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Home My WebLink AboutFCI Constructors; 2004-02-06; 3887-ADOC# 2005-1096568 Recording requested by: CITY OF CARLSBAD When recorded mail to: City Clerk City of Carlsbad 1200 Carlsbad Village Dr. Carlsbad, CA 92008 DEC 22, 2005 12:35 PM OFFICIAL RECORDS SAN DIEGO COUNTY RECORDER'S OFFICE GREGORY J. SMITH. COUNTY RECORDER FEES: 0.00 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 City of Carlsbad, 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 March 2, 2005. 6. The name of the contractor for such work of improvement is FCI Constructors. 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 construction of the Carlsbad Water Recycling Facility Pipeline to "D" Tanks Reaches 1 & 3, for the Encina Basin Water Reclamation Program, Phase II Project, Project Nos. 3887-1A and 3667. GLENN PRUIM Deputy Public Works Director VERIFICATION OF CITY CLERK I, the undersigned, say: I am the City Clerk of the City of Carlsbad, 1200 Carlsbad Village Drive, Carlsbad, California, 92008. The City Council of said City on December 13 2005, accepted the above described work as completed and ordered that a Notice of Completion be filed. I declare under penalty of perjury that the foregoing is true and correct. Executed on December 13 2005, at Carlsbad, California. CITY OF CARLSBAD LORRAINE M. WOOD City Clerk DGC# 2005-1096569 Recording requested by: CITY OF CARLSBAD When recorded mail to: City Clerk City of Carlsbad 1200 Carlsbad Village Dr. Carlsbad, CA 92008 DEC 22, 2005 12:35 PM OFFICIAL RECORDS SAN DIEGO COUNTY RECORDER'S OFFICE GREGORY J. SMITH, COUNTY RECORDER FEES: 0.00 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 March 2, 2005. 6. The name of the contractor for such work of improvement is FCI Constructors. 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 construction of the Carlsbad Water Recycling Facility Pipeline to "D" Tanks Reaches 1 & 3, for the Encina Basin Water Reclamation Project, Phase II Project, Project Nos. 3887-1A and 3667. CITY OF CARLSB^ GLENN PRUIM Deputy 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 December 13 2005, accepted the above described work as completed and ordered that a Notice of Completion be filed. I declare under penalty of perjury that the foregoing is true and correct. Executed on December 13 . 2005, at Carlsbad, California. CARLSBAD MUNICIPAL WATER DISTRICT LORRAINE M. WOOD Secretary (Vo CARLSBAD MUNICIPAL WATER DISTRICT San Diego County California CONTRACT DOCUMENTS AND SPECIAL PROVISIONS FOR ENCINA BASIN WATER RECLAhlATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO I'D" TANKS REACHES I AND 3 CONTRACT NO. 38891-A SWRCB PROJECT NO. C-06-3903-220 PWMS04-12ENG GRavised: 07/29/02 Contract No. 38871 -A Page 1 of 152 Pages . .. . Item TABLE OF CONTENTS Paqe Notice Inviting Bids .......................................................................................................................... 9 Contractor’s Proposal ................................................................................................................... 13 Equipment Material Source Information ....................................................................................... 24 Bid Security Form .......................................................................................................................... 25 Bidder’s Bond to Accompany Proposal ........................................................................................ 26 Guidelines for Completing The “Designation Of Subcontractor Amount Of Subcontractor’s Bid’’ And “Designation Of Owner Operator/Lessor & Amount Of Owner OperatodLessor Work” Forms ................................................................................................................................. 28 Designation Of Subcontractors & Amount Of Subcontractor’s Bid .............................................. 30 Designation Of Owner Operator/Lessor & Amount Of Owner Operator/Lessor Work ................ 31 Bidder’s Statement Of Financial Responsibility ............................................................................ 32 Bidder’s Statement Of Technical Ability And Experience ............................................................. 33 Bidder’s Certificate Of Insurance For General Liability. Employers’ Liability Automotive Liability And Workers’ Compensation ........................................................................................... 34 Bidder’s Statement Of Re-Debarment .......................................................................................... 35 Bidder’s Disclosure Of Discipline Record ..................................................................................... 36 Non-Collusion Affidavit To Be Executed By Bidder And Submitted With Bid .............................. 38 Contract Public Works .................................................................................................................. 39 Labor And Materials Bond ............................................................................................................ 45 Faithful PerformanceNVarranty Bond ........................................................................................... 47 Escrow Agreement For Surety Deposits In Lieu Of Retention (Optional) .................................... 49 . @Revised: 07/29/02 Contract No . 38871-A Page 2 of 152 Pages 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 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 General Provisions Terms Definitions. Abbreviations And Symbols Terms .................................................................................................................... 52 Definitions ............................................................................................................. 53 Abbreviations ........................................................................................................ 54 Scope And Control Of The Work Subcontracts ......................................................................................................... 54 Contract ................................................................................................................. 54 Plans And Specifications ...................................................................................... 56 Surveying .............................................................................................................. 58 Authority Of Board And Engineer ......................................................................... 62 Changes In Work Extra Work ............................................................................................................ 62 Changed Conditions ............................................................................................. 63 Disputed Work ...................................................................................................... 64 Control Of Materials Materials And Workmanship ................................................................................. 66 Materials Transportation. Handling And Storage ................................................. 67 Utilities ................................................................................................................... 68 Location .................................................................................................................. 68 Relocation ............................................................................................................. 68 Prosecution. Progress And Acceptance Of The Work ......................................... 68 Construction Schedule And Commencement Of Work ........................................ 68 Prosecution of Work ............................................................................................. 73 Delays And Extensions Of Time ........................................................................... 74 Time of Completion ............................................................................................... 74 Completion And Acceptance ................................................................................. 75 Liquidated Damages ............................................................................................. 75 Responsibilities Of The Contractor ....................................................................... 75 Liability Insurance ................................................................................................. 76 Workers’ Compensation Insurance ...................................................................... 76 Permits .................................................................................................................. 76 Cooperation and Collateral Work ......................................................................... 76 Project Site Maintenance ...................................................................................... 77 Public Convenience And Safety ........................................................................... 77 Laws To Be Observed .......................................................................................... 82 Measurement 81 Payment Measurement Of Quantities For Unit Price Work ................................................. 82 Payment ................................................................................................................ 82 . e= \@Revised: 07/29/02 Contract No . 38871 -A Page 3 of 152 Pages Part 2 Construction Materials Rock Materials Untreated Base Materials ..................................................................................... 86 Section 200 200-2 t Concrete. Mortar And Related Materials .............................................................. 87 Portland Cement Concrete ................................................................................... 87 Section 201 201 -1 Section 203 203-6 203-1 1 Bituminous Materials Asphalt Concrete .................................................................................................. 87 Asphalt Pavement And Crack Sealants ................................................................ 89 Section 206 206-7 206-8 206-9 Miscellaneous Metal Items Traffic Signs .......................................................................................................... 90 Light Gage Steel Tubing And Connectors ............................................................ 93 Portable Changeable Message Sign .................................................................... 94 Section 207 207-25 Pipe Underground Utility Marking Tape ........................................................................ 95 Section 209 209-1 209-2 209-3 209-5 209-7 . 209-8 Signals. Lighting And Electrical Systems General .................................................................................................................. 96 Materials And Installation .................................................................................... 101 Controller Assemblies ......................................................................................... 121 Detectors ............................................................................................................. 122 Removing. Reinstalling Or Salvaging Electrical Equipment ............................... 132 Payment .............................................................................................................. 133 Section 21 0 21 0-1 Paint And Protective Coatings Paint .................................................................................................................... 134 Section 212 21 2-2 Landscape and Irrigation Materials Irrigation System Materials .................................................................................. 134 Section 21 3 21 3-2 21 3-3 Engineering Fabrics Geotextiles .......................................................................................................... 136 Erosion Control Specialties ................................................................................. 137 Section 21 4 21 4-5 Pavement Markers Reflective Pavement Markers ............................................................................. 137 Part 3 Construction Methods Section 300 300- 1 300-2 Earthwork Clearing And Grubbing ....................................................................................... 139 Unclassified Excavation ...................................................................................... 139 Treated Soil. Subgrade Preparation and Placement of Base Materials Subgrade Preparation ......................................................................................... 139 Section 301 301 -1 i @Revised: 07/29/02 Contract No . 38871 -A Page 4 of 152 Pages Section 302 Roadway Surfacing 302-5 Asphalt Concrete Pavement ............................................................................... 140 302-1 1 Asphalt Pavement Repairs And Remediation .................................................... 141 Section 303 Concrete and Masonry Construction 303-1 Concrete Structures ............................................................................................ 142 303-5 Concrete Curbs, Walks, Gutters, Cross Gutters, Alley Intersections, Access Ramps, And Driveways ..... ....... ....... ................... .... ..... ............ ............... 142 303-6 Stamped Concrete .............................................................................................. 143 Section 306 Underground Conduit Construction 306-1 306-5 Open Trench Operations .................................................................................... 143 Abandonement Of Conduits And Structures ...................................................... 146 Section 308 308-4 Planting ............................................................................................................... 146 Landscape And Irrigation Installation Section 31 0 Painting 31 0-5 Painting Various Surfaces .................................................................................. 148 Section 31 2 31 2-1 Pavement Marker Placement And Removal Placement ........ .............. . ...... . ....... ........ ..... .. ..... ..... .. ..... .... . ............ .... . ........ ..... .. .149 Section 313 31 3-1 31 3-2 31 3-3 31 3-4 Temporary Traffic Control Devices Temporary Traffic Pavement Markers ................................................................ 149 Temporary Traffic Signing .................................................................................. 150 Temporary Railing (Type K) and Crash Cushions .............................................. 151 Measurement and Payment ....... ................. .... .............. .... .................................. 152 .- Appendices A. Residential Notification Example B. Geotechnical Investigation C. Caltrans Permit D. SDG&E Work Order 4- Revised: 07/29/02 Contract No. 38871 -A Page 5 of 152 Pages - Item Page 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 State Wage Rate Clause Labor Code Section 1776; Complete Payroll Records; Certified and Available Labor Code Section 1 777.5; 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 State MBWBE Provisions; includes Attachment A and Attachment B MUST BE SUBMllTED 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) BP -0 BP -0 BP -1 BP -3 BP -3 BP -3 BP -3 BP -3 BP -3 BP -5 BP -12 BP -12 BP -13 BP -14 BP-18 BP-19 BP -20 BP -21 BP -23 BP -23 GRevised: 07/29/02 Contract No. 38871 -A Page 6 of 152 Pages Item Pane c - STATE WATER RESOURCES CONTROL BOARD CONTRACT REQUIREMENTS 21 Non-Collusion Affidavit (Public Contracts Code Section 71 06) TO BE NOTARIZED AND SUBMllTED WITH THE BID BP -24 22 Affirmative Action and Equal Employment Opportunity minority participation table BP -25 23 Labor code Section 6500 BP -26 BP -26 24 Public Contract Code Section 71 05 25 Public Contract Code Section 9203 BP -27 GRevised: 07/29/02 Contract No. 38871 -A Page 7 of 152 Pages SPECIAL CONDITIONS TECHNICAL SPECIFICATIONS Section 01 025 Section 021 40 Section 02200 Section 02601 Section 02646 Section 02651 Section 02653 Section 02666 Section 03400 Section 05500 Section 09800 Section 0981 0 Section 10900 Section 1 1209 Section 10520 Section 151 20 Section 151 30 Section 151 40 Section 16641 Measurement and Payment Dewatering Earthwork Buried Piping Installation Plastic (PVC) Pressure Pipe ((AWWA C900) Steel Pipe - Cement Mortar Lined & Tape Coated Steel Pipe Fabricated Specials Water Pipeline Testing and Disinfection Precast Concrete Vaults Miscellaneous Metalwork Protective Coatings Tape Coating For Steel Pipe Miscellaneous Specialties Submersible Sump Pumps Valves and Appurtenances Piping Specialties Gages Pipe Hangers and Supports Sacrificial Anode Cathotic Protection 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 ASSOCIATE ENGINEER, Chris Muehlbacher PHONE (760) 602-2736 GRevised: 07/29/02 Contract No. 38871 -A Page 8 of 152 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 28Ih day October, 2003, at which time they will be opened and read, for performing the work as follows: The installation of approximately 7,000 linear feet of 24-inch cement mortar lined and tape coated steel pipe, 18,000 linear feet of distribution pipe, (ranging in size from 4 to 12-inches) a pressure reducing station, and all associated appurtenances. CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 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 the 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. 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 Agent. The Escrow Agent shall maintain insurance to cover negligent acts and omissions of the agent in connection with the handling of retentions under this section in an amount not less than $100,000 per contract. The documents which comprise the Bidder's proposal and that must be completed and properly executed, including notarization where indicated are: em %#Revised: 07/29/02 Contract No. 38871-A Page 9 of 152 Pages - 1. Contractor’s Proposal 2. Bidder’s Bond 3. Non-Collusion Affidavit 4. Designation of Subcontractors and Amount of Subcontractor Bid 5. Designation of Owner Operator/Lessors & Amount of Owner Operator/Lessor Work 6. Bidder’s Statement of Financial 7. Bidder’s Statement of Technical Ability and 8. Acknowledgment of Addendum(s) 9. State MBENVBE Information (Attachment B) Responsibility Experience 1O.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 11. Bidder’ s Statement Re Debarment 12. Bidder’s Disclosure Of Discipline Record 13. Escrow Agreement for Security Deposits - (optional, must be completed if the Bidder wishes to use the Escrow Agreement for Security) 14. EquipmentIMaterial Source Information *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 $4,129,500. 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 fhe contractor shall state their license number, expiration date and classification in the proposal, under penalty of perjury. This invitation to bid does not involve federal funds. The following classifications are acceptable for this contract: Classification “A’. I 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. 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. a %#Revised: 07/29/02 Contract No. 38871-A Page 10 of 152 Pages - The general prevailing rate of wages for each craft or type of worker needed to execute the Contract shall be those as determined by the Director of Industrial Relations pursuant to the sections 1770, 1773, and 1773.1 of the Labor Code. Pursuant to section 1773.2 of the Labor Code, a current copy of applicable wage rates is on file in the Office of the City Engineer. The Contractor to whom the Contract is awarded shall not pay less than the said specified prevailing rates of wages to all workers employed by him or her in the execution of the Contract. The Prime Contractor shall be responsible for insuring compliance with provisions of section 1777.5 of the Labor Code and section 4100 et seq. of the Public Contracts Code, "Subletting and Subcontracting Fair Practices Act." The District Engineer is the District's "duly authorized officer" for the purposes of section 4107 and 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. A pre-bid meeting and tour of the project site will not be held. All bids are to be computed on the basis of the given estimated quantities of work, as indicated in this proposal, times the unit price as submitted by the bidder. In case of a discrepancy between words and figures, the words shall prevail. In case of an error in the extension of a unit price, the corrected extension shall be calculated and the bids will be computed as indicated above and compared on the basis of the corrected totals. All prices must be in ink or typewritten. Changes or corrections may be crossed out and typed or written in with ink and must be initialed in ink by a person authorized to sign for the Contractor. 1 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 ($1 0,000,000). 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. ew $#Revised: 07/29/02 Contract No. 38871-A Page 11 of 152 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: 1) 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. 555, adopted on the 1 gth day of August, 2003. September 15, 2003 ISABEL LE PAU LS E N DEPUTY CLERK %#Revised: 07/29/02 Contract No. 38871-A Page 12 of 152 Pages CARLSBAD MUNICIPAL WATER DISTRICT CONTRACT NO. 38871-A ENClNA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES I AND 3 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. 38871-A in accordance with the Plans, Specifications, Supplemental Provisions and addenda thereto and that he/she will take in full payment therefor the following unit prices for each item complete, to At: BID SCHEDULE A PIPELINE AND PRESSURE REDUCING STATION (EXCLUDING THE WORK DESCRIBED IN BID SCHEDULES B AND C) Item - No. DescriDtion 1 Sheeting, shoring, bracing at Dollars (Lump Sum) Approximate Quantity Unit and Unit Price 1 LS $ 1.m.00 I' 2 Mobilization/demobilization at 1 LS $100.000.00 ( Not-to-Exceed) One hundred thousand dollars Dollars (Lump Sum) 3 Construction schedule at 1 LS $10,000.00 Ten thousand dollars Dollars (Lump Sum) 4 SWPPPat 1 LS $ 8DoL3.00 Dollars (Lump Sum) 5 Pressure reducing station at Dollars (Lump Sum) $ 1.2W.UO $1 00.000.00 $10,000.00 $ 8,000.00 1 LS !$ 70,oco.w $70,000 .m Revised: 10/29/03 Contract No. 3887 1 -A Addendum No. 2 Page 13 of 98 Pages Approximate Quantity and Unit I tem - No. Description Work within Caltrans right-of-way at 6 7 8 9 10 11 12 13 14 15 1 LS Dollars (Lump Sum) New 14-inch expansion joints at 4 EA Dollars Each 24-inch pipeline WSPA at 6,840 LF Dollars per Linear Foot !Ti q3.m 1,598 LF 12-inch pipeline CL 200 PVC at Dollars per Linear Foot $ 87.00 12-inch pipeline CL 150 PVC at 2,884 LF Dollars per Linear Foot 6-inch pipeline CL 200 PVC at 4,613 LF Dollars per Linear Foot 480 LF 6-inch pipeline CL 150 PVC at Dollars per Linear Foot $ -75.00 273,225,m 4-inch pipeline CL 200 PVC at 3,643 LF Dollars per Linear Foot 24-inch butterfly valves, CL 250 at 4 EA Dollars Each 24-inch buttemy valves, CL 150 at 4 EA Dollars Each e* P’SRevised: 10/29/03 Contract No. 38871-A Addendum No. 2 .-__- ~~ Page 14 of 98 Pages - Item - No. DescriDtlon 16 12-inch gate valve at Approximate Quantity Unit and Unit - Price 15 EA Dollars Each 17 6-inch gate valve at 7 EA $ 850.00 $ 5!qs0.00 Dollars Each 18 4-inch gate valve at 10 EA $ coso.00 $ I bmooo Dollars Each 2-inch air release and vacuum valve at 19 25 EA Dollars Each 20 2-inch blow-off assembly at 22 EA .- Dollars Each 21 2-inch manual air release 9 EA assembly at Dollars Each 22 2-inch irrigation service at 34 EA Dollars Each 23 4-inch blow-off assembly at 10 EA Dollars Each 24 Traffic signal video detection at 1 LS Dollars (Lump Sum) 25 Traffic control at 1 LS Dollars (Lump Sum) em %$Revised: 10/29/03 Contract No. 38871-A Addendum No. 2 Page 15 of 98 Pages Item - No. Description 26 Electrical and instrumentation at Approximate Quantity Unit and Unit Price Total 1 LS Dollars (Lump Sum) SUBTOTAL Addition (+) or Deduction (-) $%-- * TOTAL BID m Nos. 1-26 (including the AdditiodDeduction item) in Total amount of Bid Schedule A, Item Nos. 1-26 (including the Addition/Deduction item) in numbers: $ Z 2%. lm,OO Price(s) given above are firm for 90 days after date of bid opening. -1 * Provision is made here for the Bidder to include an addition or deduction in his bid, if he wishes, to reflect any last minute adjustments in prices. The addition or deduction, if made, will be proportionately applied to item(s) (fill in), and reflected in the unit prices for payment purposes. If the addition, or deduction, affects more than one (1) bid item, the proportionate application of the addition, or deduction, shall be mutually agreed upon by the Contractor and the District at the preconstruction meeting. e- %#Revised: 10129103 Contract No. 38871-A Addendum No. 2 Page 16 of 98 Pages c BID SCHEDULE B: ALDERWOOD DRIVE (%a. 1+00 to Sta. 12+40.58), BATlQUlTOS DRIVE (Sta. 1+00 to Sta. 18+97.76) OPTIONAL ADDITIVE ALTERNATIVE Item - No. Description Sheeting, shoring, bracing at Dollars (Lump Sum) Approximate Quantity Unit And Unit pr& - Total Construction schedule at 1 LS Four thousand dollars Dollars (Lump Sum) ( Not-to-Exceed) SWPPP at 1 LS Dollars (Lump Sum) 8-inch pipeline CL 200 PVC at 285 LF $4.000.00 $4.000.00 $ 3,~-00 $ 3,coo.m Dollars per Linear Foot 8-inch pipeline CL 150 PVC at 488 LF Dollars per Linear Foot 6-inch pipeline CL 200 PVC at 506 LF Dollars per Linear Foot 6-inch pipeline CL 150 PVC at 1,688 LF Dollars per Linear Foot 8-inch gate valve at 1 EA Dollars Each 6-inch gate valve at 5 EA Dollars Each em f #Revised: 10/29/03 Contract No. 38871-A Addendum No. 2 Page 17 of 98 Pages I Item - No. 10 11 12 13 Description 2-inch air release and vacuum valve at Dollars Each 2-inch blow-off assembly at Dollars Each Approximate Quantity And Unit 4 EA 3 EA 2-inch irrigation service 7 EA Dollars Each Traffic control at 1 LS Unit Price $ 3,m.oo $ Is,2m.00 Dollars (Lump Sum) Total amount of Bid Schedule B, Item NOS. 1-13, in words: Thug hui?dfid tWWh(-&C Total amount of Bid Schedule B, Item :os. 1-13, in numbers: $ '325.144 .m Price(s) given above are firm for 90 days after date of bid opening. lhW%I?ck,W hUM&Qd &h &-xlY, dotlar.; awl mrevlt 5, e- ESRevised: 10/29/03 Contract No. 38871 -A Addendum No. 2 Page 18 of 98 Pages .. BID SCHEDULE C: ASPHALT PAVEMENT OVERLAY Approximate Quantity Unit and Unit Price Total 1 LS $ b,coo.~ $ d,cCO.OO Item - No. 1 2 3 4 5 6 7 8 9 Description Traffic control at ~~ Dollars (Lump Sum) Mobilization/demobilization at Dollars (Lump Sum) Full depth asphalt concrete patch at 1 LS $1 5,000.00 $1 5,000.0U $ ‘24o.m 75 TONS 600 TONS Dollars per Ton $ i20.00 Asphalt rubber hot mix (ARHM) overlay at ~ ~~ Dollars per Ton Cold milling Swidth at $ 2.00 5,490 LF 290 LF I ~~ ~ ~ Dollars per Linear Foot Cold milling 10’ wide header cut at $ 6.60 ~ ~~ Dollars per Linear Foot Full raise of sewer & stormdrain manholes at 11 EA $ 5.170.00 Dollars Each Full raise of valve boxes, monument boxes, etc. at $ q:zm.oo 46 EA Dollars Each $ 6,500.00 1 LS Pavement delineation at Dollars (Lump Sum) Total amount of Bid 5. Price(s) given above are firm for 90 days after date of bid opening. e- ESRevised: 10/29/03 Contract No. 38871-A Addendum No. 2 Page 19 of 98 Pages BASIS OF AWARD A 1 through 26 C 1 through 9 I Enter Amount from Bid Schedule I Item Nos. I Amount+f $3 244 cq0.00 $ '144.'"59 0.00 ~ -- Total amount of Bid Schedules A and C in wrds: Thy@ Mi [/io& .