepless motor speed control with a capability of 1O:l speed range. The VFD shall be of the pulse-width modulated (PWM) type and shall consist of a full-wave diode bridge converter to convert incoming fixed voltagelf requency to a fixed DC voltage. The PWM strategy shall be of the space vector type implemented in a microprocessor which generates a sine-coded output voltage. The inverter output shall be generated by power transistors which shall be controlled by a minimum of six identical base driver circuits. The VFD shall not induce excessive power losses in the motor. The RMS motor line current measured at rated speed, torque and voltage shall not exceed 105% of the rated RMS motor current for pure sine wave operation. The VFD shall produce an adjustable AC voltage/frequency output. The VFD shall have an output voltage regulator to maintain correct voltage to frequency ratio despite incoming voltage variations. The VFD units shall be suitable for use with standard NEMA Design B squirrel- cage induction motors having a 1.15 service factor, without derating and without requiring any motor modifications. The variable frequency control shall operate satisfactorily when connected to a bus supplying other solid state power conversion equipment which may be October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-5 causing up to 10% total harmonic voltage distortion and commutation notches up to 36,500 volt microseconds, or when other VFDs are operated from the same bus. All equipment and work shall comply with the latest applicable standards of ANSI, NEMA, IEEE, and NEC. E. Features and ComDonents Unless otherwise specified, the VFD units 'shall be provided with the following minimum features and components: Main circuit breaker and in-line fuses or fused disconnect switch shall be supplied to provide NEC required branch circuit protection. The fused disconnect switch shall provide a short circuit interrupting capacity of 50,000 RMS symmetrical amps (minimum), and shall be mechanically interlocked with the VFD unit enclosure door. The minimum VFD efficiency shall be 96 percent at 100 percent speed and 90 percent at 50 percent speed. The power factor of VFD unit shall be 95 percent minimum at all speeds. Each VFD shall be provided with current overload protection for operation in bypass mode (if specified). Line reactors and filters as specified herein shall be provided for each VFD. The VFD shall have a programmable controller to provide automatic restart after any individual trip condition resulting from either overcurrent, overvoltage, undervoltage, or overtemperature. For safety, the drive shall shut down and require manual reset and restart if the automatic resethestart function is not successful within a maximum of three attempts within a short time period. A speed droop feature shall be included which reduces the speed of the drive on transient overloads. The drive is to return to set speed after transient is removed. If the acceleration or deceleration rates are too rapid for the moment of inertia of the load, the drive is to automatically compensate to prevent drive trip. Automatic restart after drive trip or utility failure. Software selectable if not desired. Speed Profile. Individual adjustable settings for start, stop, entry, slope, and minimum and maximum speed points. Process signal inverter. Software selectable to allow speed of drive to vary inversely with input signal. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-6 IO) A critical speed avoidance circuit shall be provided for selection of two critical speeds with a rejection band centered on that speed. The drive shall ignore any speed signals requiring drive operation within the rejection band. Proportional and integral setpoint process controller with menu driven selection and programming via door-mounted keypad. 11) 12) Pick up a spinning load. The VFD shall be able to determine the motor speed and resume control of a motor which is spinning in either direction without tripping. 13) Operator Interface. A door-mounted membrane keypad with integral 2- line, 24-character (minimum) LCD display shall be furnished, capable of controlling the VFD and setting drive parameters, and shall include the following features: a. Digital display shall present all diagnostic message and parameter values in English engineering units when accessed, without the use of codes. b. The keypad module shall contain a "self-test" software program which can be activated to verify proper keypad operations. c. The digital keypad shall allow the operator to enter exact numerical settings in English engineering units. A plain English user menu shall be provided in software as a guide to parameter setting, (rather than codes). Drive parameters shall be factory set in EEPROM and resettable in the field through the keypad. Password security shall be available to protect drive parameters from unauthorized personnel. d. Normally the digital display shall simultaneously display: I. Speed demand in percent ii. Output current in amperes iii. Frequency in hertz or RPM iv. Control Mode: manuaVautomatic v. Total three-phase KW or output volts 14) VFD Bvpass. Unless otherwise specified, interlocked bypass contactors, main circuit breakers, and controls shall be provided for automatic bypass of the VFD to across the line (constant speed) operation in case of VFD failure, except for condition of motor high temperature, motor over load, or motor moisture. When selector switch is in AUTO VFD mode, upon VFD failure the equipment shall stop and automatically restart in constant speed mode via bypass contactors with start/stop functioning as if operating on VFD. Time delay for restart in bypass mode shall be provided. Manual reset to return to VFD mode shall be required. The VFD shall be isolated during bypass operation. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-7 Indicating lights for operation in VFD mode and bypass mode shall be provided. Selector switch shall be provided with bypass position to allow operation in bypass mode without VFD failure. Dry contacts shall be provided for operation in bypass mode for connection to telemetry system. 15) Controls. Each VFD programmable controller shall be programmed to accept a 4-20 ma signal for automatic speed adjustment, and energized and dry contact closures from the facility control system for automatic start and stop of the driven equipment. Each VFD shall be provided with reduced voltage transformer(s). Transformer(s) shall be properly sized for controls, lights, ventilation, and heating. VFD shall be equipped to function as specified herein and as shown on the drawing. Each VFD shall be equipped with the controls shown on the drawings unless otherwise specified in Section 1.02 Specific Project VFD Requirements. Door Mounted Devices: a. Padlockable handle for fused disconnect switch. b. Power on indicator lamp (light). C. VFD on-line indicator lamp. d. Bypass on-line indicator lamp (if bypass contactors are specified). e. VFD malfunction indicator lamp. f. VFD fault reset push button. g. Motor thermal and motor overload reset push buttons. h. Operator Interface (Digital Display/Keypad Unit). Unit shall control, monitor and display VFD functions, operating conditions and faults. Operating conditions shall include, but not be limited to: output frequency, output voltage, motor current, running speed (rpm), input and output power. i. VFD Manual, VFD Auto, Off, Bypass (if bypass contactors are specified) selector switch as specified. Selector switch shall be provided with auxiliary contacts for position signal to remote control panel. j. Elapsed time meter (eight (8) digit, minimum). October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-8 k. Motor high temperature indicator lamp. I. Motor over load indicator lamp. m. Other functions and devices shown on the Drawings or otherwise specified. Motor "high temperature" control module shall be mounted within the VFD enclosure. VFD manufacturer shall coordinate control module installation with the motor manufacturer. VFD shall shut down on motor "high temperature" and "overload" conditions. External dry contacts shall be provided for each motor alarm condition and common VFD fault condition. F. Protective Features The VFD unit shall be provided with capabilities and features to protect drive components and the driven motor from damage. Protective features with user adjustable setpoints shall be accessed through the operator interface for enabling or disabling. As a minimum, the VFD unit shall be provided with the following protective features: October 2003 Single phase fault without damage to AIC minimum). or 3-phase short circuit on VFD output terminals any power component or clearing any fuses (40,000 Static instantaneous overcurrent and overvoltage trip with inverse overcurrent protection. Static overspeed (overfrequency) protection. Phase loss and undervoltage protection. Power unit overtemperature protection. Electronic motor inverse time overload protection. Responsive action to motor winding temperature detectors or thermostatic switches. Provide dry contact (NC) input to the VFD. Isolated operator controls. Input line fuses. Be insensitive to incoming power phase sequence. Desaturation circuit to drive inverter section transistor base current to zero in event of controller fault. DC bus discharge circuit with an indicator lamp for protection of operator. Variable Frequency Drives Calavera Pump Station (860-3-CAL) Contract 38891 i 6500-9 13) Input line noise suppression with line reactor. G. 14) Individual transistor overcurrent protection. Parameter Settinqs The following system configuration settings shall be provided and shall be field adjustable through the keypad/display unit or via the serial communication port. Except for motor nameplate data, all parameters shall be adjustable while the processor is on-line and the drive is running. 1) Motor Nameplate Data a. Motor frequency b. Number of poles C. Full load speed d. Motor volts e. Motor full load amps f. Motor KW g- Current minimum h. Current maximum 2) VFD Limits a. b. d. e. f. 9. h. i. C. I. Independent acceleration/deceleration rates No load boost Vmin, Vmax, V/Hz Full load boost Overload trip curve select (inverse or constant) Min/Max speed (frequency) Auto reset for load or voltage trip select Slip compensation Catch-A Spinning-Load select Overload trip time set 3) VFD Parameters a. Voltage loop gain b. Voltage loop stability C. Current loop stability 4) Controller Adjustments a. PID control enable/disable b. Setpoint select C. Proportional band select d. Reset time select e. Rate time select f. Input signal scaling October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 0 g. h. i. j. Min, Max Speed Select k. Input signal select (4-20 mA/O-5 volts) Auto start functions: On/Off, Delay On/Off, Level Select On/Off Speed Profile: Entry, Exit, Point Select Inverse profile select (allows VFD speed to vary directly or inversely with input signal) H. Diaqnostic Features and Fault Handling 1) The VFD shall include a comprehensive microprocessor based digital diagnostic system which monitors its own control functions and displays faults and operating conditions. Microprocessor systems shall be products of the same manufacturer as the VFD (to assure single source responsibility, availability of service and access to spare parts). 2) A "Fault Log" shall record, store, and display upon demand, the 16 (minimum) most recent faults. The fault log shall be accessible via the keypad display. I. Enclosures and Coolinq VFD units shall be housed in wall mounted or floor mounted enclosures equipped with door locking devices as shown on the Drawings and specified herein. Floor mounted enclosures shall be mounted on concrete bases, extending 3 inches above the surrounding ground or floor. Enclosures shall be of sufficient size to afford access to all parts and components, and installed with clearance in front of the enclosure to satisfy all code requirements. Sufficient internal lighting to perform maintenance work shall be provided. Lighting shall be controlled with an internal light switch. Where shown on Drawings or specified herein that the VFD shall be installed in MCC line-up, the enclosure shall match MCC construction including height and depth. Unless otherwise specified, the sheet metal surfaces of all enclosures shall be phosphetized and coated with a rust resisting primer. Over the primer a corrosion resistant baked enamel finish shall be applied on interior and exterior metal surfaces. Exterior color shall be medium light gray (unless otherwise specified) and interior color shall be white. All hardware shall have a corrosion resistant finish. Unless otherwise specified, outdoor electrical equipment shall be housed in weatherproof, gasketed, NEMA Type 3R enclosures, and indoor electrical equipment shall be housed in gasketed NEMA Type 1 enclosures. Enclosures shall be provided with heating system for condensation protection and shall be ventilated, or air conditioned, as specified or required for trouble- free operation, and shall be equipped with air filters to eliminate dust. All cooling devices shall be constructed to enable regular maintenance or removal without October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 1 dismantling of the VFD unit. Refer to ambient conditions as specified herein and requirement to submit cooling calculations. J. Harmonic Distortion Individual or simultaneous operation of the VFDs without operation of any linear loads shall not add more than 5% total harmonic voltage distortion to the normal bus, nor more than 10% while operating from standby generator (if applicable) per IEEE 519, 1992. Maximum allowable total and individual harmonic current distortion limits for each odd harmonic shall not exceed limits as set forth by IEEE 519, 1992. A comprehensive harmonic study of the system, including all variable frequency drive units, existing and proposed shall be prepared by the Contractor. The results of this study shall be submitted to the Owner as part of the shop drawing submittals. Should this study indicate the need for tuned filters, line reactors, or isolation equipment for the proposed VFDs, said components and equipment shall be supplied at no extra cost to the Owner. Shop drawings shall indicate the location of the harmonic suppression equipment. Harmonic suppression equipment location is subject to acceptance by the Owner. If harmonic filters and/or line reactors are required to meet IEEE 519 requirements or where specified to be provided, the VFD manufacturer shall furnish same and be responsible for their design and manufacturing. If specified in the Specific VFD Requirements herein, a preliminary harmonic analysis, which includes all harmonics to the 99th, shall be submitted at bid time. Compliance shall be verified by the VFD manufacturer with onsite field measurements of the harmonic distortion at the point of common coupling with and without VFDs operating. Specific Site Conditions for Pumping Units VFDs: The proposed VFDs will be provided with electrical power from new San Diego Gas and Electric Company transformer and service. The utility connection shall be the PCC for voltage and current distortion. The utility short circuit at the utility interface is 14,000 amps. Harmonic calculations shall be based on data provided on the Drawings ("Single Line Diagram"), except that no linear loads shall be included in the analysis. Harmonic analyses shall be prepared for pumping units operating simultaneously. K. Line Reactors Unless otherwise specified, each VFD shall be provided with a line reactor as manufactured by Trans-Coil, Inc., Mirus International, Inc., or equal. Unless shown otherwise on the Drawings, line reactor shall be factory mounted and wired within the VFD enclosure. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 1 6500-1 2 Line reactor shall be provided in the incoming power lines to the VFD to: 1) Minimize the effects of "line notching" due to the switching of power semiconductor devices for controlled rectifier type drives. 2) Prevent overvoltage trips and/or damage to the drive itself due to transients (Le. utility power capacitor switching, etc.) on the VFD incoming power lines. 3) Reduce input harmonic currents thereby improving the total power factor of the drive system. The line reactor shall provide a minimum of 2-1/2% line impedance and be designed for harmonic filtering service and for slowing the rate of rapid current changes. The line reactors shall be UL component-recognized and shall be built to comply with UL 508A standard. Construction shall be of copper wire wound on steel cores. Reactors shall be designed and rated for 150% of normal, three-phase, 60 Hz current. Reactors shall be sized appropriately for the total connected load. The design maximum temperature rise for reactors shall be 115" C. The core shall be made of laminated, grain-oriented electrical steel (grade M6 or better). Windings shall consist of copper wire or of copper foil. Terminations shall be copper alloy ring lugs, UL-recognized terminal blocks, or solid copper bus. Line reactors shall be air-gapped to avoid control point saturation. Line reactors shall be double impregnated with 100% solid epoxy resin. All insulation varnish systems shall be rated Class H (180°C) or better, 600V. Inductance shall remain above 50% of nominal for any overload up to 200% of rated current. Line reactors shall not sustain any thermal damage for levels up to 150% of RMS current for a minimum period of five minutes. L. Harmonic Filters Harmonic filters shall be provided as required to attenuate system harmonics to below IEEE 519 distortion limits. Unless otherwise specified in the Specific Project VFD Requirements herein or shown on the Drawings, harmonic filters shall be passive or active type as determined by the manufacturer's harmonic distortion study. Passivehuned filters shall attenuate specific harmonic frequencies. Active filters shall constantly monitor the current on the line and inject equal and opposite harmonics as necessary. 1) Passive Filters Passive filters, if selected, shall be provided for each VFD unit. Passive (trap) filters shall contain tuned circuits designed to remove harmonics generated within the power distribution system while improving the system power factor. Passive filters shall consist of inductive and capacitive elements arranged in a series configuration and tuned to resonate just below the harmonic frequency for which they are designed October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 3 to filter. Passive filters shall be UL-listed. Passive filters shall be as manufactured by Trans-Coil, Inc., Mirus International, Inc., or equal. High endurance capacitors shall be rated to operate continuously at 225% of nominal fundamental current. High endurance capacitor cells shall have a voltage rating capable of handling continuously the nominal system voltage plus 10% of the over voltage tolerance. High endurance capacitor cells shall be rated to operate at an air temperature of 65°C. Liquid-filled capacitor cells shall be contained in hermetically sealed metal cans filled with a biodegradable, non-PCB impregnate. Liquid-filled capacitor cells shall have a UL-listed, pressure-sensitive interrupter which, in case of a hazardous internal pressure increase, shall disconnect all three phases simultaneously. Individual high endurance capacitor cells, or groups of cells, shall be provided with a 3-phase, delta- connected discharge resistor network. The resistors shall be sized to reduce residual voltage to less than 50V within one minute of de- energization. Tuning inductors, if provided separate from line reactors, shall comply with all line reactor requirements specified herein. Contactors shall be rated for capacitor switching at 660V and at 60 Hz. Contactors shall be de-rated to compensate for extra switching loads imposed by harmonic frequencies. Internal wiring, including that for the line/tuning reactors, shall be protected by three fuses, one for each phase. Fuses shall be current-limiting at 200,000 symmetrical amperes, interrupting at 600V AC, 60Hz. Fuses shall be UL-listed, Class T. Fuses shall be sized to a minimum of 150 % of nominal capacitor rating. Fuses internal to the capacitor cell shall not be acceptable as the primary means of protection. Passive filters larger than 2OkVAR shall be protected by a 3-phase protection circuit, which shall continuously monitor operating parameters. Protection shall be provided against reactor or capacitor overload, phase imbalance, and continued operation with blown fuses. An independent form C relay contact, rated at 5 amperes, 120V AC, shall be provided for remote signaling. Passive filters shall be factory mounted and wired within the VFD enclosure, unless shown otherwise on the Drawings. 2) Active Filters Active filters, if selected, shall be connected to the distribution panel or bus supplying power to the VFD(s). Single or multiple active filters may be utilized to provide compliance with IEEE 519 harmonic distortion requirements. As a minimum, one additional active filter (size equal to largest active filter selected for IEEE 519 compliance) shall be provided for redundancy. Active filter units shall be AccuSine Power Correction System, as manufactured by Schneider Electric, or equal. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 4 Active filter units shall be designed in accordance with the applicable sections of ANSI IEEE Std C62.41-1991 [Surge Withstand Capacity], ANSI IEEE Std 519-1992 [Harmonic Limits], and UL 508C [UL Requirements for Power Conversion Equipment]. Active filter units shall be UL and CSA approved. Active filter units shall be designed to electronically inject harmonic current to cancel the load produced harmonic current such that the upstream power harmonic current and voltage are reduced to below 5% total demand distortion TDD and below 5% total harmonic voltage distortion rHD(V)]. Performance of the active harmonic filter shall be independent of the impedance of the power source. AIi performance levels shall be attained whether on the normal electrical service, standby power generator, or output of uninterruptible power supply (UPS). Reactive current compensation shall be provided for up to 0.95 lagging displacement power factor. Leading power factor is not permitted. Reactive current compensation (Le. displacement power factor correction) shall be activated via a digital keypad/display mounted on the door of the enclosure. When reactive current compensation is activated, the filter unit shall first perform harmonic current correction and then use the remaining capacity to inject reactive current compensation to the attain the specified level herein defined. Two current transformers mounted on phases A and B shall be provided per active filter location. Current transformers shall be split core type and shall be rated for the total rated rms current of the total load at each installed location. Each current transformer shall be rated for 400 Hertz. a. Enclosure Unless shown otherwise on the Drawings, each active filter unit shall be provided in floor mounted, 90" high, NEMA 1 gasketed enclosure. Where active filter units are to be installed in a MCC or VFD line up, panel height, depth, and color shall match adjacent panel(s). Enclosure ventilation shall comply with paragraph 2.01 .I herein. Each unit shall include a door-interlocked disconnect that provides power interruption when the door is opened. Disconnect device shall be lockable in the power "OFF" position. Each unit shall in shall be provided with Class T input fuses rated at 200,000 AIC (amps interrupting capacity). b. Operator Controls and Interface Each active filter unit shall be provided with a digital interface that includes an alphanumeric display consisting of 2-lines with 20 characters per line. Operator pushbuttons shall include run, stop, setup, enter, and up/down scroll. The display shall provide operating data while the unit is functioning. Display parameters shall include AC line voltage, total rms load current, load harmonic October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 5 current, load reactive current, and filter output harmonic and reactive current. When the output of the active filter unit is at full rated capacity, the display shall indicate at-maximum capacity and actuate an at-maximum capacity relay. All fault conditions shall be displayed as they occur. Output contacts shall be provided for power-on, run, fault and at-maximum capacity. Each contact shall be rated for 1 Ampere at 120/240 volts. One form C contact shall be provided for each relay. C. Design Filter units shall be defined as a power electronic device consisting of power semiconductors that switch into the AC lines to modulate its output to cancel detrimental harmonic and/or reactive currents. A DC bus shall store power for power semiconductor switching. A microprocessor shall control the operation of the power converter. Each unit shall be designed with a current limiting function to protect the semiconductors. Operation shall continue indefinitely at maximum current level without tripping off or damage to filter unit components. Each unit shall incorporate an over-temperature output roll back that reduces the total output current in order to maintain maximum current correction within the electrical system. Two distinct levels of faults shall be employed. Non-critical level faults will provide automatic restart and a return to' normal operation upon automatic fault clearance. Critical level faults stop the function of the unit and await operator action. Where multiple active filter units are provided to attenuate system harmonics, units shall be installed in parallel to inject current according to the information received from the CTs. Each unit shall function independently. If one unit is off or faulted, the remaining units shall adjust accordingly to maintain optimum harmonic cancellation levels up to the capacity of the remaining units. M. EMVRFI Filters An electromagnetic interference and radio frequency interference (EMVRFI) filter shall be provided in the incoming power lines of the VFD if required as a result of system startup and testing to: 1) Prevent conducted radio frequency noise generated by the VFD from interfering with other sensitive electronic equipment (such as lighting systems, telecommunications equipment, instrumentation, etc.). 