-f&~ hOUdQCI thidy- L4flh.t -t-cZoU~d ;s ww ad ti& A[ ks wd- Lu, C&S The basis of award will be the sum of Bid Schedule A and Bid Schedule C. The Agency reserves the right to add the wrk described in Bid Schedule B. Price(s) given above are firm for 90 days after date of bid opening. Addendum(a) No(s). I,, z hadhave been received and idare included in this proposal. OPENED, WITNESSED AND RECORDED: - DATE G ATURE em %$Revised: 10129103 Contract No. 38871-A Addendum No. 2 Page 20 of 98 Pages .- - , The Undersigned has carefully checked all of the above figures and understands that the District will not be responsible for any error or omission on the part of the Undersigned in preparing this bid. The Undersigned agrees that in case of default in executing the required Contract with necessary bonds and insurance policies within twenty (20) days from the date of award of Contract by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, the District may administratively authorize award of the contract to the second or third lowest bidder and the bid security of the lowest bidder may be forfeited. - The Undersigned bidder declares, under penalty of perjury, that the undersigned is licensed to do business or act in the capacity of a contractor within the State of California, validly licensed under license number 772589 , classification A which expires on December 31, 2003 , and that this statement is true and correct and has the legal effect of an affidavit. A bid submitted to the District by a Contractor who is not licensed as a contractor pursuant to the Business and Professions Code shall be considered nonresponsive and shall be rejected by the City 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 hidher 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 cohection 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 Bond (Cash, Certified Check, Bond or Cashier's Check) for ten percent (10%) of the amount bid. 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. c 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. qRevised: 07/29/02 Contract No. 38871 -A Page 21 of 152 Pages License Detail California Home IClassl FI Page 1 of 2 Tuesdav. November 04.2003 Description GENERAL ENGINEERING CONTRACTOR Contractor License # 772589 DISCLAIMER A license status check provides information taken from the CSLB license data base. Before relying 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 to public complaint disclosure, a link for complaint disclosure will appear below. Click on the link or button to obtain complaint and/or legal action information. are disclosed. the arbitration. onto the Board's license data base. Per B&P 7071.1 7, only construction related civil judgments known to the CSLB Arbitrations are not listed unless the contractor fails to comply with the terms of Due to workload, there may be relevant information that has not yet been entered Extract Date: 11/04/2003 * * * Business Information * * * F C I CONSTRUCTORS INC 2585 BUSINESS PARK DRIVE Business Phone Number: (760) 727-9767 Entity: Corporation Issue Date: 1211 3/1999 Expire Date: 12/31/2003 VISTA, CA 92086-8831 * * * License Status * * * This license is current and active. All information below should be reviewed. * * * Classifications * * * * * * Certifications * * * ~~ llcertll DescriDtion lmiHOME IMPROVEMEiT CERTlFlCATlONl http://www2.cslb.ca.gov/CSLB_LIBRARY/License+Detail.asp 11/4/2003 License Detail Page 2 of 2 * * * Bonding Information * * * CONTRACTOR'S BOND: This license filed Contractor's Bond number 288873 in the amount of $7,500 with the bonding company NATIONAL UNION FIRE INSURANCE COMPANY OF PITTSBURGH. PA. Effective Date: 10/30/2002 Contractor's Bondina History BOND OF QUALIFYING INDIVIDUAL(1): This license filed Bond of Qualifying Individual number 23004795 for THOMAS J RADEMACHER in the amount of $7,500 with the bonding company LIBERTY MUTUAL INSURANCE COMPANY. Effective Date: 1 1/03/1999 * * * Workers Compensation Information * * * This license has workers compensation insurance with the Policy Number: WC298849303 Effective Date: 06/01/2003 Expire Date: 06/01/2004 ZURICH AMERICAN INSURANCE COMPANY (4581 -5) Workers Compensation History Personnel listed on this license (current or disassociated) are listed on other licenses. Personnel List Other Licenses License Number Request Contractor Name Request Personnel Name Request Salesperson Request Salesperson Name Request Q 2003 State of California. Conditions of Use Privacy Policy http://www2.cslb.ca.gov/CSLB_LIBRARY/License+Detail.asp 11/4/2003 Personnel List Page 1 of 1 California Home Tuesday, November 04,2003 Personnel List CALIFORNIA CONTRACTORS STATE LICENSE BOARD Contractor License # 772589 Click on the person's name to see a more detailed page of information on that person. Name JOHN DAVID NELSON PAUL RICHARD D R I SCOLL SCOTT SLAUGHTER LYNN THOMAS J RADEMACHER ROBERT WILLIAM FRENCH - SUSAN ELAINE ELSBERRY PAUL CHARLES ROBERTS SUSAN ELAINE ROB I SON Title PRESIDENT S/T EXEC OFFICER RMO/P PRESIDENT co/s co/s VICE PRESIDENT Association Date 12/1 3/1999 la1 3/1999 12/1 3/1999 la1 3/1999 la1 3/1999 la1 3/1999 12/1 3/1999 1 2/13/1999 Disassociation Date Class More Class A More 12/1 3/1999 VICE CURTIS EVAN WELTZ PRESIDENT License ____-_. Number RequeSf Contractor Name Request Personnel Name Request Salesperson Request Salesperson Name Request 0 2003 State of California. Conditions of Use Privacv Policy 11/4/2003 License Detail pq Page 1 of 2 Description GENERAL ENGINEERING CONTRACTOR License Detail CALIFORNIA CQNTRACTORS STATE LICENSE BOARD Contractor License ## 772589 DISCLAIMER A license status check provides information taken from the CSLB license data base. Before relying 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 to public complaint disclosure, a link for complaint disclosure will appear below. Click on the link or button to obtain complaint and/or legal action information. are disclosed. I the arbitration. Per B&P 7071.1 7, only construction related civil judgments known to the CSLB Arbitrations are not listed unless the contractor fails to comply with the terms of Due to workload, there may be relevant information that has not yet been entered onto the Board's license data base. Extract Date: 01/28/2004 - * * * Business Information * * * F C I CONSTRUCTORS INC 2585 BUSINESS PARK DRIVE Business Phone Number: (760) 727-9767 Entity: Corporation Issue Date: 12/13/1999 Expire Date: 12/31/2005 VISTA, CA 92086-8831 J * * * License Status * * * This license is current and active. All information below should be reviewed. * * * Classifications * * * * * * Bonding Information * * * CONTRACTOR'S BOND: This license filed Contractor's Bond number 288873 in the http://www2.cslb.ca.gov/CSLB~LlBRARY/License+Detail.asp 01 /28/2004 License Detail Page 2 of 2 amount of $7,500 with the bonding company NATIONAL UNION FIRE INSURANCE COMPANY OF PITTSBURGH. PA. Effective Date: 10/30/2002 Contractor's Bonding History - BOND OF QUALIFYING INDIVIDUAL(1): This license filed Bond of Qualifying Individual number 23004795 for THOMAS J RADEMACHER in the amount of $7,500 with the bonding company LIBERTY MUTUAL INSURANCE COMPANY. Effective Date: 11/03/1999 * * * Workers Compensation Information * * * This license has workers compensation insurance with the ZURICH AMERICAN INSURANCE COMPANY (4581-5) Policy Number: WC298849303 Effective Date: 06/01/2003 Expire Date: 06/0 12008 Workers Compensation History Personnel listed on this license (current or disassociated) are listed on other licenses. ,- Personnel List Other Licenses License Number Request Contractor Name Request Personnel Name Request Salesperson Request Salesperson Name Request 0 2003 State of California. Conditions of Use Privacy Policy 01 /28/2004 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) Zip Code 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 City and State (4) Zip Code Telephone No. IF A CORPORATION, SIGN HERE: (1) Name under which business is conducted (Street and Number) FCI c trurtprs T~C. ... ... ... ... ... - " Thomas J. Rademacher, President (Title) Impress Corporate Seal here #Revised: 07/29/02 Contract No. 38871-A Page 22 of 152 Pages I - (3) Incorporated under the laws of the State of Delaware I ’ (4) Place of Business 2585 Business P& Drive (Street and Number) City and State Vista, CA (5) Zip Code 92081-8831 Telephone No. (760) 727-9767 NOTARIAL ACKNOWLEDGMENT OF EXECUTION BY ALL SIGNATORIES MUST BE ATACHED List below names of president, vice president, secretary and assistant secretary, if a corporation; if a partnership, list names of all general partners, an Thomas J. Rademacher, President John D. Nelson, Vice President James J. Keep, Vice President Paul R. Driscoll, Vice President, Secretary, Treasure Paul Roberts, Vice President and Assistant Secretary QRevised: 07/29/02 Contract No. 38871 -A __ Page 23 of 152 Pages #-- State of Colorado County of Adams I, a Notary Public for the said County and State, do hereby certify that Paul R. Driscoll personally appeared before me and acknowledged the execution of the foregoing instruments for the purpose therein expressed. Witness my hand and seal this 3 lSt day of October ,2003. My Commission Expires: 1 o/ 2 8 / D(& state of Cdorado c CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT I State of California I ss. Countyof San Diego On October 30. 2003 beforeme, Julie A. Patlan, Notary Public , Date Name and Tltle of Mficer (e.g.. "Jane Doe. Notary Publlc") personally appeared Paul Roberts Name(s) of Signer@) II(I personally known to me 0 proved to me on the basis of satisfactory evidence to be the person(W whose name0 is/&W subscribed to the within instrument and acknowledged to me that he-executed the same in his/- authorized capacity= and that by his/mr signature@ on the instrument the person@, or the entity upon behalf of which the person(@ acted, executed the instrument. WITNESS my hand and official seal. Y Signature of Notary Public OPTIONAL Though the information below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Document Date: October 30. 2003 Number of Pages: Signer@) Other Than Named Above: Contractor's Proposal Capacity(ies) Claimed by Signer Signer's Name: Paul Roberts 0 Individual B Corporate Officer - Title(s): 0 Partner - 0 Limited C General Secretary I Vice President and Assistant c1 Attorney-in-Fact 0 Trustee 0 Guardian or Conservator 0 Other: Signer Is Representing: FCI Constructors, Inc. u 0 1999 National Notary Association * 9350 De Solo Ave., P.O. Box 2402 - Chatsworth, CA 91313-2402 - www.natlonalnotaryorg Prod No 5907 Reorder: Call Toll-Free 1-800-876-6827 - CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT 'I State of California On October 30, 2003 beforeme, Julie A. Patlan, Notary Public , personally appeared Thomas J. Rademacher Dale Name and Tltle of Officer (e g , "Jane Doe. Notary Public") Name@) of Signer@) 181 personally known to me 0 proved to me on the basis of satisfactory evidence to be the person@) whose name&) isEB subscribed to the within instrument and acknowledged to me that heIWDttQCexecuted the same in his/lWIX& authorized capacity=, and that by hiswr signature&) on the instrument the person&), or the entity upon behalf of which the person$) acted, executed the instrument. WITNESS my hand and official seal. Signature of Notary Public Though the information below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Document Date: October 30, 2003 Number of Pages: Contractor's Proposa1 Signer(s) Other Than Named Above: Capacity(ies) Claimed by Signer Signer's Name: Thomas J. Rademacher 0 Individual @ Corporate Officer - Title(s): 0 Partner - 3 Limited 0 General 3 Attorney-in-Fact 0 Trustee 0 Guardian or Conservator 3 Other: President TOO of thumb here Signer Is Representing: FCI Constructors, Inc. u 63 1999 National Notary Association - 9350 De Soto Ave., P.0 Box 2402 * Chatswolth, CA 91313-2402 - www.nationalnotary.org Prod. No. 5907 Reorder: Call Toll-Free 1-800-876-6827 I CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT State of California Countyof San Diego } SS. On October 30, 2003 beforeme, Julie A. Patlan, Notary Public , personally appeared John D. Nelson Date Name and me of Mficer (e 9.. "Jane Doe. Notary Public') Name@) of Signer@) Ixl personally known to me 0 proved to me on the basis of satisfactory evidence commirskn # 1441764 to be the person@ whose name@) is/= subscribed to the within instrument and acknowledged to me that he-executed the same in his/- authorized capacity= and that by hisl-r signature&) on the instrument the person&), or the entity upon behalf of which the person@) acted, executed the instrument. WITNESS my hand and official seal. - A #.M ad Signature of Notary Public OPTIONAL Though the information below is not required by law, it may prove valuable to persons re/ying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Contractor's Proposal Document Date: October 30, 2003 Number of Pages: Signer(s) Other Than Named Above: Capacity(ies) Claimed by Signer Signer's Name: John D. Nelson 0 Individual 0 Partner - 0 Limited 0 General 0 Attorney-in-Fact 0 Trustee Guardian or Conservator 0 Other: Signer Is Representing: FCI Constructors, Inc Corporate Officer - Title(s): Vice President Q 1999 National Notary Association * 9350 De Soto Ave , P.0 Box 2402 - Chatsworth. CA 91313-2402 - www.nationalnotary.org Prod. No. 5907 Reorder: Call Toll-Free 1-800-876-6827 I- CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT ... rc } SS. State of California County of Sari Diego On October 30, 2003 beforeme, Julie A. Patlan, Notary Public , personally appeared James J . Keep Date Name and Title of Oflicer (e g., "Jane Doe. Notary Public") Narne(s) of Signer($ E personally known to me 0 proved to me on the basis of satisfactory evidence to be the person(@ whose name(@ is/= subscribed to the within instrument and acknowledged to me that he-xecuted the same in his/- authorized capacity(m and that by his/- signature@ on the instrument the person@, or the entity upon behalf of which the person(@ acted, executed the instrument. WITNESS my hand and official seal. f&Qd Signature of Notary Public OPTIONAL Though the information below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Document Date: October 30, 2003 Number of Pages: Signer(s) Other Than Named Above: Contractor's Proposal Capacity(ies) Claimed by Signer Signer's Name: James J. Keep Individual B Corporate Officer - Title(s): 0 Partner - 0 Limited General 0 Attorney-in-Fact 0 Trustee 0 Guardian or Conservator 0 Other: Signer Is Representing: FCI Constructors 9 Inc Vice President 0 1999 National Notary Association * 9350 De Soto Ave . P.O. Box 2402 * Chatsworth, CA91313-2402 * www.natlonalnotary.org Prod. No 5907 Reorder: Call Toll-Free 1-800-676-6827 EQUIPMENT/MATERIAL SOURCE INFORMATION TO ACCOMPANY PROPOSAL CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO I'D" TANKS REACHES 1 AND 3 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 _- 1. 24-inch Welded Steel Pipe CML&TC with Rock Shield L (Manu f act u re r) r- 2. 14-inch Double Ball FlexTend . tn)? ,a,\ 113atQ.r 1uork 5 AWcs '~1~/xTmd _- (Manu fact u rer) UMG - I 3. 24-inch Butterfly Valves uel w (Manufacturer) - qRevised: 07/29/02 Contract No. 38871 -A Page 24 of 152 Pages BID SECURITY FORM (Check to Accompany Bid) CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 (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 ($ 1 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. 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.) @Revised: 07/29/02 Contract No. 38871 -A Page 25 of 152 Pages BIDDER'S BOND TO ACCOMPANY PROPOSAL CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 I KNOW ALL PERSONS BY THESE PRESENTS: That we, FCI Constructors, Inc. as Surety are held and firmly bound unto the Carlsbad Municipal Water District, Carlsbad, California, in an amount as follows: (must be at least ten percent (10%) of the bid amount) Ten Percent (10%) of the ** for which payment, well and truly made, we bind ourselves, our heirs, executors and administrators, successors or assigns, jointly and severally, firmly by these presents. * Maryland THE CONDITION OF THE FOREGOING OBLIGATION IS SUCH that if the proposal of the above- bounden Principal for: , as Principal, and Fidelity and Deposit Compapy of * ** Total Amount of the Bid CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 in the City of Carlsbad, is accepted by the Board of Directors, and if the Principal shall duly enter into and execute a Contract including required bonds and insurance policies within twenty (20) days from the date of award of Contract by the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, being duly notified of said award, then this obligation shall become null and void; otherwise, it shall be and remain in full force and effect, and the amount specified herein shall be forfeited to the said District. .... .... .... .... .... .... .... .... .... .... .... a Revised: 07/29/02 Contract No. 38871 -A Page 26 of 152 Pages In the event Principal executed this bond as an individual, it is agreed that the death of Principal shall not exonerate the Surety from its obligations under this bond. Executed by PRINCIPAL this 30th day ,2003 . of October PRINCIPAL: FCI Constructors, Inc. (name of Principal) n Thomas J. Rademacher, President (print name here) President .- By: - -__ Paul Roberts ~~~ - (print name here) Vice President and Assistant Secretary (title and organization of signatory) day of 21st Executed by SURETY this ,2003 . October SURETY: Fidelity and Deposit Company of Maryland ~ ~~ (name of Surety) 225 S. Lake Avenue, Suite 700 Pasadena, CA 91101 (address of Surety) 626-792-2311 (tekphone number of Surety) Leigh McDonough, Attorney-in-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 onry 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 attach a statement of partnership authorizing the partner to execute this instrument.) APPROVED AS TO FORM: RONALD R. BALL General Counsel By: GRevised: 07/29/02 Contract No. 38871 -A Page 27 of 152 Pages CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT - } SS. State of California County of San Diego On October 30, 2003 beforeme, Julie A. Patlan, Notary Public , Date Name and Title of Onicer (e g , "Jane Doe, Notary Publlc") personally appeared Thomas J . Rademacher Name@) of Signer($ .CZ personally known to me 0 proved to me on the basis of satisfactory evidence to be the personm whose name(@ is/= subscribed to the within instrument and acknowledged to me that he/W&lE@$ executed the same in his/WUWb authorized capacity&), and that by his/RQtl4&& signaturem on the instrument the person(@, or the entity upon behalf of which the person$) acted, executed the instrument. WITNESS my hand and official seal. Signature of Notary Public OPTIONAL Though the information below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Bidder ' Bond Document Date: October 30, 2003 Number of Pages: Signer(s) Other Than Named Above: Capacity(ies) Claimed by Signer Signer's Name: Thomas J. Rademacher Top of thumb here 0 Individual 0 Partner - CI Limited General 0 Attorney-in-Fact 0 Trustee Guardian or Conservator c1 Other: Signer Is Representing: FCI Constructors, Inc. Corporate Officer - Title(s): President 0 1999 National Notary Association * 9350 De Solo Ave.. P.O. Box 2402 * Chatsworth. CA 91313-2402 www nationalnotary.org Prod, No, 5907 Reorder. Call Toll-Free 1-8W8764827 CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT - State of California 'I On October 30, 2003 beforeme, Julie A. Patlan, Notary Public , personally appeared Paul Roberts Date Name and Title of Officer (e g , 'Jane Doe Notary Public") Name(s) of Signer(s) 3 personally known to me 3 proved to me on the basis of satisfactory evidence to be the person(%) whose name(@ ism subscribed to the within instrument and acknowledged to me that he/- executed the same in his/- authorized capacitym), and that by his/K"r signature(@ on the instrument the person(@, or the entity upon behalf of which the persono acted. executed the instrument. WITNESS my hand and official seal. Signature of Notary Public OPTIONAL Though the information below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Document Date: October 30, 2003 Number of Pages: Signer@) Other Than Named Above: Bidder ' S Bond Capacity(ies) Claimed by Signer Signer's Name: Paul Roberts 0 Individual 24 Corporate Officer - Title(s): Vice President & Assistant Secretary 7 Partner - 2 Limited 0 General 0 Trustee 3 Guardian or Conservator J Other: Signer Is Representing: FCI COnStructors , Inc. Attorney-in-Fact Q 1999 National Notary Association * 9350 De Sot0 Ave , P.0 Box 2402 * Chatsworth, CA 91 31 3-2402 * www nationalnotary org Prod. No. 5907 Reorder: Call Toll-Free 1-800-876-6827 CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT No. 5907 State of California County of Orange On October 21, 2003 personally appeared Leigh McDonough t Ix] personally known to me - OR - 0 proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) islare subscribed to the within instrument and acknowledged to me that helshelthey executed the same in hislherltheir authorized capacity(ies), and that by hislherltheir signature(s) on the instrument the person(s), or the entity upon behalf of which the person(s) acted, executed the instrument. before me, Alexis H. Bryan, Notary Public DATE NAME, TITLE OF OFFICER - E.G., "JANE DOE, NOTARY PUBLIC NAME(S) OF SIGNER(S) OPTIONAL Though the data below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent reattachment of this form. CAPACITY CLAIMED BY SIGNER DESCRIPTION OF ATTACHED DOCUMENT INDIVIDUAL 0 CORPORATE OFFICER TITLE OR TYPE OF DOCUMENT TITLE(S) LIMITED E GENERAL 0 PARTNER(S) ATTORNEY-IN-FACT TRUSTEE(S) 0 GUARDIANlCONSERVATOR NUMBER OF PAGES 0 OTHER: SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTITY(IES) DATE OF DOCUMENT SIGNER(S) OTHER THAN NAMED ABOVE S-4067/GEEF 2/98 8 1993 NATIONAL NOTARY ASSOCIATION - 8236 Remmet Ave., P.O. Box 7184 - Canoga Park, CA 91309-718, rc Power of Attorney FIDELITY AND DEPOSIT COMPANY OF MARYLAND HOME OFFICE: 3910 KESWICK ROAD, BALTIMORE, MD 21211 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 L. L. GOUCHER, Assistant Secretary, in pursuance of authority granted by Article V1, Section 2, of the By-Laws of said Company, which are set forth on the reverse side hereof and are hereby certified to be in full force and effect on the date hereof, does hereby nominate, constitute and appoint Leigh MCDONOUGH, of Costa Mesa, Califo wful agent and Attorney-in-Fact, to make, execute, seal and deliver, for, and on its behalf as sure : any and all bonds and undertakings and the execution of such bonds or undertakings in pursu 1 be as binding upon said Company, as fully and amply, to all intents and purposes, as if they h cknowledged by the regularly elected officers of the Company at its office in Baltimore, Md., in t The said Assistant Secretary does hereby the reverse side hereof is a true copy of Article VI, Section 2, of the By-Laws of said Company, IN WITNESS WHEREOF, the said V t Secretary have hereunto subscribed their names and affixed the Corporate Seal of the said IT COMPANY OF MARYLAND, this 27th day of September, A.D. 2001. ATTEST: FIDELITY AND DEPOSIT COMPANY OF MARYLAND . L. Goucher Assistant Secretary M. P. Hammond Vice President }ss: State of Maryland County of Baltimore On this 27th day of September, A.D. 2001, before the subscriber, a Notary Public of the State of Maryland, duly commissioned and qualified, came M. P. HAMMOND, Vice President, and L. L. GOUCHER, 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 oficers 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. Carol J. Fader Notary Public My Commission Expires: August 1,2004 POA-F 012-5025H 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 original Power of Attorney of which the foregoing is a full, true and correct copy, is in full force and effect on the date of this certificate; and I do further 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.” I IN TESTIMONY WHEREOF, I have hereunto subscribed my name and affixed the corporate seal of the said Company, October 2003 this ’lst day of Assistant Secretary ZURICH T€J?S IMPORTANT DISaOSuRE NOTICE 1s PART OF YOUR BOND Fidelity and Deposit Company of Maxyhd, Colonial American Camally and SmV Company, Zurich American bumwe Company, and American Guarantee and Liability Insurance Conrpany as makiqg the fbllowiqg idonnational disclosures in compliance with The Tenolrism Risk Insurance Act of 2002. No action is quired on your part. pisclosure of Terrorhim lpremlum The pxwaziuXn charge for risk of loss resulting from acts of terrorism (as defined h the Act) wnder this bond is $-waived-. This mount is reflected in the total premium for this bond JIWosure of Availabilitv of-Coverave. for Terrorism Losses As required by the Terrorism Risk Insurance Act of 2002, we have made adable to you covemq$ fQr losses resulting fbxlactsofttmmsm * (as defined in the Act) with tams, amounts, and lMt&ms that do not differ matmially aa those far losses arising fiom events other than acts ofterrorisn The Temnjsm Risk Inrmrance Act of 2002 establishes a mechanism by which h United SWw government will &are in iumame company losses multhg fiom acts of terrorism (as defined m the Act) after a imaranm company has paid -*3sscs k excess of an annual aggregate dtdudble. For 2002, the insurance company deductible is 1% of direct earned _mmium m the prior year; far 2003,7% of direct eamed premium in the prior yeat; far 2004,100/0 of direct em pwmium in the prior year; and for 2005,15% of ditect earned premium in the prior year. The fdd share of an inauance company’s Iosses above its deductible is 90%. In the event the United States government participates in losses, the United States government may direct insuranm companies to colk a terrorism surcharge from polioyholdexs. The Act does not menay provide for ins- industry or United States government partioipation in terrorism losses that exceed $100 billion in any one d& year. pefinition ofht of Temrism The Termism Risk Insurance Ant defines “act of tm~” as any act that iS certified by the Scscretary of the Treasury, in con-ce with the Stcretary of St#e aad the Attorney General of the United States: I. tObeanactOf~O~II& 2. to bc a violent act or an act that is daqmus to buman W, property ox inltastructurc; 3. to have multed in damage within the United States, or outside of the United States in the OW of an air oanier (as defined in section 401 02 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 mwme tax is paid and whose insurance coverage is subject to regulation in he United States), or the premises of a United States missiaa; and 4. to have been committed by an individual or individuals acting on behalf of any foreign persw or foreign interest aa part of ~tl effort to coerce the civilian populadon of the uaitod States or to influence the poky or affect the conduct of the United States Government by ooercion. But, no act sbdl be ccrtificd by the Secretary as an aot of thlprism ifthe act is camitted as part of the course of a war declared by Congcegs (except for worh’ COmpM1S(LtiOt) or property ad casualty iaanance losses redtirig fkam the aot, L the -gate, do not exceed $5,OOO,OOO. -There dfsdosures are infomatlond onIy and do not modw your bond or affect yaur rlghQI under the bond. 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 800-382-2150 Agent for Service of Process ANDREW K. PLATT, C/O ZURICH NORTH AMERICA 801 N. BRAND BLVD., 13TH FLOOR GLENDALE, CA 9 1203 Unable to Locate the Agent for Service of Process? Reference Information NAIC #: 39306 NAIC Group #: 0212 California Company ID #: 2479-4 Date authorized in California: License Status: UNLIMITED-NORMAL Company Type: Property & Casualty State of Domicile: MARYLAND 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 http://cdinswww .insurance.ca.gov/pls/wu_co~prof/idb_co_prof_utl.get_co_prof?p_EID=62. . . 1 1/4/2003 Company Profile , Page 2 of 2 PLATE GLASS SPRINKLER SURETY TEAM AND VEHICLE WORKERS' COWENS ATION Company Complaint Information ComDany Enforcement Action Documents ComDany Performance & Comparison Data ComDosite ComDlaint Studies 9 Want More? HelD Me Find a ComDanv Reuresentative in My Area Financial Rating Orpanizations Last Revised - October 16,2003 01:24 PM Copyright Q California Department of Insurance Disclaimer http://cdinswww .insurance.ca.gov/pls/wu_co_prof/idb~co~prof~utl.get_co_prof?p~EID=62. . . 1 1/4/2003 . GUIDE FOR COMPLETING THE "DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID" AND "DESIGNATION OF OWNER OPERATOWLESSOR AND AMOUNT OF OWNER OPERATOWLESSOR WORK" FORMS REFERENCES Prior to preparation of the following Subcontractor and Owner Operator/Lessor disclosure forms Bidders are urged to review the definitions in section 1-2 of the SSPWC and of 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" and "Owner Operator/Lessor." Bidders are further urged to review sections 2-3 SUBCONTRACTS of the SSPWC and section 2-3.1 of these Supplemental Provisions. CAUTIONS 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 proposed to be performed by the Bidder by other than the Contractor'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 who the Bidder proposes to perform work or labor or render service in or about the work or improvement, and every subcontractor licensed by the State of California who 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 on one-half on one percent (0.5%) of the Bidder's total bid or ten thousand dollars ($10,000) whichever is greater. Said name(s) and location(s) of business of subcontractor(s) shall be set forth and included as in integral part of the bid offer. - Bidder shall use separate disclosure forms for each Subcontractor or Owner OperatodLessor (O+O) of manpower and equipment that it proposes to use to complete the Work. Additional copies of their forms must be attached if required to accommodate the Contractor's decision to use more than one Subcontractor or Owner Operator/.Lessor. All items of information must be completely filled out. These forms must be submitted as a part of the Bidder's sealed bid. Failure to provide complete and correct information may result in rejection of the bid as non-responsive. Neither the amount, in dollars, of work performed by the Bidder's own forces (as Contractor) nor the Bidder's overhead and profit for subcontracted items of the work is included to compute percentage of the work performed by Subcontractors or Owner Operators/Lessors. When the Bidder proposes that any bid item installed by a Subcontractor or Owner Operator/Lessor the amount, in dollars, of the bid item by each Subcontractor or Owner Operator/Lessor must be entered under the columns "Amount of Subcontractor's Bid in Bid Item Including Subcontractor's Overhead & Profit" or "Amount of Owner OperatodLessor Work in Bid Item Including Owner Operator/Lessor's Overhead & Profit'' unless the dollar amount of all work performed by any Subcontractor or Owner Operator/Lessor is less than one-half of one percent (0.5%) of the Bidder's total bid or ten thousand dollars ($10,000) whichever is greater. If a Subcontractor or Owner Operator/Lessor installs or constructs any portion of a bid item the entire amount of the Contract Unit Price, less the Bidder's overhead and profit shall be multiplied by the Quantity of the bid item that the Subcontractor or Owner OperatodLessor installs to compute the amount of work so installed. GRevised: 07/29/02 Contract No. 38871 -A Page 28 of 152 Pages 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, the Subcontractor, or the Owner Operator Lessor as the case may be, that the Bidder Operator/Lessor as the case may be, installing them Proposes as installer of said materials. The value of material incorporated in any Subcontractor or Owner Operator/Lessor installed bid item that is supplied by the shall be included as a part of the work that the Bidder proposes to be performed by the Subcontractor or Owner Operator/Lessor installing said item.. -- The item number from the "CONTRACTOR'S PROPOSAL" (Bid Sheets) shall be entered in the "Bid Item No." column. When a Subcontractor or Owner OperatodLessor has a Carlsbad business license the number must be entered on the form. If the Subcontractor does not have a valid business license enter "NONE" in the appropriate space. Bidders shall make any additional copies of the disclosure forms as may be necessary to provide the required information. The number of additional form pages shall be entered on the first form page of each type so duplicated. Bidder may, at its option, combine bid items on a single row in the chart on the disclosure forms. If using this option the Bidder must indicate the bid item numbers to which the information in the row pertains. This option may not be used where the subcontractor or Owner OperatodLessors constructing or installing less than 100 percent of a bid item. The percentages and dollar amounts may be the sums of the bid items listed in that row. When the Bidder proposes using a subcontractor or owner operator/Lessor to construct or install less than 100 percent of a bid item the Bidder shall attach an explanation sheet to the designation of subcontractor or designation of Owner Operator/Lessor forms as applicable. The explanation sheet shall be provided by the Contractor to clearly apprise the Agency of the specific facts that show the Bidder proposes to perform no less than fifty percent (50%) of the work with its own forces. I Determination of the subcontract and Owner Operator/Lessor amounts for purposes of award of the contract shall 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. @Revised: 07/29/02 Contract No. 38871 -A Page 29 of 152 Pages FCI CONSTRUCTORS INC . PAGE 02 bESiGNATlON OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID ITEMS CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 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 the list in accordance with applicable provisions of the specifications and section 4100 et seq. of the Public Contracts 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 than one-half of one percent (0.5%) of the Bidder's total bid of 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. Full Company Name of Subcontractor: r, Ctadvir,Jnc. Subcontractor's Location of Business Po- fiy 1453- Street Address 'Subcontractor's Telephone Number plus Area Code: ( b IS) 4-m- bob 0 'Subcontractor's California State Contractors License No. & Classification: 2q703 - C-ro 'Subcontractor's Carlsbad Business License No,: I 21 0744 m SUBCONTRACTOR'S BID ITEMS t. Exidanation: Column 1 - 6jd item No. from the bid proposal, pages 13 through 20, inclusive. Column 2 - The dollar amount of the item to be performed by the subcontractor. Column 3 - The dollar amount of the item to be performed by Contractor's own forces. I Column 4 - The dollar amount of the Bidder's overhead and profit for the item. Total dollar amount of Columns 2, 3, and 4 must be equal to the dollar amount in the bid price of the item on bid proposal pages 13 through 20 inclusive. *Pursuant to section 4104(a)(2)(A) California Public Contracts Code receipt of the portions of the information precede by an asterisk required on this document may be submitted by the Bidder up to 24 hours after the deadline for submitting bids contained in the "Notice Inviting Bids". - Page of pages of this Subcontractor Designation form GRevised: 07/29/02 Contract No. 38871 -A 11/05/2003 03: 08 7607279803 FCI CONSTRUCTORS INC PAGE 04 -. DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID ITEMS CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "0" TANKS REACHES 4 AND 3 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 the list in accordance with applicable provisions of the specifications and sectlan 4100 et seq. of the Public Contracts Code "Subletting and Subcontracting Fair Practices Act." The Bidder further certifies that no additlonal subcontractor will be allowed to perform any portion of the Work in excess of than one-half of one percent (0.5%) of the Bidder's total bid of 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. Full Company Name of Subcontractor: hkU- CAC. J.V. Subcontractor's Location of Business 5370 &..& &K n tl Street 'Address q2121- 2w Zip CA State 3J-n Dwci City *Subcontractor's Telephone Number plus Area Code: (858) b42-7500 - *Subcontractor's California State Contractors License No. & Classification: 74w95- R ;Subcontractor's Carlsbad Business License No.: 12mf g3 SUBCONTRACTOR'S BID ITEMS .. Exdanation: Column 1 - Bid Item No. from the bid proposal, pages 13 through 20, inclusive. Column 2 - The dollar amount of the item to be performed by the subcontractor. Column 3 - The dollar amount of the item to be performed by Contractor's own forces. a Column 4 - The dollar amount of the Bidder's overhead and profit for the item. Total dollar amount of Columns 2, 3, and 4 must be equal to the dollar amount in the bid price of the item on bid proposal pages 13 through 20 inclusive, "Pursuant to section 41 04(a)(2)(A) California Public Contracts Code receipt of the portions of the information precede by an asterisk required on this document may be submitted by the Bidder up to 24 hours after the deadline for submitting bids contained in the "Notice Inviting Bids". Page of pages of this Subcontractor Designation form . ~. G%vised: 07/29/02 11/05/2003 03:08 7607279803 FCI CONSTRUCTORS INC PAGE a5 DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID ITEMS CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE I1 PROJECT CWRF PIPELINE TO "D" TANKS REACHES I AND 3 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 the list in accordance with applicable provisions of the specifications and section 4100 et seq. of the Public Contracts 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 than one-half of one percent (0.5%) of the Bidder's total bid of 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. Full Company Name of Subcontractor: nc J I Subcontractor's Location of Business 120 nW4k-l kC.0 nd hvlcce Street Address ' *Subcontractor's Telephone Number plus Area Code: tb\q) 452 *@& *Subcontractor's California State Contractors License No. & Classification:- ZQ8~7-i3 c 3'2 - - "Subcontractor's Carlsbad Business License No.: 1214743 SUBCONTRACTOR'S BID ITEMS Column 2 - The dollar amount of the item to be performed by the subcontractor. Column 3 - The dollar amount of the item to be performed by Contractor's own forces. 1 Column 4 - The dollar amount of the Bidder's overhead and profit for the item. Total dollar amount of Columns 2, 3, and 4 must be equal to the dollar amount in the bid price of the item on bid proposal pages 13 through 20 inclusive. *Pursuant to section 41 04(a)(2)(A) California Public Contracts Code receipt of the portions of the information precede by an asterisk required on this document may be submitted by the Bidder up to 24 hours after the deadline for submitting bids contained in the "Notice Inviting Bids". Page of pages of this Subcontractor Designation form FCI CONSTRUCTORS INC PAGE 06 DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOR'S BID ITEMS CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE I1 PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 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 the list in accordance with applicable provisions of the specifications and section 4100 et seq. of the Public Contracts 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 than one-half of one percent (0.5%) of the Bidder's total bid of ten thousand dollars ($1 0,000) whichever is greater and that no changes in the subcontractors listed work will be made except upon the prior approval of the Agency. a iI Full Company Name of Subcontractor: The ww +wp Subcontractor's Location of Business I2VCP Wid TWZ, DriK;&LQ Z! I Street Address !I 9212 !? ZIP CA State SclnJ)iam City *Subcontractor's Telephone Number plus Area Code: (858%75-2203 *Subcontractor's California State Contractors License No. & Classification: Lwa &ruw bms -3 'Subcontractor's Carlsbad Business License No.: In pm es dob/tz, "nim (,I ceB,ie SUBCONTRACTOR'S BID ITEMS Column 2 - The dollar amount of the item to be performed by the subcontractor. Column 3 - The dollar amount of the item to be performed by Contractor's own forces. Column 4 - The dollar amount of the Bidder's overhead and profit for the item. Total dollar amount of Columns 2, 3, and 4 must be equal to the dollar amount in the bid price of the itern on bid proposal pages 13 through 20 inclusive. *Pursuant to section 4104(a)(2)(A) California Public Contracts Code receipt of the portions of the information precede by an asterisk required on this document may be submitted by the Bidder up to 24 hours after the deadline for submitting bids contained in the "Notice Inviting Bids". - Page of pages of this Subcontractor Designation form %@Revised: 07/29/02 Contract NO. 38871 .A 11/05/2003 03: 08 7607279803 FCI CONSTRUCTORS INC PAGE 03 -- DESIGNATION OF SUBCONTRACTOR AND AMOUNT OF SUBCONTRACTOfTS BID ITEMS CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE If PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 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 the list in accordance with applicable provisions of the specifications and section 4100 et seq. of the Public Contracts Code "Subletting and Subcontracting Fair Practices Act." The Bidder further certifies that no additional subcontractor will be allowed to perform any portlon of the Work in excess of than one-half of one percent (0.5%) of the Bidder's total bid of 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. Full Company Name of Subcontractor J-JQQl cC4ctvic Subcontractor's Location of Business 13Z50 J4uK.W Street Addred A J zip CA ~2oc& City State *Subcontractor's Telephone Number plus Area Code: (8W) 51 3-2525 - *Subcontractor's California State Contractors License No. & Classification: 7m588 10 'Subcontractor's Carlsbad Business License No.: I zdqo SUBCONTRACTOR'S BID ITEMS id Item No. from the bid proposal, pages 13 through 20, inclusive. Column 2 - The dollar amount of the item to be performed by the subcontractor, Column 3 - The dollar amount of the item to be performed by Contractor's own forces. 8 Column 4 - The dollar amount of the Bidder's overhead and -profit for the item. Total dollar amount of Columns 2, 3, and 4 must be equal to the dollar amount in the bid price of the item on bid proposal pages 13 through 20 inclusive. *Pursuant to section 41 04(a)(2)(A) California Public Contracts Code receipt of the portions of the information precede by an asterisk required on this document may be submitted by the Biddsr up to 24 hours after the deadline for submitting bids contained in the "Notice Inviting Bids". - Page __I of pages of this Subcontractor Designation form Contract No. 9RR71 -A DESIGNATION OF OWNER OPERATOR/LESSOR AND AMOUNT OF OWNER OPERATOWLESSOR WORK CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO “D” TANKS REACHES 1 AND 3 The Bidder certifies that it has used the sub-bid of the following listed Owner Operator/Lessor in preparing this bid for the Work and that the listed Owner OperatodLessor will be used to perform the portions of the Work as designated in the list in accordance with applicable provisions of the specifications and section 41 00 et. eq. of the Public Contracts Code “Subletting and Subcontracting Fair Practices Act. The Bidder further certifies that no additional Owner OperatodLessor will be allowed to perform any portion of the Work in excess of than one-half on one percent (0.5%) of the Bidder’s total bid or ten thousand dollars ($10,000 whichever is greater and that no changes in the Owner Operator/Lessor listed work will be made except upon the prior approval of the Agency. Full Owner Operator/Lessor Name: Location of Business - Street Address City State Zip *Owner OperatodLessor Telephone Number plus Area Code: - *City of Carlsbad Business License No.: Explanation: Column 1 - Bid Item No. from the bid proposal, pages 11 through 20, inclusive. Column 2 - The dollar amount of the item to be performed by the subcontractor. Column 3 - The dollar amount of the item to be performed by Contractor’s own forces. Column 4 - The dollar amount of the Bidder’s overhead and profit for the item. Total dollar amount of Columns 2, 3, and 4 must be equal to the dollar amount in the bid price of the item on bid proposal pages 11 through 20, inclusive. *Pursuant to section 41 04(a)(2)(A) California Public Contracts Code receipt of the portions of the information precede by an asterisk required on this document may be submitted by the Bidder up to 24 hours after the deadline for submitting bids contained in the “Notice Inviting Bids”. Page of pages of this Owner Operator/Lessor form @Revised: 07/29/02 Contract No. 38871 -A Page 31 of 152 Pages ~ ~ ~~~ ~ - BIDDER'S STATEMENT OF FINANCIAL RESPONSIBILITY (To Accompany Proposal) CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 Copies of the latest Annual Report, audited financial statements or Balance Sheets may be submitted under separate cover marked CONFIDENTIAL. Please see attached pages GRevised: 07/29/02 Contract No. 38871-A Page 32 of 152 Pages / I FCI CONSTRUCTORS, INC. Consolidated Financial Statements Years ended December 31,2002 and 2001 FCI Constructors, Inc. Consolidated Financial Statements Years ended December 3 1,2002 and 200 1 Contents Report of Independent Auditors .......................................................................................... 1 Consolidated Financial Statements ‘1 3 Consolidated Balance Sheets ................................... ........ .......... ................ . ....... ..... . ... ........ 2 Consolidated Statements of Operations .............................................................................. 4 Consolidated Statements of Stockholder’s Equity .............................................................. 5 Consolidated Statements of Cash Flows ............................................................................. 6 Notes to Consolidated Financial Statements ....................................................................... 7 _.- I Report of Independent Auditors I FCI Constructors, Inc. -1 We have audited the accompanying consolidated balance sheets of FCI Constructors, Inc. (the “Company”) as of December 31, 2002 and 2001, and the related consolidated statements of operations, stockholder’s equity and cash flows for the years then ended. These financial statements are the responsibility of the Company’s management. Our responsibility is to express an opinion on these financial statements based on our audits. We conducted our audits in accordance with auditing standards generally accepted in the United States. Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the consolidated financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial staterxents. An audit also includes assessing the accounting principles used and significant estimates made by management, as well as evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion. I - I ,1 In our opinion, the financial statements referred to above present fairly, in all material respects, the consolidated financial position of FCI Constructors, Inc. as of December 31, 2002 and 2001, and the consolidated results of its operations and its cash flows for the years then ended, in conformity with accounting principles generally accepted in the United States. February 2 1,2003 . 1 FCI Constructors, Inc. Consolidated Balance Sheets Assets Current assets: Cash and cash equivalents Cash held in escrow Receivables: Trade and other Affiliates Due from affiliate Costs and estimated earnings in excess of billings Deferred income taxes Prepaid expenses and other current assets on uncompleted contracts Total current assets Property, plant and equipment, at cost: Land Buildings Equipment Less accumulated depreciation Construction materials Deferred loss on sale of assets Other assets December 3 1, 2002 2001 $11,558,246 5,582,4 12 16,993,879 393,734 12,152,500 3,541,963 853,141 869.948 $ 5,726,203 1 3,728,246 10,351,563 522,336 17,375,000 5,761,798 670,783 917.232 51,945,823 55,053,161 3,153,121 1,958,459 3,348,150 57 1,854 8,794,646 15,435,700 1 5,295,9 17 17,966,013 (5,170,382) (6,989,021) 10,125,535 10,976,992 4,901,497 4,873,683 482,852 262,199 178,277 280,119 Total assets \’ $67,633,984 $71,446,154 2 December 31, 2002 2001 Liabilities and stockholder’s equity Current liabilities: I Accounts payable: Trade and other Affiliates -1 3 Accrued liabilities and other Note payable to sole stockholder Notes payable to affiliates Current maturities of long-tern debt Billings in excess of costs and estimated earnings on uncompleted contracts Total current liabilities i I t Long-term debt Note payable to sole stockholder Long-term debt to affiliates Deferred income taxes Total liabilities +-.. $1 6,044,283 $1 6,987,462 3,362,937 7,333,992 4,703,167 2,574,727 500,000 - 3,930,000 180,000 461,971 14,125 13,437,971 15,962,609 41,992,483 43,500,76 1 829,538 553,803 - 500,000 9,100,000 10,260,000 2,176,542 2,17 8,437 54,098,563 56,993,001 Commitments and contingencies (Notes 8, 10 and 11) - - Stockholder’s equity: Common stock, no par value, 1,000 shares authorized, 100 shares issued and outstanding 14,860,462 14,860,462 Accumulated deficit Total stockholder’s equity ( 1,325,04 1) (407,309) 13,535,42 1 14,453,153 Total liabilities and stockholder’s eauitv $67.633.984 $71.446.154 See accompanying notes. 3 ! I 3 1 Construction revenue Cost of operations: Direct costs Indirect costs Total cost of operations FCI Constructors, Inc. Consolidated Statements of Operations Operating income (loss) Other income (expense): Interest income Interest expense Other, net Other income (expense), net Income (loss) before provision (benefit) for income taxes Provision (benefit) for income taxes: Current Deferred Total provision (benefit) for income taxes Net income (loss) Year Ended December 31, 2002 2001 $134,739,076 $141,804,288 125.33 1,926 130,679,928 10.202.66 1 10.759.408 135,534,587 141,439,336 (7953 1 1) 364,952 1,253,123 2,O 19,4 1 8 (902,891) (802,905) (656,706) (1 17,955) (306,474) 1,098,5 58 (1,lO 1,985) 1,4633 10 321,076 (1 84,253) 265,970 (184.253) 587.046 $ (917,732) $ 876,464 See accompanying notes. 4 3 3 1 FCI Constructors, Inc. Consolidated Statements of Stockholder's Equity Years ended December 3 1,2002 and 200 1 Common Accumulated Stock Deficit Total Balances at December 31,2000 $14,860,462 $( 1,283,773) $13,576,689 Net income 876,464 876,464 Balances at December 31,2001 14,860,462 (407,309) 14,453,153 Net loss - (9 17,732) (917,732) Balances at December 31,2002 $14,860,462 $(1,325,041) $13,535,421 See accompanying notes. 3 5 I .., d I FCI Constructors, Inc. Consolidated Statements of Cash Flows Operating activities Net income (loss) Adjustments to reconcile net income (loss) to net cash provided by (used in) operating activities: Depreciation Gain on sale of property, plant and equipment Deferred loss on sale of assets Deferred income taxes Net change in assets and liabilities: Cash held in escrow Receivables, prepaid expenses and other Notes receivable from affiliates Costs and estimated earnings in excess of Construction materials Other assets Accounts payable, accrued liabilities and other Billings in excess of costs and estimated earnings on uncompleted contracts Net cash provided by (used in) operating activities current assets billings on uncompleted contracts Investing activities Purchases of property, plant and equipment Proceeds from sale of property, plant and equipment Proceeds from sale-leaseback transaction Distribution of joint venture cash to stockholder Net cash used in investing activities Financing activities Payments on long-term debt Proceeds from long-term debt Net payments from (advances to) affiliate Proceeds from note payable to affiliate Proceeds from long-term debt to affiliates Payments on long-term debt to affiliates Net cash provided by (used in) financing activities Net increase (decrease) in cash and cash equivalents Cash and cash equivalents, beginning of year Cash and cash equivalents, end of year Supplemental disclosure of cash flow information Cash paid for interest Year Ended December 31, 2002 2001 $ (917,732) 2,07 1,362 ( 167,466) (220,653) ( 184,253) 8,145,834 (6,466,430) - 2,2 19,835 (27,8 14) 101,842 (2,785,794) $ 876,464 2.1 12,806 (4,270) (262,199) 265,970 (3,8 8 1,369) 10,208,620 370,000 (679,03 1) 604,420 132,963 (2,981,210) (2,524,638) 1,612.217 (755,907) 8,375,381 (4,772,920) (5.0 10.673) 1,059,984 406,363 2,898,250 1,8 13,464 - (1 18,236) (1,052,439) (2,671,329) (1,025,086) (571,604) 852,975 65,050 5,222,500 (7,125,ooO) 3,750,000 - 470.000 680,000 (1,630~OOO) (1.040,oO0) 7,640,389 (7,991,554) 5,832,043 (2,287,502) 5,726,203 8,013,705 $1 1,558,246 $ 5,726,203 $ 897,714 $ 572,078 See accompanying notes. 6 FCI Constructors, Inc. Notes to Consolidated Financial Statements December 3 1,2002 3 I 1 1, Operations FCI Constructors, Inc. (“FCI” or the “Company”), a Delaware corporation, is engaged in the business of obtaining and constructing heavy civil and highway construction projects in the State of California and the southwestern United States, both directly and through construction joint ventures formed for the same purpose. FCI’s sole stockholder is HBG Flatiron, Inc. (“Flatiron”), a Delaware corporation, a wholly owned subsidiary of HBG Constructors, Inc. (“HCI”). HCI is owned 90% by HBG USA, Inc. (“HBG USA”), a Delaware corporation, and 10% by the CEO of HCI. HBG USA is owned 100% by Hollandsche Beton Groep nv, a Dutch Corporation (“HBG nv”). Until April 2002, H33G nv was a publicly traded corporation in the Netherlands traded on the Dutch stock exchange (Euronext Amsterdam). In April 2002, Grupo Dragados SA acquired in excess of 99% of the shares of HBG nv. Grupo Dragados SA is a Spanish corporation whose shares are traded on the Spanish stock market in Madrid (IBES). In June 2002, KoninWijke BAM NI3M nv (“Royal BAM Group”), announced it had reached an agreement with Grupo Dragados SA for Royal BAM Group to acquire HBG nv from Grupo Dragados SA. On November 16,2002, the purchase of HBG nv by Royal BAM Group was completed with Royal BAM Group acquiring in excess of 99% of the shares of HBG nv. Royal BAM Group is a Dutch corporation whose shares are traded on the Euronext Amsterdam stock exchange. The Company’s assets, liabilities and equity balances are reflected at their historical carrying values in the accompanying consolidated balance sheets and do not reflect the push down of the purchase price related to the acquisitions. The Company has investments in the following construction joint ventures as of December 3 1,2002: FCI Constructors/Interbeton, Inc.