2) Enable the VFD to meet RFI limits as specified by FCC Docket 20780 (Part 15, Subpart J) for conducted emissions. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 6 The EMI/RFI filter shall be capable of handling a 150% current overload for at least 1 minute. N. Motor Protection Output Filter Where the conductor length between the VFD and motor exceeds 100 feet, or where specified on the Drawings or in the specific project VFD requirements, a motor protection output filter shall be provided within the VFD enclosure. The motor protection output filter shall be a low pass filter which removes the steep edges from the PWM voltage wave form and protects the motor from voltage spiking. The output filter shall be sized for the motor load and shall be located immediately adjacent to the output terminals of the drive. The motor protection output filter shall be Model KLC as manufactured by Trans-Coil, Inc., or equal. 2.03 Spare Parts Contractor shall furnish the following spare parts for each type and size of VFD: A. Two (2) spare lamp lenses of each color. B. One (1) dozen pilot lamps. C. One (1) complete set of fuses. D. One (1) complete set of air filters for each VFD enclosure. Spare parts shall be undamaged and packaged and labeled in original containers and supplied to the Owner at time of final acceptance of the work. PART 3 - EXECUTION 3.01 Installation A. All equipment furnished hereunder shall be installed and aligned under the supervision of a factory-trained service engineer, other than a sales representative. B. Conduit stub-ups for interconnected cables and remote cables shall be located and terminated in accordance with the drive manufacturer's written recommendations which shall be subject to Owner's review and approval. C. The Contractor shall have the manufacturer examine the Contract Documents as to the operating environment that the VFD unit will be subjected to, and advise the Engineer prior to bidding of any potential problems, which could prevent the drive from functioning as intended, and its recommendations for preventing expected problems. D. Under no circumstances are any portions of the VFD unit to be energized without authorization from the manufacturer's representative. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 7 3.02 Testing, Manufacturer's Services, and Instruction A. Upon completion of manufacturing, each VFD unit shall be factory inspected and load tested. Certification that the factory inspections and load tests have been successfully performed shall be submitted to the Owner prior to shipment. B. Manufacturer or supplier of the equipment furnished under this Section shall furnish the services of competent factory-trained personnel to provide technical assistance during installation and start-up of the VFD equipment. Prior to start- up, manufacturer shall provide Owner with written certification stating that the VFD equipment, including controls, have been properly installed and are ready for operation. After the equipment has been installed, tested, and adjusted, and placed in satisfactory operating condition, the equipment manufacturer shall provide classroom instruction to Owner's operating personnel in the use and maintenance of the equipment. Four (4) hours of instruction shall be provided unless otherwise specified. Contractor shall give the Owner formal written notice of the proposed instruction period at least two weeks prior to commencement of the instruction period. Scheduled training shall be at a time acceptable to the Owner and the manufacturer. During this instruction period, the manufacturer shall answer any questions from the operating personnel. The manufacturer's obligation shall be considered ended when he and the Owner agree that no further instruction is needed. C. Field testing shall be witnessed by the Owner. Prior to the commencement of field testing service engineer shall set and/or adjust all operating parameters according to the manufacturer's written instructions and Owner's preference for VFD features which may be enabled or disabled through the operator interface. VFD field testing shall be conducted concurrently with field testing of the driven equipment. Field testing shall demonstrate satisfactory operation of all interlocks, alarms, and normal operational sequences. The drive manufacturer shall use suitable test equipment to locate and correct all malfunctions. Repeated failure of any component will cause the test to be terminated and restarted when equipment has been fixed. VFD performance shall be documented by obtaining concurrent readings showing input and output: voltage, amperage, power factor, and power over the full speed range of driven equipment. Harmonic distortion tests shall be run on the VFDs and the bus to determine the voltage distortion and current distortion and compliance with IEEE 519-1 992 standards. Measurements shall be made utilizing a Dranetz analyzer or a BMI analyzer capable of recording snapshots of the current and voltage distortions. Measurements shall include phase to phase, phase to neutral, and neutral to ground. The test shall be run over the full range of VFD operation. Graphs of the test results shall be submitted for speed values of 60%, 80%, and 100%. Also, testing shall be performed with no VFD units operating, and for 3 pumping units operating simultaneously (no concurrent linear loads). October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 8 A written report covering the service engineer's inspection findings, field test readings, field test results and installation certification shall be submitted to the Owner. The report shall include a comparison of readings from the VFD and Contractor furnished meters and an evaluation of field measured efficiencies versus manufacturer's guaranteed efficiencies. October 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Variable Frequency Drives 16500-1 9 SECTION 1661 5 TRANSIENT VOLTAGE SURGE SUPPRESSION SYSTEM PART 1 - GENERAL 1.01 Description A. Contractor shall furnish and install a modular, high-energy transient voltage surge suppression (TVSS) system as specified herein and as shown on the Drawings. The specified system shall divert surge current, clamp transient voltage, and attenuate high-frequency electrical line noise, The TVSS system shall be suitable in ANSVIEEE C62.41 Category A, B, and C3 environments, as tested according to ANSVIEEE C62.11 and C62.45. B. TVSS systems shall be provided in the following applications: 1. Mounted inside or adjacent to the service entrance switchboard. 2. Mounted inside or adjacent to distribution panel enclosures. TVSS systems mounted inside service entrance and distribution panel enclosures shall be approved for said application by the service entrance and distribution panel manufacturers. 1.02 Applicable Specifications and Standards A. The specified system shall be designed, manufactured, tested, and installed in compliance with the following standards: 1. American National Standards Institute and Institute of Electrical and Electronic Engineers (ANSVIEEE) C62.41, Recommended Practice for Surge Voltages in Low-Voltage AC Power Circuits, Category B and C. 2. ANSVIEEE C62.45, Guide on Surge Testing for Equipment Connected to Low-Voltage AC Power Circuits. 2. Federal Information Processing Standards Publication 94 (FIPS PUB 94). 3. Federal Specification (W-P-115b and W-C-375a, b). 4. National Electrical Manufacturers Association (NEMA LS-1, AB-1, PB-1, PB-1.1 and PB-1.2). 5. National Fire Protection Association (NFPA-70 [NEC], NFPA-75 and NFPA-78). 6. Military Standard 220A. September 2003 Transient Voltage Surge Suppressor Calavera Pump Station (860-3-CAL) Contract 38891 1661 5-1 7. Underwriters Laboratories: a. ANSVUL-50, Enclosures for Electrical Equipment. b. ANSVUL-67, Panelboards. C. ANSVUL-489, Molded Case Circuit Breakers and Circuit Breaker Enclosures. d. AN S I/U L-89 1 , Dead-Front Switchboards. e. ANSVUL-943, Ground Fault Circuit Interrupters. f. ANSVUL-1283, Electromagnetic Interference Filters. g. ANSVUL-1449 Second Edition, Transient Voltage Surge Suppressors. B. Individual TVSS system units shall be UL listed and labeled under ANSVUL-1449 and the surge ratings shall be permanently affixed to the unit. The units shall also be listed and labeled under ANSI/UL-1283. 1.03 Definitions A. ClamDina Voltaqe: The applied surge shall be induced at the 90-degree phase angle of the applied system frequency voltage. The voltage measured at the end of the 6 inch (maximum) long output leads of the TVSS and from the zero voltage reference to the peak of the surge. B. Let-Throuah Voltaae: The applied surge shall be induced at the 90-degree phase angle of the applied system frequency voltage. The voltage measured at the end of the 6 inch (maximum) long output leads of the TVSS and from the system peak voltage to the peak of the surge. C. Maximum Continuous OPeratinu Voltaae (MCOV): The maximum steady state voltage at which the TVSS system can operate and meet its specification within its rated temperature. D. Maximum Surqe Current: The maximum 8x20 microsecond surge current pulse the TVSS system is capable of surviving on a single-impulse basis without suffering either performance degradation or more than 10 percent deviation of clamping voltage at a specified surge current. Listed by mode, since number and type of components in any TVSS may vary by mode. E. Protection Modes: This parameter identifies the modes for which the TVSS system has directly connected protection elements, Le., line-to-neutral (L-N), line- to-line (L-L), line-to ground (L-G), neutral-to-ground (N-G). September 2003 Transient Voltage Surge Suppressor Calavera Pump Station (860-3-CAL) Contract 38891 1661 5-2 F. Surae Current per Phase: The per phase rating is the total surge current capacity connected to a given phase conductor. For example, a wye system surge current per phase would equal L-N plus L-G; a delta system surge current per phase would equal L-L plus L-G. The N-G mode is not included in the per phase calculation. 1.04 Submittals A. All submittals shall be in accordance with the General Provisions, Section 2-5.3. B. Submittals shall include, but not be limited to, the following: 1. Standard manufacturer catalog data sheets, including UL product listing data. 2. Electrical and mechanical drawings showing unit dimensions, weights, component and connection locations, mounting provisions, connection details, and wiring diagram. 3. Certified test data from a third party laboratory, verifying clamping voltage rating, surge current rating, repetitive surge current rating, and noise attenuation compliance. Testing shall be in accordance with ANSMEEE C.45 and MILSTD-220A. 4. Written approval from service entrance and distribution panel manufacturers for TVSS systems mounted internally within panel enclosures. 5. Instructions for installation and connection (external units only). C. Operation and maintenance manuals covering all TVSS system equipment and components. Operation and maintenance manuals shall be provided in accordance with the Special Construction Provisions. 1.05 Quality Assurance TVSS systems shall be as manufactured by Current Technology, LEA International Inc., Liebert, or equal. 1.06 Warranty Manufacturer shall provide a product warranty for a period of not less than five (5) years from date of acceptance by Owner. Warranty shall cover unlimited replacement of TVSS modules during the warranty period and shall include all parts and labor at no cost to the Owner. September 2003 Calavera Pump Station (860-3-CAL) Contract 38891 Transient Voltage Surge Suppressor 16615-3 PART 2 - PRODUCTS 2.01 TVSS System A. ODeratina Conditions 1. Frequency: 47 to 63 hertz. 2. Ambient temperature: -40 OF to +140 OF. 3. Relative humidity: 5 % to 95 % (non-condensing), 4. Altitude: 0 to 12,000 feet above sea level. 5. Noise: less than 45 dBA at 5 feet. 6. Seismic: UBC Seismic Zone 4 7. No appreciable magnetic fields. System shall be capable of use directly in computer rooms or in any other location without danger to data storage systems or devices. B. Electrical Requirements and Performance 1. The nominal unit operating voltage and configuration shall be as indicated on the Drawings. 2. Each TVSS unit shall include a safety interlocked disconnect switch in the unit enclosure with an externally mounted manual operator. The switch shall be rated 600 VAG. Each TVSS unit mode shall be fused with a 200 kAlC surge rated fuse. Systems using fuses that open below the maximum surge current level are unacceptable. Disconnect switch and fusing system shall be included in the surge current testing of the TVSS unit. 3. The maximum continuous operating voltage (MCOV) of all suppression components utilized in the unit shall be greater than 11 5 percent of the nominal system operating voltage. 4. Tested and suitable for ANSIAEEE C62.41 Category C3 environments. 5. Protection modes: a. For a wye configured system, device must have directly connected suppression elements between line-neutral (L-N), line- ground (L-G), neutral-ground (N-G), and line-line (L-L). September 2003 Transient Voltage Surge Suppressor Calavera Pump Station (860-3-CAL) Contract 38891 16615-4 6. Maximum surge current rating: a. Service entrance applications: 1) Maximum surge current rating per phase shall be minimum 250kA. 2) Maximum surge current rating per mode shall be minimum 125kA. b. Branch circuit applications: 1) Maximum surge current rating per phase shall be minimum 120kA. 2) Maximum surge current rating per mode shall be minimum 60kA. The maximum surge current rating shall be based on testing of a complete TVSS unit, including integral disconnect, fuses, and all components that make up the TVSS system. Units that derive a maximum surge current rating by adding test results of individual components are not acceptable. 7. Suppression voltage rating (SVR) shall be tested with the integral disconnect in accordance with ANSI/UL-1449. The SVR values shall not exceed the following: a. 277/480V system: 800 volt (L-N, L-G, N-G), 1500 volt (L-L) b. 480 delta system: 1500 volt (L-G, L-L) 8. Maximum ANWIEEE Category C3 let through voltage based on IEEE C62.41 and C62.45 recommended procedures for Category C3 surges (20 kV, 10 kA): a. 277/480V: 1225 volt (L-N), including integral disconnect. 9. Each TVSS unit shall be capable of surviving repetitive ANSMEEE C62.41 Category C3 transients without failure or more than 10 percent degradation of UL 1449 clamping voltage. The minimum number of surges per phase the unit shall be able to protect against are as follows: a. Service entrance applications: 7,500. b. Branch circuit applications: 2,500. 10. EMVRFI filter shall provide minimum 40 dB noise attenuation at 100 kHz with an insertion ratio of 50:l using MIL-STD-220A. September 2003 Transient Voltage Surge Suppressor Calavera Pump Station (860-3-CAL) Contract 38891 16615-5 11. Surge current shall be equally distributed to all components to ensure equal stressing and maximum performance. 12. Multiple TVSS units shall not be connected in series to achieve the specified performance. 13. As a minimum, safety and diagnostic monitoring shall include the following: a. Solid-state monitoring of each mode and power loss in any phase. Monitoring of fuse status only is unacceptable. b. Audible alarm and surge counter. Surge counter shall utilize self- contained batteries with a nominal life of ten (10) years. An alarm on/off switch shall be provided to silence the alarm. An alarm push-to-test switch shall be provided to test the alarm function. C. Form C dry contacts (NO/NC) for remote status monitoring. Alarm contact shall change state if any fault condition occurs. d. Externally visible greedred solid-state indicator lights. Absence of a green light and presence of red light shall indicate which mode@) or phase(s) have been damaged. Fault detection shall activate a flashing trouble light. C. Externally mounted TVSS units. 1. Indoors: TVSS units shall be provided with general purpose NEMA 1 enclosures. Outdoors: TVSS units shall be provided with weatherproof NEMA 3R enclosures. 2. Diagnostics shall be mounted on the cover of the enclosure and shall be visible with the cover closed. PART 3 - EXECUTION 3.01 Installation A. Where the TVSS system is specified for installation as part of a new service entrance section, main service switchboard, or distribution panel, all TVSS system units shall be factory installed and connected within the service or distribution panel enclosures. B. Where the TVSS system is specified for installation as part of an existing electrical system, Contractor shall install TVSS system equipment external to existing panels. Installation shall be in accordance with the manufacturer’s printed instructions and in accordance with the applicable portions of the NEC, state, and local codes. September 2003 Transient Voltage Surge Suppressor Calavera Pump Station (860-3-CAL) Contract 38891 1661 5-6 Externally mounted TVSS equipment: 1. Mount where indicated on the Drawings and/or as close as practical to the panel bus. 2. Conductors shall be as short and straight as possible between bus and TVSS unit. 3. Conductors size shall be minimum #lo. Provide larger conductors as recommended by the manufacturer. 4. Contractor shall twist input conductors together to minimize conductor impedance. 5. WSS system shall be connected to a ground system having measured DC resistance of 25 ohms or less. 3.02 Start-up and Training Manufacture's representative shall verify installation, provide start-up assistance and training of Owner's operations personnel, and provide written certification that the TVSS system has been properly installed and is ready for operation, and manufacturer's warranties are in full effect. END OF SECTION September 2003 Transient Voltage Surge Suppressor Calavera Pump Station (860-3-CAL) Contract 38891 1661 5-7 SECTION 17000 GENERAL INSTRUMENTATION AND CONTROL COMPONENTS TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 Description The Contractor shall furnish, install, coordinate, design, fabricate, start-up, and place into service instrumentation and controls for the project to provide complete and operable systems as specified in the Contract Documents. The Contractor shall provide and designate Electrical and Instrumentation Subcontractors to perform said work. The Instrumentation Subcontractor shall be responsible to perform engineering and design of control panels and components, select equipment and controls to interface with various instrumentation and control equipment, package systems, furnished and manufactured motor control centers, and instrumentation centers. Instrumentation Subcontractor shall design and prepare or coordinate, preparation of control and interconnect diagrams. Instrumentation Subcontractor shall coordinate services of manufacturer's engineering representatives for services during installation, start-up, operation, and instruction of Owner for instrumentation and control equipment. Instrumentation Subcontractor shall coordinate work so that all components of the instrumentation system, including primary measuring, indicating, transmitting, receiving, recording, totalizing, controlling, alarming devices, and all appurtenances are completely compatible and shall function as specified, and shall furnish and install such additional equipment and accessories to meet this requirement at no cost to the Owner. Electrical Subcontractor shall subcontract the work specified herein to a qualified Instrumentation Subcontractor. All work performed is the responsibility of the Contractor even though references are made herein to work requirements and responsibilities of the Electrical and Instrumentation Subcontractors. 1.02 Performance Specifications and Drawings Equipment control/monitoring systems shall be furnished and installed to provide equipment performance, operation control, and/or monitoring functions as specified on Drawings in specific Equipment Technical Specifications, or in the System Operation Description Technical Specifications. Control Schematic drawings, where provided, show control loops and control panels with component locations. Instrumentation Subcontractor shall prepare all wiring and control diagrams, and computer programs, and furnish and install all instrumentation and control components to provide said specified performance and operation. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 Instrumentation and Control 17000-1 1.03 Instrumentation and Control Components instrumentation and control components shall be as specified herein, per Technical Specifications, Basic Electrical Specifications, and as shown on the Drawings or manufacturer shop drawings where included in these Contract Documents. Not all products specified herein are necessarily required for this project. 1.04 Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. The Instrumentation Subcontractor shall prepare and submit, through the Contractor, complete and organized shop drawings as specified herein. Interface between instruments, motor starters, control valves, variable speed drives, chemical analyzers, flow meters, chemical feeders, Owner furnished equipment, and other equipment related to the instrumentation and control system, shall be included in the shop drawing submittals. Shop drawings prepared by the MCC, VFD, and other electrical equipment suppliers shall be reviewed and approved by the Instrumentation Subcontractor. Said subcontractor shall date and sign shop drawings prior to submittal to the Owner for review. Shop drawings shall be submitted in complete bound sets indexed by specification and description of the items being submitted. Manufacturer's specification or data sheets shall be clearly marked to delineate the options or styles to be furnished. Only complete systems, not pieces of equipment from various systems shall be submitted. Submittals shall show dimensions, physical configurations, methods of connecting instruments and control equipment together, mounting details, single loop system drawings, and wiring schematics in conventional ladder diagram form. Control program for programmable controllers (if specified) shall be submitted in conventional ladder diagram form with complete labeling and comments. Fabrication data, nameplate, legends, and control panel internal wiring, including material specifications, shall be submitted. Submit data for each item of equipment which summarizes the specified features and include such other necessary data as would provide a complete specification for reordering an exact duplicate of the original item from the manufacturer. Submit, for approval, a written plan for demonstrating that each system of equipment meets the specified operational requirements. Submit a written plan for procedures to be used in final operation testing of entire systems. As-built drawings and operation and maintenance manuals shall be submitted. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 Instrumentation and Control 17000-2 1.05 Quality Assurance A. Qualification and Manufacturers Instrumentation Subcontractor shall have been regularly engaged in providing similar equipment on a single system responsibility basis for municipal water and wastewater projects of similar or larger magnitude. Personnel employed for system engineering, supervision, start-up, operational testing, and training shall be regularly employed and trained by the Instrumentation Subcontractor. The Instrumentation Subcontractor shall be responsible for the technical supervision of the installation to ensure that it is proper in all respects. B. Standard of Qualitv Equipment of the types and sizes specified which has been demonstrated to operate successfully shall be furnished. Substitution of equivalent equipment will be permitted as specified per Contractor Submittals Technical Specifications. C. Coordination with Electrical Subcontractors and Suppliers Prior to installation of any conduit the Instrumentation Subcontractor shall verify conduit size and conduit runs with the Electrical Subcontractor, and equipment suppliers for specific equipment to be furnished, and notify the Owner of any conflicts or deviations prior to installation. D. Instrumentation Subcontractor's Certifications Prior to start-up and initial operation of instrumentation and control equipment, the Instrumentation Subcontractor shall submit a written report stating that equipment has been coordinated, calibrated, properly installed, and is ready for start-up. After start-up and when equipment is ready to be operated, the Instrumentation Subcontractor shall submit a written report for the instrumentation and control equipment and associated field instruments certifying that the equipment is ready to be operated, is safe to operate and has been checked, inspected, calibrated, and adjusted as necessary; has been operated under maximum power variation conditions and operated satisfactorily; and is fully covered under the terms of the guarantee. PART 2 - PRODUCTS 2.01 General A. Where shown on the Drawings, specified by Special Requirements or Technical Specifications, or required by the specified equipment operation per System Operation Description Technical Specifications, the instrumentation and control components shall be as specified herein. Products not necessary for this project are identified herein as "Not Required". March 2004 Instrumentation and Control Calavara Pump Station (860-3-CAL) Contract 38891 17000-3 B. All meters, instruments, and other components shall be the most recent field proven models marketed by their manufacturers at the time of submittal of the shop drawings. C. All panel mounted instruments shall have matching style and general appearance. Instruments performing similar functions shall be of the same type, model, or class, and shall be of one manufacturer. D. All outdoor instrumentation shall be suitable for operation in the ambient conditions at the equipment installation locations. Heating, cooling, and dehumidifying devices shall be incorporated with the outdoor instrumentation in order to maintain it within its rated environmental operating ranges. The Contractor shall furnish and install all power wiring for these devices (e.g., heaters, fans, etc.). NEMA rated outdoor enclosures suitable for the environment shall be furnished. E. All instrumentation in hazardous areas shall be intrinsically safe and shall be approved for use in the particular hazardous (classified) location in which it is to be installed. F. Analog measurements and control signals shall be electrical as indicated herein, and shall vary in direct linear proportion to the measured variable, except as noted. Electrical signals outside control board@) shall be 4 to 20 milliamperes DC except as otherwise noted. 2.02 Control Panels Unless otherwise specified or shown on the Drawings, indoor control panels shall be NEMA Type 12 enclosures and outdoor control panels shall be NEMA Type 12 enclosures with drip shields for rain tight construction. Enclosures shall be single or double door, single or dual access as shown on the Drawings. As a minimum, each enclosure shall be furnished with interior back panels, and padlockable door handles. Free standing control panel enclosures shall be as manufactured by Hoffman, Robroy Industries, Inc., or equal and shall be securely anchored to the floor with a minimum of four stainless steel anchor bolts in each section. Free standing control panel enclosures 72" and less in height shall be provided with floor stand kits (12" height, minim urn). Surface or wall mounted enclosures shall be as manufactured by Hoffman, Robroy Industries, Inc., or equal and shall be anchored to the wall with a minimum of four 3/8 inch diameter stainless steel anchor bolts. Where control panels are part of the MCC line up, they shall match the MCC equipment in height, depth, and color. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 Instrumentation and Control 17000-4 2.03 General Instrumentation Enclosure Components and Requirements A. General General electrical components shall be as shown on the Drawings and specified in the Basic Electrical Specification, Equipment Technical Specifications, System Operation Description Technical Specifications, and herein. B. Siqnal Isolators, Converters, and Power Supplies Signal isolators shall be furnished and installed in each measurement and control loop, wherever required to ensure adjacent component impedance match, or where feedback paths may be generated. Signal converters shall be included where required to resolve any signal level incompatibilities. Signal power supplies shall be included, as required by the manufacturer's instrument load characteristics, to ensure sufficient power to each loop component. C. Nameplates Nameplates shall be provided for instruments, function titles for each group of instruments, and other components mounted on the panel fronts as shown on the drawings. A nameplate shall be provided for each signal transducer, signal converter, signal isolator, electronic trip, and the like, mounted inside the panel@). These shall be descriptive, to define the function and system of such element. These nameplates shall be of the same material as those on the panel fronts. Nameplates shall be fabricated from laminated engraving plastic. Nameplates shall be fabricated from VI-LAM, Catalog No. 200, manufactured by N/P Company, or equivalent by Formica, or equal. Colors, lettering, styles, and sizes shall be as shown on the drawings or as selected by the Owner. Adhesives are not acceptable for attaching nameplates. Nameplates shall be attached with stainless steel fasteners. D. Terminal Blocks Terminal blocks shall be molded plastic with barriers and box lug terminals, and shall be rated 15 amperes at 600-Volts. White marking strips, fastened securely to the molded sections, shall be provided, and wire numbers or circuit identifications shall be marked thereon with permanent marking fluid. E. Signal and Control Circuit Wirinq 1. Wire Tvpe and Sizes Where conductors are within the control panel, they shall be flexible stranded copper machine tool wire; these shall be UL listed Type MTW and shall be rated 600-Volts minimum 14 AWG. Shielded cables shall be No. 16 AWG minimum as manufactured by Belden, Carol Cable Co., or equal. Where conductors are run to MCC sections or to field March 2004 Instrumentation and Control Calavara Pump Station (860-3-CAL) Contract 38891 17000-5 locations, they shall be minimum 12 AWG of the UL type specified on the Drawings or by the Basic Electrical Specifications. 2. Wire Insulation Colors Conductors supplying 120-Volts AC power on the line side of a disconnecting switch shall have a black insulation for the ungrounded conductor. Grounded circuit conductors shall have white insulation. Insulation for ungrounded 120-Volt AC control circuit conductors shall be red. All wires energized by a voltage source external to the Control Board(s) shall have yellow insulation. Insulation for all DC conductors shall be blue. 3. Wire Termination Conductors from field componenets or from MCC sections shall terminate in the control panels at terminal blocks. Control circuit wiring shall connect from terminal blocks to relays, controls, and programmable controllers. 4. Wire Markinq Each signal, control, alarm, and indicating circuit conductor connected to a given electrical terminal point shall be designated by a single unique number which shall be shown on all shop drawings. These numbers shall be marked on all conductors at every terminal using white numbered wire markers which shall be plastic-coated cloth, Brady Type 6-500, Thomas and Betts "E-Z Code," or equal, or shall be permanently marked heat-shrink plastic. F. Forced Air Ventilation Svstem Forced air ventilation system, thermostat controlled, shall include the following: 1. Intake Louvers Design air louver plate kits with design air filters to fit and one can of spray adhesive, or equal. Intake louvers shall be sized to provide maximum air velocity of 500 feet per minute. 2. Air Exhauster Air exhauster shall be Dayton centrifugal type suitable for 110 volt power with discharge duct and screen, or equal. Locate exhauster at top or top side of panel. Exhauster shall be sized to provide minimum of 15 air changes per hour at static pressure of 0.25 inches or that created by system, which ever is greater. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 Instrumentation and Control 17000-6 3. Thermostat 2.04 2.05 2.06 Thermostat shall be line voltage Dayton attic fan type, or equal with 15°F differential to turn on at 105°F and off at 90°F. Manufacturer/supplier shall submit data to support ventilation equipment selection. Solenoid Valves Solenoid valves shall be packless construction, two-way, three-way, or four-way as required, and shall be correctly sized for the application, unless specifically sized on the Drawings. They shall be for normally energized or de-energized operation as shown on the Drawings. Valve bodies shall be forged brass unless otherwise recommended by the manufacturer for a particular application. The solenoids shall be rated for continuous operation at 11 5% of rated voltage. They shall be AC or DC current operated as specified or required. AC current coils shall have a shading ring. DC current operated coils shall be provided with a spark suppression device. If this device polarizes the coil, a reverse polarity protection diode shall be provided to prevent damage in the event of accidental reverse voltage application. Polarity of the coil shall be clearly marked on the terminals. All coils shall be housed in NEMA 4 cases with provision for 1 /2" electrical conduit connection. Thermostats Thermostats shall be single stage or two stage (as required) cooling, line voltage type, 120 V with contacts rated minimum 16 amps and minimum 3°F differential and setting range 30°F to 100°F. Thermostats shall be heavy duty, rated for minimum 3/4 horsepower motor starting, and shall be as manufactured by Dayton, Honeywell, or equal. Conductance Liquid Level Measurement System Each conductance liquid level measurement system shall consist of level sensors, connection fitting, and relays as shown on the Drawings and specified herein. Contractor shall furnish and install all material and appurtenances as necessary to provide a complete liquid level measurement system. Level sensors shall be conductance type, utilizing electrodes and the conductivity of the process fluid itself to measure level. The system shall be equipped with multiple level sensing electrodes and one ground electrode. The number and lengths of level sensing electrodes shall be as shown on the Drawings. Unless specified otherwise, the electrodes shall be constructed of 316 stainless steel and shall be provided with PVC heat shrink sheathings. Each connection fitting shall be pressure-tight, and suitable for connection to the flanged top outlet of a pressure vessel. Connection fitting shall be provided with an integral epoxy coated aluminum terminal housing and 31 6 stainless steel electrode couplings. The number of electrode couplings shall accommodate the number of March 2004 Instrumentation and Control Calavara Pump Station (860-3-CAL) Contract 38891 17000-7 level-sensing electrodes shown on the Drawings and required grounding electrode. Connection fitting flange shall be constructed of 1018 steel, and shall be rated for a minimum working pressure of 275 psig at 100°F. Contractor shall coordinate the size of the pressure vessel top outlet flange with the connection fitting flange provided by the level measurement system manufacturer. Liquid level measurement system relays shall be solid-state, plug-in modules suitable for 11 -pin octal sockets. Relays shall be general purpose, single level or differential service, with DPDT dry contacts rated for 5A (minimum) at 120 VAC. Relays shall be suitable for operation on 120 VAC primary voltage with 12 VAC secondary voltage. Conductance liquid level measurement system shall be as manufactured by Warrick Controls Inc., Gems Sensors Inc., or equal. 2.07 Timers Timers for ventilation equipment shall be 0 to 24 hour type with tabs permitting 15 minute interval settings. Timers shall be 120 V, 60 Hz, single phase, with contacts rated at a minimum of 5 amps when operating control circuit for 3 phase equipment or rated to start minimum 1 horsepower motor when starting equipment motor directly. 2.08 Pressure Gauges Unless otherwise shown or specified, pressure gauges shall be weatherproof and provided with 4-1/2" dials, 1/4" threaded connections, epoxy coated aluminum cases with safety glass windows, 31 6 stainless steel shut-off valves, 31 6 stainless steel pulsation dampeners (except where diaphragm seals are required), and 31 6 stainless steel close nipples. Bourdon tubes, bellows or diaphragm, and socket and tip shall be 316 stainless steel. Gauges subject to shock or vibration shall be wall mounted or attached to galvanized channel floor stands and connected to equipment by flexible connectors. Gauges shall be calibrated to read in applicable units, with an accuracy of *l%, to 150% of working pressure or vacuum of the monitored medium. Pressure gauges shall be as manufactured by Ashcroft, Marsh, U.S. Gauge, or equal. 2.09 Diaphragm Seals Where shown on the drawings or specified elsewhere, diaphragm seals shall be provided between the process medium and the pressure sensing element (e.g. gauge, transmitter, or switch). Unless otherwise specified, diaphragm seals shall have 316 stainless steel diaphragms and bottom housings. Bottom housings shall be provided with 1/4" flushing connection, 31 6 stainless steel shut-off valve, and 31 6 stainless steel close nipples. Diaphragm seals shall be as manufactured by Ashcroft, Marsh, or equal. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 Instrumentation and Control 17000-8 2.1 0 Pressure and Differential Pressure Switches Pressure and differential pressure switches shall utilize bourdon tubes, diaphragms, or bellows as the sensing/actuating element. Unless otherwise specified, the sensing/actuating element material shall be 31 6 stainless steel. The set point shall be readily field adjustable over the range specified. Switches shall have deadband adjustable up to a maximum of 100% of switch range. Switches shall be SPDT, rated for 15A at 120 VAC. Switch enclosures shall be rated NEMA 4X. Process connections shall be 1/4" or 1/2" NPT, and shall be provided with 316 stainless steel shut-off valves, 31 6 stainless steel pulsation dampeners (except where diaphragm seals are required), and 31 6 stainless steel close nipples. Pressure switches and differential pressure switches shall be as manufactured by Ashcroft, Allen-Bradley, or equal. 2.1 1 Pressure Transmitters Pressure transmitters shall be electronic two wire devices with the following features: adjustable span, zero and damping adjustments, integral indicator scaled in engineering units, solid state circuitry and 4-20 mA output. Accuracy shall be &0.25% of span. Overrange capacity, without affecting calibration, shall not be less than 150% of maximum range. Process wetted materials shall be 316 stainless steel. Body material shall be 316 stainless steel. Process connections shall be 1/4" or 1/2" NPT, and shall be provided with 316 stainless steel shut-off valves, 316 stainless steel pulsation dampeners (except where diaphragm seals are required), and 31 6 stainless steel close nipples. Fill fluid, unless otherwise specified, shall be silicone oil. Transmitter housing shall be epoxy coated low copper aluminum alloy and rated NEMA 4X. Pressure transmitters shall be as manufactured by Rosemount, Foxboro, or equal. 2.12 Differential Pressure Transmitters Differential pressure transmitters shall be electronic two wire devices with the following features: adjustable span, zero and damping adjustments, integral indicator scaled in engineering units, solid state circuitry and 4-20 mA output. Accuracy shall be &25% of span. Overrange capacity, without affecting calibration, shall not be less than 150% of maximum range. Span shall be field adjustable over at least a 4 to 1 range. Process wetted materials shall be 316 stainless steel. Body material shall be 316 stainless steel. Process connections shall be 1/4" or 1/2" NPT. Fill fluid, unless otherwise specified, shall be silicone oil. Transmitter housing shall be epoxy coated low copper aluminum alloy and rated NEMA 4X. A three (3) valve manifold shall be provided with the transmitter. Manifold wetted surface materials shall be 31 6 stainless steel. Pressure transmitters shall be as manufactured by Rosemount, Foxboro, or equal. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 Instrumentation and Control 17000-9 2.13 Control Valve Limit Switches Control valve limit switch assemblies shall provide remote indication of valve opening and closing. Limit switches shall be single pole, double throw type, with weatherproof enclosures. Limit switches shall be rated 15A at 120/240 VAC. Contractor shall review each control valve installation and shall determine the necessary limit switch accessories. Contractor shall furnish and install all limit switches, and accessories necessary for a complete and operable system. Control valve limit switch assemblies shall be as manufactured by CLA-VAL Company. 2.1 4 Electrical Service Power Failure Protection System The electrical service power failure protection system consists of an electronic device which provides protection against three-phase electrical motor loss due to power failure conditions. Power failure conditions include: low voltage, phase loss, unbalanced voltage and phase reversal. The power failure protection device shall be Model EAC-800 as manufactured by Watsco Components Inc., Motorsaver Model 250A as manufactured by SymCom, Inc., or equal. Contractor shall install the power failure protection system as shown on the Drawings or specified in the Technical Specifications. The protection system shall monitor electrical line side power of specified equipment or facilities. The power failure protection system shall automatically stop all electrical motors upon output relay deactivation (unstable power conditions) and shall transmit a power failure alarm signal to the local RTU (where specified). PART 3 - EXECUTION 3.01 General The Instrumentation Subcontractor shall perform work and provide services as specified herein and per Basic Electrical Specifications. It is the general intent of this Contract that furnishing all equipment instrumentation and controls; all field wiring, conduit installation, and wiring external to the MCC, control panels and electrical equipment shall be furnished and installed by the Electrical Subcontractor. It is intended that the design or the coordination of design of controls within motor control center(s) and control panels and compatibility of design with equipment and equipment systems and programming of programmable controllers and control system start-up shall be the responsibility of the Electrical and Instrumentation Subcontractors. The Instrumentation Subcontractor's attention is directed to the electrical and mechanical details of this project. Referral to these portions of the Contract Documents shall be required in order to understand the full intent and scope of work required. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 instrumentation and Control 1 7000- 1 0 3.02 Control Panel Signal And Control Circuit Wiring A. Wirina Installation All wires within control panels shall be run in plastic wireways. Wiring run from components on a swing-out panel to other components on a fixed panel shall be made up in tied bundles. These bundles shall be tied with nylon wire ties, and shall be secured to panels at both sides of the "hinge loop" so that conductors are not strained at the terminals. Wiring run to control devices on the front panels shall be tied together at short intervals with nylon wire ties and secured to the inside face of the panel using epoxy adhesive, T & B or Panduit. Standard adhesive mounts are not acceptable. Wiring to rear terminals on panel-mount instruments shall be run in plastic wireways secured to horizontal brackets run above or below the instruments in about the same plane as the rear of the instruments. Conformance to the above wiring installation requirements shall be reflected by details shown on the shop drawings for the Owner's review. B. Wire Markinq Each signal, control, alarm, and indicating circuit conductor connected to a given electrical point shall be designated by a single unique number which shall be shown on all shop drawings. These numbers shall be marked on all conductors at every terminal using white numbered wire markers which shall be plastic-coated cloth, or permanently marked heat-shrink plastic. 3.03 Installation, Calibration, Testing, Start-up, And Instruction A. General Under the supervision of the Instrumentation Subcontractor, all systems specified herein shall be installed, connected, calibrated, tested, and started in coordination with the equipment manufacturer and the Owner. This shall include final calibration in concert with equipment specified elsewhere in these Contract Documents. B. Factorv Testinq of Control Panels Instrumentation Subcontractor shall verify wiring continuity and panel operation by simulated inputs and outputs to assure controls are operable and meet the requirements of these Specifications. March 2004 Calavara Pump Station (860-3-GAL) Contract 38891 Instrumentation and Control 17000-1 1 C. Manufacturer's Enaineerina Remesentative The services of manufacturer's engineering representative especially trained and experienced in the installation of the equipment shall be provided to supervise the installation, be present when the instruments and equipment are first put into operation, and inspect, check, adjust as necessary, and calibrate the instruments. All costs for representative's services shall be included in the Contract Price. D. Certifv Proper Installation After all installation and connection work has been completed, the Instrumentation Subcontractor shall check it all for correctness, verifying polarity of electric power and signal connections, making sure all process connections are free of leaks, and all other similar details. The manufacturer's representative shall certify in writing to the Instrumentation Subcontractor that for each loop or system checked out, that equipment is installed properly and ready for start-up. See item 1.05D herein for Instrumentation Subcontractor's Certification. E. Calibration All instruments and systems shall be calibrated after installation, in conformance with the component manufacturer's instructions by the Instrumentation Subcontractor and manufacturer's representative. Those components having adjustable features shall be set for the specific conditions and applications of the project, and shall be within the specified limits of accuracy. Elements and equipment which cannot achieve proper calibration or accuracy, either individually or within a system, shall be replaced. F. Start-up and Instruction When all systems have been assessed by the Contractor to have been successfully carried through complete operational tests with not less than a minimum of simulation, and the Owner concurs in this assessment, plant start- up can follow. Fifteen days (minimum) prior to start-up, Owner's operating and maintenance personnel shall be instructed in the functions and operation of each system and shall be shown the various adjustable and set point features which may require readjustment, resetting or checking, recalibration, or maintenance by them from time to time. Instruction shall include interactions of the systems, operations, shutdowns, alarms, failure, and controls. This instruction shall be scheduled at a time arranged with the Owner at least two weeks in advance. instruction shall be classroom type for minimum of four hours or as required by the Special Requirements or Special Construction Provisions for instrumentation and controls. Instruction shall be given by the Instrumentation Subcontractor and other qualified persons who have been made familiar in advance with the systems in this plant. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 instrumentation and Control 1 7000- 1 2 steel tube, carbon steel flanged, and polyurethane lined, with a nominal diameter as listed herein. External surfaces shall be factory finished with a high build epoxy paint or better for corrosion prevention. The flow meter electrodes and built in grounding electrodes shall be Type 316 stainless steel. If built in grounding is not provided Type 316 stainless steel grounding rings shall be mounted in each end of the meter. The preamplifier input impedance shall not be less than 1011 ohms and shall be capable of operating with a power supply of 120 volts *lo%, 60 hz *5Y0 and power consumption shall not exceed 11 VA. The sensor shall be NEMA 4X, accidental submergence proof (30 W48 hours) and certified for use in Class 1, Division 1, Groups B, C, and D. Accuracy of the flow meter system shall be *lY0 of rate above 1 fps and +0.1% of full scale below 1 fps. Accuracy shall be verified by calibration in a flow laboratory traceable to the U.S. National Bureau of Standards. The meter shall incorporate an empty pipe detection feature which shall cause the meter to register zero flow when the sensor is not full. Where shown on the Drawings, the meter shall include a positive zero circuit to register zero flow when pumping units are not operating. B. Schedule of Maqnetic Flow Meters Magnetic flow meters shall be provided as follows: Minimum Nominal Pressure Flow Dia. Rating Range Location Service (inches) (psi) (gpm) Discharge Header Recycled 8” 300 0 to 2000 Water Magnetic flow meter shall be provided with ANSI Class 300 flanges. 2.02 Signal Converterflransmitter Signal converter shall be provided for each meter for meter mounting or remote mounting as shown on the Drawings. Interconnecting cable of adequate length shall be provided by the meter manufacturer. The converter shall be NEMA 4X, accidental submergence proof (30 fV48 hours) and certified for use in Class 1, Division 1, Groups B, C, and D (unless specified for panel mounting). Signal converter shall be designed for out-of-door use and exposed to the sun light. If the display must be protected from the sun the converter shall be furnished with an enclosure or sun shield. Signal converter shall provide a 16 character alphanumeric display indicating flow units as specified herein and total flow in Cubic Feet XIOO. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 Magnetic Flow Meter 1721 0-2 SECTION 1721 0 MAGNETIC FLOW METER TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 General Requirements Contractor shall furnish and install magnetic flow meters and all appurtenant materials, equipment, and work suitable for the services listed, complete and operable in accordance with requirements of the Contract Documents and in conformance with the manufacturer's recommendations. Upon completion of installation, the work shall be tested to demonstrate compliance with the specifications. 1.02 Submittals All submittals shall be in accordance with the General Provisions, Section 2-5.3. A. Shop Drawinas Contractor shall submit shop drawings in accordance with the Contractor Submittals Technical Specification and shall include, but not be limited to, the following : 1. Details of all components of all meters including detailed installation instructions. 2. Electrical schematics and instrumentation specifications. 3. Meter cable. 4. Manufacturer's application performance guarantee for each meter location, and recommendations for installation at each location. B. Operation and Maintenance Manual Contractor shall submit a detailed operation and maintenance manual for the flow metering system@) specified herein. PART 2 - PRODUCTS 2.01 Magnetic Flow Meter A. Desian and Construction The magnetic flow meter shall use characterized electromagnetic introduction to produce a voltage linearly proportional to the average flow rate. Each magnetic flow meter shall be microprocessor based, and utilize D.C. bipolar pulsed coil excitation, automatically re-zeroing after every cycle. The sensor shall be carbon March 2004 Calavara Pump Station (860-3-GAL) Contract 38891 Magnetic Flow Meter 1721 0-1 Features allowing menu selection, calibration, and program changes to be made from outside the housing shall be incorporated. It shall produce a 4-20 mA DC output signal into a minimum load of 800 ohms, linear to flow, and scaled pulsed output to permit operation of a flow recorder. The signal converter shall be suitable for out-of-doors installation, wall mounting, or flush mounting within panel door as shown on the Drawings. Where specified or shown on the Drawings, a remote flow indicator shall be panel mounted in the main control panel. 2.03 Manufacturer Magnetic flow meters shall be the product of Sparling Instrument Co. Inc., ABB, or equal. Manufacturers shall modify or supplement standard equipment to provide features as specified herein. PART 3 - INSTALLATION Installation of magnetic flow meters and signal converters/transmitters shall be in accordance with manufacturer's written instructions. Manufacturers shall guarantee equipment against defects in material and workmanship for a period of two years from date of project acceptance. The instrumentation subcontractor shall coordinate with the manufacture to provide suitable sun shield or enclosure to protect the meter and signal converter in the location (environment) shown on the drawings. March 2004 Calavara Pump Station (860-3-CAL) Contract 38891 Magnetic Flow Meter 1721 0-3 SECTION 1731 0 SECURITY AND SMOKE DETECTION EQUIPMENT TECHNICAL SPECIFICATIONS PART 1 - GENERAL 1.01 1.02 1.03 1.04 Description Contractor shall furnish and install security and smoke detection equipment as specified herein and as shown on the Drawings to sense a security violation or the presence of smoke or heat and cause an alarm and signal for remote telemetry. System shall be complete with sensors and control modules. Specific Project Requirements Smoke detector sensors shall be installed in the Equipment Building as shown on the Drawings. Security detection shall be provided with magnetic sensors (door switches) at each Equipment Building door and a wall mounted motion detector sensor as shown on the Drawings. One control module shall be provided to indicate security breach. Alarm detection shall activate individual alarm light on the module for smoke and for each door or motion detector for security. One common alarm light shall be mounted in the main control panel. One dry alarm contact for smoke and one dry contact for security on the control module shall provide signals to the telemetry system. Submittals Contractor shall submit shop drawings and catalog cut sheets in accordance with the General Provisions to show complete details, components, description, and wiring. Quality All equipment furnished shall be of current design and manufacture that has been utilized in similar applications and environments. Manufacturers shall be as specified for various components. Equipment shall be U.L. listed, components shall meet the requirements of NFPA 72A, B, and C, and be approved by the State of California Fire Marshall (CFM) whether or not the system is only security and not smoke (fire). PART 2 - PRODUCTS 2.01 Detector Control Module Detector control module(s) shall be an expandable type furnished suitable to operate the number of sensors per zone or sensors per location specified or shown on the Drawings and display alarm signal for each zone or location. Modules shall be powered by 120 VAC single phase 60 Hz input power, be provided with alarm light and reset for each zone or each location, reduced voltage transformer for 12 or 24 VDC power to sensors, October 2003 Security and Smoke Detection Calavara Pump Station (860-3-CAL) Contract 38891 1731 0-1 standby batteries, and battery charger. Voltage of module(s) and sensors shall be compatible LED indicators and associated sensors for AC power on, system trouble, zone alarm, zone trouble, location alarm, low battery, ground fault, and alarm circuit trouble shall be provided. Switches for system reset, sound silence, and zone or location walk test shall be provided. Remote contacts for remote alarm indication suitable for 120 VAC, 10 AMP; contacts with output power (12 or 24 VDC) to activate an alarm bell; contacts for operation of remote sprinkler system, and dry contacts to operate remote exterior light shall be provided. The control module(s) shall be lntelliguard Model 5505 as manufactured by Honeywell or equivalent equipment manufactured by Electro Signal Lab, Inc., Alarm Industry Products, or equal. 2.02 Smoke Detector Sensors Photoelectric type ceiling mount smoke detector sensors suitable for operation on 12 or 24 volt D.C. power from the control module shall be furnished and installed as shown on the Drawings. Sensors shall be, furnished with 30 mesh insect screen, shielded electronics, indicators for power on and alarm and a test switch. Detectors shall be Honeywell Model 200, Alarm Industry Products, or equal. Smoke detector sensors shall be activated by smoke activating an alarm signal calibrated for 2% to 3% gray smoke obscuration. In addition, sensors shall be equipped with an integrated heat detector, such that an alarm signal is activated at 135°F. 2.03 Security Sensors Security sensors shall be magnetic type contacts provided at doors and windows or infrared motion type as specified herein and shown on the Drawings and shall operate on power provided from the control module. Magnetic sensors shall be suitable for type of door or window being secured. Hinged door types shall be recessed into the door and door jamb at top. If being installed on existing metal frame that has been grouted in place, a surface mount type may be provided if approved by Owner. Detector shall be 1075 Series for wood door and jamb, or 1078 Series for metal door and jamb as manufactured by Sentrol, Inc., or equal biased type. Roll up type doors and windows shall be provided with surface mount 2500 series or equal biased type. Motion detector sensors shall be U.L. approved dual passive infrared Model 774i as manufactured by Honeywell, or equal. Unit shall be furnished complete with swivel mounting hardware. Features shall include four sensing elements where thermal/detection change can be verified by an adjacent motion detector to activate an alarm. The range shall be based on specified location of the detector. October 2003 Calavara Pump Station (860-3-CAL) Security and Smoke Detection 1731 0-2 Contract 38891 2.04 Alarm Bell or Light An alarm bell or red alarm light as shown on Drawings suitable for mounting on exterior of building and compatible with operation by the control module shall be provided to signal an audible or visible alarm. Where shown on the Drawings, separate alarm bell or lights. 2.05 Spare Parts Spare parts shall include two of each size fuse and one extra smoke detector sensor and motion detector sensor. PART 3 - EXECUTION 3.01 General The security and smoke detection system shall be installed and tested as shown on the Drawings and specified herein: A. The Contractor shall arrange to have the manufacturer or supplier of the equipment furnished under this Section, furnish the services of competent factory-trained personnel to supervise the installation and start up on all equipment. Allowance for this service shall be included by the manufacturer in the price of his equipment. Installation and erection of all assemblies and components shall be in accordance with the details indicated on the Drawings, approved shop drawings, and the printed instructions of the manufacturer. B. After installation, the systems shall be put through all operations. 3.02. Instruction After the equipment has been installed, tested, and adjusted, and placed in satisfactory operating condition, the equipment manufacturer shall provide class room instruction to Owner's operating personnel in the use and maintenance of the equipment. One (1) hour of instruction shall be provided unless otherwise specified. Contractor shall give the Owner formal written notice of the proposed instruction period at least two weeks prior to commencement of the instruction period. Scheduled training shall be at a time acceptable to the Owner and the manufacturer. During this instruction period, the manufacturer shall answer any questions from the operating personnel. The instruction period shall be as long as necessary to address details of operation, routine maintenance, repair, and special equipment features. October 2003 Calavara Pump Station (860-3-CAL) Contract 38891 Security and Smoke Detection 1731 0-3 APPENDIX A RESIDENT NOTIFICATION EXAMPLE APPENDIX “A” RESIDENT NOTIFICATION EXAMPLE CITY OF CARLSBAD CONSTRUCTION WORK ABC CONTRACTORS OFFICE # (76O)XXX-XXXX FlELD # (76O)XXX-XXXX Dear resident: 4s a part of the City of Carlsbad’s and Carlsbad Municipal Nater District’s ongoing program to maintain its water and sewer facilities, your street will be closed to allow for pipeline :onstruction. This construction will require the closing of your street to through traffic for X days. Your street, from XYZ St. o XU Ave. will be closed to through traffic on: MON. TUE. WED. THU. FRI. DATE: ‘rom 7:OOA.M. to 5:OO P.M. If you don’t plan to leave your home by 7:OO A.M. on the above date(s) please park your car on an adjacent street in lour neighborhood that will not be impacted. ABC is the Contractor that will be performing the :onstruction work for the city and you may call them at ‘760)xxx-x>ooc if you have any questions regarding the xoject. Mail delivery may be delayed if the postman cannot *each the mailbox that day. If you have a moving company scheduled for that day please call and inform the Contractor of he date. If you have any concerns which cannot be addressed by the Contractor, you may call the City’s Engineering Inspection Department at 438-1 161x4323. 9etter City of Carlsbad. Thank you for your cooperation as we work to make a APPENDIX B CARLSBAD CONDITIONAL USE PERMIT 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 COBblISSION RESOLUTION NO. 5628 A RESOLUTION OF THE PLANNING COMMISSION OF THE CITY OF CARLSBAD, CALIFORNIA, APPROVING A CONDITIONAL USE PERMIT TO CONSTRUCT AND OPERATE A RECYCLED WATER PUMP STATION ON PROPERTY GENERALLY LOCATED WEST OF COLLEGE BOULEVARD, SOUTH OF CARLSBAD VILLAGE DRIVE IN LOCAL FACILITIES MANAGEMENT ZONE 7. CASENAME: CALAVERA RECYCLED WATER PUMP STATION CASE NO.: CUP 03-30 WHEREAS, Carlsbad Municipal Water District, “Owner/Developer,” has filed a verified application with the City of Carlsbad regarding property described as Lot 118 of CT 01-06, filed in the Office of the County Recorder of San Diego County, State of California on July 21,2002 (“the Property”); and WHEREAS, said verified application constitutes a request for a Conditional Use Permit as shown on Exhibits “A” - bCI” dated May 19, 2004, on file in the Carlsbad Planning Department, CALAVERA RECYCLED WATER PUMP STATION - CUP 03-30 provided by Chapter 21.42 andor 2 1 SO of the Carlsbad Municipal Code; and WHEREAS, the Planning Commission did, on the 19th day of May 2004, 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 Conditional 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. 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 B) That based on the evidence presented at the public hearing, the Commission APPROVES CALAVERA RECYCLED WATER PUMP STATION - CUP 03-30, based on the following findings and subject to the following conditions: Findings: 1. 2. 3. 4. 5. 6. 7. That the requested use is necessary or desirable for the development of the community, is essentially in harmony with the various elements and objectives of the General Plan, and is not detrimental to existing uses specifically permitted in the zone in which the proposed use is located, in that the Jl-acre site is specifically designated for a recycled water pump station as part of the Village X approvals within the Calavera Hills Master Plan. The proposed recycled water pump station is part of the new citywide network and will increase the efficiency of reclaimed water delivery services. That the site for the intended use is adequate in size and shape to accommodate the use, in that the site has adequate space for the location, operation, maintenance and screening of the proposed 704 square foot, 15-foot tall pump station and related surge tank. That all the yards, setbacks, walls, fences, landscaping, and other features necessary to adjust the requested use to existing or permitted future uses in the neighborhood will be provided and maintained, in that the site can accommodate the split block wall pump station structure, surge tank and ornamental landscaping for screening purposes. The building will be setback 20 feet from College Boulevard at its closest point; the site has room for maintenance personnel and vehicles to maneuver onsite; and the project is compatible with the adjacent Village X residential subdivision, including architecture and landscaping. That the street system serving the proposed use is adequate to properly handle all traffic generated by the proposed use, in that College Boulevard is a public street that will be able to handle the traffic involved with this project since only Water District personnel can access the locked and secured site. Site access to College Boulevard will be in addition to internal site access via Vitlage X, and traffic will be limited to City and Water District staff. That the project is consistent with the City’s Landscape Manual (Carlsbad Municipal Code Section 14.28.020 and Landscape Manual Section I B). That the Planning Director has determined that the project belongs to a class of projects that the State Secretary for Resources has found do not have a significant impact on the environment, and it is therefore categorically exempt from the requirement for the preparation of environmental documents pursuant to Section 15303 - Class 3, New Construction of Small Structures of the state CEQA Guidelines. In making this determination, the Planning Director has found that the exceptions listed in Section 15300.2 of the state CEQA Guidelines do not apply to this project. 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 PC RES0 NO. 5628 -2- 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 to mitigate impacts caused by or reasonably related to the project, and the extent and the degree of the exaction is in rough proportionality to the impact caused by the project. Conditions: Note: 1. 2. 3. 4. 5. 6. 7. Unless otherwise specified herein, all conditions shall be satisfied prior to building permit issuance. 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 implemented and maintained according to their terms, the City shall have the right to revoke or modify all approvals herein granted; deny or Mer condition issuance of all future building permits; deny, revoke or further condition all certificates of occupancy issued under the authority of approvals herein granted; institute and prosecute litigation to compel their compliance with said 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 Conditional Use Permit. Staff is authorized and directed to make, or require the Developer to make, all corrections and modifications to the CUP 03-30 documents, as necessary to make 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 development different from this approval, shall require an amendment to this approval. Developer shall comply with all applicable provisions of federal, state, and local laws and regulations in effect at the time of building permit issuance. If any condition for construction of any public improvements or facilities, or the payment of any fees in-lieu thereof, imposed by this approval or imposed by law on this Project are challenged, this approval shall be suspended as provided in Government Code Section 66020. If any such condition is determined to be invalid this approval shall be invalid unless the City Council determines that the project without the condition complies with all requirements of law. Developer shall submit to Planning Director a reproducible 24" x 36" mylar copy of the Site Plan reflecting the conditions approved by the final decision making body. This project shall comply with all conditions and mitigation measures, which are required as part of the Zone 7 Local Facilities Management Plan and any amendments made to that Plan prior to the issuance of building permits. This Conditional Use Permit shall be reviewed by the Planning Director annually to determine if all conditions of this permit have been met and that the use does not have a substantial negative effect on surrounding properties or the public health and welfare. If the Planning Director determines that the use has such substantial negative effects, the Planning Director shall recommend that the Planning Commission, after providing the permittee the opportunity to be heard, add additional conditions to reduce or eliminate the substantial negative effects. PC RES0 NO. 5628 -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 8. 9. 10. 11. 12. Developer shaIl submit and obtain Planning Director approval of a Final Landscape and Irrigation Plan showing conformance with the approved Preliminary Landscape Plan and the City's Landscape Manual. Developer shall construct and install a11 landscaping as shown on the approved Final Plans, and maintain all landscaping in a healthy and thriving condition, free from weeds, trash, and debris. The first submittal of Final Landscape and Irrigation Plans shall be pursuant to the landscape plan check process on file in the Planning Department and accompanied by the project's building, improvement, and grading pIans. Developer shall submit and obtain Planning Director approval of an exterior lighting plan including parking areas. All lighting shall be designed to reflect downward and avoid any impacts on adjacent homes or property. No outdoor storage of materials shall occur onsite unless required by the Fire Chief. When so required, the Developer shall submit and obtain approval of the Fire Chief and the Planning Director of an Outdoor Storage Plan, and thereafter comply with the approved plan. All roof appurtenances, including air conditioners, shall be architecturally integrated and concealed from view and the sound buffered from adjacent properties and streets, in substance as provided in Building Department Policy No. 80-6, to the satisfaction of the Directors of Community Development and Planning. Engineering General 13. Prior to hauling dirt or construction materials to or from any proposed construction site within this project, Contractor shall apply for and obtain approval from, the City Engineer for the proposed haul route. Dedicationsflmprovemen ts 14. Developer shall install public improvements shown on the site plan and the following improvements including, but not limited to paving, base, sidewalks, curbs and gutters, grading, clearing and grubbing, storm drain system, and reclaimed water, to City Standards to the satisfaction of the City Engineer. The improvements are: A. Access and utilities fronting College Boulevard. 