-Conned in 1997 by FCI (70%) and Interbeton, Inc., a wholly owned subsidiary of HCI, (30%) for the purpose of jointly constructing the seismic retrofit of a bridge in the State of California. In a separate agreement between FCI and Flatiron, the 70% interest held by FCI is shared among FCI (20%) and Flatiron (50%). FCI Constructors/Cleve&znd Bridge California, Inc.-Formed in 2000 by FCI (65%) and Cleveland Bridge California, Inc. (35%) for the purpose of jointly obtaining and constructing a bridge project in the State of California. In a separate agreement between FCI, Flatiron, and Interbeton, Inc., a wholly owned subsidiary of HCI, the 65% interest held by FCJ is shared among Flatiron (30%), FCI (25%), and Interbeton, Inc. (10%). I I 7 ,/- I -1 I FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 1. Operations (continued) Kiewit/FCI/Manson-Fonned in 2001 by FCI (27%)’ Kiewit Pacific Co. (65%), and Manson Construction Co. (8%) for jointly obtaining and constructing projects in the State of California. In a separate agreement between FCI and Flatiron, the 27% interest held by FCI is shared among FCI (13.5%) and Flatiron (13.5%). Effective May 3, 2001, Redwood City Dredging Company (“Redwood”) was acquired and merged into the Company, with FCI being the surviving company. Redwood engaged in the business of renting marine equipment. 2. Summary of Significant Accounting Policies The significant accounting policies of the Company are as follows: Basis of Presentation The consolidated financial statements include the accounts of the Company together with its proportionate share of the assets, liabilities, revenues and expenses of the construction joint ventures. All significant intercompany accounts and transactions, including the Company’s proportionate share of intercompany balances and transactions with construction joint ventures, have been eliminated. Recognition of Revenues and Costs Income from uncompleted contracts is recorded on the percentage-of-completion method, measured by the percentage of direct contract costs incurred to date to estimated total direct contract costs. Provisions for estimated losses on uncompleted contracts are made in the period in which such losses are determined. Revenues in connection with contract claims and change orders are recorded when realization is probable and the amount can be reliably estimated. Use of Estimates The preparation of the consolidated financial statements in conformity with accounting principles generally accepted in the United States requires management to make estimates and assumptions that affect the amounts reported in the consolidated financial statements and accompanying notes. The principal area involving the use of such estimates relates to income recognized on long-term construction contracts, including the valuation of claims. Due to uncertainties inherent in the estimation process, it is at least reasonably possible that actual results could differ materially from those estimates in the near term. i\ 8 -1 f i FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 2. Summary of Significant Accounting Policies (continued) Classification of Current Assets and Liabilities The Company’s operating cycle is the length of each individual contract, which may extend beyond one year. Therefore, costs and estimated earnings in excess of billings on uncompleted contracts, along with all other contract-related receivables and cash held in escrow, are included in current assets. Billings in excess of costs and estimated earnings on uncompleted contracts, along with all other contract-related payables, are included in current liabilities. A one-year time period is used as the basis for classifying all other current assets and liabilities. Cash and Cash Equivalents The Company considers all highly liquid investments with an original maturity of three months or less to be cash equivalents. A portion of the Company’s cash and cash equivalents represent its proportionate share of joint ventures’ cash and cash equivalent balances and may not be available to the Company to meet its current operating needs. Cash Held in Escrow Cash totaling $5,582,412 and $13,728,246 at December 31, 2002 and 2001, respectively, is held in escrow by various banks in lieu of contract retainages. This cash will be released by the project owner upon the Company’s satisfactory completion of contract provisions. The Company does not expect that $3,469,282 of escrow balances at December 31,2002 will be released within the next fiscal year. Property, Plant and Equipment Property, plant and equipment is stated at cost. Depreciation is computed using the straight-line and declining-balance methods over the estimated useful lives of the assets, which range from three to 15 years, with an appropriate provision for estimated salvage values. Construction Materials The Company accounts for construction materials at the lower of cost or estimated recoverable value. 9 d I -- FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 2. Summary of Significant Accounting Policies (continued) Credit Risks Concentrations of financial instruments that potentially subject the Company to credit risk consist of cash and cash equivalents, cash held in escrow, accounts receivable, and unbilled contract receivables. The Company, by policy, limits the amount of credit exposure by placing its cash and cash equivalents with financial institutions evaluated as highly creditworthy. Risks associated with concentrations of credit with respect to accounts receivable and unbilled contract receivables are limited due to the Company’s credit evaluation process. Historically, no significant credit-related losses have been incurred. Accounting for the Impairment or Disposal of Long-Lived Assets In accordance with Statement of Financial Accounting Standards (“SFAS”) No. 144, Accounting for the lmpaiment or Disposal of Long-Lived Assets, long-lived assets and certain identifiable intangibles to be held are reviewed for impairment whenever events or changes in circumstances indicate that the carrying amount of an asset may not be recoverable. The Company believes that there have been no impairments in the carrying value of long-lived assets during the years ended December 31,2002 and 2001. Income Taxes The Company joins with the parent and the parent’s other subsidiaries in filing a U.S. federal income tax return on a consolidated basis. Income taxes are calculated on a separate-return basis with consideration of the tax-sharing agreement between the parent and its subsidiaries. Reclassifications Certain prior year amounts have been reclassified to conform to the current year’s presentation. These reclassifications had no effect on net income or retained earnings as previously stated. I 1 ! i 10 ‘t 1 I J .- I FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 3. Trade Receivables and Trade Payables The Company’s trade and other receivables consist of the following: December 31, 2002 2001 Contracts in process Retainages Interest and miscellaneous $14,069,802 $ 8,830,318 2,123,890 876,568 800.187 644.677 $16,993,879 $10,351,563 Retainages include $1,008,930 at December 31, 2002, which the Company does not expect to collect within the next fiscal year. At December 31, 2002, trade accounts payable includes subcontractor retainages of $5,436,263, of which $1,030,068 is not expected to be paid within the next fiscal year. 4. Costs and Estimated Earnings on Uncompleted Contracts The Company’s cumulative costs and estimated earnings and related billings on uncompleted contracts are as follows: December 31, 2002 2001 Contract amount earned to date Billings to date Net $546,738,073 $528,628,983 (556,634,081) (538,829,794) $ (9.896.008) $ (10.200.81 1) Costs and estimated earnings on uncompleted contracts are included in the accompanying balance sheets under the following captions: December 31, 2002 2001 Costs and estimated earnings in excess of billings on uncompleted contracts $ 3,541,963 $ 5,761,798 Billings in excess of costs and estimated earnings on uncompleted contracts (13,437,971) (15,962,609) Net $ (9,896,008) $(10,200,811) t ! 11 ,I I ! _- FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) I 5. Long-Term Debt Long-term debt consists of the following: December 31, 2002 2001 7 I j I i b , ! $780,000 unsecured promissory note to a third party, payable in monthly installments of interest only of $5,200 through January 2007, when the remaining principal and interest are due and payable. $1,166,764 promissory note to a bank, collateralized by equipment of the Company, payable in monthly installments of $23,535, including interest at 7.78%. $841,061 notes to an equipment manufacturer, collateralized by equipment of the Company, payable in total monthly installments of $28,367, including interest rates ranging from 2.67% to 7.00%. Other Less current portion - $780,000 $ - 734,836 - 280,938 63.663 - 843,663 1 ,O 15,774 14,125 46 1,97 1 $829,538 $ 553,803 The aggregate payments of long-term debt outstanding at December 31,2002, and for the next five years, are summarized as follows: 2003 2004 2005 2006 2007 $ 14,125 21,983 22,8 17 4,738 780.000 Total $843,663 12 i 7 1 i J . f I i 1 i FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 6. Employee Benefit Plan The Company participates in a profit-sharing plan (the “Plan”) that is qualified under Section 401(k) of the Internal Revenue Code and is sponsored by HCI. The Plan covers substantially all non-union employees of the Company. The Company’s contributions to the Plan totaled $384,303 and $397,258 for the years ended December 31, 2002 and 2001, respectively. 7. Related-Party Transactions Accounts receivable and payable from affiliates includes amounts due frodto affiliated entities for management fees, equipment rentals, income taxes, and administrative and other purchased services. Cash balances in excess of current operating needs are transferred to HCI, where cash funds are either invested in temporary cash investments or used to fund the cash needs of other HCI subsidiaries or repay debt. Short-term advances to and borrowings from HCI accrue interest at 6% and are payable on demand. At December 31, 2002 and 2001, the balance due from HCI was $12,152,500 and $17,375,000, respectively. During the years ended December 31, 2002 and 2001, the Company recognized interest income of $686,745 and $1,053,604, respectively, on such advances. Note payable to sole stockholder of $500,000 at December 31,2002 and 2001, represents a promissory note payable to Flatiron. The note bears interest at 6% and matures on March 31, 2003. The Company recognized interest expense of $30,000 related to this note during each of the years ended December 31,2002 and 2001. Long-term debt to affiliate of $9,100,000 and $10,260,000 at December 31, 2002 and 2001, respectively, represents the Company’s proportionate share of a joint venture’s notes payable to HCI and the Company’s promissory notes payable to HCI. The notes bear interest at the rate of 6% and mature on April 1,2004. During the years ended December 31, 2002 and 2001, the Company incurred interest expense of $734,239 and $703,741, respectively, in conjunction with these notes. Notes payable to affiliates of $3,930,000 and $180,000 at December 31, 2002 and 2001, respectively, represents promissory notes payable to FCKB ($3,750,000 and $0 at December 3 1, 2002 and 2001, respectively) and Interbeton, Inc. ($1 80,000 at December 31, 2002 and 2001), which bear interest at rates ranging from 4% to 5.5% and mature on March 31, 2003. The Company recognized interest expense of $65,614 and $12,600 related to the notes during the years ended December 31,2002 and 2001, respectively. t 13 I 1 FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 7. Related-Party Transactions (continued) Total fees charged by HCI for certain management, financial, and other services were $3,098,869 and $3,261,498 for the years ended December 31, 2002 and 2001, respectively, and have been included in indirect costs in the accompanying consolidated statements of operations. The Company has entered into certain transactions with its joint ventures, principally for labor, equipment rentals, and other costs. The revenues and expenses associated with such transactions have been included in the accompanying consolidated statements of operations net of the Company’s proportionate share in the joint venture. The extent to which the consolidated financial statements would have been affected if the Company were not affiliated with other corporations, partnerships and joint ventures, or if transactions with the affiliates had been with non-related entities, has not been determined. 8. Lease Commitments During the years ended December 31, 2002 and 2001, the Company sold various pieces of equipment for $3,586,250 and $1,813,464, respectively. Concurrent with the sales, the Company leased the equipment back for a period of three years. The leases are renewable at the Company’s option in 12-month increments for an additional two years. The Company also has the option to repurchase the equipment at the end of each lease term at the contractually determined residual value, which is expected to approximate the fair value of the equipment. The sales of the equipment generated losses, net of expenses, of $323,327 and $280,796 during the years ended December 31,2002 and 2001, respectively, which are deferred and are being amortized ratably over the estimated lease term of five years. The unamortized balance of the deferred loss at December 31, 2002 and 2001 is $482,852 and $262,199, respectively. The future minimum annual rental payments due under the noncancelable portion of these operating leases are included in the future minimum annual rental payments reported. I 1 * 14 I I 11 1 1 FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 8. Lease Commitments (continued) The Company leases certain other plant, office space, and equipment under operating leases. The Company’s future minimum annual rental payments under all noncancelable operating leases (including related-party leases discussed in Note 7) as of December 31, 2002 are as follows: 2003 2004 2005 2006 Total $1,153,295 83 1,928 649,216 7,460 $2.641.899 Rental expense (including related-party rentals discussed in Note 7 and casual rentals) included in direct and indirect costs for the years ended December 3 1, 2002 and 200 1 is $1 8,233,558 and $14,436,685, respectively. 9. Income Taxes The Company accounts for income taxes under SFAS No. 109, Accounting for Income Taxes. A deferred income tax asset or liability is determined by applying currently enacted income tax laws and rates to the cumulative temporary differences between the carrying amount of assets and liabilities for financial reporting and income tax purposes. Deferred income tax expense is measured by the change in the net deferred income tax asset or liability during the year after considering any valuation allowances provided against deferred income tax assets. J I 15 ... I FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 9. Income Taxes (continued) The components of the Company’s provision (benefit) for income taxes are as follows: Year Ended December 31, 2002 2001 Provision (benefit) for income taxes: Current: Federal $ - $250,150 State - 70,926 321,076 Total current - Deferred: Federal State (159,162) 256,952 (25.091) 9.01 8 Total deferred (1 84,253) 265,970 Total provision (benefit) for income taxes $( 184,253) $587,046 Variations from the federal statutory rate are as follows: Year Ended December 31, 2002 2001 i Expected provision (benefit) for federal income taxes at statutory rate of 34% $(374,675) $497,593 State tax provision (benefit), net of federal benefit 79,944 Effect of permanent differences 15,537 9,509 Impact of provision to return adjustments 23 1,503 - Total $( 184,253) $587,046 (56,6 1 8) 16 -i I t 3 1 I FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 9. Income Taxes (continued) The components of the Company’s deferred income tax assets and liabilities are as follows: December 31, 2002 2001 Deferred income tax assets: Net operating loss carryforwards $ 878,371 $ - Accrued vacation 122,255 110,196 Accrued workers’ compensation and other insurance Total deferred income tax assets 729,505 560,587 1,730,13 1 670,783 Deferred income tax liabilities: Accelerated depreciation 2,983,073 2,098,142 Other, net 70,459 80,295 Total deferred income tax liabilities 3,053,532 2,178,437 Net deferred income tax liability $(1,323,401) $(1,507,654) At December 31, 2002, the Company has net operating loss (“NOL”) carryforwards of $2,231,630 available to offset future income tax liabilities. The NOL carryforwards expire in 2022. The Company’s ability to utilize these NOL carryforwards is dependent on the existence of future taxable income, which the Company has projected will occur before the expiration period. The Company is a member of a group that files a consolidated income tax return. The liability for current income taxes of the consolidated group is allocated to members of the group based on each member’s taxable income (loss) and is included in accounts payable from affiliates in the accompanying balance sheets ($1,342,46 1 and $1,573,964 at December 3 1,2002 and 2001, respectively). 10. Contingencies and Settlements 4 The Company has initiated several claims with project owners for additional compensation related to various contract changes and differing conditions. In connection with these claims, the Company has forecasted the minimum amounts believed to be probable of recovery of $1.1 million and $1.9 million cumulatively through December 31, 2002 and 2001, respectively. Certain claims that were outstanding at December 31, 2001 were settled during 2002. I 17 .. . ._, .,. ” .... ~ .,,-.,.,. ’... .,-7. .171-ilim“Y.,” 1 i 3 .- FCI Constructors, Inc. Notes to Consolidated Financial Statements (continued) 11. Letters of Credit At December 31, 2002, the Company and its subsidiaries and construction joint ventures had $5.7 million of irrevocable standby letters of credit outstanding with expiration dates ranging from December 31, 2003 through September 1, 2006. The letters of credit were issued in favor of project owners or joint venture partners to guarantee performance or payment on certain construction contracts. The Company also has an irrevocable standby letter of credit in the amount of $28.8 million that was issued by a bank at the request of one of the Company’s construction joint ventures (the “Venture”) to guarantee payment to a subcontractor for the supply of materials to the Venture. The letter of credit obligation will be reduced as payments are made to the subcontractor by the Venture. Management anticipates that the total balance of the letter of credit will be decreased by approximately $25.0 million by June 30, 2003. The expiration date of the letter of credit is March 31, 2004. As of December 31, 2002, an irrevocable standby letter of credit of $10.1 million has been issued by one of the Venture’s partners in favor of HBG nv for its share of the amounts owed to the subcontractor. The letters of credit have been arranged by HIBG nv through its credit facilities. The Company and its subsidiaries and construction joint ventures are ultimately responsible for any amounts drawn against the letters of credit; however, the management of the Company believes the likelihood of any amounts being drawn is remote. f I 18 BIDDER'S STATEMENT OF TECHNICAL ABILITY AND EXPERIENCE (To Accompany Proposal) CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 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. PLEASE SEE ATTACHED SHEET I I I I Date Name and Phone Amount Completed of the Employer to Contract Work Contract Contract Name and Address No. of Person Type of of Revised: 07/29/02 Contract No. 38871 -A Page 33 of 152 Pages BIDDER'S CERTIFICATE OF INSURANCE FOR GENERAL LIABILITY, EMPLOYERS' LIABILITY, AUTOMOTIVE LIABILITY AND WORKERS' COMPENSATION (To Accompany Proposal) CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 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 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. a Revised: 07/29/02 Contract No. 38871 -A Page 34 of 152 Pages hilb rogal 6 hobbs” November 4,2003 720 5. Colorado BLvd., Ste. 600N P.O. Box469025 Denver, CO 80246 3, 303-722-7n6 i 303-722-8862 4 w.hrh.com Carlsbad Municipal Water District 163 5 Faraday Avenue Carlsbad, CA 92008-73 14 Re: FCI Constructors, Inc.-Bid for Encina Basin Water Reclamation Program Phase II To Whom It May Concern: The carrier shown on the certificate of insurance-Zurich American currently carries in force policies for General Liability, Employer’s Liability, Automobile Liability & Workers’ Compensation in conformance with the requirements for the above project, and the current policies will apply to this project if the insured is awarded the job. The Automobile policy covers any vehicles used in the performance of the contract, whether owned, non-owned or hired and whether scheduled or non-scheduled. Sincerely, HRH of Colorado Barbara J. Ellis Account Representative 303 765-3618 Lic. #OB44539 Signed before me otNovember 4,2003 at Denver, CO. BZE I612583 Client#: 21 329 FClCONSl I PRODUCER HRH of Colorado 720 S. Colorado Blvd Ste PH N -q. Box 469025 I ,iver, CO 80246-9025 I ACORD, CERTIFICATE OF LIABILITY I THIS CERTIFICATE IS ISSUED AS A MATTER OF INFORMATION ONLY AND CONFERS NO RIGHTS UPON THE CERTIFICATE HOLDER. THIS CERTIFICATE DOES NOT AMEND, EXTEND OR ALTER THE COVERAGE AFFORDED BY THE POLICIES BELOW. INSURERS AFFORDING COVERAGE NAIC # dSURANCE POLICY NUMBER GL0298849403 DATE (MhUDDIYYW) I 01/06/04 POLICY EFFECllVE DATE lMMlDDNYI 06/01/03 I DESCRIPTION OF OPERATIONS I LOCATIONS I VEHICLES I I EXCLUSIONS ADDED BY ENDORSEMENT/ SPECIAL PROVISIONS AUTO ONLY - EA ACCIDENT OTHERTHAN EAACC AGG AUTO ONLY: $ $ S B A EXCESSUMBRELLA LlABlUN OCCUR CLAIMS MADE DEDUCTIBLE RETENTION 0 10,000 WORKERS COMPENSATION AND EMPLOYERS' LIABILITY ANY PROPRIETOWPARTNEREXECUTNE OFFICEWMEMBER EXCLUDED? WC298849303 06lQ1 IO3 - City of Carlsbad Purchasing Dept. 1635 Faraday Avenue Carlsbad, CA 92008-7314 SHOULD ANY OF THE ABOVE DESCRIBED POLICIES BE CANCELLED BEFORE THE EXPIRATION DATE THEREOF, THE ISSUING INSURER WlLL~~RX~MAlL 2 DAYS WRITTEN NOTICE TO THE CERTIFICATE HOLDER NAMED TO THE LEFT, RXRWSmURICXSmMX ~RWIRI4MKJWKRK---RRXXX R-KK"XXX AUTHORIZED REPRESENTATIVE eL&SU.-7- INSURER& Zurich-American Ins. Co. ,+ 9( J c/e-1/19445 INSURER B: National Union Fire Ins. of PA INSURED FCI Constructors, Inc. 2585 Business Park Drive Vista, CA 92083-8831 I INSURER C: I INSURER D ! COVERAGES ~~ THE POLICIES OF INSURANCE LISTED BELOW HAVE BEEN ISSUED TOTHE INSURED NAMED ABOVE FOR THE POLICY PERIOD INDICATED. NOTWlTHSTANDlNG ANY REQUIREMENT, TERM OR CONDITION OF ANY CONTRACT OR OTHER DOCUMENT WlTH RESPECT TO WHICH THIS CERTIFICATE MAY BE ISSUED OR MAY PERTAIN, THE INSURANCE AFFORDED BY THE POLICIES DESCRIBED HEREIN IS SUBJECT TO ALL THETERMS, EXCLUSIONSAND CONDITIONS OF SUCH POLICIES. AGGREGATE LIMITS SHOWN MAY HAVE BEEN REDUCED BY PAID CLAIMS. rn LTR A - A -- POLICY EXPlRAllON DATE (MMIDDNY) 06/01/04 LIMITS I EACHOCCURRENCE I ~1,000,000 DAMAGE TO RENTED PREMISES (Ea occu nence) I$500,000 CLAIMS MADE OCCUI GEN'L AGGREGATE LIMIT APPLIES PEI 7 rn JPERCO~ n LOC AUTOMOBILE LIABILI'IY ALL OWNED AUTOS SCHEDULED AUTOS HIRED AUTOS NON-OWNED AUTOS BAP298849503 06/01 IO4 I COMBINED SINGLE LIMIT ,ooo,~~~ (Ea accident) 06/01/03 BODILY INJURY (Per accident) PROPERTY DAMAGE (Per accident) ANY AUTO BE3204856 06/01/04 06/01/03 06/01 104 ~~~ ~~ CERTIFICATE HOLDER CANCELLATION i 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). 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. DESCRIPTIONS (Continued from Page I) Insureds as respects to General Liability 8 Auto Liability only if required by written contract and coverage applies only as respects ongoing operations -rformed by Insured for the Certificate Holder. All coverage terms, conditions and The General Liability 8 Automobile coverages are Primary 8 non-contributing per the policy terms 8 conditions only if required by written contract. Except 10 Days Notice for Non-Payment of Premium and Workers Compensation for any cause of cancellation. I Ausions of the policy apply. - - AMS 25.3 (2001108) 3 Of3 #SI 92399iM182963 -- i= (3 L i CY N UPJI 6 E,?: GLO 2 9 8 8 4 9 40 3 C 0 MM ER C IAL G EN ERA L L I A B I Lf TY CG 20 37 ?O 01 THIS ENDORSEMENT CHANGES THE POLICY. PLEASE READ IT CAREFGLL'r'. . -. I nis endorseiilent iilou'ifies instrrence provided under the following: Name of Person or Organization: .. . ___ -. . Location And Description of Completed Operztions: A dditi o nai P rem i urn : In c I uded I 1 (ti no entry appears above, information required to complete this endorsement will be shown in the Declarations as applicable to this endorsement.) Sectian I[ - Who Is An Insu'red is amended to include as an insured the person or organization shown in the Schedule, but only with respect to liability arising aut of "your work" at the location designated and described in the schedule of this endorsement performed for that insured and included in the "products-completed operations h zz a rd 'I. Coverage is primary & non-contributing per the policy terms & condit.ions only if required by written contract. The policy will not be canceled, materially changed nor the amount of coverage reduced until thirty (30) days after receipt of written notice of cancellation or reduction in coverage by the ,City Clerk of the City of Carlsbad, California. COMMERCIAL AUTO CA 20 48 02 99 THIS ENDORSEMENT CHANGES THE POLICY. PLEASE READ iT CAREFULLY. DlESfGNATED INSURED This endorsement modifies insurance provided under the following: BUSfNESS AUTO COVERAGE FORM GARAGE COVERAGE FORM MOTOR CARRiER COVERAGE FORM TRUCKERS COVERAGE FORM With respect to coverage provided by this endorsement, the provisions of the Coverage Form apply unless rnodi- fied by this endorsement. This endorsement identifies per$on(s} or organization@) who are "insureds" under the Who Is An Insured Provi- sion of the Coverage form. This endnrsement daes not after coverage provided in the Coverage Form. This endorsement changes the policy effective on the inception date of the policy unless another date is indi- cated below. _- ~ ~~~~ Endorsement Effective: I - ~- - Countersigned By: r I I L f Named Insured: &M-(*XOb nfative)l SCHEDULE Name of Person(s) or Organization(sf: BLANKET AS REQUIRED BY WRITTEN CONTRACT (If no entry appears above, information required to complete this endorsement will be shown in the Declamions as applicable to the endorsement.) Each person or organization shown in the Schedule is an "insured" for Liability Coverage, but only to the extent that person or organization qualifies as an "insured" under the Who Is An Insured Provision contained in Section II of the Coverage Form. Coverage is primary & non-contributing per the policy terms 6 conditions only if required by written contract. The policy will not be cancelled, materially changed nor the amount of coverage reduced until thirty (30) days after receipt of written notice of cancellation or reduction in coverage by the City Clerk of the City of Calrsbad, California. BIDDER'S STATEMENT RE DEBARMENT (To Accompany Proposal) CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 1. Have you or any of your subcontractors ever been debarred as an irresponsible bidder by another jurisdiction in the State of California? X ' yes no 2. If yes, what wadwere the name(@ of the agency(ies) and what wadwere the period(s) of debarment(s)? Attach additional copies of this page to accommodate more thin two debarments. - party debarred party debarred .- agency agency - period of debarment period of debarment L - BY CONTRACTOR: Constructors, Inc. -- _- ($gn here) Thomas J. Rademacher. President (print namekitle) Page of 1 of 1 pages of the Re Debarment form GRevised: 07/29/02 Contract No. 38871 -A Page 35 of 152 Pages BIDDER'S DISCLOSURE OF DISCIPLINE RECORD (To Accompany Proposal) .. .- CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 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? __ x no 2) Has the suspension or revocation of your contractors license ever been stayed? -_ x 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? v -A- no 4) Has the suspension or revocation of the license of any subcontractor's that you propose to perform any portion of thwork ever been stayed? - -A- no I 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.) I_ .- Page 1 of z pages of this Disclosure of Discipline form @Revised: 07/29/02 Contract No. 38871 -A Page 36 of 152 Pages -- I BIDDER'S DISCLOSURE OF DISCIPLINE (CONTINUED) (To Accompany Proposal) RECORD ENCINA CONTRACT NO. 38871 -A CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT 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. BY CONTRACTOR: FCI Constructors Inc. n tracto r) (sign here) Thomas J. Rademacher, President (print namekitle) Page 2 of pages of this Disclosure of Discipline form a Revised: 07/29/02 Contract No. 38871 -A Page 37 of 152 Pages NON-COLLUSION AFFIDAVIT TO BE EXECUTED BY BIDDER AND SUBMllTED WITH BID PUBLIC CONTRACT CODE SECTION 7106 ENCINA -- I State of California County of CONTRACT NO. 38871 -A CWRF PIPELINE TO I'D" TANKS REACHES 1 AND 3 BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT ) ) ss. 1 Thomas J. Rademacher , being first duly sworn, deposes (Name of Bidder) and says that he or she is President (Title) of FCI Constructors, Inc. (Name of Firm) the party making the foregoing bid that the bid is not made in the interest of, or on behalf of, any undisclosed person, partnership, company, association, organization, or corporation; that the bid is genuine and not collusive or sham; that the bidder has not directly or indirectly induced or solicited any other bidder to put in a false or sham bid, and has not directly or indirectly colluded, conspired, connived, or agreed with any bidder or anyone else to put in a sham bid, or that anyone shall refrain from bidding; that the bidder has not in any manner, directly or indirectly, sought by agreement, communication, or conference with anyone to fix the bid price of the bidder or any other bidder, or to fix any overhead, profit, or cost element of the bid price, or of that of any other bidder, or to secure any advantage against the public body awarding the contract of anyone interested in the proposed contract; that all statements contained in the bid are true; and, further, that the bidder has not, directly or indirectly, submitted his or her bid price or any breakdown thereof, or the contents thereof, or divulged information or data relative thereto, or paid, and will not pay, any fee to any corporation, partnership, company association, organization, bid depository, or to any member or agent thereof to effectuate a collusive or sham bid. I declare under penalty of perjury that the foregoing is true and correct and that this affidavit was executed on the 30th , 20-. 03 Subscribed and sworn to before me on the (NOTARY SEAL) - a Revised: 07/29/02 Contract No. 38871 -A Page 38 of 152 Pages I *- JURAT WITH AFFIANT STATEMENT State of California County of Sari Diego [XI See Attached Document (Notary to cross out lines 1-8 below) 0 See Statement Below (Lines 1-7 to be completed only by document signer[s], not Notary) Signature of Document Signer No 1 Signature of Document Signer No 2 (If any) Subscribed and sworn to (@ha&-) before methis 30th dayof October Name of Signer(@ Name of Signer(s) Place Notary Seal Above Signature of.f.rota& Public Though the information below IS not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document Further Description of Any Attached Document Title or Type of Document: Non-Collusion Affidavit Document Date: October 30,2003 Number of Pages: Signer(s) Other Than Named Above: 0 1996 National Notaty Association - 9350 De Sot0 Ave , PO Box 2402 Chatsworth, CA 91313-2404 Prod, No 5924 Reorder Call Toll-Free 1-800-876-6627 CONTRACT PUBLIC WORKS This agreement is made this & day of Fk-bCUC4 , 2004 , by and between the Carlsbad Municipal Water District of Carlsbad, aifornia, a municipal corporation, (hereinafter called "District"), and FCI CONSTRUCTORS whose principal place of business is 2585 BUSINESS PARK DRIVE VISTA CA 92081-8831 (hereinafter called "Contractor"). District and Contractor agree as follows: 1. for: Description of Work. Contractor shall perform all work specified in the Contract documents CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 (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 qelative 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, Distriet shall make payment to the Contractor per section 9-3 PAYMENT of the Standard Specifications for Public Works Construction (SSPWC) 2003 Edition, and the 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. 8- @Revised: 07/29/02 Contract No. 38871 -A Page 39 of 152 Pages 5. 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. Independent Investigation. 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. Differing Conditions, Subsurface or latent physical conditions at the site differing from those indicated. C. Unknown Physical Conditions. Unknown physical conditions at the site of any unusual nature, different materially from those ordinarily encountered and generally recognized as inherent in work of the character provided for in the contract. District shall promptly investigate the conditions, and if it finds that the conditions do materially so differ, or do involve hazardous waste, and cause a decrease or increase in contractor's costs of, or the time required for, performance of any part of the work shall issue a change order under the procedures described in this contract. In the event that a dispute arises between District and Contractor whether the conditions materially differ, or involve hazardous waste, or cause a decrease or increase in the contractor's cost of, or time required for, performance of any part of the work, contractor shall not be excused from any scheduled completion date provided for by the contract, but shall proceed with all work to be performed under the contract. Contractor shall retain any and all rights provided either by contract or by law which pertain to the resolution of disputes and protests between the contracting parties. 7. Immigration Reform and Control Act. Contractor certifies it is aware of the requirements of the Immigration Reform and Control Act of 1986 (8 USC sections 1101 -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. @Revised: 07/29/02 Contract No. 38871 -A Page 40 of 152 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. GRevised: 07/29/02 Contract No. 38871 -A Page 41 of 152 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) Cost Of Insurance. The Cost of all insurance required under this agreement shall be included in the Contractor's bid. e kg Revised: 07/29/02 Contract No. 38871 -A Page 42 of 152 Pages 11. Claims and Lawsuits. All claims by contractor for $375,000 or less shall be resolved in accordance with the provisions in the Public Contract Code, Division 2, Part 3, Chapter 1, Article 1.5 (commencing with section 20104) which are incorporated by reference. A copy of Article 1.5 is included in the Supplemental Provisions I section. The contractor shall initially submit all claims over $375,000 to the District using the informal dispute resolution process described in Public Contract Code subsections 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, 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. GRevised: 07/29/02 Contract No. 38871 -A Page 43 of 152 Pages 14. Security. Securities in the form of cash, cashier's check, or certified check may be substituted for any monies withheld by the District to secure performance of this contract for any obligation established by this contract. Any other security that is mutually agreed to by the Contractor and the District may be substituted for monies withheld to ensure performance under this Contract. 15. Provisions Required by Law Deemed Inserted. Each and every provision of law and clause required by law to be inserted in this Contract shall be deemed to be inserted herein and included herein, and if, through mistake or otherwise, any such provision is not inserted, or is not correctly inserted, then upon application of either party, the Contract shall forthwith be physically amended to make such insertion or correction. 16. Additional Provisions. Any additional provisions of this agreement are set forth in the "General Provisions" or It Supplemental Provisions" attached hereto and made a part hereof. NOTARIAL ACKNOW LE EXECUTION BY ALL SIGNATORIES MUST BE ATTACHED CONTRACTOR: ATER DISTICT, a J (Si@ here) James J. Keep, Vice President WEST: - title) Paul C. Roberts, Assistant Secretary (pridname and title) \fr- .. President or $&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 Revised: 07f29/02 Contract No. 38871 -A Page 44 of 152 Pages CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT State of California Countyof Sari Diego } SS. On January 7, 2004 before me, Julie A. Patlan, Notary Public, personally appeared James J. Keep Date Name and Title of Onicer (e g , "Jane Doe, Notary Public') Name@) of Signer@) B personally known to me 0 proved to me on the basis of satisfactory evidence to be the person@ whose name@ isla subscribed to the within instrument and acknowledged to me that he-executed the same in his/t%H&XX authorized capacity(w, and that by his- signature@) on the instrument the person@), or the entity upon behalf of which the person@) acted, executed the instrument. WITNESS my hand and official seal. ()&A. $4%?.2%4d) Signature of Ndaly Public OPTIONAL Though the information below is not required by law, it may prove valuable to persons re/ying on the document and could prevent fraudu/ent removal and reattachment of this fom to another document. Description of Attached Document Title or Type of Document: Document Date: January 7, 2004 Number of Pages: Signer(s) Other Than Named Above: Contract Public Works Capacity(ies) Claimed by Signer Signer's Name: Individual N Corporate Officer - Title(s): 0 Partner - 0 Limited 0 General 0 Attorney-in-Fact Trustee 0 Guardian or Conservator James J. Keep Vice President Other: Signer Is Representing: FCI Constructors. Inc. - D 1999 National Notary Association 9350 De Sot0 Ave., P.0. Box 2402 - Chatsworth. CA91313-2402 www.nationalnotary.org Prod. No. 5907 Reorder: Call Toll-Free 1-800-876-6827 - CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT State of California County of San Diego } SS. On January 7, 2004 before me, Julie A. Patlan, Notary Public, personally appeared Paul C . Roberts Date Name and Xtle of Oflicer (e g , "Jane Doe, Notary Public") Name($ of Signer@) ll personally known to me 0 proved to me on the basis of satisfactory evidence to be the person(q whose name(q isla subscribed to the within instrument and acknowledged to me that he/X&Wb&&xecuted the same in his/h&%KXX authorized capacity(iw, and that by hisAWtl@X signature#$ on the instrument the person(q or the entity upon behalf of which the person(% acted, executed the instrument. WITNESS my hand and official seal. Signature of Notary Public OPTlONAL Though the information below is not required by law, if may prove valuable to persons re/ying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Document Date: January 7, 2004 Number of Pages: Signer(@ Other Than Named Above: Contract Public Works Capacity(ies) Claimed by Signer Signer's Name: Paul C. Roberts 0 Individual [IP Corporate Officer - Title(s): 0 Partner - 0 Limited [3 General 0 Attorney-in-Fact 0 Trustee 0 Guardian or Conservator 0 Other: Assistant Secretary Signer Is Representing: FCI Constructors. Inc. u 0 1999 National Notary Association 9350 De Soto Ave , P.0. Box 2402 - Chatswoeh. CA 9131 3-2402 www.nationalnotary.org Prod. No. 5907 Reorder: Call Toll-Free 1-800-876-6827 Bond No. 08719715 Premium included in charge for the Performance Bond - LABOR AND MATERIALS BOND WHEREAS, the City Council of the City of Carlsbad, State of California, by Resolution No. - 344, adopted DECEMBER 16,2003, has awarded to (hereinafter designated as the "Principal"), a Contract for: 2003- FCI CONSTRUCTORS, Inc. CONTRACT NO. 38871 -A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 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 City Clerk of the City of Carlsbad and all of which are incorporated herein by this reference. WHEREAS, Principal has executed or is about to execute said Contract and the terms thereof require the furnishing of a bond, providing that if Principal or any of their subcontractors shall fail to pay for any materials, provisions, provender or other supplies or teams used in, upon or about the performance of the work agreed to be done, or for any work or labor done thereon of any kind, the Surety on this bond will pay the same to the extent hereinafter set forth. NOW, THEREFORE, WE, FCI CONSTRUCTORS, Inc. 9 as Principal, (hereinafter designated as the "Contractor"), and as Surety, are held firmly bound unto the City of Carlsbad in the sum - of THREE MILLION, FOUR HUNDRED THIRTY-EIGHT THOUSAND, SEVEN HUNDRED EIGHTY Dollars ($ 3,438,780.00 ), said sum being an amount equal to: One hundred percent (100%) of the total amount payable under the terms of the contract by the City of Carlsbad, and for which payment well and truly to be made we bind ourselves, our heirs, executors and administrators, successors, or assigns, jointly and severally, firmly by these presents. Fidelity and Deposit Company of Maryland 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 3248. This bond shall inure to the benefit of any of the persons named in California Civil Code section 3181, 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 any such Contractor shall not exonerate the Surety from its obligations under this bond. e= Revised 7/29/02 Contract No. 38871 -A Page 45 of 152 Pages ,- Executed by CONTRACTOR this 7 th Executed by SURETY this 7th day day of January ,20%. of January ,20K. CONTRACTOR: SURETY: FCI Constructors, Inc. Vice President, FCI Constr Atitle qnd organization of signatory) By: /- I - (sign here) Fidelity and Deposit Company of Maryland (name of Sure ) 801 North Brand Blvd., 9 enthouse Suite I Glendale, CA 91203 (address of Surety) (818) 409-2800 (telephone number of Surety) ~ -- (?3gn&re of Attorney-ii-Fact) Jeri Apodaca, Attorney-in-Fact -. \ By: QLL AfiL.W(l - (printed name of Attorney-in-Fact) Paul C. Roberts (attach corporate resolution showing current power (print name here) of attorney) Assistant Secretary, FCI Constructors, Inc. (title and organization of signatory) - (Proper notarial acknowledgment 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 City Attorney 43 Revised 7/29/02 Contract No. 38871-A Page 46 of 152 Pages CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT I State of California On ~ January 7, 2004 beforeme, Julie A. Patlan, Notary Public , personally appeared James J Keep Date Name and ntle of Officer (e.g., "Jane Doe, Notary Public") Name@) of Signer@) GI personally known to me C proved to me on the basis of satisfactory evidence to be the person(df whose name(4 is/% subscribed to the within instrument and acknowledged to me that heBfZXQW$executed the same in his/hlWflWK authorized capacity(i€G$, and that by his/hXKtWU signature@$ on the instrument the person(% or the entity upon behalf of which the person(3 acted. executed the instrument. WITNESS mv hand and official seal. Signature of Notary Public OPTIONAL Though the information below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Document Date: January 7, 2004 Number of Pages: Signer(s) Other Than Named Above: Labor and Materials Bond Capacity(ies) Claimed by Signer Signer's Name: James J Keep 0 Individual Corporate Officer - Title@): 0 Partner - 0 Limited 0 General 0 Attorney-in-Fact 0 Trustee 0 Guardian or Conservator 0 Other: Vice President Signer 1s Representing: FCI Constructors 9 Inc Q 1999 National Notary Association * 9350 De Solo Ave., P.O. Box 2402 * Chatsworth. CA 91313-2402 - w.nationalnotary.org Prod. No. 5907 Reorder: Call Toll-Free 1-800-876-6827 CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT State of California Countyof Sari Diego On January 7, 2004 beforeme, Julie A. Patlan, Notary Public , personally appeared Paul C. Roberts Date Name and mtle 01 Officer (e.g., '"Jane Doe. Notary Public') Name@) of Signer(s) N personally known to me 0 proved to me on the basis of satisfactory evidence to be the person(4 whose name@ ism subscribed to the within instrument and acknowledged to me that helW@Egexecuted the same in his/- authorized capacity(W), and that by his/- signature(@ on the instrument the person(q, or the entity upon behalf of which the person(@ acted, executed the instrument. Though the information below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent removal and reattachment of this form to another document. Description of Attached Document Title or Type of Document: Document Date: January 7. 7.004 Signer(s) Other Than Named Above: Capacity(ies) Claimed by Signer Labor and Materials Bond Signer's Name: Paul C. Roberts Corporate Officer - Title(s): Assistant Secretary 13 Partner - 0 Limited 0 General 0 Attorney-in-Fact Signer IS Representing: FCI Constructors 9 Inc 0 1999 National Notary Association * 9350 De Sot0 Ave , PO. Box 2402 * Chatswoiih, CA 913iZ-2402 * www natlonalnoiary.org Prod No. 5907 Reorder: Call Toll-Free 1-800-876-6827 ALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT No. 5907 State of California County of Orange On January 7 2004 before me. Leigh McDonough, Notary Public DATE NAME, TITLE OF OFFICER - E.G.. "JANE DOE. NOTARY PUBLIC" personally appeared Jeri Apodaca NAME@) OF SIGNER(S) IX1 personally known to me - OR - 0 proved to me on the basis of satisfactory evidence to be the person(s) whose name(s) islare subscribed to the within instrument and acknowledged to me that helshelthey executed the same in hislherltheir authorized caDacitvks). and that bv hislherltheir ~. .. 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. I 0 SIGNATURE OF NOTARY OPTIONAL Though the data below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent reattachment of this form. CAPACITY CLAIMED BY SIGNER DESCRIPTION OF ATTACHED DOCUMENT 0 INDIVIDUAL 0 CORPORATE OFFICER TITLE OR TYPE OF DOCUMENT TITLE(S) LIMITED E GENERAL PARTNER(S) [XI ATTORNEY-IN-FACT 0 TRUSTEE@) 0 GUARDlANlCONSERVATOR 0 OTHER: NUMBER OF PAGES SIGNER IS REPRESENTING: NAME OF PERSONW OR ENTITY(1ES) DATE OF DOCUMENT SIGNER(S) OTHER THAN NAMED ABOVE S4067lGEEF 2/98 0 1993 NATIONAL NOTARY ASSOCIATION. 8236 Remmel Ave.. P.O. Box 7184. Cancga Park, CA 91309-71 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 PAUL C. ROGERS, Vice President, and T. E. SMITH, Assistant Secretary, in set forth on the reverse appoint Jeri APODACA, of Irvine, California, i deliver, for, and 00 its behalf as surety, and as its a nd the execution of APODACA, dated The said Assistant Section 2, of the By- affixed the Corporate Seal of the said FIDELITY AND DEPOSIT COMPANY OF MARYLAND, this 14th day of April, A.D. 2003. ATTEST FIDELITY AND DEPOSIT COMPANY OF MARYLAND - T. E. Smith Assistant Secretary Paul C. Rogers Vice President State of Maryland ss: On this 14th day of April, A.D. 2003, before the subscriber, a Notary Public of the State of Maryland, duly commissioned and qualified, came PAUL C. ROGERS, Vice President, and T. E. SMITH, Assistant Secretary of the FIDELITY AND DEPOSIT COMPANY OF MARYLAND, to me personally known to he the individuals and officers described in and who executed the preceding instnrment, 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 fust above written. City of Baltimore I Sandra Lynn Mooney Notary Public My Commission Expires: January 1,2004 POA-F 012-5025J 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, moltgages 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 cettify that the foregoing Power of Attorney is still in full force and effect on the date of this certificate; and I do futther cettify 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, ZURICH THIS IMPORTANT DISCLOSURE NOTICE IS PART OF YOUR BOND - Fidelity and Deposit Company of Maryland, Colonial American Casualty and Surety Company, Zurich American Insurance Company, and American Guarantee and Liability Insurance Company are making the following informational disclosures in compliance with The Terrorism Risk Insurance Act of 2002. No action is required on your P"t. 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 Terrorbm Losses As required by the Terrorism Risk Insurance 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 limitations that do not differ materially as those for losses arising from events other than acts of terrorism. Disclosure of Federal Share of Insurance Companv'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 direct earned premium in the prior year; and for 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 direct 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. Defmition 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 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. These disclosures are informational only and do not modify your bond or affect your rights under the bond. Copyright Zurich American Insurance Company 2003 . Bond No. 08719715 s Premium $26,403.00 FAITHFUL PERFORMANCWARRANTY BOND WHEREAS, the Board of Directors of the Carlsbad Municipal Water District of the City of Carlsbad, State of California, by Resolution No. 2003-344 , adopted -ifi, has awarded designated as the "Principal"), a Contract for: to FCi rnNSTRllrTf3R)F , Inc. , (hereinafter CONTRACT NO. 38871-A ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES I AND 3 in the Carlsbad Municipal Water District, in strict conformity with the contract, the drawings and specifications, and other Contract Documents now on file in the Office of the Secretary of the Board of Directors (City Clerk of the City of Carlsbad), all of which are incorporated herein by this reference. WHEREAS, Principal has executed or is about to execute said Contract and the terms thereof require the furnishing of a bond for the faithful performance and warranty of said Contract: NOW, THEREFORE, WE, FCI CONSTRUCTORS, Inc. , as Principal, (hereinafter designated as the "Contractor"), and Fidelity and Deposit Company of Maryland , as Surety, are held and firmly bound unto the Carlsbad Municipal Water District, in the sum of -THREE MILLION FOUR HUNDRED THIRTY EIGHT THOUSAND, SEVEN HUNDRED EIGHTY Dollars ($~38.780.onl said sum beina eaual to one hundred percent (100%) of the estimated amount of the Contract, to be paid to fistrict or its certain attorney, its successors and assigns: for which payment, well and truly to be made, we bind ourselves, our heirs, executors and administrators, successors or assigns, jointly and severally, firmly by these presents. THE CONDITION OF THIS OBLIGATION IS SUCH that if the above bounden Contractor, their heirs, executors, administrators, successors or assigns, shall in all things stand to and abide by, and well and truly keep and perform the covenants, conditions, and agreements in the 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 obligation secured hereby and in addition to 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: 07/29/02 Contract No. 38871-A Page 47 of 152 Pages 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 CONTRACTOR this 7th Executed by SURETY this 7th day of day of January ,20 04 . January ,20 04 . CONTRACTOR: SURETY: FCI Constructors. Inc. Fidelitv and DeDOSit ComDanv of Marvland James J. Keep Vice President, FCI Constructors, Inc. (Title and Organization of Signatory) - By: I (sign he re) Paul C. Roberts (print name here) Assistant Secretary, FCI Constructors, (Title and Organization of signatory) (name of Surety) 801 North Brand Blvd., Penthcuse Suite Glendale, CA 91203 -- (address of Surety) (818) 409-2800 (telephone number of Surety) By: Jeri ADodaca, Attornev-in-Fact (printed name of Attorney-in-Fact) (Attach corporate resolution showing current power of attorney.) Inc . (Proper notarial acknowledge of execution by CONTRACTOR and SURETY must be attached.) (President or vice-president and secretary or assistant secretary must sign for corporations. If only one officer signs, the corporation must attach a resolution certified by the secretary or assistant secretary under corporate seal empowering that officer to bind the corporation.) APPROVED AS TO FORM: RONALD R. BALL General Counsel By: General Counsel aRevised: 07/29/02 Contract No. 38871 -A Page 48 of 152 Pages CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT State of California I Julie A. Patlan, Notary Public On January 7, 2004 before me, personally appeared James J . Keep Date Name and mUe of Officer (e.g.. "Jane Doe, Notary Public") Name@) of Signer(s) 6 personally known to me 0 proved to me on the basis of satisfactory evidence to be the person(q whose name($ is/= subscribed to the within instrument and acknowledged to me that he/swexecuted the same in his/- authorized capacity(@, and that by his/- signature($ on the instrument the person($, or the entity upon behalf of which the person($ acted, executed the instrument. WITNESS mv hand and official seal. WflflI SiEnature of Notary Public OPTIONAL Though the information below is not required by law, if may prove valuable to persons relying on the documenf and could prevenf fraudulent removal and reaftachment of this form to another document. Description of Attached Document Title or Type of Document: Faithful Performance/Warranty Bond Document Date: January 9 2004 Number of Pages: Signer@) Other Than Named Above: Capacity(ies) Claimed by Signer Signer's Name: James J . Keep 0 individual a Corporate Officer - Title(s): Vice President Partner - C Limited 0 General 0 Attorney-in-Fact 0 Trustee 0 Guardian or Conservator 0 Other: 0 1999 National Notary Association * 9350 De Sot0 Ave PO Box 2402 * Chatsworth, CA 91313-2402 www nationalnotary org Prod No 5907 Reorder Call Toll-Free 1-800-876-6827 CALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT State of California County of San Dieno on January 7, 2004 before me, Julie A. Patlan, Notary Public Data Name and T,tls Of m,cer (e 9 Jane Oae NOtaly PYI.') personally appeared Paul C. Roberts Nameid of S#pner(rl a personally known to me 3 proved to me on the basis of satisfactory evidence to be the person(% whose name(@ isla subscribed to the within instrument and acknowledged to me that he/slWW&executed the same in his/tWW& authorized capacity(=), and that by his/iTKDBkX signature(@ on the instrument the person(@, or the entity upon behalf of which the person(g0 acted, executed the instrument. WITNESS my hand and official seal OPTIONAL Though the ;"formation below is not reqdred by law, ;t may pmve valuable to persons relying on the document and could prevent fraudulent removal and reanachmenf of this form to another document. Description of Attached Document Document Date: January 7, 2004 Number of Pages: Signer@) Other Than Named Above: Capacity(ies) Claimed by Signer Signer's Name: Paul C. Roberts 0 Individual gl Corporate Officer-Title($: Assistant J Partner - -3 Limited 0 General U Attorney-in-Fact 0 Trustee 0 Guardian or Conservator U Other: Signer Is Representing: FCI Constructors, Inc. u ALIFORNIA ALL-PURPOSE ACKNOWLEDGMENT NO. 5907 State of California Countyof Orange On January 7 2004 before me, Leigh McDonough, Notary Public personally appeared Jeri Apodaca DATE NAME, TITLE OF OFFICER - E.G.. "JANE DOE, NOTARY PUBLIC 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) Mare subscribed to the within instrument and acknowledged to me that helshelthey executed the same in hislherltheir authorized capacity(ies), and that by hislherltheir 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. d4 OPTIONAL Though the data below is not required by law, it may prove valuable to persons relying on the document and could prevent fraudulent reattachment of this form. CAPACITY CLAIMED BY SIGNER DESCRIPTION OF ATTACHED DOCUMENT 0 INDIVIDUAL 0 CORPORATE OFFICER TITLE OR TYPE OF DOCUMENT TITLE(S) LIMITED GENERAL 0 PARTNER(S) w ATTORNEY-IN-FACT TRUSTEE(S) 0 GUARDlANlCONSERVATOR 0 OTHER: NUMBER OF PAGES SIGNER IS REPRESENTING: NAME OF PERSON(S) OR ENTIN(1ES) DATE OF DOCUMENT SIGNER(S) OTHER THAN NAMED ABOVE S467lGEEF 2/98 0 1993 NATIONAL NOTARY ASSOCIATION. 