15. Developer shall comply with the City's requirements of the National Pollutant Discharge Elimination System (NPDES) pennit, latest version. Developer shall provide improvements constructed pursuant to best management practices as referenced in the "California Storm Water Best Management Practices Handbook" to reduce surface pollutants to an acceptable level prior to discharge from the site. Plans for such PC RES0 NO. 5628 -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 16. 17. improvements shall be submitted to and subject to the approval of the City Engineer. Said plans shall include but not be limited to notifymg station operators of the following: A. B. C. Station operators shall coordinate efforts to establish or work with established disposal programs to remove and properly dispose of toxic and hazardous waste products. Toxic chemicals or hydrocarbon compounds such as gasoline, motor oil, antifreeze, solvents, paints, paint thinners, wood preservatives, and other such fluids shall not be discharged into any street, public or private, or into storm drain or storm water conveyance systems. Use and disposal of pesticides, fungicides, herbicides, insecticides, fertilizers and other such chemical treatments shall meet Federal, State, County and City requirements as prescribed in their respective containers. Best Management Practices shall be used to eliminate or reduce surface pollutants when planning any changes to the landscaping and surface improvements. Prior to issuance of a Building Permit, developer shall submit and receive approval from the City of Carlsbad Engineering Department of a Storm Water Management Plan (SWMP). This project is required to capture and reduce pollutants to a level of insignificance. The organization and content of the SWMP shall be prepared in accordance with the guidelines as established by the San Diego Region of the California Regional Water Quality Control Board and as modified by the City of Carlsbad. The SWMP shall address the anticipated pollutants of concern associated with the project and shall suggest the type(s) of post-construction (source and structural) Best Management Practices (J3MP) required to avoid contact with storm water of filter pollutants of concern. Prior to occupancy, Developer shall implement the necessary BMP measures required to capture and filter the anticipated pollutants of concern associated with the project in accordance with the City-approved SWMP, the latest California NPDES permit requirements, and the City of Carlsbad Standard Urban Stormwater Management Plan. Code Reminders: The project is subject to all applicable provisions of local ordinances, including but not limited to the following 18. The project is subject to all applicable provisions of local ordinances, including but not limited to the following: 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. PC RES0 NO. 5628 -5- 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 19. 20. 21. 22. 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. Premise identification (addresses) shall be provided consistent with Carlsbad Municipal Code Section 18.04.320. Any signs proposed for this development shall at a minimum be designed in conformance with the City’s Sign Ordinance and shall require review and approval of the Planning Director prior to installation of such signs. Contractor 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. NOTICE Please take NOTICE that approval of your project includes the “imposition” of fees, dedications, reservations, or other exactions hereafter collectively referred to for convenience as “fees/exactions.” You have 90 days from date of final approval to protest imposition of these fees/exactions. If you protest them, you must follow the protest procedure set forth in Government Code Section 66020(a), and file the protest and any other required information with the City Manager for processing in accordance with Carlsbad Municipal Code Section 3.32.030. Failure to timely follow that procedure will bar any subsequent legal action to attack, review, set aside, void, or annul their imposition. You are hereby FURTHER NOTIFIED that your right to protest the specified fees/exactions DOES NOT APPLY to water and sewer connection fees and capacity charges, nor planning, zoning, grading or other similar application processing or service fees in connection with this project; NOR DOES IT APPLY to any feedexactions of which you have previously been given a NOTICE similar to this, or as to which the statute of limitations has previously otherwise expired. ... ..I ... ... ... PC RES0 NO. 5628 -6- 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 It li 15 13 2c 21 21 2: 2f 22 2t 2; 21 PASSED, APPROVED AND ADOPTED at a regular meeting of the Planning Commission of the City of Carlsbad, California, held on the 19th day of May 2004 by the following vote, to wit: AYES: Chairperson White, Commissioners Baker, Dominguez, Heineman, and Whitton NOES: None ABSENT: Commissioners Montgomery and Segall ABSTAIN: None &/& MELISSA WHITE, Chairperson CARLSBAD PLANNING COMMISSION ATTEST: \ Planning Director PC RES0 NO. 5628 -7- I APPENDIX C SDG&E DRAWINGS San Dieqo Gas S Electrlc - $?l Enterbtise Street Es&didc, C4 9tOZa-1?44 PROJ# 342295-010 May 21,2004 City of Carlsbad Chris M uehl bache r 1635 Faraday Ave. Carlsbad, Ca. 92008 Dear Chris: PROJECT: Calavera Recycled-Water Pump Station The engineering required for SDG&E to provide electric service to your project has been completed. Meter and service location information, and other technical information is enclosed for your use. Construction responsibilities are outlined following. And, the related costs are attached as the “Cost Summary Sheet”. ELECTRIC SERVICE Underground service will be supplied under the provisions of Electric Rule 16. Accordingly, you are responsible for providing a clear path, the trench, backfill, conduit and concrete substructure (Also, you will be responsible for the on-going maintenance of these facilities.) We will install and connect the electric service conductors. We will extend underground electric service lines to serve your project. There will be no charge for this extension. EASEMENTS Easement(s) are required before our facilities can be installed. To proceed, a fee, as specified in the Cost Section, is required for easement acquisition and processing. Also, please have the enclosed easement form signed and notarized, and returned to SDG&E in the enclosed return envelope. Questions regarding the easements should be directed to the right-of-way agent. If you are installing an electrically operated gate for your project, there are several things you need to know. First, 24-hour access to the meters is required by the Fire Department and SDG&E. Because of the serious safety issues involved, we cannot set meters until access is guaranteed. You should contact the Fire Department to obtain their specific requirements, but our minimum requirements are: 1. A Schlage VTQP Quad Section cylinder in a key switch wired to the gate controller. A list of locksmiths authorized to sell SDG&E approved locks is available on request. 342295-01 0 2 May 21,2004 2. A means of opening the gate from the inside without the use of a vehicle to activate the controller. This will require the installation of an additional key switch inside the gate if there is no unsecured switch available. TRENCHING, CONSTRUCTION. INSPECTION After you have been notified by us that your construction order has been issued, you or your contractor must notify our Construction Department by phone, 48 hours prior to having the trench ready. Please call 760-432-5805 to arrange a pre-construction meeting or to discuss any construction-related questions. Inspection of your work by our inspector is required at the: trenching; conduit installation; conduit mandreling; backfilling and compaction; substructure installation; and, completion stages. When calling our Construction Department, the following will identify your project: Project Name: Order # 2792460 Calavera Recycled-Water Pump Station TRENCHING ADVISORIES Prior to trenching /excavating, please contact DigAlert (USA Markout) at least 48 hours in advance at 1-800-227-2600. We will locate and mark-out our facilities. Failure to call may result in serious injuries and/or substantial damage for which you will be responsible. You, probably, will need an excavation permit from the City of Carlsbad prior to your excavation work. Additionally, you are responsible for obtaining any other necessary permits and for adhering to all applicable governmental and regulatory statutes, codes, and rules. Finally, before you begin trenching, I strongly suggest you contact the local telephone and cable television companies for their requirements and any charges they may have. CHECKLIST There are, of course, a few other things to be done before the meters actually can be set. I have prepared a checklist for your use. 0 Your work must be completed and accepted, and SDG&E's portion of the work must be completed. 0 Ensure that the address we have on record and your permit address match. 0 Whoever is going to be responsible for the billing needs to call our Customer Contact Center and make application. The Center is open 7-24 and the number is toll free: 1-800-411- SDGE(7343). 0 We must receive either permanent or temporary inspection clearances from the City of Carlsbad. 342295-01 0 3 May 21, 2004 COSTS All costs and offers quoted in this letter shall expire at the end of the business day on July 21, 2004. If business negotiations are not completed, or if you request revised costs after that date, an engineering fee may be required. Also, please understand that SDG&E is subject to California Public Utilities Commission decisions -any changes directed by the Commission can affect the quotes. The costs quoted in this letter include a cost component to cover SDG&E’s estimated liability for State and Federal Income Tax. Note: if you cancel your request, we will retain a portion of your payment to cover SDG&E’s expense for processing. The remaining amount, if any, will be refunded to you. Once all necessary easements are obtained, your service order will be issued THANK YOU We appreciate your business and hope you are very satisfied with our service. If I may be of further assistance or should you have any questions, please call me or my assistant at the number below. Our normal office hours are 7:OO a.m. to 4:OO p.m., Monday through Friday. Sincerely, ’L Maria Higgins Customer Project Planner Telephone: (760) 480-7647 Enclosures MEH:alr 342295-01 0 4 COST SUMMARY SHEET Rule 16 Electric Service a. Rule 16 b. Total electric service lateral cost May 21, 2004 !§ 0.00 $ 0.00 General Conditions for Underground Electric Distribution, Service Systems Construction and Gas Trench CONSTRUCTION RENCH INSPECTIONS PH: 7&9 - c- r& u3- M ARK-OUT 1-800-227-2600 NOTICE ALL WORK DONE PURSUANT TO THE AITACHED MUST BE ACCOMPLISHED IN COMPLIANCE WITH THE FEDERAL AND STATE OF CALIFORNIA OCCUPANTIONAL SAFETY AND HEALTH ACT. ONE COPY TO BE KEPT AT PROJECT SITE 11 11 .O SCOPE OF GENERAL CONDITIONS 12.0 3.0 1 1 .o 12.0 13.0 7.0 8.0 9.0 10.0 11 .o 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21 .o 22.0 23.0 24.0 25.0 26.0 DEFINITION OF TERMS CONTRACT DOCUMENTS INSPECTION OF WORK AND INTERPRETATION OF CONTRACT DOCUMENTS SDG&E’S RIGHT TO DO WORK SCHEDULING SURVEY AND EASEMENTS PAVEMENT REMOVAL AND REPLACEMENT EXCAVATIONS INSTALLATION OF CONDUIT BACKFILL AND COMPACTION SUBSTRUCTURES CABLE INSTALLATIONS (NEW) SAFEGUARDS CHANGES IN WORK PHASING FOR ENERGIZING DRAWINGS AND PRINTS RELATIONSHIP OF PARTIES FINAL ACCEPTANCE WARRANTY PERMITS AND LICENSES INDEMNITY PUBLIC RELATIONS UNION LABOR IF APPLICABLE RISK OF LOSS OR DAMAGE NOTICE OR DEMAND 1 .O SCOPE OF GENERAL CONDITIONS These General Conditions apply to new underground electric facilities and gas trench where the facilities being installed by an Applicant or by an applicant's contractor are for operations by SDG&E. 2.0 DEFINITION OF TERMS The following terms in these General Conditions shall be applied as follows: 2.1 "Agent" - Those persons authorized to act for or represent the Applicant or SDG&E. 2.2 "Applicant" - The party or parties contracting with SDG&E for underground facilities and to perform work described in these General Conditions. 2.3 "Contract Documents" - The Contracts, Agreements, Specifications, General Conditions, SDG&E Standards, drawings, permits and other papers for the purpose of construction or pertaining to construction of underground electric facilities and gas trench. 2.4 "Day or Days" - Normal SDG&E work days (Monday through Friday) unless otherwise specified. 2.5 "Excavation" - Trenching, boring, and removal of soil required for the installation of substructures, all necessary backfilling including required imported backfill material and removal of trench spoil, and acceptable surface repair to the local governing authority's specifications. 2.6 "Final Acceptance" . SDG&E's acceptance of all work performed by the Applicant includes "as-built" drawings and reconciliation of all material obtained for SDG&E. 2.7 "Final Grade" - The grade after paving and landscaping are completed. 2.8 "Finish Grade" - The grade shown on plans. 2.9 "Improvements"- The requirements of either the governing municipality or SDG&E which will ensure protection for SDG&E facilities and provide verification of finish grade. Improvements include, but are not limited to, curbs, sidewalks, berms, barricades, bridle or pedestrian paths, raised planters or parking lot berms in residential, commercial, manufacturing, or industrial projects, when these improvements are specified adjacent to SDG&E's facilities. 2.1 0 "Inspector" - The SDG&E employee assigned to inspect and accept or reject work on the basis of compliance or lack thereof with the Contract Documents, SDG&E standards, specifications and policies. 2.1 1 "Issued and Released" - When the specifications have been issued to the Construction Department and all related holds (monies, contracts, Right of Ways, etc.) have been removed. 2.12 "Landowner" - Public or private entity, or a natural person or persons, whose property is affected in any way by construction performed by Applicant. 2.1 3 "Project Coordinator" - The SDG&E employee assigned to coordinate projects through construction. The Project Coordinator will work with the SDG&E Inspector and Applicant to coordinate the scheduling of SDG&E crews. 2.14 2.1 5 2.16 2.17 2.18 2.1 9 "SDG&E" - San Diego' Gas & Electric Company (including its contractor subcontractors, employees, representatives or agents). "SDG&E Standards" - SDG&E Gas and Electric Construction Standards, including SDG&E's "Service Guide" (available upon request!. "Specifications" - The construction .drawings (including any revisions, supplements or SDG&E approved field changes) furnished to the Applicant detailing the work be performed. . "Substructures" - Includes, but are not limited to, manholes, handholes, vaults, pads (for transformers, terminators or fuse cabinets), grounding grids and other structures needed to accommodate cables, connections, transformer and appurtenances. "Vault Book" - SDG&E transformer vault specifications. . "Work" - The performing of all labor and the furnishing and installing of all material and equipment, necessary to accomplish all the duties and obligations imposed by the Contract Documents and Specifications. 3.0 CONTRACT DOCUMENTS 3.1 These Contract Documents are mutually binding on all and the Applicant must be thoroughly familiar with them. Technical trade terminology shall retain well-known meanings. All Applicant work responsibility and any work reasonably inferred necessary to produce the intended results, shall be supplied by the Applicant Specified dimensions (except as provided in section .15.0) shall govern. Work no specified shall be performed in the same manner as similar work specified. Specific details take precedence in the manner of construction. 4.0 INSPECTION OF WORK AND INTERPRETATION OF CONTRACT DOCUMENTS 4.1 4.2 4.3 4.4 All work and materials shall be of SDG&E approved manufacture class or grade specified in the Contract Documents. It shall be the Applicant's responsibility to thoroughly familiarize all of its Agents with the contents of the Contract Documents and to accurately advise SDG&E of its construction schedule. SDG&E will be represented in the field by an Inspector and all work and material shall be subject at all times to inspection by the Inspector. Applicant is required to call the number in Section 6.0 for inspection of his.work by 2:30 p.m. one workday prior to the date inspection is requested. The Inspector will inspect each completed stage of Applicant's work including: trenching, substructure installation, conduit installation, backfill, compaction, and cabling. As each stage is completed, the Inspector will approve it. If SDG&E crews are needed, they will be dispatched as available after the Inspector has verified that the Applicant has satisfactorily performed his portion of the work. Any workmanship or material supplied by the Applicant which does not meet the criteria specified in the Contract Documents may be rejected by the Inspector whose decisions shall be finaland conclusive. The decision of SDG&E shall be final as to all matters of interpretation of the Contract Documents. Any workmanship or material rejected by the Inspector shall be replaced by Applicant at Applicant's expense. Inspections and final acceptance shall not relieve the Applicant's obligation to complete the work in accordance with the Contract 5.0 SDG&E’S RIGHT TO WORK If the Applicant fails to perform the work in accordance with the standards, within the prescribed time period, or any obligation imposed by the contract documents, SDG&E, except as indicated below, after giving seven days’ written notice to the Applicant, may take over and finish the Applicant’s work c may correct any defects at the Applicant’s expense. If SDG&E is unable to collect reimbursement for its cost of work after 30 days from completion of the work, the actual cost may be deducted from Applicant’s refundable monies on deposit with SDG&E, or, at its option, SDG&E may-recover such cost by claim against the surety on the performance bond furnished by the Applicant. 6.0 SCHEDULING After receipt of written notification from SDG&E that construction orders have been released and issued, the Applicant shall immediately advise SDG&E of the construction schedule, arrange a pre construction meeting with the Project Coordinator and verbally confirm the start date two working day in advance of trenching. 6.1 6.2 6.3 6.4 All work by Applicant shall be coordinated with SDG&E in a manner that will permit SDG&E or its Agents to perform its work without delay and in an efficient manner throughout the period of construction without being required to reschedule it: construction forces after starting the field installation. The Applicant understands that trenching and backfilling must be coordinated with the installation of facilities such as gas piping and/or equipment by SDG&E. The Applicant shall contact the Project Coordinator to avoid SDG&E construction schedule delays. The Inspector will specify the amount of clear open trench for SDG&E work. Inspector and Construction Crew work will be performed during normal business hours. The Applicant shall continue trenching to allow the project to be completed in an efficient manner. Joint trench agreements with other underground utilities muS1 be approved by SDG&E before the start of construction and coordinated to avoid conflicts between construction forces. The Applicant should call Underground Service Alert (1 -800-422-41 33) for mark-ou1 two working days before trenching. The Applicant must locate all existing facilities before construction and protect them throughout the construction period. Gas and electric facilities will not be installed until all wet utilities have been installed and backfilled. Pressurized sprinklers and irrigation lines installed after SDG&E’s facilities must maintain the minimum clearances specified in SDG&E Standards. Applicant shall report to Project Coordinator any damage to any facilities resulting from the construction and shall file a complete written report with SDG&E of the surrounding circumstances within 24-hours of the incident or by the end of the next working day. 7.0 SURVEY AND EASEMENTS The Applicant shall be responsible for establishing and maintaining alignment and finish grade for SDG&E substructures and trenches throughout the construction of the project. SDG&E will survey, obtain easements and stake trench positions when easements dictate a definite route on private property, or in a dedicated street position. 8.0 PAVEMENT REMOVAL AND REPLACEMENT 8.1 Applicant agrees, that when trenching or excavating in paved streets or sidewalks, all cutting, removal and replacement of pavement or concrete shall be performed by methods which meet the requirements of all governmental authorities having jurisdiction. 8.2 Applicant agrees that any curtailment or rerouting of traffic necessitated t Applicant’s work within streets or sidewalk areas shall be coordinated with. governmental authorities having jurisdiction. 9.0 EXCAVATIONS 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 Excavations for substructures shall be made to such dimensions and grade lines a are necessary to perform the work shown by Specifications and to a depth that will provide the ground coverage between the top of the conduit entering the substructures and finish grade directed in the appropriate SOG&E Standards. Applicants shall verify in writing that all substructures are set to finish grade prior to backfilling The Applicant shall maintain finish grade stakes .for all four corners of a substructures until final backfill and compaction has been completed and accepted b Inspector. Should any adjustments to substructures be required due to variations in final grade not previously submitted to SDG&E, all costs for adjustments made b’ SDG&E shall be borne by the Applicant. Trenches shall be excavated in accordance with location and alignment shown on the Specifications and to provide minimum width and depth necessary to install the substructures, electric lines or gas pipe as specified in SDG&E Standards. Bottom of excavations and trenches shall be free of rocks, dirt clods and pockets and shall be graded with a base so that sags will not occur in any conduit or gas pipe placed therein as specified in SDG&E Standards. Any excavation made to an incorrect depth shall be adjusted to the correct depth and thoroughly compacted by Applicant in accordance with the compaction requirement- of the Contract Documents. Where excavations occur in soil, which is, in the opinion of the Inspector, unstable and unsuitable for adequately supporting the conduit, gas pipe or substructures, reinforcement shall be required and constructed to accommodate the individual case as determined by SDG&E. The Applicant shall not place excavated soil where it would pose a hazard to pedestrian or vehicular traffic or interfere with the installation of SDG&E facilities. The Applicant is responsible for the disposal of all excess soil. If SDG&E encounters hazardous or toxic material while performing construction on the project, SDG&E will halt work immediately, and it will be the Applicant’s responsibility to remove and or clean up a// hazardous toxic material. SDG&E will have no liability or obligation whatsoever to clean up, remove or remediate any hazardous or toxic materials discovered during the course of construction, unless the material were deposited through the negligence of SDG&E. The location of all excavation is subject to change as necessitated by conflicts, obstacles, or field conditions revealed by actual examination during construction and Applicant agrees to pay any additional trenching, excavation, backfill, compaction, pavement replacement or other costs required by such changes in location. When pad mount equipment is to be installed in a location which requires equipment barriers or retaining walls, Applicant shall install them in accordance with SDG&E 9.1 0 Retaining walls may be used as an acceptable alternative to establishment of proper grade. They shall be provided and installed at Applicant’s expense per SDG&E Standards. If retaining walls are required for any reason during the warranty period, they also shall be provided and installed at Applicant’s expense. 