8238 Remmel Am. P.O. Box 7184. Canoga Park, CA 91309-711 NOT APPLICABLE ATTACHMENT A MINORITY BUSINESS ENTERPRISE/WOMEN'S BUSINESS ENTERPRISE (MBEIWBE)' SELF CERTIFICATION STATE WATER RESOURCES CONTROL BOARD DIVISION OF CLEAN WATER PROGRAMS Firm Name: Phone: Address: Principal Service or Product: 0- MBE 0- WBE I I B- Prime Contractor 0- Subcontractor 0- Broker 0- Supplier of MateriaVService I 0- Sole Ownership f3- Corporation 0- Partnership 0- Joint Venture I Names of Owners Percent MBE- WBE Ownership Ethnic Identity' Additional proofs may be required upon written challenge of this certification by any person or agency. Falsification of this certification by a fm selected to perform Federally funded work may result in a determination that the fm is non-responsible and ineligible for future contracts. Certified Title: by: Name: Date: (Signature) ' Refer to definitions on the next page. March 17,2000 BP-9 LOAN RECIPIENTS NAME CONTRACT NO. OR SPECIFICATION NO. Contract No. 38871-A PROJECT DESCRlPTlON Encina Basin water Reclamation Program Phase I1 Project CWRF Pipeline to "D" Tanks Reaches 1 and 3 PROJECT LOCATION Carlsbad, CA I WORK TO BE PERFORMED I FCI Constructors, Inc. 2585 Business Park Dr., Vista, CA 92081-8831 PHONE (760) 727-9767 AMOUNT OF CONTRACT MBE/WBE INFORMATION 0 MBE /WE NAME AND ADDRESS (Include ZIP Code, DOB, & SSN) March 17,2000 JOINTVENTURE BP-11 I 0 SUPPLIEWSERVICE BROKER .I. WORK TO BE PERFORMED 0 MBE WE NAME AND ADDRESS (Include ZIP Code, DOB. & SSA) 0 SUBCONTRACTOR 0 SUPPLIEWSERVICE 0 JOINTVENTURE 0 BROKER AMOUNT OF CONTRACT PHONE WORK TO BE PERFORMED 0 MBE 0 WBE NAME AND ADDRESS (Include ZIP Code, DOB, & SSN) 0 SUBCONTRACTOR 0 SUPPLIEWSERVICE 0 JOINTVENTURE 0 BROKER mont bl 1 yIIkhcl/l AMOUNT OF CONTRACT PHONE 0 MBE 0 WE 0 SUBCONTRACTOR 0 SUPPLIEWSERVICE 0 JOINTVENTURE 0 BROKER AMOUNT OF CONTRACT NAME AND ADDRESS (Include ZIP Code, DOB, & SSN) PHONE TOTALMBEAMOUNT: $ \b,fJW.60 TOTAL WBE AMOUNT: $ ACTUAL MBE PARTICIPATION: /f? % ACTUAL WE PARTICIPATION: MBE GOAL: 2o % WBEGOAL: SIGNATURE OF PERSON COMPLETING FORM: TITLE: Jim Keep, Chief Estim PHONE: 1760) 737-9767 DATE: ORM 4700-8 (rev 2/98) % % 11/4/2003 - City of Carlsbad October 27,2003 ADDENDUM NO. 1 + RE: CONTRACT NO. 3887-14 TITLED “ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO “D” TANKS REACHES 1 AND 3” Please include this addendum in the Notice to Bidder/Request for Bids you have for the above project. .“ The deadline for bid submissions has been postponed. The new bid due date is NOVEMBER 4. 2003. The time remains unchanged at 4:OO PM on this day. This addendum - receipt acknowledged - must be attached to your Proposal FordBid when your bid is submitted. KEVIN DAVIS BUYER I ACKNOWLEDGE RECEIPT OF ADDENDUM NO. 1 n 1635 Faraday Avenue Carlsbad, CA 92008-7314 (760) 602-2430 - FAX (760) 602-8553 www.ci.carlsbad.ca.us Business License (760) 602-2495 - Utility Billing (760) 602-2420 @ Purchasina (760) 602-2460 - FAX (760) 602-8556 - Bid Line (760) 602-2464 - City of Carlsbad October 29,2003 ADDENDUM NO. 2 RE: ENCIWA BASIN WATER RECLAMATION PROGW PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 CONTRACT NO. 3887-1A Please include the attached addendum in the Notice to Bidder/Request for Bids you have for the above project. This addendum--receipt acknowledged-must be attached to your Request for Bid when your bid is submitted. c KEVIN DAVIS Buyer KD:jlk Attachment I ACKNOWLEDGE RECEIPT OF ADDENDUM NO. 2 raa Bidder's Signature ..-- 1635 Faraday Avenue e Carlsbad, CA 92008-7314 e (760) 602-2430 FAX (760) 602-8553 www.ci.carlsbad.ca.us Business License (760) 602-2495 e Utility Billing (760) 602-2420 @ Purchasing (760) 602-2460 - FAX (760) 602-8556 - Bid Line (760) 602-2464 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 Project CWRF Pipeline to "D" Tanks Reaches 1' and 3, Contract No. 33871-A, 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 Contr&tor 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. - aRevised: 07/29/02 Contract No. 38871 -A Page 49 of 152 Pages 6. Contractor shall have the right to withdraw all or any part of the principal in the Escrow Account only by written notice to Escrow Agent accompanied by written authorization from District to the Escrow Agent that District consents to the withdrawal of the amount sought to be withdrawn by Contractor. 7. The District shall have a right to draw upon the securities in the event of default by the Contractor. Upon seven days' written notice to the Escrow Agent from the District of the default, the Escrow Agent shall immediately convert the securities to cash and shall distribute the cash as instructed by the District. 8. Upon receipt of written notification from the District certifying that the Contract is final and complete and that the Contractor has complied with all requirements and procedures applicable to the Contract, the Escrow Agent shall release to Contractor all securities and interest on deposit less escrow fees and charges of the Escrow Account. The escrow shall be closed immediately upon disbursement of 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: For Contractor: For Escrow Agent: GRevised: 07/29/02 Title FINANCE DIRECTOR Name Signature Address Title Name Signature Address Title Name Signature Address Contract No. 38871 -A Page 50 of 152 Pages At the time the Escrow Account is opened, the District and Contractor shall deliver to the Escrow Agent a fully executed counterpart of this Agreement. IN WITNESS WHEREOF, the parties have executed this Agreement by their proper officers on the date first set forth above. For District: Title MAYOR Name Signature Address For Contractor: - For Escrow Agent: @Revised: 07/29/02 Title Name Signature Address Title Name Signature Address Contract No. 38871 -A Page 51 of 152 Pages SUPPLEMENTAL PROVISIONS FOR ENCINA BASIN WATER RECLAMATION PROGRAM PHASE II PROJECT CWRF PIPELINE TO "D" TANKS REACHES 1 AND 3 CONTRACT NO. 33871 -A SUPPLEMENTAL PROVISIONS TO STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART 1, GENERAL PROVISIONS SECTION 1 -- TERMS, DEFINITIONS ABBREVIATIONS AND SYMBOLS 1-1 TERMS' Add the following section: 1-1.1 Reference to Drawings. Where words "shown", "indicated", "detailed", "noted", "scheduled", or words of similar import are used, it shall be understood that reference is made to the plans accompanying these provisions, unless stated otherwise. Add the following section: 1-1.2 Directions. Where words "directed", "designated", "selected", or words of similar import are used, it shall be understood that the direction, designation or selection of the Engineer is intended, unless stated otherwise. The word "required" and words of similar import shall be understood to mean "as required to properly complete the work as required and as approved by the Engineer," unless stated otherwise. Add the following section: 1-1.3 Equals and Approvals. Where the words "equal", "approved equal", "equivalent", and such words of similar import are used, it shall be understood such words are followed by the expression "in the opinion of the Engineer", unless otherwise stated. Where the words "approved", "approval", "acceptance", or words of similar import are used, it shall be understood that the approval, acceptance, or similar import of the Engineer is intended. Add the following section: 1-1.4 Perform. The word "perform" shall be understood to mean that the Contractor, at its expense, shall perform all operations, labor, tools and equipment, and further, including the furnishing and installing of materials that are indicated, specified or required to mean that the Contractor, at its expense, shall furnish and install the work, complete in place and ready to use, including furnishing of necessary labor, materials, tools, equipment, and transportation. GRevised: 07/29/02 Contract No. 38871 -A Page 52 of 152 Pages 1-2 DEFINITIONS. Modify as follows: The following words, or groups of words, shall be exclusively defined by the definitions assigned to them herein. Agency -the Carlsbad Municipal Water District 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. 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 Contractor’s Own Organization and will not be included for the purpose of compliance with section 2-3.1 of the Standard Specifications and these Supplemental Provisions. Owner Operatorkessor - 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. Project Manager - the District Engineer of the Carlsbad Municipal Water District or his/her approved representative. Senior Inspector - the Project Inspector’s immediate supervisor and first level of appeal for informal dispute resolution. QRevised: 07/29/02 Contract No. 38871 -A Page 53 of 152 Pages - 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 LCW D MSL MTBM NCTD OHE OMWD ROW S SDNR SDRSD SFM T UE W VWD Word or Words Apartment and Apartments Building band Buildings Carlsbad Municipal Water District Carlsbad Supplemental Standard Drawings Cubic Feet per Second Commercial Dimension Ratio Electric Gas Gallon and Gallons Garage and Garages Ground Not Visible gallons per minute Invert Elevation Leucadia County Water District Mean Sea Level (see Regional Standard Drawing M-12) Microtunneling Boring Machine North County Transit District Overhead Electric Olivenhain Municipal Water District Right-of-way Sewer or Slope, as applicable San Diego Northern Railway San Diego Regional Standard Drawings Sewer Force Main Telephone Underground Electric Water, Wider or Width, as applicable Vallecitos Water District SECTION 2 -- SCOPE AND CONTROL OF THE WORK 2-1 AWARD AND EXECUTION OF CONTRACT, add the following: Basis of Award shall be the sum of Bid Schedules A and C. Bid Schedule B is an optional additive alternative. The Agency reserves the right to add Bid Schedule B to the Contract, as optional additive alternative. The three Schedules are named as follows: Bid Schedule A - Pipeline and Pressure Reducing Station (Excluding the Work Described in Bid Schedules B and C) Bid Schedule B - Alderwood Drive (sta. 1+00 to sta. 12+40.58),Batiquitos Drive (sta. 1+00 to sta. 18+97.76) Optional Additive Alternative Bid Schedule C - Asphalt Pavement Overlay 2-3 SUBCONTRACTS. Revised: 07/29/02 Contract No. 38871 -A Page 54 of 152 Pages 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 version of US. 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 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 ($1 0,000,000). 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). 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 liabilities in an amount equal to or in excess of the amount of the bond. The bonds are to contain the following documents: 1) An original, or a certified copy, of the 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. QRevised: 07/29/02 Contract No. 38871-A Page 55 of 152 Pages 2-5 PLANS AND SPECIFICATIONS. 2-5.1 add the following: The specifications for the work include the Standard Specifications for Public Works Construction, (SSPWC), 2003 Edition, and the 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. General, The construction plans consist of one set of drawings. The drawing set is designated as City of Carlsbad Drawing No. 403-1 B and consists of 11 5 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. 2-5.2 Precedence of Contract Documents, modify as follows: If there is a conflict between Contract Documents, the document highest in precedence shall control. The precedence shall be the most recent edition of the following documents listed in order of highest to lowest precedence: Permits from other agencies as may be required by law. Technical Specifications Supplemental Provisions. Plans. State Water Resource Control Board Contract Requirements. 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. Standard Specifications for Public Works Construction. Reference Specifications. Manufacturer's Installation Recommendations. Change Orders, Supplemental Agreements and approve revisions to Plans and take precedence over items 2) through 9) above. Detailed plans and plan precedence over general plans. Specifications will views shall have 2-5.3 Shop Drawings and Submittals 2-5.3.1 General, replace the first sentence of the second paragraph with the following: Materials shall not be manufactured, fabricated or produced, and shall not be provided to the project site, nor any work done for which shop drawings and submittals are required, before those shop drawings and submittals have been reviewed and approved, as provided in this subsection. 2-5.3.2 Shop Drawings, add the following: Each drawing shall be labeled with the following: 1. Specification Section 2. Submittal Number GRevised: 07/29/02 Contract No. 38871 -A Page 56 of 152 Pages 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 contain the following: 1) Project title and Agency contract number. 2) Number of complete sets. 3) Contractor's certification statement. 4) Specification section number@) 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 10 copies of said revised submittal to the ENGINEER. GRevised: 07/29/02 Contract No. 38871-A Page 57 of 152 Pages 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 with the following: The Contractor shall not cover or disturb permanent survey monuments or benchmarks without the consent of the Engineer. Where the Engineer concurs, in writing, with the Contractor that protecting an existing monument in place is impractical, the Contractor shall employ a licensed land surveyor or a registered civil engineer authorized to practice land surveying within the Sate 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 55 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’/; 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 55 8700 - 8805 of the Sate of California Business and Professions Code when the surveyor performs any surveying that such map is required under $5 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 GRevised: 07/29/02 Contract No. 38871 -A Page 58 of 152 Pages steel and all monuments and marks that are at, or accessory to, property corners and street centerlines are permanent survey monuments. The Record of Survey shall show all monuments set, control monuments used, the basis of bearings and all other data needed to determine the procedure of survey and the degree of accuracy attained by the field surveying including the unadjusted ratio of closure. The unadjusted ratio of closure shall not exceed 1 part in 40,000. The record of survey shall show the location and justification of location of all permanent monuments set and their relation to the street right-of-way. Record(s) of Survey(s) shall be submitted for the Engineer’s review and approval before submittal to the County Surveyor and before submittal to the County Recorder. Add the following section: 2-9.2.2 Survey Requirements, Stakes shall be set at offsets approved by the Engineer at no greater intervals than specified in TABLE 2-9.2.2(A) as measured along the project stationing. Stakes shall be set to show the location and grade of future curbs adjacent to traffic signal locations where the curb is not being built as a part of this contract. Staking and marking shall be completed by the Surveyor and inspected and approved by the Engineer before the start of construction in the area marked. Centerline monument shall have the disk stamped with the date the monument was set and the registration number of the Surveyor. Habitat mitigation sites and other areas to be preserved that are shown on the plans shall be staked and flagged prior to the start of any other activities within the limits of the work. When curb and gutter does not exist and is not being installed as a part of the project the location of adjacent facilities being constructed as a part of the contract the Contractor shall place stakes defining the horizontal and vertical location of such adjacent utility vaults, poles or other facilities that are being installed as parts of, or adjunct to, the project either by the Contractor and/or those noted on the plans as to be installed by others. TABLE 2-9.2.2(A) Survey Requirements for Construction Staking QRevised: 07/29/02 Contract No. 38871-A Page 59 of 152 Pages ~ _____ 10 mm (‘/$) Horizontal & 7 mm (l/4”) Vertical ~ ~~ ~~~ ntervisible & I 7.5m (25’), beginning and end BC & EC of facilities, Grade breaks, Alignment breaks, Junctions, Inlets & similar facilities, Risers & similar facilities (except as appropriate Drainage Structures, Pipes & similar FacilitiesO, 0 Curb RP + Marker Stake RP + Marker Stake plumbing), Skewed cut-off lines ’ I7.5m (25’). BC & EC. at %A, %A & %A on 10 mm (;1/8”) Horizontal & 7 mm (l/40) Vertical ( constant off set) cwb returns & at beainnina & end Traffic Signal O Sianal Poles & Vertical locations shall be based on the ultimate elevation of curb and sidewalk at each pole & controller location 10 mm (“/a”) Horizontal & 7 mm (l/4”) Vertical 10 mm (“/E”) Horizontal as appropriate RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake + Line Stake RP + Marker Stake + Line Stake RP + Marker Stake + Line Joint +Guard Stake Eontroller o Junction Box at each junction box location as appropriate 7 mm (lj4”) Vertical 10 mm (‘/E”) Horizontal Conduit O as appropriate as appropriate I 15 m (50’) on tangents & curves when R2 300m (1000’) & I 7.5m (25’) on curves when R I 300m (1 000’) or where grade I 0.30% & when depth cannot be measured from existing pavement 7 mm ?/C) Vertical 10 mm (“/$I Horizontal Minor Structure for catch basins: at centerline of box, ends of box & wings & at each end of the local depression 6 & 7 mm <‘/4n) Vertical (when vertical data needed) 30 mm (0.1 ’) Vertical & Horizontal 7 mm (’/4’’) Horizontal & 7 mm (l/~) Vertical I 15 m (50’) & along end slopes & conic transitions as appropriate Abutment Fill as appropriate Wall O 5 15 m (50’) and at beginning & end of: each wall, BC & EC, layout line angle points, :hanges in footing dimensions &/or elevation & wall height 3 m to 10 m (1 0’ to 33’) as required by the Engineer, BC & EC, transition points & at leginning & end. Elevation points on footing: at bottom of columns 1 m to 10 m (10’ to 33’) sufficient to use string lines, BC & EC, transition points & at ,eginning & end. Elevation points on footing: at bottom of columns Major Structure 0 Footings, Bents Abutments & W ingwalls - 10 mm (‘/f) Horizontal & 7 mm ( /4“) Vertical RP + Marker Stake + Line ’oint +Guard Stake RP as appropriate 10 mm (‘/f) Horizontal & 7 mm ( /C) Vertical Superstructure: as appropriate Miscellaneous 6 Contour Gradin$ O I 15 m (50’) along contour line RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake + Line Joint +Guard Stake RP + Marker Stake RP + Marker Stake RP + Marker Stake RP + Marker 30 mm (0.1’) Vertical & Horizontal 10 mm (‘/$) Horizontal Utilities 0, 0 as appropriate as appropriate Line point I 15 m (50’) on tangents & curves when R2 300m (1 000’) & I 7.5m (25’) on curves when R I 300m (1 000’) or where grade I 0.30% intervisible & I30 m (loo’), BC & EC of facilities, Grade breaks, Alignment breaks, Junctions, Inlets & similar facilities At sign location & 7 mm (’/;I Vertical 30 mm (0.1’) Horizontal &7 mm Channels, Dike5 & Ditches 0 (l/;) Vertical 30 mm (0.1’) Vertical & Signs O Horizontal Subsurface Drains O 30 mm (0.1’) Horizontal & 7 mm (l/4“) Vertical 30 mm (0.1’) Horizontal & 7 mm (‘/;I Vertical 7 mm (I/;) Horizontal as appropriate 9t beginning & end intervisible & I 15m (50’), BC & EC of facilities, Grade breaks, Alignment breaks, Junctions, Inlets & similar facilities, Risers & similar facilities longitudinal location Overside Drains 0 - Markers O At marker location(s) for asphalt street surfacing I 15 m (50’) on angents & curves when R2 300m (1 000’) & 5 7.5m (25) on curves when R I 300m (1 000’). At beginning & end and I 15 m (50’) on Railinas & 10 mm (’/$) Horizontal at railing & @Revised: 07/29/02 Contract No. 38871 -A Page 60 of 152 Pages Barriers (D I Slake Itangents &curves when R 5 300m (1000') & SI barrier I 8 Vertical AC Dikes 0 Box Culverts 7.<m (25') on curves when R 5 300m (1Ooo') At beginning & end 3 m to 10 m (10' to 33') as required by the Enoineer. BC 8 EC. transition Doinls & at location(s) as appropriate 30 mm (0.1') Stake Horizontal & Vertical as appropriate 10 mm ('I{) Horizontal & 7 mm 1,") Vertical RP + Marker Pavement Markers0 I I surfaced streets lane cold joints will suffice I I 0 Slaking for feature may be omined when adjacent marker stakes reference the offset and elevation of those features and the accuracv reauirements of the RP meet the reauirements for the feature .. beginhng &end. Elevation poi& on footings 8 at invert 60 m (200') on tangents, 15m (50') on curves when R 5 300m (1000') & 7.5m (25') on curves when A s 300m (1000') For PCC RP at pavement marker location(s) 7 mm (I/<) Horizontal 0 Reference poi& shall be sufficiently durable and set securely enough to survive with accuracy intact throughout tne installation & inspection of the features or adjacent facilities lor which they provide control. RP means reference uoint for the purposes of this table a Perpendicular to centerline. 0 Some features are not necessarily parallel to centerline but are referenced thereto 0 Multi-plane surfaced features shall be staked so as to provide line 8 grade information for each plane of the feature @ 2 means greater than, or equal to. the number following the symbol. 5 means less than. or equal to. the number 0 The cut datum for storm drainage & sanitaty sewer pipes 8 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(8) following the symbol. TABLE 2-9.2.2(8) Survey Stake Color Code for Construction Staking Type of Stake I Descrlption I color Horizontal Control I Coordinated control points, control lines, control reference points. centerline, I WhiteIRed Vertical Control Clearing Grading alignments, etc. Bench marks W hite/Orange Limits of clearing Yellow/Black Slope, intermediate slope, abutment fill, rough grade, contour grading, final Yellow Structure Drainage, Sewer, Curb Right-of-Way Miscellaneous #Revised: 07/29/02 grade, etc. Bridges. sound and retaining walls, box culverts. etc. Pipe culverts, junction boxes, drop inlets, headwalls. sewer lines, storm drains, slope protection, curbs, quners. etc. Fences, W W lines, easements, property monuments. etc. Signs, railings, barriers, lighting. etc. While Blue WhitePlellow Orange Contract No. 38871 -A Page 61 of 152 Pages 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. SECTION 3 -- CHANGES IN WORK 3-2 CHANGES INITIATED BY THE AGENCY 3-2.2.1 Contract Unit prices, add the following: In the case of an increase or decrease in quantity of a minor bid item in excess of 25 percent of the original quantity bid adjustment of contract unit price for such items will be limited to that portion of the change in excess of 25 percent of the original quantity listed in the Contractor’s bid proposal for this contract. Adjustments in excess of 25 percent may, at the option of the Engineer, be paid pursuant to section 3-3, Extra Work. 3-3 EXTRA WORK. 3-3.2.2 ( c ) Tool and Equipment Rental, second paragraph, modify as follows: Regardless of ownership, the rates and right-of-way delay factors to be used in determining rental and delay costs shall be the edition of the, “Labor Surcharge & 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. Revised: 07/29/02 Contract No. 38871 -A Page 62 of 152 Pages 3-3.2.3 Markup, Delete section 3-3.2.3 from the 1995 and 1996 Supplements to the SSPWC and ~~ , replace with the following: (a) and shall constitute the markup for all overhead and profits: 1) Labor ................................... 20 2) Materials ............................. 15 3) Equipment Rental ................... 15 4) Other Items and Expenditures .. 15 To the sum of the costs and markups provided for in this section, 1 percent shall be added as compensation for bonding. (b) Work by Subcontractor. When all or any part of the extra work is performed by a Subcontractor, the markup established in 3-3.2.3(a) shall be applied to the Subcontractor’s actual cost of such work. A markup of 10 percent on the first $5,000 of the subcontracted portion of the extra work and a markup of 5 percent on work added in excess of $5,000 of the subcontracted portion of the extra work may be added by the Contractor. 3-3.3 Daily Reports by Contractor, Payment for extra work will not be made until such time that the Contractor submits completed daily reports and all supporting documents to the Engineer. 3-4 CHANGED CONDITIONS. delete the second sentence of paragraph three, delete paragraph five (5), and add the following: The Contractor shall not be entitled to the payment of any additional compensation for any act, or failure to act, by the Engineer, including failure or refusal to issue a change order, or for the happening of any event, thing, occurrence, or other cause, unless the Contractor shall have first given the Engineer due written notice of potential claim as hereinafter specified. Compliance with this section shall not be required as a prerequisite to notice provisions in Section 6-7.3 Contract Time Accounting, nor to any claim that is based on differences in measurement or errors of computation as to contract quantities. The written notice of potential claim for changed conditions shall be submitted by the Contractor to the Engineer upon their discovery and prior to the time that the Contractor performs the work giving rise to the potential claim. The Contractor’s failure to give written notice of potential claim for changed conditions to the agency upon their discovery and before they are disturbed shall constitute a waiver of all claims in connection therewith. 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 12650-12655, ’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.” Work by Contractor. The following percentages shall be added to the Contractor’s costs add the following after the second sentence: ~. . By: Title: Date: Company Name: -1 @Revised: 07/29/02 Contract No. 38871-A Page 63 of 152 Pages 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 Cod e. - 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. 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 201 04) 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 Revised: 07/29/02 Contract No. 38871 -A Page 64 of 152 Pages that "public work does not include any work or improvement contracted for by the state or the Regents of the University of California. (2) "Claim" means a separate demand by the contractor for (A) a time extension, (B) payment of money or damages arising from work done by, or on behalf of, the contractor pursuant to the contract for a public work and payment of which is not otherwise expressly provided for or the claimant is not otherwise entitled to, or (C) an amount the payment of which is disputed by the local agency. (c) The provisions of this article or a summary thereof shall be set forth in the plans or specifications for any work which may give rise to a claim under this article. (d) This article applies only to contracts entered into on or after January 1, 1991. 20104.2. For any claim subject to this article, the following requirements apply: (a) The claim shall be in writing and include the documents necessary to substantiate the claim. Claims must be filed on or before the date of final payment. Nothing in this subdivision is intended to extend the time limit or supersede notice requirements otherwise provided by contract for the filing of claims. (b)(l) For claims of less than fifty thousand dollars ($50,000), the local agency shall respond in writing to any written claim within 45 days of receipt of the claim, or may request, in writing, within 30 days of receipt of the claim, any additional documentation supporting the claim or relating to defenses to the claim the local agency may have against the claimant. (2) If additional information is thereafter required, it shall be requested and provided pursuant to this subdivision, upon mutual agreement of the local agency and the claimant. (3) The local agency's written response to the claim, as 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 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. GRevised: 07/29/02 Contract No. 38871-A Page 65 of 152 Pages 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 15-day 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 1141 .lo) of Title 3 of Part 3 of the Code of Civil Procedure, notwithstanding Section 11 41.1 1 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 1141.1 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. aRevised: 07/29/02 Contract No. 38871 -A Page 66 of 152 Pages 4-1.4 Test of Materials, 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 the Agency. Add the following section: 4-2 MATERIALS TRANSPORTATION, HANDLING l? 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. delete the phrase, “and a reasonable amount of retesting”, from the third - - QRevised: 07/29/02 Contract No. 38871-A Page 67 of 152 Pages -. 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. 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 fourteen (14) calendar days after receipt of the "Notice to Proceed". Add the following section: 6-1.1 Pre-Construction Meeting. After, or upon, notification of contract award, the Engineer will set the time and location for the Preconstruction Meeting. Attendance of the Contractor's management personnel responsible for the management, administration, and execution of the project is mandatory for the meeting to be convened. Failure of the Contractor to have the Contractor's responsible project personnel attend the Preconstruction Meeting will be grounds for default by Contractor per section 6-4. No separate payment will be made for the Contractor's attendance at the meeting. The notice to proceed will only be issued on or after the completion of the preconstruction meeting. Add the following section: 6-1.1.1 Baseline Construction Schedule Submittal. The Contractor shall submit the Baseline Construction Schedule per the submittal requirements of section 2-5.3. The submittal of the Baseline Construction Schedule shall include each item and element of sections 6-1.2 through 6-1.2.9 and shall be on hard (paper) copy and electronic media conforming to section 6-1.3.3 Electronic 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. QRevised: 07/29/02 Contract No. 38871 -A Page 68 of 152 Pages 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. 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 Soflware. The Contractor shall use commercially available software equal to the Windows 2000 compatible "Suretrak" program by Primavera or "Project" program by Microsoft Corporation to prepare the Baseline Construction Schedule and all updates thereto. The Contractor shall submit to the Agency a 89 mm (3.5) data disk with all network information contained thereon, in a format readable by a Microsoft Windows 2000 system. The Agency will use a "Suretrak", "Project" or equal software program for review of the Contractor's schedule. Should the Contractor elect to use a scheduling program other than the "Suretrak" program by Primavera or "Project" program by Microsott 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 p~blisher for up to eight Agency staff members. The classes shall be presented on Mondays through Tliursdays, 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 Coristruction 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 eqiiipment 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: 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 6-1 2.7 Restraints to Activities. Any submittals, utility interfaces, or any furnishing of Agency -, Contract No. 38871-A -0 b Revised: 07/29/02 Page 69 of 152 Pages I 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 6-4. 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 implementing all contractual requirements including liquidated damages in accordance with the revised duration. Add the following section: 6-1.2.1 0 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: 6-1.2.1 0.1 “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: 6-1.2.1 0.2 “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: 6-1.2.1 0.3 “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. I @Revised: 07/29/02 Contract No. 38871 -A Page 70 of 152 Pages Add the following section: - 6-1.3 Preparation of Schedule Updates and Revisions. The Contractor shall meet with the Engineer during the last week of each month to agree upon each activity’s schedule status and shall submit monthly updates of the Baseline Construction Schedule confirming the agreements no later than the fifth working day of the following month. The monthly update will be submitted on hard (paper) copy and electronic media conforming to section 6-1.3.3 Electronic Media per the submittal requirements of section 2-5.3 and will include each item and element of sections 6-1.2 through 6-1.2.9 and 6-1.3.1 through 6-1.3.7. Add the following section: 6-1.3.1 Actual Activity Dates. The actual dates each activity was started and/or completed during the month. After first reporting an actual date, the Contractor shall not change that actual date in later updates without specific notification to the Engineer with the update. Add the following section: 6-1.3.2 Activity Percent Complete. 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 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. 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. For each activity underway at the end of the month, the - A list of all changes made to the activities or to the interconnecting logic, 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 QRevised: 07/29/02 Contract No. 38871-A Page 71 of 152 Pages ~~ ~~~~ ~ - Add the following section: 6-1.4.2 “Accepted with Comments.” The Contractor may proceed with the project work. The Contractor must resubmit the Updated Construction Schedule to the Engineer incorporating the corrections and changes noted in the Engineer’s comments prior to receipt of payment per section 6-1.8.2. Add the following section: 6-1.4.3 “Not Accepted.” The Contractor must resubmit the Updated Construction Schedule to the Engineer incorporating the corrections and changes noted in the Engineer’s comments prior to receipt of payment per section 6-1.8.2. The Contractor, at the sole option of the Engineer, may be considered as having defaulted the contract under the provisions of section 6-4 DEFAULT BY CONTRACTOR if the changes of the comments are not submitted and marked “Accepted” by the Engineer before the last day of the month in which the Updated Construction Schedule is due. If the Contractor fails to submit the corrected Updated Construction Schedule as required herein the Contractor may elect to proceed with the project at its own risk. Should the Contractor elect not to proceed with the project, any resulting delay, impact, or disruption to the project will be the Contractor’s responsibility. Add the following section: 6-1.5 Late Completion or Milestone Dates. Should the Schedule Update indicate a completion or contractually required milestone date later than the properly adjusted contract or milestone duration, the Agency may withhold Liquidated Damages for the number of days late. Should a subsequent “Accepted” Schedule Update remove all or a portion of the delay, all or the allocated portion of the previously held Liquidated Damages shall be released in the monthly payment to the Contractor immediately following the “Accepted” schedule. Add the following section: 6-1.6 Interim Revisions. Should the actual or projected progress of the work become substantially different from that depicted in the Project Schedule, independently of and prior to the next monthly update, the Contractor will submit a revised Baseline Construction Schedule, with a list and explanation of each change made to the schedule. The Revised Construction Schedule will be submitted per the submittal requirements of section 2-5.3 and per the schedule review and acceptance requirements of section 6-1, including but not limited to the acceptance and payment provisions. - 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 preparation and updates for all phases of work shown and specified in Bid Schedules A, B, and C will be paid for at the stipulated lump sum price of ten thousand ($10,000) for Bid Schedules “A” and “C” and at the stipulated lump sum price of four thousand dollars ($4,000.00) for Bid Schedule “B” for a total stipulated lump sum price of fourteen thousand dollars ($14,000.00) for Bid Schedules A, B, and C. 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 - ’3Revised: 07/29/02 Contract No. 38871 -A Page 72 of 152 Pages 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 the 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. Three thousand dollars ($3,000.00) of the stipulated lump sum bid for the Construction Schedules “A and “C and a one thousand two hundred dollars ($1,200) of the stipulated lump sum bid for the Construction Schedules “B” 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 five hundred dollars ($500.00) for Bid Schedules “A and “C” and payments of two hundred dollars ($200.00) for Bid Schedule “B 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 two thousand dollars ($2,000.00) for the Construction Schedules “A and “C and an eight hundred dollars ($800.00) for the Construction Schedule ”8” 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. , - 6-2 PROSECUTION OF WORK, Add the following: 6-2.1 Summary of Work. The work to be done shall consist of furnishing all labor, equipment and materials, and performing all operations necessary to complete the Project Work as shown on the Project Plans and as specified in the Specifications. The work includes construction of approximately 7,000 linear feet of 24-inch cement mortar lined and tape coated steel pipe, 18,000 liner feet of distribution pipe (PVC), ranging in size from 4 to 12 inch diameter, a pressure reducing station, and all appurtenances and incidentals, all in accordance with the plans, specifications and special provisions. The work to be performed is within the City of Carlsbad and includes work within the public right-of- way, private roads, and the CalTrans (State) right-of-way. The State right-of-way encroachment permit has been obtained by the Agency and is included in the Appendix of these Specifications; refer to 7-5.1 of these Special Provisions. QRevised: 07/29/02 Contract No. 38871-A Page 73 of 152 Pages Additionally the work to be performed includes the Contractor’s coordination with SDG&E and work required by the Contractor to procure and install a new electrical service for the pressure reducing station located at Avenida Encinas. The SDG&E service order defining the coordination and work required by the Contractor has been obtained by the Agency and is contained in the Appendix of these Specifications; also see 7-7.1.1 of these Special Provisions. Under Bid Schedule A, the major elements of the recycled water pipeline work to be performed includes: Contractor to inspect and evaluate the existing 14-inch expansion joints (double ball flex- tends) within the State right-of-way in accordance with the plans, specifications and special provisions and replace if deemed necessary per the Specifications; remove and replace the 14-inch butterfly valves; construct the 24-inch transmission main; construct the 12-inch transmission main in Paseo del Norte; construct the various distribution pipelines; construct the pressure reducing station. Under Bid Schedule B (Optional Additive Alternate), the major elements of the recycled water pipeline work to be performed includes: distribution pipelines in Alderwood Drive (Sta. 1+00 to Sta. 12+40.58) and Batiquitos Drive (Sta. 1 +00 to 18+97.46). Under Bid Schedule C, the major elements of the work includes pavement overlay and restriping in Paseo del Norte and Camino del Parque. The descriptions for Bid Schedules A through C are overviews only and shall not relieve the Contractor from its responsibilities to perform the coordination and work in accordance with the Plans and Specifications. Some phases or portions of phases may overlay each other and/or occur during the same time period. 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”, SSPW C. No separate payment for attendance of the Contractor, the Contractor’s Representative or any other employee or subcontractor or subcontractor‘s employee at these meetings will be made. 6-6 DELAYS AND EXTENSIONS OF TIME. 6-6.4 Written Notice and Report. Modify as follows: The Contractor shall provide written notice to the Engineer within two hours of the beginning of any period that the Contractor has placed any workers or equipment on standby for any reason that the Contractor has determined to be caused by the Agency or by any organization that the Agency may otherwise be obligated by. The Contractor shall provide continuing daily written notice to the Engineer, each working day, throughout the duration of such period of delay. The initial and continuing written notices shall include the classification of each workman and supervisor and the make and model of each piece of equipment placed on standby, the cumulative duration of the standby, the Contractor’s opinion of the cause of the delay and a cogent explanation of why the Contractor could not avoid the delay by reasonable means. Should the Contractor fail to provide the notice(s) required by this section the Contractor agrees that no delay has occurred and that it will not submit any claim(s) therefor. 6-7 TIME OF COMPLETION. Add the following: The Contractor shall diligently prosecute the work to completion within two hundred (200) working days after the starting date specified in the Notice to Proceed. ’$Revised: 07/29/02 Contract No. 38871 -A Page 74 of 152 Pages 6-7.2 Working Day. Add the following: Unless otherwise approved in writing by the Engineer or shown on the contact drawings, the hours of work shall be between the hours of 7: 00 a.m. and 4:OO p.m. on Mondays through Fridays, unless otherwise indicated on the Traffic Control Plans, 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 office of the San Diego County Recorder. The date of recordation shall be the date of completion of the Work. Delete the first sentence of the third paragraph and substitute the following two sentences: All work shall be warranted for one (1) year after recordation of the "Notice of Completion" and any faulty work or materials discovered during the warranty period shall be repaired or replaced by the Contractor, at its expense. Twenty-five percent of the faithful performance bond shall be retained as a warranty bond for the one year warranty period. 6-9 LIQUIDATED DAMAGES. Modify the last sentence of the first paragraph and the first sentence of the second paragraph and add the following: For each consecutive calendar day in excess of the time specified for completion of Work, as adjusted in accordance with 6-6, the Contractor shall pay the Agency, or have withheld monies due it, the sum of Five-Hundred Dollars ($500.00). Execution of the Contract shall constitute agreement by the Agency and Contractor that (Five Hundred Dollars) 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 CONTRACTOR'S EQUIPMENT AND FACILITIES, Add the following: 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. GRevised: 07/29/02 . Contract No. 38871-A Page 75 of 152 Pages 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, 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 all permits for the disposal of all materials removed from the project. The cost of said permit(s) shall be included in the price bid for the appropriate bid item and no additional compensation will be allowed therefor. Delete the first sentence and add the following four sentences: 7-5.1 Agency Permits. Agency permits for the Work are included in Appendix of these special provisions. Resource agency permits pertaining to this project include: 1 ) State Department of Transportation Encroachment Permit No 11 -02-NUX0701. The Contractor shall be responsible for complying with all requirements of the above referenced permit. The cost to comply with the permit requirements shall be included in the price bid for the appropriate bid item and no additional compensation will be allowed therefor. - 7-7 COOPERATION AND COLLATERAL WORK. Add the following: 7-7.1 Coordination. The Contractor shall coordinate and cooperate with all the utility companies during any relocation or construction of their lines. The Contractor may be granted a time extension if, in the opinion of the Engineer, a delay is caused by the utility company. No additional compensation will be made to the Contractor for any such delay. 7-7.1.1 SDG&E Service Order. The Agency has obtained the SDG&E service order required to provide the new electrical service for the pressure reducing station. The SDG&E service order is included in the Appendix of these Special Provisions. The Contractor shall include in the bid for the pressure reducing station all the work required in performance of the work associated with the SDG&E service order and in conformance with the Contract Documents. Note: The Contractor must schedule a pre-construction meeting with SDG&E as stipulated in the service order prior to beginning the work for the new electrical service. 7-7.1.2 HOA Access and Coordination. The Contractor shall coordinate and cooperate with each Home Owners Association (HOA) to maintain access to the entrances of the HOA and cooperate with the HOA to minimize impacts due to the construction activities within the HOA and the private streets. The Contractor shall contact each HOA representative prior to the commencement of work in the private roads. .- e= tpRevised: 07/29/02 Contract No. 38871 -A Page 76 of 152 Pages 7-8 PROJECT SITE MAINTENANCE. 7-8.1 Cleanup and Dust Control. Add the following: Cleanup and dust control required herein shall also be executed on weekends and other non-working days when needed to preserve the health safety or welfare of the public. The Contractor shall conduct effective cleanup and dust control throughout the duration of the Contract. The Engineer may require increased levels of cleanup and dust control that, in his/her sole discretion, are necessary to preserve the health, safety and welfare of the public. Cleanup and dust control shall be considered incidental to the items of work that they are associated with and no additional payment will be made therefor. 7-8.5 Temporary Light, Power and Water. Add the following: The Contractor shall obtain a construction meter for water used for the construction, plant establishment, maintenance, cleanup, testing and all other work requiring water related to this contract. The Contractor shall contact the appropriate water agency for requirements. The Contractor shall pay all costs of temporary light, power and water including hookup, service, meter and any, and all, other charges, deposits and/or fees 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. 7-8.6 Storm Water Pollution Prevention Plan (SWPPP). Add the following: The Contractor shall prepare the SWPP for review and approval by the Agency. The SWPPP shall comply with all requirements of the California State Water Resources Control Board order number 2001 -01, NPDES General Permit number CAS01 08758 and the "Water Discharge Requirement for Discharges of Storm Water Runoff Associated with Construction Activity". The Contractor shall implement, maintain A current updated copy of the SWPPP shall be kept on the construction site at all times. The Contractor is responsible for the removal of all temporary erosion and sediment control measures upon project completion. 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. and update the approved SWPPP in conformance with all jurisdictional requirements. - 7-10 PUBLIC CONVENIENCE AND SAFETY. 7-10.1 Traffic and Access. add the following: In order to minimize impacts to the business community and the residents of Carlsbad, the following work area restrictions shall be observed: 1. The work zone during working hours shall not exceed the lengths as shown on the Traffic Controls Plans, and shall be no wider that as shown on the Traffic Control Plans. 2. The Contractor shall schedule his daily activities such that access to all driveways shall be provided at the end of each working day.unless permission is otherwise obtained from the property owner and approval is received from the Engineer. 3. All traffic lanes shall be maintained at all times except as permitted/shown on the traffic control plans provided. construction. At the end of each work day all material and equipment placed in the median shall be removed and the roadway placed in a safe condition. 4. Construction activities within Poinsettia Lane permit the use of the median during - QRevised: 07/29/02 Contract No. 38871-A Page 77 of 152 Pages 5. 6. 7. Construction activities in the intersection of Poinsettia Lane at Batiquitos and Aviara Parkway require detours at night time construction. The Contractor shall post signs on each approach to each intersection a minimum of ten (10) working days before start of construction notifying the public of the times and days the detours and night construction will occur. Construction activities in Avenida Encinitas at the Coaster Station access driveway requires night construction. The Contractor will coordinate with NCTD to maintain access to the Coaster Station for a minimum of 1 hour before and after each scheduled Coaster stop. The Contractor shall post signs a minimum of five (5) working days prior to start of work notifymg patrons the days and times construction will occur. Construction activities at the following intersections will damage and/or require modification of the traffic signal detection system: Poinsettia Lane at Paseo Del Norte Poinsettia Lane at Batiquitos Drive Poinsettia Lane at Aviara Parkway Paseo Del Norte at Camino De La Ondas 0 0 0 0 Prior to construction affecting traffic operation at these intersections the contractor shall install video detection system specified on the plans and coordinate with the Engineer for the required changes to the vehicle detection at the beginning of work day and at the end of the work day when the roadways are returned to normal operation. The Contractor shall minimize the inconvenience and the time period that driveways will be closed. The Contractor shall notify and coordinate with the owner or occupant (if not owner-occupied) of the closure of the driveways at least five (5) working days prior to the closure. During non-working hours, all excavations shall be backfilled and asphalt surface installed or plated with steel plates to the satisfaction of the Engineer. - Upon completion of trench backfill, the surface of the roadway shall be resurfaced with asphalt concrete pavement. Excavations in street intersections must be paved with asphalt concrete pavement immediately after backfill. 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 notificatioh 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. 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. - It shall be a minimum size of 3-1/2 inches by 8-1/2 inches and shall be aRevised: 07/29/02 Contract No. 38871 -A Page 78 of 152 Pages 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 2) Carlsbad fire Department Dispatch .................................................... (760) 931-2197 3) Carlsbad Police Department Dispatch .............................................. (769) 931-21 97 4) Carlsbad Traffic Signals Maintenance ............................................... (760) 438-2980 5) Carlsbad Traffic Signals Operations .................................................. (760) 438-1161 6) North County Transit District .............................................................. (760) 743-9346 7) Coast Waste Management ................................................................ (760) 929-9400 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: 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 21 0-1.6 for materials and section 31 0-5 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 .. - GRevised: 07/29/02 Contract No. 38871-A Page 79 of 152 Pages 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 (67, 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 all existing traffic lanes, bike lanes and pedestrian walkways shall be maintained except as shown on the detailed traffic control plans for each construction area. 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. 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. .- GRevised: 07/29/02 Contract No. 38871 -A Page 80 of 152 Pages Add the following section: - 7-10.3.5 Temporary Pavement Delineation. Temporary pavement delineation shall be furnished, placed, maintained and removed in accordance with the minimum standards specified in Chapter 5 of the 'Traffic Manual", 1996 edition published by CALTRANS. Whenever the work causes obliteration of pavement delineation, temporary or permanent pavement delineation shall be in place prior to opening the traveled way to public traffic. Lane line or centerline pavement delineation shall be provided at all times for traveled ways open to public traffic. All work necessary, including any required lines or marks, to establish the alignment of temporary pavement delineation shall be performed by the Contractor. When temporary pavement delineation is removed, all lines and marks used to establish the alignment of the temporary pavement delineation shall be removed by grinding. Surfaces to receive temporary pavement delineation shall be dry and free of dirt and loose material. Temporary pavement delineation shall not be applied over existing pavement delineation or other temporary pavement delineation. Temporary pavement delineation shall be maintained until superseded or replaced with permanent pavement delineation. Temporary pavement delineation shall be removed when, as determined by the Engineer, the temporary pavement delineation conflicts with the permanent pavement delineation or with a new traffic pattern for the area and is no longer required for the direction of public traffic. When temporary pavement delineation is required to be removed, all lines and marks used to establish the alignment of the temporary pavement delineation shall be removed. 