10.0 INSTALLATION OF CONDUIT THE FOLLOWING PROVISIONS APPLY TO APPLICANT’S INSTALLATION OF CONDUIT: 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.1 1 10.12 Conduits shall be installed in the trench in the alignment shown on the Specifications and all material used shall be those specified in SDG&E Standards. On approval of Inspector, ground cover may be reduced where the specified minimum ground cover cannot be obtained in crossing over storm drains, foreign substructures, or other obstacles. Extreme care shall be exercised to ensure that foreign matter does not enter the conduits during installation, or at any other time thereafter. When such responsibilities are shown on the Specifications, cable pole conduits shall be SDG&E approved and installed per SDG&E Standards unless otherwise instructed by the Inspector. Manufactured horizontal bends in the conduit shall be installed according to SDG&E Standards. Should field conditions warrant a lesser radius, the Applicant shall obtain SDG&E approval. All concrete, unless otherwise permitted by Inspector, shall be ready mixed and shall meet the requirements of SDG&E Standards. The installation of conduit by Applicant must be coordinated with SDG&E or its Agent to permit the installation of substructures and any conduit which may be installed by SDG&E. After the substructures are placed in position, the conduits shall be terminated in the substructure per SDG&E Standards. Service conduit stubs shall be extended and marked three feet beyond the substructure or retaining wall according to SDG&E Standards. Any trench or excavation of 5 feet or more in depth, which will be entered by SDG&E employees, requires spoil to be placed a minimum of 24 inches from edge of excavation. Depths of less than 5 feet, require a minimum clearance of 12 inches. Shoring or sloping may be required in depths less than 5 feet and is required for depths 5 feet or more (OSHA). Gas and electric facilities in conflict with other construction must be shown on plans provided by Applicant, and SDG&E must be notified prior to trenching. Street light circuits, CATV and telephone positions must be verified by the Applicant with each serving agency and installed to their specifications in addition to SDG&E Specifications. Each run between substructures, pads, customer‘s service, risers, etc., shall be one size conduit continuously, i.e., no reducers are allowed except where the conduit enters the substructure or above the ground level on a riser pole. Deviations must be approved by SDG&E. 10.13 All plastic conduit shall comply with SDG&E Standards, identified by manufacturer marking, and be verified that it is an approved conduit. Conduit found to be defectil or not on approved supplier's list shall not be acceptable. 10.1 4 Installation of electric conduits with concrete substructures must be coordinated with SDG&E. All conduits shall enter a substructure in a horizontal plane, using bono set of knockouts first, exception being a 3315,3316 and 3324 manhole in whit part of the job package are pages showing conduit placement to assure correct cab training and connections. Conduits shall be terminated in substructures per SDG& Standards. Open conduit ends shall be sealed during construction to prevent contamination inside conduit. Conduits must be watertight and mechanically sound at entry point. 10.15 Core boring can only be authorized by SDG&E to insure against structural damage. All work must be performed per SDG&E Standards. Conduits used with core boring must be grouted. 10.1 6 Mandreling of conduit must be performed by the installer in the presence of SDG&E Inspector. The conduit installer must provide a 311 6-inch polypropelene pullrope in each conduit. The rope shall be approved by SDG&E and have a minimum average tensile strength of 720 Ibs. Pullrope tails of 24 inches shall be secured at each en( of the conduit. 11 .O BACKFILL AND COMPACTION When Applicant's responsibility under the Contract Documents includes base, shading, backfill ant compaction, the following provisions apply: 11 .1 1 1.2 11.3 11.4 11.5 Backfill, base and shading shall be made with materials and by methods which will meet the requirements of all applicable codes, ordinances and SDG&E Standards. 11 must be approved by SDG&E Inspector. Compaction shall be performed in accordance with governmental agencies and shall have a minimum of 90% relative compaction. When gas piping is installed and not energized, shading will be done the same day, if practical, but not later than the following calendar day. Gas mains must be shaded and backfilled before they are energized. Gas services, when energized, must be covered during the same working day. During construction, new service lines must be made safe from normally anticipated hazards. Energized service lines left unattended must have a minimum of 12ft cover on private property and 18ft on public property. Completion of the backfill must be made in a timely manner. Shading between the different levels of jointly used trench must be compacted with reasonable care to prevent damage to the facilities installed and shall be compacted before proceeding with the next utility installation. Soil filled sacks or redwood timber breakers shall be installed across trenches as required by the Inspector in banks exceeding 25% slope. Water diversion berms shall be cut diagonally across trenches and working strips on banks exceeding 35% slope. The Inspector may require cement slurry backfill on slopes as specified in SDG&E Standards. 12.0 SUBSTRUCTURES 12.1 12.2 12.3 12.4 12.5 GENERAL Unless otherwise specified, all substructures, and related hardware including, but not limited to, frames, covers, barrier posts, ladders, ground rods, ground grids and cable supports shall be provided and installed by the party responsible for installing the substructures and shall comply with SDG&E Standards and SDG&E Vault Books. All of the substructures and related hardware used are to be approved by SDG&E. The above facilities, if applicable, will be installed at locations specified by the Specifications and in a manner prescribed by SDG&E Standards. PRIMARY MANHOLES AND VAULTS The location of conduit entrances or recesses and sumps shall be as shown in SDG&E Standards. Manhole or Vault entrances shall be installed as shown on the specifications. Neck extensions shall be ordered with the manhole or vault and shall be adjusted to permit installation of the cover at final grade. PRIMARY HANDHOLES When Applicant’s responsibility under the Contract Documents includes all or a portion of the substructures, Applicant shall adjust the top section and lid to final grade per SDG&E Standards. Conduits entering handholes shall be terminated in accordance with section 10.8. Where any substructures are to be installed by SDG&E or its contractors and Applicant is responsible for excavation, finish grade must be established to within 3 ft before substructure can be set. The top section and lid shall be adjusted to final grade by SDG&E or its contractor if less than a 3ft adjustment is required. The developer is responsible for maintaining the excavations for substructures for a period of five days. If SDG&E has not installed the substructures within the five-day period, SDG&E assumes responsibility for the excavation. TRANSFORMER AND EQUIPMENT PADS AND SECONDARY HANDHOLES Prior to the installation of these facilities, the Applicant must complete the improvements adjacent to these facilities including barrier posts. Proper compaction, and final grade must be established by Applicant and inspected by SDG&E for the transformer and equipment pads. Applicant must complete the required excavation for secondary handholes and site preparation for pads. Comdetion OF IMPROVEMENTS The Applicant must complete improvements (including proper compaction, final grade, excavation and site preparation) adjacent to pads and secondary handholes prior to scheduling SDG&E crews for installation and energizing of facilities. If improvements are to be installed in segments, a minimum of 10 feet of improvements fronting electric facilities is required. Any damaged substructure shall be replaced by the Applicant before the system is energized. 13.0 CABLE INSTALLATIONS THE FOLLOWING PROVISIONS APPLY TO APPLICANT’S INSTALLATION OF CABLE: 13.1 It shall be Contractor’s responsibility to protect the cable and other material furnished by SDG&E against damage. Cable pulling methods shall be subject to the approval of the Project Coordinator. If cable or associated materials are damaged due to Contractor‘s negligence or faulty equipment, Contractor shall replace damaged section in a manner satisfactory to SDG&E and at no additional cost to SDG&E. All sections of cable that are damaged by the application of grips shall be discarded. 13.2 All cable ends shall be sealed to effectively prevent moisture from entering the cable 13.3 HANDLING REELS InsDection Contractor shall inspect each reel upon receipt to determine whether 01 not visible damage has occurred during transit and/or storage. Loadina and Unloadina Reels shall be handled in such manner as to prevent smashing, nicking, cutting or other damage to the cable. When unloading reels from trucks, reels shall not be dropped to the ground or allowed to roll freely down ramps. Cranes or other equipment of adequate capacity shall be utilized, and care shall be taken to avoid damage to the cable or reels. Final InsDection After removing lagging or other protective covering from reels, Contractor shall examine outside layer of each reel to be sure that the cable is undamaged and that no nails, staples, or other sharp objects which would damage the cable during unreeling protrude on the inside of the reelheads. EmDtv Reels Contractor shall return all empty returnable reels prior to completion of the work as instructed by the Project Coordinator. Contractor shall dispose of all empty non-refundable reels. 13.4 SPLICES Unless otherwise directed, splices shall be made in accordance with SDG&E Standards. The Project Coordinator shall be present when all primary splices are performed, and shall reject those splices which do not comply with SDG&E Standards. Failure to notify the Project Coordinator is justification for rejection of the splices not performed in the Project Coordinator’s presence. The tools required for splicing the cable shall be furnished by Contractor and approved by SDG&E. 13.5 PROOF TESTING All primary installations shall be proof-tested prior to permanent connection to the distribution system. The Project Coordinator shall be present during all proof testing. Failure to notify the Project Coordinator is justification for rejection of the tests not performed in the Project Coordinators presence. The devices and methods utilized by Contractor for proof testing shall depend upon the circuit configuration and type of equipment. Testing methods shall be in accordance with approved SDG&E procedures. 14.0 SAFEGUARDS All material, work, traffic control and work areas shall comply with all applicable Federal, State, and local safety laws or rules that are necessary to protect Applicant’s and SDG&E’s employees, the public, and workmen during the time of construction. Applicant shall take all steps to protect property adjacent to the construction project from damage resulting from work specified and performed hereunder. 15.0 CHANGES IN WORK Modification of the Specifications may be made in writing by mutual agreement between the Applicant and SDG&E. Requests for changes shall be directed to Planner. Such ch2nges may cause delays in construction and require an engineering fee and revision to the Specifications, and costs resulting from work changes are the Applicant’s responsibility under section 20.0. Minor changes for adverse field conditions may be approved in writing at the job site by the Inspector to facilitate construction. 16.0 PHASING FOR ENERGIZING (Applies only when cabling is installed by SDG&E) When SDG&E and the Applicant agree before the completion of final Specifications, portions of the underground facilities may be phased for energizing before Final Acceptance provided the phasing does not delay completion of the entire project, SDG&E retains control of the energized portion, and the energized area is compatible with the system design and SDG&E’s safety practices. Energizing portions of systems shall in no way relieve the Applicant of any of its duties. 17.0 DRAWINGS AND PRINTS 17.1 Applicant shall at all times maintain a set of the current Specifications at the job site, and these will at all times be available for inspection by the Inspector who shall have access thereto on request. Applicant shall maintain at the job site any related project plans (e.g. alignment and finish grade of street improvements) approved by the governmental agencies having jurisdiction. 17.2 Prior to energizing, Applicant shall provide as-built drawings of facilities installed by the Applicant or his contractor per SDG&E Standards. 18.0 RELATIONSHIP OF PARTIES In assuming and performing the obligations of these Contract Documents, Applicant is acting as an independent contractor. Applicant shall assume full responsibility for the ownership, custody, and control of work and facilities to be constructed. All persons employed by Applicant in connection herewith shall be employees of Applicant. SDG&E’s inspections, or any suggestions or objections made by SDG&E shall not constitute or be construed as an exercise of management or supervision over the work, nor shall it be construed as acceptance of the work, or any part thereof, as it progresses, nor shall it limit or affect the right of SDG&E to reject any part or all of the work when completed in case the same does not conform to Contract Documents. 19.0 FINAL ACCEPTANCE Final acceptance by SDG&E will be made when Applicant has provided “as-built” drawings and satisfactorily completed all work and improvements as called for in the Contract Documents including reconciliation of materials. SDG&E shall notify Applicant in writing of final acceptance of the work. Failure or neglect on the part of SDG&E to reject inferior work during the construction period shall not be construed to imply acceptance of such work nor to preclude its right to reject it. Applicant shall be required to correct all defects which become evident at any time prior to final acceptance of Applicant’s work by SDG&E. The cost of all such repairs, material, labor, and overheads shall be borne by Applicant. Ownership, custody, and control of the work and facilities shall pass to SDG&E only upon Final Acceptance. ’ 20.0 WARRANTY The Applicant expressly represents and warrants that all work performed and all materials used are f from defects of workmanship and conform to the Applicant’s Contract obligations. This warranty shall commence upon Final Acceptance and end one year from that date. The Applicant shall pay the act cost to SDG&E for any breach of this warranty corrected by SDG&E (including labor, material c overheads). If SDG&E is unable to collect for the work after 30 days from completion, the actual CI may be deducted from the Applicant’s refundable monies on deposit with SDG&E. SDG&E may recover such cost by claim against the surety on the performance bond furnished by the Applicant 21 .O PERMITS AND LICENSES The Applicant shall obtain and pay for all permits and licenses required by governing agencies before starting any work. In the event any governmental agency imposes conditions which necessitate a1 changes in the trench or conduit system shown on the Specifications, the Applicant agrees not proceed with any work affected by the conditions until SDG&E has completed the necessary redesign of construction drawings and new agreement documents have been signed by SDG&E and t Applicant. New agreements shall be the standard agreements in effect at the time the changes a made. 22.0 INDEMNITY Applicant will indemnify, defend, hold SDG&E its employees and agents harmless from any and c claims, demands, loss, liability or expense (including attorneys’ fees) for injury to or death of any person,. or damage to or destruction of any property, in any way resulting from or connected with the performance of the work by Applicant’s Contractor, its agents, employees, or subcontractors regardless of the negligence of SDG&E except in those cases where SDG&E has been solely negligent or SDG&E’s willful misconduct caused the damage or injury. For purposes of this indemnification, SDG&E’s inspections, objections or comments shall NQI be construed as an exercise of management or supervision. 23.0 PUBLIC RELATIONS The Applicant shall maintain a good public image. Excess soil, litter and debris around the work are shall be removed during construction. Due precaution shall be observed to avoid damage to lawns trees, shrubs, flowers, fences and other property. All landowners and tenants shall be notified in advance when work interferes with their use of walks, driveways, roadways or entrances. An’ disagreements, problems or adverse criticism in connection with the work from area landowners tenants, the general public or public officials shall be reported promptly to the Project Coordinator. 24.0 UNION LABOR IF APPLICABLE If for any reason, any work is performed by Applicant upon facilities that are at the time of work b) Applicant, owned and maintained by SDG&E, Applicant agrees that such work shall be done in compliance with the terms and conditions of that amended Agreement between SDG&E and Local Union 465, International Brotherhood of Electrical Workers, or such other agreements as may be entered into between the Applicants’ Contractor and bona fide unions of international organization- affiliated with the American Federation of labor and Congress of Industrial Organizations or other bono fide labor organizations. 25.0 RISK OF LOSS OR DAMAGE The Applicant must take proper care to protect, and avoid any loss or damage to, material and/or equipment furnished by the Applicant or by SDG&E until Final Acceptance. Any damage, injury or loss shall be repaired, corrected or replaced by the Applicant at his sole expense. If the Applicant fails to Applicant, or SDG&E may, at its option, recover such cost by claim against the surety on the performances bond furnished by Applicant. 26:O NOTICE OR DEMAND Any notices or demand which mayor must be given by either party to the other hereunder unless otherwise specified shall be made in writing and shall be deemed to have been duly given when delivered by personal service, or 24-hours after it is deposited for mailing at San Diego, California, by certified United States mail, postage prepaid, addressed as follows, or to such other place as the parties may hereafter in writing direct: TO UTILITY: TO APPLICANT: San Diego Gas & Electric Company P.O. Box 1831 San Diego, CA 921 12 4150 Address Attention: Attention: I Nl :E 14 I I I I I I I I I I I I4 ;5 :a: I2 I? 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I E &E EEI 0 00 001 N NN "I I I I I I I I I I I I I I I I I XI E-11 WI dl €- a V WO rnm bZ 3 2 Om VQ 2: HH nm ril I rnl x NI -+ ~ PI ..IO I I I fl! I I I I I I I I I I I I I I I 1 I I I I I I I I I I I I I I I , I I I I I I I I I I I I I I I I I I I I I I I I I I I 0: I om I mm I rlrl I T? I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I w b m SI SI m 4n ow Q FIX GI0 WU xw mn: SCOPE: THIS STANDARD SHOWS THE CONDUIT AND FITTINGS USED TO CONSTRUCT UNDERGROUND CONDUIT SYSTEMS. NOTES: CONDUIT AND FllllNGS IN THIS STANDARD SHALL BE USED IN BELOW-GROUND OR BRIDGE CELL APPL~CAT~ONS. - (PVC) POLWINYLCHLORIDE CONDUIT - - PVC CONDUIT SHALL BE GRAY OR BUCK IN COLOR. NO OTHER COLOR IS ACCEPTABLE ON THE COMPANY - FOR SCHEDULE 40 AND SCHEDULE 80 ABOVE-GROUND COMPONENTS TO CONSTRUCT CABLE POLE RISERS, SEE - ALL 5" CONDUIT MUST BE ENCASED WITH CONCRCrrE SLURRY. CONDUIT SYSTEM. UNDERGROUND STANDARD 4204. (1-SACK MIX), - DB CONDUIT IS REQUIRED FOR INSTALLATIONS REQUIRING DIRECT BURIED MATERIAL, i.e. SAND, DECOMPOSED LENGTH 'L' CONDUIT SIZE TYPE GRANITE (DG), NATIVE, nc. - FOR DIRECT BURIED INSTALLATIONS, DB 60 IS REQUIRED FOR 2". 3" & 5" CONDUIT. DB 100 IS STOCK ASSEMBLY UNITS NUMBER 1-SACK ENCASE W/SPACERS I PRIMARY 1 SEC/SERV REQUIRED FOR 4" CONDUIT. - ALL COUPLINGS, BENDS AND SWEEPS CLASSIFIED AS DB ARE TO BE USED WITH DE AND EB CONDUIT. - DE = DIRECT BURIED CONDUIT. - EB = ENCASED BURIED CONDUIT. - THE SHELF LIFE FOR DB CONDUIT, BENDS, AND END OR SPIGOT CONDUIT STRAIGHT SECTIONS CO~ PL~NG FIllINGS EXPOSED TO SUNLIGHT IS 6 MONTHS flRST LOCATION SHALL BE INSTALLED IN 2" CONDUIT. MAXIMUM. 2-#8 FROM A RISER POLE TO THE ** - SCHEDULE 40 CONDUIT IS REQUIRED IN BRIDGE CELLS. sL' -1 2" 3" 4" 5" DB 60 20' 249632 1 EB21N 1 DB2-P 1 DB2-S DB 60 20' 249664 1 EB31N 1 DB3-P 1 DB3-S DB 100 20' 2497 10 1 EB41N 1084-P 1 DB4-S DB 60 20' 249728 1, 2DB5SL - 1085-5 ** SCH40 10' 25 1 408 - S40-5" S40-5" TYPE 1" SDR 9 2" SCH 40 SCH 40 3" CONDUIT SIZE COIL LENGTH STOCK NUMBER ASSEMBLY UNIT 2000' 249630 1" PE 252002 - 2500' 1000' 252004 - 4" I SDR 15.5 I 500' NOTES: POLYETHYLENE CONDUIT SHALL BE BLACK OR BLACK WITH THREE EQUALLY SPACED RED STRIPS. NO OTHER COLOR IS ACCEPTABLE ON THE COMPANY CONDUIT SYSTEM. CORRUGATED POLYnHYLENE CONDUIT IS NOT ACCEPTABLE ON THE COMPANY CONDUIT SYSTEM. - 252006 CONDUIT COUPLINGS REVISION FIGURES A & B NUMBER 279904 DB MOLDING COUPLING (BOTH WITH 279936 280032 DB SWEDGE COUPLING FIGURE A FIGURE B SDGBE ELECTRIC STANDARDS REFERENCE: SEE STANDARD 3383 FOR SPLICING OR REPAIRING 1 " POLYETHYLENE CONDUIT. NOTES: *** S/N 200304 SCH 40 PVC MAY BE USED AS A REPLACEMENT ON A TEMPORARY BASIS. (DEPENDS ON SUPPLIER OF COUPLING). FIGURE C DB STRAIGHT COUPLING (WITHOUT CENTER STOPS, TO BE USED ONLY WHEN REPAIRING EXISTING CONDUIT SYSTEMS) FIGURE C NUMBER 279920 4" 279952 280064 CONDUIT PLUG CONDUIT BELL REDUCER CONDUIT END CAP CONDUIT STOCK ASSEMBLY CCN" SIZE STOCK ASSEMBLY CONDUIT STOCK ASSEMBLY SIZE NUMBER UNITS X TO Z NUMBER UNITS SIZE NUMBER UNITS 2" 203296 RED3-2 573380 RED4-3 3" 203328 RED4-3 ' 4" 544704 PLUG-4 573384 REDS-4 4" 203360 RED5-4 5" 544736 PLUG-5 5" 203392 RED6-5 2" 544768 PLUG-2 3" - 2 I' 573376 RED3-2 544800 PLUG-3 4"-3" 5 ** - 4 " 3" PULL ROPE TAB FOR SECURING X +I --- TAB FOR SECURING ----- i PULL ROPE c* 22- 1/2O 49 90" 5" 11 I I 1 I I 5 25'4" DE 60 32 1856 1 €85-S 1 DBSPS 1 DESSs 36" DB 60 32 1960 1 EB5-8 1 DES-8 1 DB5S8 36" DE 60 322 1 12 1 EB5-B 1 DB5-8 1 DE5SB SERVICE GUIDE I CONDUIT BENDS (EXAMPLES) I Cornpleteiy Revised New Poge Information Removed lndicotes Latest Revision kr4 TANGENT STRAIGHT 3373.2 BlLL OF MATERIAL: REVISION SDG&E ELECTRIC STANDARDS CONDUIT AND CONDUIT FITTINGS DATE 1-1-96 22-1/Z0 SWEEP/25' RADIUS 22- 1 /2O 25'-0' 45O 24"(SECONDARY ONLY) I 2" 4 so 136" goo I 24"(SECONDARY ONLY) goo 136" 22-1/Z0 25'-0" 3" 4S0 36" I 90" 136" I 90" 36" I 11-1/4' 25'-0" I-- GM GS P S ES ME SL L U PROPERTY SlOE .1 GASMAlN GAS SERVlCE PRIMARY ELECTRIC SECONDARY ELECTRIC ELECTRIC SERVICE MULTIPLE ELECTRIC CONFIGURATION INCLUDING SPACERS AND I-SACK CONCRETE SLURRY) SDGdrE STREET UGHT FOREIGN UTILITY STREET LIGHT FOREIGN UTILITY (P OR S OR ES OR T, STACKED 1" T &PROPERTY SIDE (TELCO. CATV) . SDGdcE ' TELECOMMUNICATIONS PROpERlY SIDE Informotion Removed GG STO. 7405.1 - - -1" 1 SERVICE GUIDE 3370.1 SERVICE TRENCH PUBLIC PROPERTY FIG 7 ON FIG a ON ' SERVICE TRENCH PRIVATE PROPERTY '..':.:I lndiccles Lotesl Revision I 1 Cornplelely Revised New Poge R EVlS I ON I. SDG&E ELECTRIC STANDARDS UNDERGROUND DISTRIBUTION (UD) TRENCHES DATE 1-1-98 AND UTILITY POSITIONING - S.D. COUNTY - NOTES: - .DRAWINGS ARE NOT TO SCALE. PROPERV SIDE - 12" TE:JL u 9" 12' . . .. _. -j- 1 -1 '1 ~..- ..:..:. .. LS, SL. L ' or T - - THE FOLLOWING CHARTS SHOW THE MINIMUM CGVER FOR EACH UTILITY. THE MINIMUM SEPARATION BETWEEN SPACE ALLOTMENTS AND THE MAXIMUM SIZE FOR EACH SPACE ALLOTMENT. TO READ THE CHARTS, READ ACROSS AND DOWN UNTIL THE TWO JOIN IN A SGIJPRE. AND THAT IS THE DISTANCE REQUIRED BETWEEN THE TWO UTILITIES. II I VERTICAL 11 HORIZONTAL I EXAMPLE ES ES GS 1 I ELECTRiC SERVICE - @ 12" UNDER VERTICAL, "ES" & "ES" JOIN AT @WHICH REFERS TO INSTALLATION NOTE 0. UNDER HORIZONTAL, "ES" h "GS" JOIN AT 12 INCHES WHICH WOULD BE THE DISTANCE REQUIRED FROM THE OUTER EDGE OF THE ELECTRIC SERVICE (SPACE ALLOTMENT) TO THE OUTER EDGE OF GAS SERVICE (SPACE ALLOTMENT). U 7 MAIN TRENCH, EERVICE TRENCH PUBLIC PROPER^ (MINIMUM SEPARATION FROM) - - 12" I VERTICA 12" - STREET LIGHT I (TELCO. CATV) ' SDG&E TELECOMMUNICATIONS L 12" . 4' HORIZONTAL ti5 L3 Mt U L I COVER 1 ALLOTMENT (MAX) - 12" - 12" 12" I __" ... 1 'MIN. I FACILITY SPACE I ESI sLI MEI 1 I COVER ALLOTMENT (MAX> 12-1 I 12"1 12" I I I I g;" tFX 2-1/2" x 2-1/2" 24" 5-1/2" x 5-1/2" @ @ @ @ 12" 12" 30" 5-1/2-x5-1/2' @ @ @ @ 12" 12" 30" 5-/2"x5-1/2" 24" 18' x 14' @@@@- (4 DUCTS) 12" 12" 12" - 24" 2-1/2'~2-1/2' 12" 12" 12" 12" 9" x 24" @ @ @ 0 12' 12" 30" 4-1/2'~4-1/2' - 30" l"or less - 12" - 24" WILL VARY DUE TO BOARD AMPACITY * ALL MINIMUM COVER DEPTHS MEASURED FROM FINAL GRADE. DEPTHS THAN WHAT IS SHOWN UNDER "MINIMUM COVER". REDUCED DEPTHS IN NOTE @ ARE LESSER , - I - I NOT ALLOWED SERVICE TRENCH PRIVATE PROPERTY (MINIMUM SEPARATION FROM) VE RTlCAL HORIZONTAL ^^ -- ..r .. . I WIN. 1 FACILITY SPACE FOREIGN UTlLlM 00000 UVFHJ - 12" 6" - 12" 12" 12" - - 12" 18" 9" x 9" FOREIGN UTILITY oooo 12" 12" 12" 12" - 12" 12" - 2" 1" or 8" 2-1/2" x 2-1/2" TELCO, CATV STREET LIGHT less I GS I ES .. . ;. CAS STD 7403.2 ;..:.:. Indicates Latest Revision I :S 1 ELECTRIC SERVICE 11 2"l @ lnformotion Removed SEWE Gum Completely Revised New Page AE MULTIPLE ELECTRIC -112-*1 @ R EVl SlON ME 12" - SDG&E ELECTRIC STANDARDS I )ATE 1-1-96 I UNDERGROUND DISTRIBUTION (UD) TRENCHES I 3370.2 @/qI AND UTILITY POSITIONING -. SiD. COUNTY INSTAWTION: I A. AN EFFORT SHOULD BE MADE TO KEEP THE TRENCH DEPTH LESS THAN 60 INCHES. IF A PERSON IS REQUIRED TO ENTER A TRENCH 60 INCHES OR DEEPER, IT SHALL BE SHORED, BENCHED, OR SLOPED TO PREVENT MOVEMENT OF EARTH THAT MAY ENDANGER LIFE OR PROPERTY. THE TRENCH CONFIGURATION, UTILITY POSITIONING AND ALL OTHER RELATED CONSTRUCTION MUST CONFORM TO THIS STANDARD AND THE STATE OF CALIFORNIA PUBLIC UTILITIES COMMISSION GENERAL ORDERS 7 28 AND 1 120. AND ANY OTHER APPROPRIATE GOVERNMENTAL AGENCY HAVING JURISDICTION OVER CONSTRUCTION. UNDERGROUND DISTRIBUTION (UD) TRENCHES DATE 3-1-02 AND UTILITY POSITIONING - S.D. COUNTY APPDrn/,@, NOTE: BENCHING THE TRENCH IS FOR SAFETY REASONS ONLY AND NOT TO BE USED FOR INSTALLATION PURPOSES WHERE THE TRENCH DEPTH CANNOT BE MET, G.O. 128 REQUIRES ONE OF THE FOLLOWING: (1) STEEL, OR (2) SCHEDULE 40 PVC OR SCHEDULE 80 PVC CONDUIT WITH A MINIMUM WALL THICKNESS OF 0.15 INCHES, OF? (3) A 3 B THE TRENCH DEPTH IN THIS STANDARD SHALL BE FOLLOWED FOR ALL NORMAL INSTALLATIONS. IN INSTALLATIONS REDUCED -._--.-.--.- --- c my CONDUIT COMBINATION SMALLER THAN 5 INCH, (NOT MULTIPLE ELECTRIC-ME OR SERVICE CONDUITS) ARE PERMITTED WITHOUT SEPARATION WHEN INSTALLED IN A HORIZONTAL CONFIGURATION. SOCLE TELECOMMUNICATIONS SPACE ALLOTMENT IS PERMITTED NEXT TO THE ELECTRIC SPACE ALLOTMENTS WITHOUT SEPARATION. (6 INCH MINIMUM TRENCH WIDTH, 24 INCH MAXIMUM TRENCH WIDTH) (SEE STANDARD 3376 FOR CONDUIT/TRENCH CONFIGURATION). @ BASE AND SHADING MATERIAL FOR GAS TRENCH ONLY IMPORTED MATERIAL CONSISTING OF NATURAL SAND OR MANUFACTURED SAND, EXISTING NATIVE MATERIAL. OR AND SHADING MATERIAL PROVIDED IT COMPLIES WITH GAS STANDARD COMPLY WITH COMPACTION REOUIREMENTS OF GOVERNMENTAL THAT THE MATERIAL MUST HAVE A MIXTURE OF PARTICLE SIZES G NATM MATERIAL AND IMPORTED MATERIAL PROVIDED BY A DEVELOPER INDEPENDENT PROFESSIONAL TESTING FIRM IF. IN THE OPINION OF THE SHADING MATERIAL FOR ELECTRIC TRENCH ONLY ELECTRIC SHADING MATERIAL (ESM) SPECIFICATION. ACCEPTABLE MATERIAL FOR (DE) DIRECT BURIED CONDUITS. NATURAL SAND, MANUFACTURED SAND, DECOMPOSE0 GRANITE, ROCK FREE SANDY LOAM, EXISTING NATIVE MATERIAL OR COMBINATION THEREOF. AGGREGATE COMPOSITION SHALL BE CAPABLE OF PASSING THROUGH A 1/2 INCH SIM. GRAVELS SHALL NOT AMOUNT TO MORE THAN 50% OF THE MIXTURE. SCREENING OR OTHER . L GAS STD. SERvlCE GUIDE ':XI lndicotes Lolcst Revision I I Completely Revised New Page In formotion Removed ~~~0~.~ SDG&E ELECTRIC STANDARDS RDJlSlON SLJ~TABLE MEANS MAY BE-REOUIRED AT THE DISCRETION OF THE SDG~E INSPECTOR TO MEET THIS (ESM) SHADING MATERIAL SPECIFICATION. NOT ACCEPTABLE ARE SOILS OF HIGHLY ORGANIC CONTENT IDENTIFIED BY ODOR OR SPONGY FEEL AND HIGHLY PLASTIC (SOGGY) CLAYS, SILTS OR METALLIC SLAG. BACKFILL MATERIAL FOR CAS AND/OR ELECTRIC: THE MATERIAL USED FOR BACKFILLING THE TRENCH ABOVE THE SHADING MATERIAL AND EXTENDING UPWARD TO I THE SUBGRADE SHALL BE FREE OF ROCKS OR CLODS LARGER THAN 6 INCHES IN ANY DIMENSION. THE COARSE MATERIAL SHALL BE WELL DISTRIBUTED THROUGHOUT THE FINER MATERIAL. THE AMOUNT OF ROCKS OR CLODS SHALL BE LIMITED, IN THE OPINION OF THE INSPECTOR, TO ALLOW FOR BAR TESTING FOR GAS LEAKS. THE BACKFILL MATERIAL SHALL MEET THE REQUIREMENTS OF ALL APPLICABLE CODES, ORDINANCES AND SDGdtE STANDARDS AND BE FREE OF DEBRIS AND ORGANIC MATTER. ~~ MATERIAL. MEET THE REOUIREMENTS OF GOVERNMENTAL AGENCIES AND SDGLE STANDARDS. 1 -SACK CONCRETE SLURRY MIX IS PREFERRED FOR BACKFILL.nRY INSTALLATION SHALL MEET BASE INSTALLATION FOR GAS: FOR GAS, 3 INCHES OF BASE MATERIAL IS REWIRED ON THE BOTOM OF THE TRENCH TO PREVENT DAMAGE FROM ROCKS. SAGS, OR POCKETS. EARTH TRENCH BOTTOM INSTALLATION FOR ELECTRIC: (EB h DE CONDUIT) THE 1 INCH EARTH TRENCH BOTTOM SHALL BE STABLE WITH A UNIFORM GRADE CONTAINING NO HARD CLODS, ROCKS, ETC. THAT MAY DAMAGE THE CONDUIT. IF, IN THE OPINION OF THE SDGhE INSPECTOR, THE CONDUIT MAY BE DAMAGED, TAMPING, WETTING OR A 3 INCH EASE ELECTRIC SHADING MATERIAL (ESM) MAY BE REOUIRED. COMPACTED SHADING MATERIAL 4 INCHESPFTER COMPACTION) SHALL BE ELECTRIC CONDUIT. A MlNlMU b 12 INCHES OF COMPACTED SHADING MATERIAL WILL BE REOUIRED IF. IN THE OPINION OF THE INSPECTOR, THERE IS AN EXCESSIVE AMOUNT OF ROCK AND CLODS IN THE BACKFILL. THE SHADING MATERIAL MUST BE INSTALLED AND COMPACTED AT EACH LEVEL BEFORE INSTALLING THE NEXT UTILITY. THE SHADING MATERIAL MUST BE INSTALLED BEFORE THE TRENCH IS BACKFILLED TO PREVENT DAMAGE FROM ROCKS, CLODS, ETC. GAS PIPE SHALL NEVER BE CONCRETE OR SLURRY ENCASED, AND SHALL HAVE THE PROPER BASE, SHADING, BACKFILL. AND COMPACTION. I 3370-3 I COMPACTION: EXTREME CAPE SHALL BE TAKEN TO ENSURE THAT SHADING MATERIAL IS ADEQUATELY COMPACTED BOTH UNDERNEATH AN0 AROUND GAS PIPE AND FITTINGS TO PREVENT EXCESSIVE STRESS AND SHEARING FORCES. HAND TEMP AROUND FITTINGS WHERE MECHANICAL COMPACTION CANNOT BE USED. COMPACTING WITH A HYDRAHAMMER OR SIMILAR EQUIPMENT SHALL NOT BE ALLOWED ON TRENCHES WHERE POLYETHYLENE PlPE HAS BEEN INSTALLED. WHEN THE SHEEP'S FOOT METHOD OF COMPACTION IS USED. A MINIMUM OF 18" OF COVER IS REQUIRED BEFORE COMPACTING. WHEEL ROLLING WITH A HEAW VEHICLE. COMBINED WITH ADEQUATE MECHAMCblC.OMPACTION. IF NEEDED. IS ALLOWED FOR COMPACTING BACKFILL MATERIAL PROVIDED A MINIMUM OF$FTNC%-iz.$OF MECHANICALLY COMPACTED SHADE MATERIAL AND A MINIMUM Of 12" Of BACKFILL MATERIAL EXG=ETm=HE GAS PIPE OR ELECTRICAL CONDUIT. WHEN FLOODING Of THE TRENCH IS DONE TO CONSOLIDATE BACKFILL, CARE MUST BE TAKEN TO ENSURE THAT GAS PlPE OR ELECTRIC CONDUIT HAS NOT FLOATED FROM ITS POSITION IN THE TRENCH. COMPACTION BY THE WATER JETTING METHOD IS NOT ALLOWED. ALLOWED. SHADING AND BACKFILL SHALL BE COMPACTED IN ACCORDANCE WITH GOVERNMENTAL AGENCIES AND SHALL HAVE A MINIMUM OF 90 PERCENT RELATIVE COMPACTION. ALL BASE, SHADING, AND BACKFILL MATERIAL MUST BE APPROVED BY AN SDG&E INSPECTOR. @ ONE OR MORE 5 INCH PRIMARY CONDUITS SHALL BE SLURRY ENCASED. @ FOREIGN UTILITIES MUST NOT BE LOCATED UNDER ANY SDG&E FACILITIES, SUCH AS HANDHOLES, TRANSFORMER PADS, ETC. GAS . SINGLE GAS - SERVICE 1 INCH AND LESS 6 INCHES SINGLE GAS 2 INCH 9 INCHES SINGLE GAS 3 AND 4 INCHES 12 INCHES SINGLE GAS 6 AND 8 INCHES 18 INCHES r SINGLE ELECT. 2 INCH CONDUIT 6 INCHES SINGLE ELECTRIC & FOREIGN UTILITIES (EXCLUDING GAS) 2 INCH CONDUIT 6 INCHES ELECT. ELECTRIC ALL SIZES 9 INCHES UTILITIES (EXCLUDING GAS) LARGER THAN 2 INCH 12 INCHES JOINT UTILITIES ALL PERMITTED SIZES 12 INCHES MULTIPLE ELECTRIC SPACERS AND 1 -SACK CONCRETE SLURRY 9 INCHES ~~~~~~ ' SINGLE ELECTRIC & FOREIGN FOR A GAS OR ELECTRIC SERVICE. IF ANY OBSTRUCTION IS ENCOUNTERED (WATER PIPES, ETC.), A 2 FOOT WIDE X 3 FOOT LONG HOLE MAY BE REOUIRED FOR WORKING ROOM IN THE AREA OF THE OBSTRUCTION. THIS IS TO BE DETERMINED BY AN SDG&E INSPECTOR. H THE FOREIGN UTILITY (U) SPACE ALLOTMENT MUST BE A MINIMUM OF 6 INCHES BELOW THE GAS MAIN AND 12 INCH RADIAL SEPARATION FROM ALL OTHER UTILITIES MUST BE MAINTAINED (SEE FIGURES 1 AND 5). IF (U) SPACE ALLOTMENT EXCEEDS A 9 INCH HORIZONTAL MEASUREMENT, IT MUST BE PLACED ,DIRECTLY ABOVE THE ELECTRIC SPACE ALLOTMENTS AND SHALL NOT EXTEND PAST THE OUTER SIDES OF ELECTRIC SPACE ALLOTMENTS. 3. & 4. ELECTRIC (SEE FIGURE 6). DE CONDUIT MAY ALSO BE SLURRY ENCASED IF INCLUDED IN THE MULTIPLE ELECTRIC PACKAGE. IN A SERVICE TRENCH. ALL EB CONDUIT SHALL BE ENCASED WITH CEMENT SLURRY (1 SACK). DB CONDUIT MAY ALSO BE CONCRETE OR SLURRY ENCASED IF INCLUDED IN THE MULTIPLE ELECTRIC PACKAGE. (FOR INSTALLATION PURPOSES, BENCHING THE TRENCH IS NOT ALLOWED), SEE FIGURES 2. IF (U) SPACE ALLOTMENT IS 9" X 9" OR SMALLER, IT IS ALLOWED AT THE SAME LEVEL AS THE 1 ALL EB CONDUIT, REGARDLESS OF THE SIZE, SHALL BE CONCRETE ENCASED WITH 1-SACK CEMENT SLURRY. GAS STD. 7403.4 REV1 SI ON DATE 1 - 1-2000 'X'I Indicates Latest Revision I I Completely Revised New Poge Information Removed SERvlCE GUlOE SDG&E ELECTRfC STANDARDS UNDERGROUND DISTRIBUTION (UD) TRENCHES 3370.4 AND UTILITY POSITIONING - S.D. COUNN @ MINIMUM SEPARATION MAIN TRENCH UTILITY HORIZONTAL SEPARATION TELCO MULTIPLE CONCRETE DUCT (CONDEX), TRANSITE, WATER, NOT PERMITTED IN JOINT TRENCH SEWER, FUEL. OIL. DIESEL, PROPANE GAS, SPRINKLER, DRAIN, WITH GAS AND/OR ELECTRIC LEACH LINES, STEEL GAS MAIN LARGER THAN 2'. PRIVATELY OWNED UTILITIES ;.e. PRIVATE TELCO. VIDEO, AUDIO, SECURITY WIRES, FIRE ALARM. STREET LIGHTING, ETC.. ~ FUEL OIL. GASOLINE, DIESEL WATER, SEWER, EXISTING GAS OR ELECTRIC, STORM DRAINS, 5 FEET WITH 3 FEET OF STEAM, IRRIGATION PIPE, SPRINKLER PIPE LARGER THAN 4", UNDISTURBED SOIL PRIVATE TELCO TRANSITE, PROPANE GAS SERVICE GUIDE SEWAGE LEACH LINES OR SEEPAGE PITS IRRIGATION, SPRINKLER PIPE 4" AND LESS Indicates Latest Revision Completely Revised New Poge I I Informotion Removed I E3yD. REVISION SDG&E ELECTRIC STANDARDS 5 FEET FROM MAIN TRENCH FOR EACH 1' DEPTH OF MAIN TRENCH 3 FEET PROVIDED DEPTH OF PIPE DOES *NOT EXCEED DEPTH OF GAS OR ELECTRIC FROM GAS-15 FEET, FROM ELECT.-5 FEET WITH 3 FEET OF UNDISTURBED SOIL IN CONSIDERATION FOR THE SAFETY OF THE GENERAL PUBLIC, PERSONS ENGAGED IN CONSTRUCTION. PROPERTY, AND FOR THE OPERATION AND MAINTENANCE OF SDGLE SYSTEM, PROPANE GAS LINES ARE NOT PERMITTED IN A JOINT TRENCH WITH SDGdtE FACILITIES. IF FIELD CONDITIONS WILL NOT PERMIT ANY OF THESE SEPARATIONS. THEN APPROVAL OF REDUCED SEPARATIONS MUST COME FROM BOTH THE CUSTOMER PROJECT PLANNER AND SDG&E INSPECTOR. ON FIELD CONDITIONS THAT WILL NOT PERMIT STANDARD PARALLEL SEPARATIONS, A 12 INCH MINIMUM SEPARATION IS REQUIRED. PROPANE GAS SHALL ALWAYS HAVE A 5 FOOT SEPARATION. UTILITY ALL WET UTILITIES, TELCO, W. GAS, ELECT. FUEL OIL, GASOLINE, DIESEL VERTICAL (CROSSING) SEPARATION MIN. 6 INCHES FROM GAS, 12 INCHES FROM ELECT. 6 INCHES ARC-WELDABLE PIPELINES 3" AND LARGER 18 INCHES STEAM (SEE NOTE) FROM GAS, POLY PIPE 5 FEET FROM ELECT., 5 FEET I NOTE: PLACE INSULATING BARRIER BETWEEN STEAM MAIN AND POLYETHYLENE PIPE AND/OR ELECTRIC. MINIMUM SEPARATION SERVICE TRENCH IN A SERVICE TRENCH, WATER, SEWER, PROPANE GAS. SPRINKLER, DRAIN, LEACH LINES, PRIVATELY OWNED UTILITIES i.e.. PRIVATE TELCO. VIDEO, AUDIO, SECURITY WIRES, FIRE ALARM, STREET LIGHTING, ETC., ARE NOT PERMITTED IN THE SAME TRENCH WITH GAS OR ELECTRIC. WHEN THESE FACILITIES PARALLEL GAS OR ELECTRIC. 12 INCHES SEPARATION BETWEEN SEPARATE TRENCHES SHALL BE MAINTAINED BETWEEN THE UTILITIES WITH AT LEAST 12 INCHES OF UNDISTURBED NATIVE SOIL BETWEEN TRENCHES. PROPANE GAS SHALL ALWAYS HAVE A 5 FOOT SEPARATION. WHEN CROSSING, A 6 INCH VERTICAL SEPARATION IS REOUIRED. (EXCEPTION) WHEN THERE IS NO SDG&E GAS IN THE SERVICE TRENCH, A SINGLE NATURAL GAS LINE MAY BE INSTALLED IN THE TRENCH, PROVIDED A 12 INCH RADIAL SEPARATION IS MAINTAINED. (THIS IS FOR AN INDlVlDUAL HOUSE ON A CASE BY CASE BASIS. NOT A GROUP OF HOUSES/BUILDINGS). FUEL OIL. GASOLINE, AND DIESEL LINES MUST MAINTAIN A 15 FOOT SEPARATION FROM GAS PIPELINES AND A FIVE FOOT SEPARATION WITH THREE FEET OF UNDISTURBED SOIL SEPARATION FROM ELECTRIC CONDUITS. IF FIELD CONDITIONS WILL NOT PERMIT THESE SEPARATIONS, THEN APPROVAL OF REDUCED SEPARATIONS MUST COME FROM BOTH THE CUSTOMER PROJECT PLANNER AND SDGCkE INSPECTOR. WHEN FIELD CONDITIONS WILL NOT PERMIT STANDARD PARALLEL SEPARATIONS. A 12 INCH MINIMUM SEPARATION IS REQUIRED. PROPANE GAS SHALL ALWAYS HAVE A 5 FOOT SEPARATION. 3370.5 UNDERGROUND DISTRIBUTION (UD) TRENCHES IDATE 1-1-96 I APPD g$o-/q AND UTILITY POSITIONING - . S.D. COUNTY THE GAS MAIN SHALL BE THE IAST INSTALLED, SHALL BE ON THE PROPERTY SIDE OF THE TRENCH, AND SHALL HAVE A MINIMUM OF 4 INCH PAD (AFTER COMPACTION) OF SHADING MATERIAL THE WIDTH OF THE TRENCH ABOVE ANY FOREIGN UTILITY. ANY CROSSING INVOLVING GAS SHALL MAINTAIN A MINIMUM VERTICAL SEPARATION OF 6 INCHES. A GAS SERVICE INSTALLED IN A MAIN TRENCH OR A SERVICE TRENCH ON PUBLIC PROPERW SHALL REQUIRE THE SAME COVER AND CLEARANCES AS A GAS MAIN. A GAS SERVICE jN A TRENCH ON PRIVATE PROPERN MAY BE INSTALLED ON THE SAME LEVEL AS FOREIGN UTILITY OR ELECTRIC LEVEL THE GAS SERVICE IS INSTALLED ON PRIVATE PROPERN. SDG&E INSTALLED STREET LIGHT CIRCUITS. WHEN INSTALLED ALONE IN A TRENCH, SHALL BE AT A MINIMUM DEPTH OF 24 INCHES EVERYWHERE EXCEPT ON PRIVATE PROPERTY. WHERE THE MINIMUM MAY BE 18 INCHE: BELOW FINAL GRADE. THE ELECTRIC PRIMARY WILL BE ON THE STREET SIDE OF THE TRENCH. THE SDG&E STREET LIGHT CIRCUITS WILL BE ON THE PROPERTY SIDE OF THE TRENCH WHENEVER POSSIBLE. FOREIGN UTILITY STREET LIGHTS (NOT SERIES) SHALL BE ON THE PROPERTY SIDE OF THE TRENCH AT THE SAME LEVEL AS SDG&E CONDUITS AND SHALL MAINTAIN A 12 INCH RADIAL SEPARATION. ALL UTILITIES SHALL MAINTAIN A 6 INCH SEPARATION WHEN CROSSING ALL SDG&E ELECTRIC. FOR SEPARATION ON THE SERVICE TRENCH, SEE CHART ON PAGE 7403.2 (3370.2). MINIMUM HORIZONTAL SEPARATION FROM GAS PIPE TO ANY FOREIGN SUBSTRUCTURE (VAULTS, HANDHOLES, UC.) SHALL BE 12 INCHES. GAS LINES MUST NOT BE LOCATED UNDER ANY STRUCTURE, SUCH AS BUILDINGS, CARPORTS, PATIOS, BREEZEWAYS, EQUIPMENT PADS, AND FACILITIES, SUCH AS SPLICE BOXES FOR ELECTRIC. CATV. TELCO, ETC. TREES OR SHRUBBERY MUST NOT BE PLANTED OVER ANY GAS PIPELINE. A THREE FOOT SEPARATION MUST BE MAINTAINED BETWEEN THE TREE ROOT BALL AND THE GAS PIPELINE. IF AN AGENCY OR UTILITY SUCH AS THE U.S. GOVERNMENT. SAN DIEGO UNIFIED PORT DISTRICT, TELCO. CATV, ETC. REQUIRES CONCRETE ENCASEMENT, CONCRETE MAY BE SUBSTITUTED FOR THE BACKFILL. BASE & SHADING SHALL BE PER SDGdrE STANDARDS. ON SDGdrE CONDUITS, EITHER DIRECT BURIED OR CONCRETE ENCASED, A MINIMUM 4 INCH COMPACTED SHADING MATERIAL SHALL BE INSTALLED OVER THE UPPERMOST DB CONDUITS BEFORE THE CONCRlTE BACKFILL IS INSTALLED. ALL OTHER INSTALLATIONS SHALL PROVIDE THE REQUIRED MATERIALS AS SPECIFIED IN THIS STANDARD AND STANDARDS 3365 & 3376. NOTE: THE GAS MAIN, GAS SERVICE SHALL NEVER BE CONCRETE OR SLURRY ENCASED AND SHALL HAVE THE PROPER BASE, SHADING, BACKFILL. AND COMPACTION. MINIMUM SEPARATION OF ANY FOREIGN UTILITY INCLUDING WATER PIPES, SEWER, EX.. FROM SDGLE SUBSTRUCTURES SHALL BE 12 INCHES. PROPANE GAS SHALL BE 5 FEET. BUT SHALL NOT BE DEEPER THAN THE ELECTRIC SERVICE. 'SDGhE INSPECTOR IS TO DETERMINE AT WHICH Information Removed GAS 5TD. Indicates Latest Revision Completely Revised New Page REFERENCE: SERVlCE GUIDE SEE STANDARD PAGE 3364.1 FOR UTILITY LOCATIONS IN LOCAL AND COLLECTOR STREETS. SEE STANDARD PAGE 3364.2 FOR UTlLlM LOCATIONS IN MAJOR STREETS, PRIME ARTERIALS AND EXPRESSWAYS. SEE STANDARD PAGE 3364.3 FOR JOINT TRENCH MPICAL LOCATION FOR UNDERGROUND CONVERSIONS. SEE STANDARD PAGE 3365 FOR IMPORTED OR NATIVE BACKFILL MATERIAL. SEE STANDARD PAGE 3365 FOR SLURRY BACKFILL MATERIAL. CONCRETE OR CONCRETE SLURRY ENCASEMENT OF ELECTRIC CONDUITS SHALL BE IN ACCORDANCE WITH STANDARD 3376. SEE STANDARD PAGE 3376, 3421. 3425. 3426, AND 3427 FOR CONDUIT CONFIGURATIONS ALLOWED IN THE SERVICE TRENCH. SEE STANDARD 4620 TELECOMMUNICATIONS INSTALLATION. FOR TRENCHING AND SHORING QUESTIONS, SEE SDG&E TRENCHING AND SHORING MANUAL. DATE 1 - 1 -2000 APPD &/& UNDERGROUND DISTRIBUTION (UD) TRENCHES AND UTILIN POSITIONING - S.D. COUNN I 3370*6 SCOPE: THIS STANDARD SHOWS THE (PREFERRED I ) TRENCH GROUND WIRE INSTALLATION USED TO PROVIDE GROUNDING. THIS METHOD SHALL BE USED WHEN THE SAME PARR IS RESPONSIBLE FOR THE CONDUlT AND PAD INSTALLATION AND WHEN A SYSTEM NEUTRAL FROM A SUBSTATION OR GROUNDING BANK IS PRESENT. USE ALTERNATE TRENCH GROUND WIRE METHOD PAGE 4510.2 WHEN A SYSTEM SERVlCE CUIOE indicates Lotest Revision FIGURE 1 informotion Removed Completely Revised New Page TRENCH BO'ITOM OF TRENCH REVISION DATE 1-1-96 APPD $&-/qy FIGURE 2 SDGBcE ELECTRIC STANDARDS - TRENCH GROUND WIRE 4510.1 (PREFERRED I ) SCOPE: THIS STANDARD SHOWS THE ALTERNATE TRENCH GROUND WIRE INSTALLATION USED TO PROVIDE GROUNDING. THIS METHOD SHALL BE USED WHEN THE SAME PARTY IS RESPONSIBLE FOR THE CONDUIT AND PAD INSTALLATION AND WHEN A SYSTEM NEUTRAL FROM A SUBSTATION OR GROUNDING BANK IS NOT PRESENT. USE PREFERRED GROUNDING METHOD ON PAGE 4510.1 WHEN A SYSTEM NEUTRAL IS PRESENT. @ - GROUND WIRE GROUND FIGURE 3 \r \ \ ASSEMBLY UNITS TG -T- R \ a24” EXPOSED TAILOUT SERVICE GUIDE 451 0.2 Indicates Latest Revision Completely Revised New Poge Information Removed REVISION SDGdtE ELECTRIC STANDARDS TRENCH GROUND WIRE DATE 1-1-96 (ALTERNATE) 1 ApPDg&/g 1 DESCRIPTION BILL OF MATERIAL: ASSEMBLY STOCK NUMBER UNIT QUANTITY 2 3 WIRE, BARE COPPER, #2, 7 STR. SOFT DRAWN GROUND ROD, 5/8” X 8’-0”, COPPERWELD AS REQ’D 603072 - AS REQ’D GDWlRE ~~ ~ ~ ~ 4 GROUND ROD, CLAMP I AS REQ’D I 2300 1 6 - SERVICE GUIDE REVISION NOTES: - ~ lndicotes Lotest Revision Completely Revised I I New Page I I informotion Removed SDG&E ELECTRIC STANDARDS CUSTOMERS SERVtCE TRENCH: - THE SERVICE TRENCH IS ON PRIVATE PROPERN AND BELONGS TO THE CUSTOMER, THEREFORE, THE TRENCH GROUND WIRE SHOULD NOT BE INSTALLED IN THE CUSTOMER TRENCH. THE SITUATION IS DIFFERENT ON A RULE 16JOB WHERE THE PAD-MOUNTED EQUIPMENT, PRIMARY/SECONDARY AND SERVICE TRENCH ARE ALL ON PRIVATE PROPERTY AND THE PAD AND CONDUIT BELONGS TO THE CUSTOMER AND REMAINS THE CUSTOMERS RESPONSIBILITY. IN THIS CASE, THE TRENCH GROUND WIRE COULD BE INSTALLED IN EITHER THE PRIMARY/SECONDARY OR THE SERVICE TRENCH. INSTALLATION: @ GROUND RODS TO HAVE A 6 FOOT MINIMUM SEPARATION. @ LEAVE 24 INCHES OF WIRE (EXPOSED TAILOUT) ABOVE THE TOP OF FINAL GRADE. C. USE EQUIPMENT GROUNDING INSTALLATION (PREFERRED II ) ON STANDARD PAGE 4512.1 IF TRENCH GROUND WIRE WAS NOT INSTALLED PRIOR TO BACKFILLING THE TRENCH. 0 LOCATE GROUND RODS SO THEY DO NOT TOUCH CONDUITS. GENERAL ORDER 128 REQUIRES GROUND RODS TO BE DRIVEN. THEY MAY BE DRIVEN AT AN ANGLE IF IT IS DIFFICULT IF NOT IMPOSSIBLE TO DRIVE STRAIGHT DOWN. REFERENCE: E. SEE STANDARD 3484.1 FOR PAD INSTALLATION OF PAD-MOUNTED EQUIPMENT. 0 SEE STANDARD 4002.2 FOR WIRE INFORMATION. G SEE STANDARD PAGE 4512.1 FOR (PREFERRED II ) EQUIPMENT GROUNDING INSTALLATION WHEN DIFFERENT PARTIES ARE RESPONSIBLE FOR THE CONDUIT AND PAD INSTALLATION. @ SEE STANDARD 451 2.2 FOR EQUIPMENT GROUNDING INSTALLATION. DATE 1-1-91 I TRENCH GROUND WIRE I 4510.3 (PREFERRED I OR ALTERNATE) APPD /g!&/qy 1 SCOPE: THIS STANgARD SHOWS REQUIREMENTS FOR INSTALLING A 3425 THREE-PHASE PAD FOR DEAD FRONT TRANSFORgER APOLICAT~ON THROUGH 300 KVA. TRANSFORMER. ALSO FOR 3750 KVA HHR DEAD FRONT BOOSTER SERVICE GUIDE Indicates Latest Revision Completely Revised New Page PAD WUCHT: igoo# MAX. Information Removed STOCK NUMBER PAD 5 1 3998 ASSEMBLY UNIT 3425-3 MAXIMUM PRIMARY CONDUITS ALLOWED 2 RUNS OF 4" (€6 OR OB) PRIMARY CONDUIT 6-4" SECONDARY~ 5-5" SECONDARY-S NOTES: - - TRANSFORMER COOLING FINS MAY OVERHANG REAR OF PAD BY 6 INCHES. - IF NUMBER OF SECONDARY CONDUITS IS GREATER THAN MAXIMUM SHOWN, USE PAD PER STANDARD 3426 OR 3427. - TRANSFORMER PAD MAY NOT BE POURED IN PLACE. USE PRECAST PADS ONLY. INSTALLATION: SERVICE GUIDE 3425.2 @ 1 INCH EARTH IN THE BOTTOM OF THE TRENCH IS REQUIRED TO PREVENT DAMAGE FROM ROCKS, SAGS, AND POCKETS. Indicates Latest Revision Completely Revised New Poqe Information Removed SDG%E ELECTRIC STANDARDS REVISION THREE-PHASE TRANSFORMER PAD INSTALLATION 3425 DATE 1-1-98 @ PLACE ALL PRIMARY AND SECONDARY CONDUITS WITHIN THE PAD OPENING AS SHOWN ON PAGE 3425.1. TERMINATE PRIMARY AND SECONDARY CONDUITS FLUSH WITH THE TOP OF THE PAD. DO NOT CUT INTO THE CURVED PORTION OF THE ELBOWS. RADIUS OF CURVATURE IS 36” MINIMUM FOR 3 INCH, 4 INCH AND 5 INCH CONDUITS. c THE CONDUIT CONFIGURATION REOUIREMENT BETWEEN TERMINATING POINTS LIMITS THE SECONDARY CONDUIT SURROUNDED ON ALL FOUR SIDES BY OTHER CONDUITS). USING SPACERS AND 1 SACK CONCRETE SLURRY BACKFILL. CONDUITS MAY ALSO BE INSTALLED SIDE BY SIDE ON THE BOTTOM OF THE TRENCH WITHOUT SPACERS OR CONCRETE SLURRY (4 CONDUITS MAX.). IN THE TRANSITION AREA WHERE THE CONDUITS FROM THE BOllOM OF THE TRENCH START TOWARD THE SURFACE (THE STRAIGHT PORTION BY THE 90’ BEND), SPACERS MAY BE REOUIRED TO ALLOW THE 90’ BENDS TO ENTER STRAIGHT INTO THE PAD OPENING. AT THE SURFACE POINT. THE CONDUITS MAY BE BUNDLED TOGETHER. USE SDGdrE APPROVED BASE. SHADING AND BACKFILL. *CoNFlGURATlON TO 2 WIDE X 3 DEEP OR 3 WIDE X 2 DEEP (NO ONE CONDUIT IS TO BE COMPLETELY @ANY COMBINATION OF 3. 4 OR 5 INCH SECONDARY CONDUITS MAY BE USED, PROVIDED THEY DO NOT EXCEED THE TOTAL OF 6 OR THE MAXIMUM OF EACH SIZE CONDUIT AS SPECIFIED ON PAGE 3425.1. AN EXCEPTION WOULD BE WHEN THE TRANSFORMER FEEDS ONE CUSTOMER WITH A 2000 AMP MAIN TWO EXTRA 1 INCH OR TWO EXTRA 2 INCH CONDUITS MAY BE ADDED TO SERVE STREET LIGHTS. RECREATION BUILDINGS, ETC. WHICH REQUIRES FIVE-5 INCH CONDUITS. NO FUTURE CUSTOMERS ARE ALLOWED IN THIS INSTALLATION. 2 WIDE X 3 DEEP 3 WIDE X 2 DEEP 1 -SACK CONCRETE SLURRY BACKFILL / MAXIMUM OF 4 CONDUITS WITHOUT SPACERS OR CONCRETE SLURRY @WHEN NUMBER OF REQUIRED CONDUITS IS LESS THAN THE TOTAL ALLOWABLE SHOWN ON PAGE 3425.1, INSTALL IN NUMBERED SEQUENCE AS SHOWN. INSIALLATION CON’T: I REFERENCE: K. SEE STANDARD 321 1 FOR PAD IDENTIFICATION. L. SEE STANDARD 3370 OR 3371 FOR TRENCH, UTlLlM POSITIONING, SHADING AND BACKFILL REOUIREMENTS. M. SEE STANDARD 3376 FOR CONCRETE SLURRY. N. SEE STANDARD 3481 FOR TRANSFORMER BARRIER PROTECTION. 0. SEE STANDARD 3483 FOR MINIMUM OPERATING AND CLEARANCE REOUIREMENTS (PA0 PLACEMENT). P. SEE STANDARD 3484 FOR PAD INSTALLATION OF PAD-MOUNTED EQUIPMENT. 0. SEE STANDARD 3486 FOR RETAINING WALL REOUIREMENTS AND CLEARANCES FROM REVERSE S UBGRADE RETAl N I NG WALLS. . R. SEE STANDARD 3487 FOR RETAINING WALLS. S. SEE STANDARD 3751 FOR TRANSFORMER INSTALLATION. T. SEE STANDARD 451 2 FOR EQUIPMENT GROUNDING. U. SEE STANDARD 451 4 FOR GROUNDING TELCO CONDUCTOR IN PAD-MOUNTED EQUIPMENT. ~ 1 SERVICE GUIDE I lndicotes Latest Revision I I Completely Revised I I New Poge I I Information Removed 1 REVISION SDG&E ELECTRIC STANOARDS I G. &SOFT SOILS A CONCRETE BACKFILL (1 -SACK MIX.) IS REQUIRED UNDER THE PAD. 12 INCHES BEYOND THE SIDE EDGES OF PAD AND 12 INCHES DEEP. 3425.3 THREE-PHASE TRANSFORMER PAD INSTALLATION 3425 DATE 1-1-98 APPD m/m I APPENDIX D MISCELLANEOUS STANDARD DRAWINGS CARLSBAD MUNICIPAL WATER DISTRICT STANDARD DRAWINGS SEWER CLEAN - OUT RISERS SCREW IN PUIG. CARLSBAD MUNICIPAL WATER DISTRICT ,Revision STANDARD ORAWINGS FOR SEWER SEWER MAIN CLEANOUT District Engineer DWG. NO. S6 x)P OF PAVEMENT. G5-7 EN Ammedl BY 12'WIDEX 6' THICK WITH 2 ASPHALTIC c0NCFQ-E COUAR CONCRETE OVERLAY mxAL). SEWER MAIN CLEANOUT 1338' 4 ' 34" .) NOTES I . GATE CAP SHALL BE LABELED SEWER. 2. CLEANOUTS MAY BE USED WITH. PVC. SEWER MAIN. 3. RISER SHALL BE SAME DIAMETER AS SEWER MAIN. CLEAN- OUTS IN YARD To BE WRED WITH 10' PLASTIC COVER BY CARSON PART NQ 910 O.AE CLEAN-CUTS IN CONCRETE TO HAVE CONCRETE BOX WITH TRAFFIC LID BY JBR OR BROOKS PART NO. 3-R-T. SEWERW-OUTRlSERS70BE 1 " FlTTED WITH 'MALE' SCREW. iN PWG. I OPTloNAL WE ( WHEN APPROVED 1. - MII NOTES : I . THE LATERAL SHALL 8€l3lE0 THE 5. AS- BUILT SEWER LATERAL LOCATIONS SHALL BE FURNISHED TO THE CITY SAME AS THE MAN LJNE SfWER. 2. IN NO CASE SHALL A LATERAL CONNECT TO THE SEWER MAIN DIRECTLY ON TUP OF THE PIPE. MINIMUM SWE. 3. SEWER LATERLUS SW HAVE A 2% INSPECTOR ON FORMS PROVIDED .PRIOR TO FINAL APPROVAL OF WORK. 6. ALL LATERAL TRENCHES TO 'PROPERTY LINE AND SEWER MAIN TRENCHES TO BE COMPACTED PER S5. 7. CLEAN - OUT TO BE ADJUSTED TO GRADE AFTER FINAL FINISH GRADING. 4. ALL JOINTS ON SEWER LATERAL PIPE SW BE COMPRESSION TYPE OR APPROVED SOLVENT WELD. v. (WITH OPTIONAL WYE) I 29 5/aw I b 1 ON APPR DATF BELOW SURFACE I & 2" AIR-VACUUM VALVE ASSEMBLY & APPURTENANCE 1- -1 STD. DWG. NO. Wl MAY 2003 HORIZONTAL HOLE SPACING 1. SEE SPECIFICATIONS FOR 8 SOLDERING REQUIREMENTS. 4. ALL VALES AND FlrnNGS OR 2. SEE SPECIFICATIONS FOR SHALL BE SAME SIZE AS PAINTING REQUIREMENTS. AIR VENT INLET. @ 3* SEE lMPRoVEMENT PLANS FOR ASSEMBLY SIZE. 5. POSITON ANODE MIDWAY BETWEEN PIPELINE AND VALVE BOX. D.I. MAIN ITEM D ESCR I P TI ON 1 DOUBLE BAND BRASS SERVlCE SADDLE. 2 CORP. STOP 1" WATER SERVICE. 3 CORP. STOP 2" WATER SERVICE. 4 CORP. STOP 1" AIR VACUUM VALVE ASSEMBLY. 5 CORP. STOP 2" AIR VACUUM VALVE ASSEMBLY. 6 1" MANUAL AIR RELEASE ASSEMBLY. 7 2" BLOW-OFF MANUAL AIR RELEASE ASSEMBLY. 8 10 3000 PSI FORGED STEEL COUPLING WELDED TO MAIN. 11 INSULATING BUSHING. LEXAN OR DELRIN 1. 2" BLOW-OFF / AIR RELEASE ASSEMBLY. STEEL MAIN SPEC/DWG 3 4 7 7 5 6&7 6&7 10 10 %/% FOR WATER SERVICE 3FVlslON APPR DATE. OUTLETS ON D.I. OR STEEL MAIN FOR I INCH THRU 2 INCH ASSEMBLIES CONNECTION [ TYP. 1 STD. DWG. NO. w9 MAY 2003 FIELD APPLIED CEMENT MORTAR ALL AROUND. -w 6 SIZING TABLE I COPPER I VALVE OR I STEEL IlNSULATlNd 1" & 2" COPPER SERVlCE PIPE TYPE "K" SOFT 1. I SECTION A-A EVlSlON NOTES: 1. DIELECTRIC CONNECTIONS SHALL BE REQUIRED ON ALL AIR AND VACUUM VALVE STD. DWG. NO. WIO DIELECTRIC CONNECT1 ON APPR DATE TO STEEL MAIN MAY 2003 ASSEMBLIES, MANUAL AIR RELEASE ASSEMBU ES. BLOW- OFF ASSEMBLIES AND WATER- SERVICE ASSEMBLIES WHERE COPPER TUBING OR BRASSS PIPE CONNECTIONS ARE MADE TO STEEL MAINS. I SECTION A-A SECTION B-B , ITEM DESCRIPTION SPEC/DWG 1 ,2 3 4 5 6 mi MMW FNF WRAP VAL BOX & COVER WlTH 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 OR COMP. STRENGTH I DOMESTIC WATER REVISION RECLAIMED WATER STD. DWG. NO. WI3 VALVE BOX AP PR DATE ASSEMBLY MAY 2003 I NOTES: 1. IN NON-ROAD AREAS PLACE MARKER POST NEXT TO VALVE BOX ASSEMBLY AS N?ECTED BY THE HJGINEER. ( SEE DRAWING NO. 23 ). 2. SEE DRAWING NO. 23 FOR GATE VALVE EXTEN SI ON. 3. UPPER SIDE OF LID TO RECIEVE 2 COATS OF PAINT. SEE SPECIFICATIONS FOR PAINTING REQUIREMENTS, ( PAGE 4 ). VERTICAL BEND. ITEM DESCRIPTION 1 CONCRETE THRUST BLOCK. (560-C-3250) 2 POLYETHYLENE WRAP. 3 NO. 4 REINFORCING STEEL. 4 VALVE BOX ASSEMBLY. 5 FL X RT OR FL X MJ GATE VALVE. 11 1 /4',221/2#, 45',50',60'. -- SPEC/DWG HORIZONTAL & VERTICAL BEND. ON APPR DATF CONCRETE THRUST BLOCKS FOR NON-RESTRAINED JOINTS NOTES: 1. FITTINGS SHALL BE DUCTILE IRON FOR D.I.P. & P.V.C.; CAST IRON FOR A.C.P. (CEMENT LINED SHORT BODY). STD. DWG. NO. MAY 2003 W15 TEE (SIDE VIEW). 2. FOR A.C. PIPE A MIN.'3'-3" TO A 6'-6" MAX LENGTH INTO AND OUT OF ALL FITTINGS. 3. CONCRETE SHALL BE 6 SACK, 3250 P.S.I.). HYDROSTATIC TEST. 4. SEE DWG'S. NO. 17 & 18 FOR REDUCER, PLUG, & BUTTERFLY VALVE THRUST BLOCKS. A MIN. 3 DAY CURING TIME BE 1 ORE FINISHED mmqYq I TEM 1 2 3 4 5 TRENCH ELEVATION REINFORCING TRENCH ELEVATION PVC PIPE STEEL DETAIL. P.V.C. & D.I.P. PIPE DESCRl PTI ON SPEC/DWG GATE VALVE POLYETHYLENE WRAP. NO. 4 REINFORCING STEEL. CONCRETE THRUST BLOCK. (3250 P.S.I.) 560-C-3250 19 VALVE BOX ASSEMBLY. 13 -I I 1-1 I I- I 1-1 11-1 VlSlON TRENCH SECTION APPR DATF STD. DWG. NO. Wl6 GATE VALVE INSTALLATION P.V.C., D.I.P., A.C.P. 8 STEEL PIPE. MAY 2003 (TYPICAL) TRENCH ELEVATION STEEL PIPE I I I I 6 8 10 12 Pipe Diameter in Inches 14 16 1. BASED ON 225 PSI TEST PRESSURE AND BEARING VALUES OF DRY SOILS. 2. VALUES FROM CURVES ARE FOR TEES AND DEADENDS, LE. ; STRAIGHT LINE THRUST. 3. FOR C NDlTlONS NOT COVERED BY CURVES, SPECIAL THRUST BLOCKS MUST BE COMPUTED FOR 90’ BMD 1.4 VALUE FROM CURE FOR 45’ BEND: 0.6 VALUE FROM CURVE. FOR 22 1/2’ BEND 0.4 VALUE FROM CURVE. AND A B PROVED. CARLSBAD MUNl Cl PAL- WATER DISTRICT ~ THRUST BLOCK BEARING AREAS STD. DWG. NO. W19 MAY 2003 NOTES: - 1 1. THERE SHALL BE NO FlllINGS OR CONNECTIONS BETWEEN ME METER 36" MAX. 4 -@ 36" MAX. ~ ~- AND BACKFLOW ASSEMBLY. ITEM 1 2 3 4 5 6 3. DO NOT INSTALL IN AREA SUBJECT TO FLOODING. DESCRIPTION SPEC/DWG METER AND VALVE ( BY DISTRICT ). TYPE K HARD OR TYPE L HARD COPPER OR BRASS RISER. 9 COPPER OR BRASS 90' ELBOW ( SOLDER JOINTS OR THREADED FITTINGS ). COPPER OR BRASS NIPPLE. BRASS UNION. APPROVED BACKFLOW PREVENTER ASSEMBLY. -+--- 4- -T- EVlSlON L - MAX -I APPR DATF STD. DWG. NO. w20 2 INCH AND UNDER BACKFLOW INSTALLATION MAY 2003 -'/ / -PUBLIC PRIVATE CONSUMERS RESPONSIBILITY E=,- - TO BE INSTALLED PURSUANT TO MUNICIPAL CODE CALIFORNIA ADdlNlSTRATlVE CODE. BOOK 14.08.010 4001-SEC.5 & TITLE 17 OF THE I I 8 I METER BOX ( BY DISTRICT ). I I I CARLSBAD MUNICIPAL WATER DISTRICT 1114" BEVEL EXTENSION STEM AND EVlSION APPR DATE MARKER POST t 3 STD. DWG. NO. w25 MAY 2003 DOMESTI NOTES: * i 1 I ;E . 1. ENTIRE MARKER POST SHALL BE PAINTED PRIOR TO INSTALLATION. * ! i I t 9 I t RECLAIMED WATER '18" IF VALVE SET AT FINISH GRADE. - r EXTENSION STEM SHALL BE REQUIRED WHEN OPERATING NUT IS 5' OR MORE BELOW TOP OF VALVE COVER. @- ITEM 1 2 3 I- DESCRIPTION SPEC/DWG 4" STEEL PIPE. GALVANIZED / PAINTED 470-C-2000 CONCRETE FOOTING. FILL PIPE WlTH 470-C-2000 CONCRETE ( ROUND OFF TOP ). h 0 I r) CI FVISION FINISHED 1GRADE. APPR DATE STD. DWG. NO. PROTECTION POST W24 MAY 2003 NOTE: PIPE SHALL BE PAINTED IN CONFORMANCE WITH DISTRICT SP ECI FI CAT1 ONS. WRING AND INSTALLA llON SEE DWG. NO. W28 GREEN AREA SIDEWALK EX0 lHERMIC WELD D WG. CARLSBAD MUNl CI PAL WATER DISTRICT STD. DWG. NO. W26 AT GRADE 2-WIRE TEST STATION RMSlON APPR DATE MAY 2003 WITH ANODES CML&TC STEEL REC WATER 1 1-NO. 12 WHITE THW ANODE LEAD HMWE PIPE LEADS 2-NO. 8 BLACK 6’ MIN (SEE NOTE 2) MAGNESIUM ANODE SEE DWG. NO. W29 SEE NOTE 1 (2 REQRD) NOTES: 1. 1 ANODE SHOW, 2 ARE REQUIRED. ANODES TO BE INSTALLED PARALLEL TO THE PIPE, 15 FEET APART IN AUGERED HOLES 12’ DEEP. ANODE LEADS TO BE TRENCHED TO CTS AT A DEPTH OF 36”. 2. INSTALL ANODES AT A 6’ MINIMUM DISTANCE FROM PIPE. 31 t WARNING TAPE -. nr h NO SCALE GRAPHITE COER STARTING POWER METAL ELDING POWDER GRAPHIlE MOLD USION APPR DATE - EXOTHERMIC WELD PROCESS &r3 STEP 1. NLE STRUCTURE CONNECTION AREA (3 IN x 3 IN) TO BARE SHINY METAL AND CLEAN. STD. DWG. NO. w27 0 SEP 2. SRIP INSULATION FROM WRE. ATTACH SLEEVE WERE REQUIRED B Y MA NUFA C TURER. b-3 STEP 3, HOLD MOLD FIRMLY WlH OPENING AWAY FROM b-7 STEP 4. REMOVE SLAG FROM CONNECTION AND PEEN OPERATOR AND IGNITE WITH FLINT GUN. WELD FOR SOUNDNESS. STEP 5. COER CONNECTION AND EXPOSED STRUCTURE SURFACE WITH A BITUMINOUS COATlNG COMPOUND. PLACE PLAS77C SHIELD CAP FIRMLY OVER CONNECTION. NOTES: 1. ALL WRE WELDS SHALL BE MINIMUM 3 INCHES APART: 2. STANDARD WELD CARRIDGES SHALL BE USED FOR STEEL SURFACES, NO SCALE CARLSBAD MUNl CI PAL WATER DlSTRl CT I MAY 2003 CONCRETE CONCRETE TEST BOX, SEE PA VEMENT OR DWG. NO. W30 PAD 24" SQ X 4" THICK IN BRASS UNPA VED AREAS NO. 4 REBAR (ALL FOUR SIDES OF PAD ONLY) TO ANODES TO CML&TC STEEL REC WA TER LINE WRE 1. D. LEGEND N WIRE SIZE LABEL IDEN TlFICA TlON A&B 2 - NO8 HMWPE STL/CML&TC RW APPR DATF STD. DWG. NO. W28 2-WIRE TEST STATION WITH ANODES WIRING DIAGRAM MAY 2003 NOES: 1. NO WIRE OR CABLE SPLICES ARE PERMITTED EXCEPT AS INDICA TED IN THE DRA WNGS OR AS SPECIFICALLY APPROVED BY THE ENGINEER, 2. MRES SHALL BE TAGGED USING MINIMUM 10 PI FONT AND CONTAIN: PIPELINE MAERIAL & SIZE DA lE INSTALLED PIPELINE STAnON NO. 3. PROVIDE 18" SLACK WRE AT ELD TO PIPE AND COILED IN EST BOX. NO SCALE // ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 ON ANODE LEAD THWN (WHITE) APPR DATE STD. DWG. NO. W29 MAY 2003 MAGNESIUM ANODE ............ ........... MA GNESIUM INGOT DIMENSIONS: 5” X 6” X 32” LONG INGOT WEIGH? 48 LBS. PKGD WEIGHR 105 LBS. (A PPROX.) NO. ii AWG- S TRA NDED COPPER WIRE SIL VER SOLDERED CONNECTION MAGNESIUM ALLOY INGOT - GALVANIZED STEEL CORE - PACKAGED BACKFILL COMPOS1 TION: 75% GYPSUM 20% BEN TONI TE 5% SODIUM SULPHATE CHEMICAL COMPOS1 TlON (HIGH POTENTIAL) ELEMENT CONTENT % Aluminum 0.010 Manganese 0.50 TO 1.30 Copper 0.02 MAX Nickle 0.001 MAX iron 0.03 MAX Other 0.05 MAX Magnesium BALANCE NO SCALE CARLSBAD MUNICIPAL WATER DISTRICT CAST IRON COVER MARKED AS SHOWN SlON CONCREE BODY APPR DATF STD. DWG. NO. W30 MAY 2003 CONCRETE TEST BOX COVER KIGHE 12 LBS. BODY WEIGHE 54 LBS. NO TES: 1. ALL AT GRADE EST STAnONS SHALL BE THE CIRCULAR, CONCRETE, AT-GRADE TYPE WTH A METAL LID. A. BOTTOM OF EST BOX SHALL BE NATIVE SOIL. B. A REINFORCED CONCRETE PAD (24” SQUARE X 4” THICK) IS REQUIRED AROUND EST BOXES LOCATED IN UNPAVED AREAS. CITY OF CARLSBAD. DO NOT PLACE IN STREET OR MEDIAN. C. PLACE EST BOX BEHIND SIDEWALK KITH APPROVAL OF NO SCALE I GASKET - TYPE "E" GIO GLASS W/ RECT. O-RING SLEEVE - GlO GLASS WASHER - G10 GLASS I STEEL WASHER & NUT (BOTH SIDES)(2 PLS) INSULA TlNG WASHER (BOTH SIDES) INSULAllNG SLEEVE STUD (2 PLS) (FULL L ENG lH) 'CAnONS -\ (TYPE E) r PROCESS. (TYP) IITWLA IUM ?AP SEE \ r INSULA TING GASKET EXOlHERMIC E,! EXTERNAL PET"^' An''1 ' WAX TAPE Wi SPECIR CML&C/STEEL REC. WATER IY SEE NOlE 1 - .D SEE NOES: 1. FULL LENGTH INSULAllNG SLEEVES REQUIRED AT ALL THRU-FLANGE BOLTS OR STUDS. HALF LENGTH SLEEVES REQUIRED AT THREADED BOLT HOLES AT VALVE BONNET AND BASE. ON THIS SHEET; 2. INSTALL EST BOX BEHIND CURB SIMILAR TO DETAIL 1 NO SCALE CARLSBAD M UNI C I PAL ED INSULAT WATER DISTRICT ING FLANGE STD. DWG. NO. MAY 2003 W3I FLEXIBLE COUPLING REVISION APPR DATE MECHANICAL JOINT BOND 2-BOND WIRES-A WG NO. 2 I-NO 6 AWG HMWPE STRD. COPPER WIRE (TYP) (TYP) SEE NOTE 4 WITH HMWPE INSUL. /- wc - .,,.f - STD. DWG. NO. MAY 2003 W32 EX0 THERMIC WELD BEND (TYP) SEE DWG. NO. W27 SPOOL TEE VAL VE N 0 TES: 1. ALL WRE WELDS SHALL BE 3” APART MIN. 2. ALL BOND WIRES SHALL BE INSTALLED AT MINIMUM LENGTHS. 3. BOND WIRfS SHALL NOT BE INSTALLED ACCROSS INSULATING JOINTS 4. BOND WIRE SIZE SHALL BE AWG NO 2. TWO ARE REQUIRED. ONE NO. 6 A WG HMWPE IS REQUIRED FROM PIPE TO VAL VE BODY, .SPOOL, COUPLING, AND TEE. NO SCALE 1 I I I I I I SAN DIEGO COUNTY REGIONAL STANDARD DRAWINGS Thk drawing k NUT In donnonce with kbat UBC ond rhould k d with cam and judgd I-1/2: 1 Slope Unlimited r OR 457mm (1’-6”) 610mm (2’-0”) 91 4mm (3’-0”) 1.22m (4’-0”) 1.52m (5’””) 1.83m (6’-0”) 914mm (3’-0”) 1.22r-n (4’-0”) 1.52m (5‘-0”) 1.83m (6’-0”) 51mm (1”) Chamfer- \L 305mm (1 ’-0”) .042 cu m (1.50 cu ft.) 305mm (1’-0”) .057 cu m (2.00 cu ft.) 71 1 mm (2‘-4”) 1.41 cu m (4.99 cu ft.) 864mm (Z’-lO”) .217 cu m (7.66 cu ft.) 1.02m (3’-4“) .306 cu m (10.82 cu ft.) 1.17m (3’- 10”) .410 cu m (14.49 cu ft.) 457rnm (1’-6”) .IO6 cu rn (3.75 cu ft.) 61 Omm (2’-0“) .I70 cu m (6.00 cu ft.) 762mm (2’-6”) ,248 cu m (8.75 cu ft.) 91 4mm (3’-0”) .340 cu m (12.00 cu ft.) irrace -_.- (I ’-0”) Min. TYPE-A WALL 1 (Applicable for all types of backfill loadings) H/2+254mm (IO”) Revision ’ ’91GINAL Expansion joint Q 9.14m (30’-0”)5 centers (max) and/or Q each step. . SAN DIEGO REGIONAL STANDARD DRAWING By Approved Date Kercheval 12/75 TYPE-B WALL TYPE-C WALL /Top I Of Wall MFinished Ground Line I I r3- E LVEVATIO N WALL C 0 N CR ETE I TYPE I 1 BASE 1 CU M - CF/R NOTE See Standard Drawings C-10 for Section A-A, notes and details. G RAVlTY RETAINING WALL§ * RECOMMENDED BY THE SAN DIEGO REGIONAL STANDARDS COMMITTEE \ ChGrperson R.C.E. 19246 Date DRAWlNG c-g NUMBFR This dmwing is NOT in conformance with latest UEC and should be used with care and judgment. Revision *J RI G I N AL I Metnc CONCRETE Concrete shall be 332 kg/M3 -C-22Mpa DES IG N CON DIT1 0 N S Walls are to be used far the loading conditions shown for each type woll. xceeded by six inches before going to next size. :---I 1- lop extension if specified Filler Material: 25.4mm (1”) max. crushed aggregate .1 13 cu m (4 cu. ft.) min at each drain. 102mm (4”) dia. drains with 6.35mm (1/4”) galv. wire mesh screen, 203mm (8“) above outside ground surface, slope 13mm (1 /2”) per ft. Locate drains @ 4.6m (15’-0”) center to center or as directed by the (560-C-3250) Design H may be DESIGN DATA Fc = 8.3 Mpo (1200 psi) RECOMMENDED BY THE SAN DIEGO SAN DIEGO REGIONAL STANDARD DRAWING REGIONAL STANDARDS COMMITTEE By Approved Date Kerchevol 12/75 T. Stonton 03/03 \ ChGrperson R.C.E. 19246 Date DRAMNG c-10 GENERAL NOTES AND DETAILS NUMBER FOR G RAVlTY RETAINING WALLS F’c = 20.7 Mpa (3000 psi) Earth = 1922 kg/cu m (120 pcf) and equivalent fluid pressure = 176 kg/sq m (36 psf) per 305mm (foot) of height Walls shown for 1-1/21 unlimited sloping sucharge are designed in accordance with Rankine’s Formula far unlimited sloping surcharge with # = 33’ 13m (42’). Note: 143.6 Kpa (I-1/2 tons/sq. ft.). required where footing material is incapable of supporting this pressure. Maximum toe pressure under wall footing = Special design EXCAVATION AND BACKFILL Compaction of backfill material by jetting or ponding with water will not be permitted. Each layer of backfill shall be moistened os directed by the Engineer and thoroughly tomped, rolled or otherwise compacted until the relative compaction is not less than 90 percent. No backfill material shall be deposited against concrete retaining walls until the concrete has developed a strength of 17 Mpa (2,500 psi) in compression as determined by test cylinders, or until 28 days after wall hos been placed. Engineer. TYPICAL DRAINAGE WHEN H IS GREATER THAN 1.22m (4’-0”) 13rnm (1/2”) Expansion joint, fill with premolded expansion joint filler. Locate joints at approx. 9.14m (30’-0”) centers or as directed by the 13mm (1/2”) Water stop, use only when chamfer watertight joint is required, see water stop detail. SECTION A-A Embedment 60mm (2-3/8”) min. +--Ft-+ 9.53mm LSplit permitted (3/8”) dia. R U E B E R WATER STOP Use only when watertight joint is required. A-7 I I Revision 'IRIGINAL Metric II II LJ ri II II I/ RECOMMENDED BY THE SAN DIEGO SAN DIEGO REGIONAL STANDARD DRAWING REGIONAL STANDARDS COMMITTEE By Approved Date Kercheval 12/75 T. Stonton 03/03 \ Ch6rperson R.C.E. 19246 Date DRAMNG D-13 WELDED STEEL GRATE FRAME NUMBER 102MM (4") (4") X 76mm (3") X 6.35mm (1/4") 4.76mm (3/16") +-----l / / \ \ II II LJ ri r? I1 I1 I1 I I 1.05rn (3'-5 3/8") I Ad PLAN =I ul 51mm (2") NOTE Hot dip galvanize 011 parts after fabrication. SECTION A-A This drawing it NOT in conformanca with latost UBC and should be used with care and judgmnt. Revision ‘:RIGINAL 1.54rn 102mm - SAN DIEGO REGIONAL STANDARD DRAWING By Approved Date Kercheval 12/75 9.53mm0 (3/8”@) Bar f a3 3; 7 T- i .-- v E E 0 0 a c t -1 PLAN ‘1 6”) fillet bar & every 3rd terminal bar. 3.20mm (1 /8“) 9.53mmQ (3/8”0) Bar-, ,P*<Typ. 64mm (1/2”) x 9.53mm (3/8”) End Bars mm 63.5mm (2-1 /2”) SECTION A SECTION B NOTES 1. Hot dip galvanize 011 parts after fabrication. 2. Dimensions to centerline of bars unless otherwise noted. 3. Weight: 64kg (141) pounds. 4. Not to be used in pedestrian areas. Metric I IT. Stonton I03/031 1-1 DRAINAGE STRUCTURE GRATE I I, I (2 1/2“)x (3/8”) End RECOMMENDED BY ME SAN OIEGO REGIONAL STANDARDS COMMITTEE Charpe&n R.C.E. 19246 Date ORAMNG ~45 NUMBER This drawing is NOT in conformance with latest UBC and should be used with core and judgment. Revision VIGINAL Metric i ". 0 .E -1 E Sn Et; E, 'Do .- II TJ If 00 7 By Approved Date RECOMMENDED BY THE SAN DIEGO Kercheval 12/75 T. Stantan 03/03 \ Ch5roerson R.C.E. 19246 Date CORRUGATED STEEL PIPE INLETS Punch 25rnm (1") hole in CSP Place pipe so bars of grate will be parallel with main surface flow. 76mm (3") x 13mm ( r 7 r? Join to csp '722m (4'-0") dia bas: - L 76mm (3") X 3.5mm (2-1/23 X 9.53mm (3/8") Rivet, Spot Weld or Tack Weld at 1/8 points or better to C.S.P.6 \ spot weld or tack weld at 3.20mm oints or &- 1/2") bars See Detail "8" 102mrn (4") for bottom design) SECTION C-C TYPE B SECTION A-A TYPE A r. 13mm (1/2") dia. rnin +G-? r 30.2mm (1 -3/16"), +0mm (1 -9/16') x 9.53mm (3/8") D ETA1 L NOTES 1. All components shall be galvanized. 2. Inlet and outlet pipes shall be set at factory and positioned as shown on plans 3. Lodders ond Steps: None required where "H" is 1.10rn (3'"'') or less. Where "H" is between 1.10m (3'-6") and 1.50m (4'-11") place one step t 406mm (16") above the floor. If "H " is 1.52m (5') or more install a ladder placing lowest rung 406mm (16") above the floor and the highest rung not mare than 356mm (14") below top of inlet. opening . ' ' B" Place single step or ladder in wall with wall 4. See Standard Orawing 0-17 for additional details. 5. Grate to be provided when specified. 6. Grate detail shall be as shown on Standard Drawing D-17 unless otherwise approved by Agency. 19.53rnm (3/ i ") Rivets, spot weld or tack weld at 3.20mm (1/8") points or better SECTION F-F p v cv t- 13mm (1/2") dia. x 76mrn (3") Slot 19mm (3/4") x 51mm (2") 14.2mm (9/16") Hole in ongle ,- 6.35mm (1 /4") Checkered Tack weld 457rnrn (1 8") of 6.35mm (1 /4") heat-treated chain to frame and cover (See w Note 5) '9.53mrn (3/8") Rivets, spot weld or tack weld at 3.20mm (1/8") points or better DETAIL "A" DRAMNG 8-16 NUMBER TYPES A AND B This drawing is W in conformance with latest UBC and should be used with care and judgment. 4.76mrn (3/167 TYPE Welded Steel Cost anal 4" 6" NO. OF CLEAR BAR X EARS SPACING SPACING SPACING 15 51mm (2") 14.2rnrn (9/16") 95mm (3-3/47 146mm (5-3/4") 13 51mm (2") 54mm (2-1/8") 95mm (3-3/4") 146rnrn (5-3/4") (3") Bars Revision By qRIGINAL splice x 9.53mm - SAN DIEGO REGIONAL STANDARD DRAWING Approved Date Kercheval12/75 I /See Detail A GRATE DETAILS L76mm (3") x 63.5mm 63.5mm (2-1/2")x 9.53rnm (3/8") 13mm (1/2") Hole ' SECTION B-B pipe to receive lug DETAIL A ALTERNATIVE CAST NODULAR IRON GRATE OR CAST STEEL GRATE 9.53mm0 (3/8"0) & 3.20rnm (1 /B") 3/8"0 Cross bars may be fillet welded, resistance welded or electroforged to bearing bars. CROSS BAR DETAIL TYPE WELDED STEEL GRATE CROSS BAR DETAIL ALTERNATIVE CAST NODULAR IRON GRATE OR CAST STEEL GRATE GRATE BAR SPACING TABLE I I I I I " -1 Metric I IT. Stantan I03/031 CORRUGATED STEEL PIPE INLETS DETAILS T- a 0 1 A c I I L-B PLAN / Finish Grade A _c For frame and grate detail ~ see Drawing D-13 & D-15 #13(#4) total 4 7#13(#4)0 Q305rnm(1Zn) 76mm (3") Fillet SECTION A-A 4-#13(#4) around pipe opening NOTES 1. See Standard Drawing D-11 for additionol notes and details. 2. When "V" exceeds 4', steps shall be installed I .. .. .. .. 0 .. .. Rounded Pipe Ends, see Drawing D-61 Elevation shown on plan ---, 12:l 1 ::I::. c -0. . .a. : I. :. 1.1. . -0. : .+y . -0.. 0. ! i ............ .... I I I ir L38mrn(l 1/2" typ.) I 1.0m (3'-3 1/27 r- SECTION B-El LEGEND ON PLANS 101 - This drowing is NOT in conformance with latest UBC and should be used with care and judgment. (min.) 19mm (3/4”) Crushed Rock SECTION NOTES 1. For trenching on improved streets see Stondard Drawing G-24 2. (*) indicates minimum relative compaction. or G-25 for resurfacing details. SAN DIEGO REGIONAL STANDARD DRAWING I Metric I I I1 I I PIPE BEDDING AND TRENCH BACKFILL RECOMMENDED BY THE SAN DIEGO REGIONAL STANDARDS COMMITTEE ChGrperson R.C.E. 19246 Date NI IMRFR FOR STORM DRAINS NOTES 6 ,,---- Finished Grade '.51mrn 51mrn1, - (2") - e, Imported Topsoil or amended rock free Native Soil. 5 2 (-J (-J g3 (2"); Native soil free of large (76mm (3") dia. or greater) rocks and debris. $ 6 p::..; :!.: Polyvinyl Chloride Pipe 4. or Copper Pipe 7.2 1 :. -CY ,.I, ..;. :. . . ._ . . ... . y, v E" :. - ..+' .: 1 Revision IRIGINAL I Metric I Sand, Class or approved RECOMMENDED BY THE SAN DIEGO SAN DIEGO REGIONAL STANDARD DRAWING REGIONAL STANDARDS ~MTTEE By Approved Date Parkinson 02/95 T. Stanton 03/03 3twm \ ChGrperSDn R.C.E. 19246 Dote TRENCH DETAIL P.V.C. AND/OR A Topsoil, equal. Details not shown ore same as above. 1. Backfill material shall be compacted to a relative compaction of 90,: or more. 2. All P.V.C. pipe shall lay free in the trench with no induced strain and with sufficient allowance for expansion and contraction as recommended by the manufacturer. 3. Teflon tape, 19mm (3/4") wide shall be used on all threaded connections. 4. The letter W shall be stamped or chiseled on the improvement (curb-sidewalk) directly above the pressure pipeline. 5. All plastic pipe under pavement shall be installed in a P.V.C. 2leeve. 6. Minimum clearonce between pressure pipes shall be 51mm (2 ) lhl COPPER PIPE (76mm (3") AND SMALLER) 1 DRAWING NI IMAFR 1-25 KRIEGER & STEWART STANDARD DRAWINGS W z 2 WARNING TAPE PIPE ONLY) PIPE ZONE BACKFILL, 1" MAXIMUM SIZE IN ACCORDANCE WITH BASIC PIPELINE SPECIFICATIONS. COMPACTED TO 9OX RELATIVE COMPACTION, MINIMUM. (POLWlNYLCHLORlDE E w u I u 6 I- PIPE DIAMETER (INCHES) 12 OR LESS 14 THRU 18 TRENCH BACKFILL, 8" MAXIMUM SIZE IN LAYERS NOT EXCEEDING 1' IN DEPTH IN ACCORDANCE WITH BASIC PIPELINE SPECIFICATIONS GROUND SURFACE, COMPACTED TO 90% RELEATlVE COMPACTION, MINIMUM, (IMPROVED OR UNIMPROVED) TRENCH - BOTTOM WIDTH MINIMUM (FEET) MAXIMUM (FEET) 2.0 2.5 2.5 3.5 LOCATOR WIRE TRENCH. BY REVISION DATE STANDARD DRAWING W101 I 20 THRU 27 I 3.0 I 4.0 I I 30 THRU 36 I 4.0 I 5.0 I NOTES: 1. PIPELINE COVER SHALL BE 42" MINIMUM UNLESS SPECIFIED OTHERWISE. 2. TRENCH SIDES SHALL BE SLOPED OR SHORED IN ACCORDANCE WITH CAL OSHA CONSTRUCTION SAFEV - ORDERS FOR TRENCH DEPTHS 5' AND GREATER. 3. ALL EXISTING PAVEMENT SHALL BE SAWCUT PRIOR TO TRENCHING, AND WHERE TRENCH SIDES SLUFF AND PAVEMENT BREAKS AWAY, IT SHALL BE SAWCUT PRIOR TO PERMANENT PAVEMENT REPAIR. 4. WHENEVER MISTING CURBS ARE BEING USED FOR GRADE CONTROL, PIPELINES SW BE LAID ON PROJECTED CONTINUOUS SLOPES THROUGH LOCAUZED HILLS, HUMPS, AND MOUNDS AS AT STREET INTERSECTIONS AND CHANNEL BERMS. WITH CONTINUOUS PIPELINE SLOPE. PIPELINE TRENCH DEPTHS SHALL BE INCREASED TO ACCOMPLISH SAME AND PIPELINE COVER SW BE INCREASED ACCORDINGLY. 5. WHENEVER EXISTING UTlLlM FACILITIES, EXCEPT SEWERS, ARE ENCOUNTERED, PIPELINES SHAU CLEAR THEM BY 12" MINIMUM, BOTH HORIZONTALLY AND VERTICALLY, CONSISENT WITH ABOVE PIPELINE REQUIREMENTS. PIPELINES SHALL CLEAR SEWERS IN ACCORDANCE WITH STANDARD DRAWING W102A AND W102B. SPECIRED CLEARANCES OR SEPARATIONS SHALL NOT BE REDUCED UNLESS ORDERED OR PERMlllED BY DISTRICT. PIPELINES SW NOT BE IN CONTACT WITH OR REST AGAINST OTHER UTILITY FACILITIES. 6. WHERE BOTTOM OF EXCAVATION IS IN ROCK WHICH CANNOT BE EXCAVATED TO PROVIDE UNIFORM BEARING FOR THE PIPE, TRENCH Swul BE OVERWCAVATED 8" MINIMUM AND RELlLLED WITH SELECT EXCAVATED MATERIAL OR IMPORTED BACKFILL MATERIAL COMPACTED TO 90% MINIMUM RELATIVE COMPACTION. PIPELINE GRADES SHALL BE SELECTED TO MAINTAIN MINIMUM COVER APPROVED: KRIEGER k STEWART, ENGINEERING CONSULTANTS KRIEGER 8c STEWART tNCORPORATED DATE I PIPELINE TRENCH R.C.E. I1 TYPICAL WT-TO-FIT DETAILS W~ES~IORZ AS REWIRD) LAP WELD BELL WT-TD-Fll. HO-D CD4TING AS REOURED FDR CUT-TO-FIT, 773% FIELD APPLY TO COMPLETE RDWCKED PER WTERYIIN WITLRUAIN TYPE 1 DAD CUT-TO-FIT OPTIONAL TO THE LAP WnD 63. TYPE I CUT-TO-FIT CONTRACTDR, UNLESS OTHWSE SPLCIFIS TYPE ID CUT-TO-FIT II II 1 STANDARD DRAWING wi37 REVISION I BY 1 DATE TYPE n CUT-TO-FIT TYPE N CUT-TO-FIT TYPICAL JOINT REPAIR DETAIL [FIELD CONSTRUCTIDN) INSTALL HANDHCILES (I OR 2 AS REOUIREDJ REINFORCED PER STANDIRD DRAWING WI# REMOVE BLOXN OUT GISKET WHERE P0SS18LE IN-A' L FILLER ROD AND WELD WI~R%GI~. WATERMAIN WSTING BELL END LXlSTlNG SPIGOT D13 KRIEGER 8t STEWART INCORPORATED APPROVED : KRIEGER 6 STEWART, ENGINEERING CONSULTANTS R.C.E. It WELDED STEEL PIPE CUT-TO-FIT & JOINT I II I -- REPAIR DETAIL It STEEL SHEAR RING 1 /4" STEEL REINFORCING COLLAR 4" MINIMUM 1 (UNIFORM CIRCUMFERENCE) PIPE DIAMETER SHEAR RING THICKNESS I 4 - 12 I 1/2 I I II -I- f II - - - - - - - -- 14 - 24 I+ APPURTENANCE . - - I ! PIPE CYLINDER ' CEMENT MORTAR LINING TYPICAL SHEAR RING DETAIL ITEM 1 'PIPE COATING MAY BE DELETED AT SHEAR RING PROViDED PIPE CYLINDER APPROVED DESCRIPTION MATERIAL LIST NO. A-Ol/D-Ol CEMENT MORTAR LINED OR CEMENT MORTAR COATED WELDED STEEL PIPE OR AND SHEAR RING ARE FULLY ENCASED BY SHEAR RING BLOCK. 2 3 SHEAR RING FLANGE c-01 FLANGED BY PUSH-ON ADAPTOR D-03 NO OTHER FITTINGS OR APPURTENANCES UNLESS SPECIFIED OTHERWISE 5'-0" L 5'-0" APPROVED: KRIEGER & STEWART, ENGINEERING CONSULTANTS DATE I THRUST BLOCK KRIEGER & STEWART INCORPORATED -BUND FLANGE FOR END OF PIPELINE OR STEEL FLANGED COUPLING ADAPTER, FLANGED VALVE. OR FLANGED APPURTENANCE R.C.E. II 1 SHEAR RING INSTALLATION - WELDED STEEL PIPE WELDED STEEL PIPE SHEAR RING DETAIL SHEAR SPOOL INSTALLATION - WELDED STEEL PIPE I I AS SPECIFIED FOR PIPELINE. I I II I STANDARD DRAWING W138 REVISION I BY I DATE APPENDIX E CMWD'S APPROVED MATERIALS LIST FOR USE ON CONSTRUCTION OF POTABLE AND RECYCLED WATER FACl LIT1 ES Y d a a a 21 I p 5 Z 111 a Q a - I I I I ! I I I ! i C C r 0 m 0 0 0- 0 w 3 x J a a a u) a, ~a Ph - I z 0 I si C a, c 3 3 3 .- 0' u iz fn C a, X w 4 -I W W I- 7- c 1: Ln N 9 n n a X Z w a - >- *e m w c3 -9 c: x n n A 6 a Is