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 construction activities that are located within the traveled 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 traveled surface differs from the finished pavement elevation vertical curves must also be shown. The Contractor may choose to modify, add to or supplement the TCP shown on sheets (45 thru 108) of Drawing (40318) of the contract documents or substitute TCP to further its own interests. Such substitution shall be prepared in type and kind as sheet(s) (45 thru 108) of Drawing (4031 B). The level of detail, format, and graphics shall be of quality and size no less than shown on sheets (45 thru 108) of Drawing (4031B) 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 sLch 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 have such new or modified TCP prepared and submitted as a part of the Work for any and all I modifications, supplements, and/or new designs to the TCP when, in the Engineer's sole opinion, - GRevised: 07/29/02 Contract No. 38871-A Page 01 of 152 Pages 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: 7-1 0.3.7 Payment The Contractor shall provide traffic control at the contract lump sum price bid. The contract lump sum price paid for "traffic control" shall include full compensation for furnishing all labor (including flagging costs), materials (including signs), tools, equipment and incidentals, and for doing all the work involved in preparation, reproduction and changing of traffic control plans, placing, applying traffic stripes and pavement markers with bituminous adhesive, removing, storing, maintaining, moving to new locations, replacing, and disposing of the components of the traffic control system as shown on the plans and approved additions and modifications, as specified in these special provisions, and as directed by the Engineer. All expenses and time to prepare and review modifications, additions, supplements and/or new TCP designs shall be included in the lump sum bid for traffic control and no additional payment will be made therefore. Flagging costs will be paid for as a part of the Lump Sum Amount for "Traffic Control." The cost of labor and material for portable concrete barriers will be paid for at the unit price bid. When there is no bid item for the cost of labor and material for portable concrete barriers, they will be paid as an incidental to the work being performed, and no additional payment will be made therefore. Progress payments for "Traffic Control" will be based on the percentage of the improvement work completed. Add the following section: 7-10.4.4 Safety and Protection of Workers and Public. The Contractor shall take all necessary precautions for the safety of employees on the work and shall comply with all applicable provisions of Federal, State and Municipal safety laws and building codes to prevent accidents or injury to persons on, about, or adjacent to the premises where the work is being performed. The Contractor shall erect and properly maintain at all times, as required by the conditions and progress of the work, all necessary safeguards for the protection of workers and public, and shall use danger signs warning against hazards created by such features of construction as protruding nails, hoists, well holes, and falling materials. 7-13 LAWS TO BE OBSERVED. Add the following: Municipal ordinances that affect this work include Chapter 11.06. Excavation and Grading. If this notice specifies locations or possible materials, such as borrow pits or gravel beds, for use in the proposed construction project which would be subject to Section 1601 or Section 1603 of the Fish and Game Code, the conditions established pursuant to Section 1601 et seq. of the Fish and Game Code shall become conditions of the contract. SECTION 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 US. Standard Measures. 9-3 PAYMENT. 9-3.1 General. Delete the eighth paragraph and substitute the following: Guarantee periods, shall not be affected by any payment but shall commence on the date of recordation of the "Notice of Completion." GRevised: 07/29/02 Contract No. 38871 -A Page 82 of 152 Pages 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 685.010 of the Code of Civil Procedure. Add paragraph 6 et seq. as follows: After final inspection, the Engineer will make a Final Payment Estimate and process a corresponding payment. 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. QRevised: 07/29/02 Contract No. 38871-A Page 83 of 152 Pages - 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. 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 not be included in the progress estimate. The cost of materials and equipment delivered but not incorporated Add the following section: 9-3.4.1 Mobilization and Preparatory Work. Payment for mobilization and preparatory Work will be made at the stipulated lump-sum price bid therefor in the bid schedule. The Contract lump-sum price paid for mobilization shall not exceed one hundred thousand dollars ($1 00,000.00) for Bid Schedules A&B and shall not exceed fifteen thousand dollars ($15,000) for bid Schedule C, and includes full compensation for furnishing all insurance, bonds, licenses, labor, materials, utilities, tools, equipment and incidentals, and for doing all the work involved in mobilization and preparatory work and operations, including, but not limited to, those necessary for the movement of personnel, equipment, supplies, and incidental to preparing to conduct work on and off the project site and other offsite facilities necessary for work on the project; for all other facilities, sureties, work and operations which must be performed or costs incurred prior to beginning work on various contract items on or off the project site, excepting those specifically paid for under separate sections of these specifications. The Contractor hereby agrees that the stipulated lump sum amount is sufficient for Mobilization and Preparatory Work, as described in this section, and that the Contractor shall have no right to additional compensation for Mobilization and Preparatory Work. Progress payments for Mobilization and Preparatory Work will be made as follows: For the first progress payment (after the issuance of the Notice to Proceed), forty percent (40%) of the amount bid for Mobilization And Preparatory Work will be allowed. For the second progress payment, an additional sixty percent (60%) of the amount bid for mobilization and preparatory work will be allowed therefor. Revised: 07/29/02 Contract No. 38871 -A Page 84 of 152 Pages SUPPLEMENTAL PROVISIONS TO STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART 2, CONSTRUCTION MATERIALS Sieve Sizes 50-mm (2) 37.5-mm (I ’/;) 1 9-mm (‘//4”) 12.5-mm (’/;) 4.75-mm (No. 4) 2.36-mm (No. 8) 75-pm (no. 200) 9.5-mm (’/;I SECTION 200 - ROCK MATERIALS 200-1 ROCK PRODUCTS Add the following section: 200-1.2.2 Permeable Material. Permeable materii. __ ,911 consist of hard, L. rable, clean sani-, gravel, or crushed stone, and shall be free from organic material, clay balls, or other deleterious substances. Class 1 and Class 2 permeable material shall have a Durability Index of not less than 40. Class 2 Permeable material shall have a Sand Equivalent value of not less than 75. Class 1 permeable material shall conform to the requirements in this section and Table 200-1.2.2(A). Class 2 permeable material shall conform to the requirements in this section and Table 200-1.2.2(8). When permeable material is required and the class or kind is not specified, Class 1 permeable material shall be used. The alternative gradings within Class 1 permeable material are identified by types. Unless otherwise shown on the plans the Contractor will be permitted to furnish and place any one of the types provided for this class. The percentage composition by mass of permeable material in place shall conform to the gradings in Tables 200-1.2.2(A) and 200-1.2.2(8). TABLE 200-1.2.2(A) CLASS 1 PERMEABLE MATERIAL I Percentaae Passina ., Type A Type 8 ___ 100 _-- 95-1 00 100 50-1 00 95-1 00 70-1 00 15-55 0-55 0-25 0-1 0 0-5 0-3 0-3 -__ Sieve Sizes 25-mm (1”) 19-mm e/:) 9.5-mm e/,,”) 4.75-mm (No. 4) 2.36-mm (No. 8) 600-pm (No. 30) 300-pm (No. 50) 75-pm (no. 200) TABLE 200-1.2.218) Percentage Passing 100 90-1 00 40-1 00 25-40 18-33 5-15 0-7 0-3 ?@Revised: 07/29/02 Contract No. 38871-A Page 85 of 152 Pages I 200-2 UNTREATED BASE MATERIALS r 200-2.1 General. Aggregate base shall be Class 2 Aggregate Base per Caltrans Standard Specification, July 1 999, Section 26: Aggregate Bases, Subsection 26-1.02A Class 2 Aggregate Base and as specified herein. Add the following: Add the following section: 200-2.7 Class 2 Aggregate Base. Aggregate for Class 2 aggregate base shall be free from organic matter and other deleterious substances, and shall be of such nature that it can be compacted readily under watering and rolling to form a firm, stable base. Aggregate may include material processed from reclaimed asphalt concrete, portland cement concrete, lean concrete base, cement treated base or a combination of any of these materials. The amount of reclaimed material shall not exceed 50 percent of the total volume of the aggregate used. Aggregate shall conform to the grading and quality requirements shown in the following tables. At the option of the Contractor, the grading for either the 11/2-inch maximum or 3/4 inch maximum shall be used, except that once a grading is selected it shall not be changed without the Engineer’s written approval. AGGREGATE GRADING REQUIREMENTS Percentage Passing 1W Maximum 3/4” Maximum Operating Operating Sieve Sizes Range Range - 2’ .................................. 1 00 1 112“ 90-1 00 - 1 00 1‘ .................................. 314’ ............................... 50-85 90-1 00 No. 4 ............................. 25-45 35-60 No. 30 ........................... 10-25 10-30 No. 200 ........................ 2-9 2-9 ............................. - I QUALITY REQUIREMENTS Operating Tests Range Resistance (R-value) 78 Min. Sand Equivalent 25 Min. Durability Index 35 Min. The aggregate shall not be treated with lime, cement or other chemical material before the Durability Index test is performed. If the results of either or both the aggregate grading and Sand Equivalent tests do not meet the requirements specified for “Operating Range” but meet the “Contract Compliance” requirements, placement of the aggregate base may be continued for the remainder of that day. However, another day’s work may not be started until tests, or other information, indicate to the satisfaction of the Engineer that the next material to be used in the work will comply with the requirements specified for “Operating Range.” If the results of either or both the aggregate grading and Sand Equivalent tests do not meet the requirements specified for “Contract Compliance,” the aggregate base which is represented by these tests shall be removed. However, if requested by the Contractor and approved by the Engineer, the aggregate base may remain in place and the Contractor shall pay to the City $2.25 per cubic yard for such aggregate base left in place. The City may deduct this amount from any grading and Sand Equivalent do not conform to the “Contract Compliance” requirements, only one adjustment shall apply. - moneys due, or that may become due, the Contractor under the contract. If both the aggregate @Revised: 07/29/02 Contract No. 38871 -A Page 86 of 152 Pages Type of Construction All Concrete Used Within the Right-of-way Trench Backfill Slurry Street Light Foundations and Survey Monuments Traffic Sianal Foundations I I .. - (590-C-3750) Concreted-Rock Erosion Protection 31 0-C-17 I per Table 300-1 1.3.1 Concrete Maximum Class Slump mm (Inches) 330-C-23 FJ (560-C-3250) ('I (1 90-E-400) (560-C-3250) 11 5-E-3 200 (8) 330-C-23 100 (4") 350-C-27 100 (4) I (520-C-25OOP) I ' (1) Except that concrete required to be of higher strength by Table 201-1 .I .2(A) SSPWC shall be as per Table 201-1 .I .2(A) SSPWC. (2) As per Table 201 -1 .I .2(A) SSPWC. (3) Portions of Table 201 -1 .I .2(A) of the Standard Specifications for Public Works Construction not shown herein as changed are not affected by this table. 201-1.2.4 Chemical Admixtures. (e) Air-entraining Admixtures. Substitute the following: The air content shall not deviate from the percentage specified or permitted by more than 1-112 percentage points. The air content of freshly mixed concrete will be determined by California Test Method No. 504. 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. GRevised: 07/29/02 Contract No. 38871 -A Page 87 of 152 Pages 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 21 72, and Calif. Test 202. 2. Stability’ using: a. 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. b. 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). 2Use Marshall Stability when the deviation between individual Stabilometer Values are greater than +/-4. 1 - When using core sample analysis, the samples must be properly prepared to safeguard against influx of outside contaminates and so that the cut surfaces do not influence the test results. The amount of asphalt binder used in asphalt concrete placed in dikes, gutters, gutter flares, overside drains and aprons at the ends of drainage structures shall be increased one percent by mass of the aggregate over the amount of asphalt binder determined for use in asphalt concrete placed on the traveled way. 203-6.3.3 Acceptance. Wet Mix or Core sampled asphalt concrete will be considered in conformance with the mix design when the asphalt content is within +/-.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. 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: from the Engineer’s field laboratory”. Last paragraph, add after D 21 72: “method A or B.” Third paragraph, last sentence, delete “and @Revised: 07/29/02 Contract No. 38871 -A Page 88 of 152 Pages 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 section: add the following: 203-11 ASPHALT PAVEMENT CRACK SEALANTS 203-1 1 .I Elastomeric Sealant. Elastomeric sealant shall be a polyurethane material of a composition that will, within its stated shelf life, cure only in the presence of moisture. No elastomeric sealant shall be incorporated into any portion of the work that is beyond the shelf life recommended by its manufacturer. No elastomeric sealant shall be incorporated into any portion of the work that has been stored under conditions not recommended by its manufacturer. Sealant shall be suitable for use in both asphalt concrete and portland cement concrete. The cured sealant shall have the performance characteristics in Table 203-1 1 (A). property Hardness (indentation) Tensile Strength Elongation Flex at -40°C Weathering Resistance Salt-Spray Resistance Dielectric Constant 1 ELASTOMERIC Measuring Standard (ASTM Designation) ASTM D 2240 Rex. Type A, Model 1700 ASTM D 412 Die C, ASTM D 41 2 Die C, 0.6 mm (25 mil) Free Film Bend (1 80") ASTM D 822 Weatherometer 350 h ASTM B 1 17 28 days at 38°C ASTM D 150 BLE 203-1 I .I (A) IEALANT CHARACTERIS Results 65 - 85 3.45 MPa, minimum 400%, minimum No cracks Slight chalking 3.45 MPa, minimum tensile; 400% minimum Elongation Less than 25% change cs Conditions 25°C @ 50% relative humidity pulled at 508 mm (20) per . .. minute pulled at 508 mm (20) per over 13 mm ('/?) Mandrel Cured 7 days at 25°C @ minute -, 50% relative humidity 5% NaCI, Die C, pulled at 508 mm (20) per minute over a temperature range of -30°C to 50% 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 (45OF). 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 (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). eRevised: 07/29/02 Contract No. 38871-A Page 89 of 152 Pages 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. Ductility, Flash Point, COC, “C ASTM D 92 288 “C, min. Viscosity, Brookfield ASTM D 4402 2.5-3.5 Pa-s Thermosel, Designation) ASTM D 11 3 300 mm, min. SECTION 206 - MISCELLANEOUS METAL ITEMS Conditions 25”C, 150 g, 5 s 25°C 25”C, 50 mm/min No. 27 Spindle, 20 rpm, 190°C, Add the following section: 206-7 TRAFFIC SIGNS. Add the following section: 206-7.1 Permanent Traffic Signs. Permanent traffic signs shall consist of 1 O-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 and/or its employees or officials, such rights shall be vested in the Engineer. Add the following section: 206-7.1.2 Sign Identification. Modify the “SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993 as follows: Sign identification shall be as per “SPECIFICATIONS FOR REFLECTIVE SHEETING SIGNS, October 1993”, except that the notation shall be “PROPERTY OF THE CITY OF CARLSBAD”. Add the following section: 206-7.1.3 Drawings. Modify the “Specifications For Reflective Sheeting Signs, October 1 993” 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. aRevised: 07/29/02 Contract No. 38871 -A Page 90 of 152 Pages 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 111 encapsulated lens sheeting conforming to the requirements of this specification. Add the following section: 206-7.1.5 Substrate. Modify the “Specifications For Reflective Sheeting Signs, October 1993 as follows: All permanent traffic signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall use aluminum substrate. Add the following section: 206-7.1.6 Mounting Traffic Signs. Traffic signs shall be installed on 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 IO-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 Standard drawing M-45. Add the following section: 206-7.2 Temporary Traffic Signs. Temporary traffic signs shall consist of all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic during the Contractor’s performance of the Work. Temporary traffic signs include both stationary and portable signs. Add the following section: 206-7.2.1 General. Materials, legend, proportion, size, and fabrication of all temporary traffic signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall conform to the requirements of “Specifications For Reflective Sheeting Signs, October 1993”, Sheets 1 through 5 that 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. Posts shall be constructed of IO-gage or 12-gage cold-rolled steel Add the following section: 206-7.2.2 Drawings. Modify the “Specifications For Reflective Sheeting Signs, October 1993 as follows: Standard temporary traffic signs shall be as per the most recently approved “Approved Sign Specification Sheets” of the State of California, Department of Transportation. The date of approval shall be the date most closely preceding the date of manufacture of the sign(s) or the date of the “Notice to Proceed of this contract, whichever is most recent. GRevised: 07/29/02 Contract No. 38871-A - 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 conforming to the requirements of this specification. Add the following section: 206-7.2.4 Substrate. Modify the “Specifications For Reflective Sheeting Signs, October 1 993” as follows: Excepting only construction warning signs used at a single location during daylight hours for not more than five (5) consecutive days, all signs used for the direction, warning, and regulation of vehicle (including bicycle) and pedestrian traffic shall be stationary mounted and shall use aluminum substrate. Add the following section: 206-7.2.5 Stationary Mounted Temporary Traffic Signs. Stationary mounted temporary traffic signs shall be installed on 10-gage and 12-gage cold-rolled steel perforated tubing posts in the same manner shown on the State of California, Department of Transportation “Standard Plans” 1995 edition standard plans numbers RS1 , RS2, RS3 and RS4 for installation of roadside signs, except as Wood posts shall not be used. Back braces and blocks for sign panels will not be required. The height to the bottom of the sign panel above the edge of traveled way shall be at least 2.1 m (7’). 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 @)of sign area, or the signs may be installed on existing lighting standards when approved by the Engineer. Sign panels mounted on temporary traffic sign posts shall conform to the requirements specified for aluminum signs in the “Specifications For Reflective Sheeting Signs, October 1993. Add the following section: 206-7.2.6 Temporary Traffic Sign Posts. Posts shall be 10-gage or 12-gage cold-rolled steel perforated tubing used for the support and stabilization of stationary mounted temporary signs. Post size and number of posts shall be as shown on the plans, except. that when stationary mounted signs are installed and the type of sign installation is not shown on the plans, post size and the number of posts will be determined by the Engineer. Sign panels for stationary mounted signs shall consist of reflective sheeting applied to a sign substrate. Add the following section: 206-7.2.7 Portable Temporary Traffic Signs. Each portable temporary traffic sign shall consist of a base, standard or framework and a sign panel. The units shall be capable of being delivered to the site of use and placed in immediate operation. Sign panels for portable signs shall conform to the requirements of sign panels for stationary mounted signs in the “Specifications For Reflective Sheeting Signs, October 1993, or shall be cotton drill fabric, flexible industrial nylon fabric, or other approved fabric. Fabric signs shall not be used during the hours of darkness. Size, color, and legend requirements for portable signs shall be as described for stationary mounted sign panels in section 206-7.2 of these Supplemental Provisions. The height to the bottom of the sign panel above the edge of traveled way shall be at least 0.3-m (12”). All parts of the sign standard or framework shall be finished with 2 applications of an orange enamel which will match the color of the sign panel background. Testing of paint will not be required. I @Revised: 07/29/02 Contract No. 38871 -A Page 92 of 152 Pages Add the following section: 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. Add the following section: 206-8.2 Tolerances. Wall thickness tolerance shall not exceed +0.28 mm, -0.13 mm (+0.01 l”, -0.005). Convexity and concavity measured in the center of the flat side shall not exceed a tolerance of 4.25 rnm (+O.OIO”) applied to the specific size determined at the comer. Straightness tolerance variation shall not exceed 1.6 mm in 1 m (1116 “ 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 (10’). Tolerance on hole size is plus or minus 0.40 mm (1/64“) on a size. Tolerance on hole spacing is plus or minus 3.2 mm in 6.1 m (1/8 in 20’). In addition, for the following specific sizes of light gage steel tubing, dimensional tolerances shall not exceed those listed in tables 206-8.2 (A) and 206-8.2(8). 206-8 LIGHT GAGE STEEL TUBING AND CONNECTORS. Mm (inches) (1 x 1) (1 ’/4 x 1 ‘/4) (1 ‘/2 x 1 I/*) (1 74 x 1 25 x 25 32 x 32 38 x 38 44 x 44 51 x51 (2 x 2) 56 x 56 57 x 57 64 x 64 (2%6 x 2716) (2’/4 X 2’/4) (2 ‘72 x 2 I/*) 51 x76 (2 x 3) TABLE 206-8.21Al mm (inches) 0.13 0.005 0.1 5 0.006 0.15 0.006 0.20 0.008 0.20 0.008 0.25 0.010 0.25 0.010 0.25 0.01 0 0.25 0.01 0 LIGHT GAGE STEEL TUBING SIZE TOLERANCE Nominal Outside Dimensions I Outside Tolerance for All Sides at Corners TABLE 206-8.2(8) 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. ‘‘I 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. QRevised: 07/29/02 Contract No. 38871 -A Page 93 of 152 Pages ~ .- ~~~~ 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 I Add the following section: 206-9 PORTABLE CHANGEABLE MESSAGE SIGN Add the following section: 206-9.1 General. Each portable changeable message sign (PCMS) unit shall consist of a controller unit, a power supply, and a structural support system all mounted on a trailer. The PCMS unit shall be assembled to form a complete self-contained portable changeable message sign which can be delivered to the site of the work and placed in immediate operation. The complete PCMS unit shall be capable of operating in an ambient air temperature range of -20% (-49F) to +70% (158°F) and shall not be affected by unauthorized mobile radio transmissions. The trailer shall be equipped so that it can be leveled and plumbed. Full operation height shall be with the bottom of the sign at least 2.1 m (7’) above the ground and the top no more than 4.4 m (14.5’) above the ground. After initial placement, PCMS shall be moved from location to location as directed by the Engineer Add the following section: 206-9.2 Message Board. The message displayed on the PCMS shall be visible from a distance of 460 m (1500’) and shall be legible from a distance of 230 m (750‘), at noon on a cloudless day, by persons with vision corrected to 20/20. The sign panel shall be 3-line matrix and shall display not less than 7 characters per line. Sign messages to be displayed shall be as approved by the Engineer. The sign face shall be flat black and shall be protected from glare of the sun by a method which does not interfere with the clarity of the sign message. The sign shall be raised and lowered by means of a power driven lifting mechanism. The matrix sign shall be capable of complete alphanumeric selection. Lamp matrix type signs shall be equipped with an automatic dimming operational mode that automatically compensates for the influence of a temporary light source or other abnormal lighting conditions. The sign shall have manual dimming operation modes of 3 or more different lamp intensities. Matrix signs not utilizing lamps shall be either internally or externally illuminated at night. The controller shall be an all solid-state unit containing all the necessary circuitry for the storage of at least 5 pre-programmed messages. The controller shall be installed in a location allowing the operator to perform all functions from one position. A keyboard entry system shall be provided to allow an operator to generate an infinite number of additional messages over the pre-programmed stored messages. The keyboard shall be equipped with a security lockout feature to prevent unauthorized use of the controller. The controller shall contain a nonvolatile memory to hold the keyboard created messages in memory during periods when the power is not activated. The controller shall provide for a variable message display rate which allows the operator to match the information display to the speed of the approaching traffic. The flashing off time shall be operator adjustable within the control cabinet. GRevised: 07/29/02 Contract No. 38871 -A Page 94 of 152 Pages Add the following section: - 206-9.3 Operation and Maintenance. PCMS shall be furnished, placed, operated, and maintained at locations shown on the plans, specified herein, or designated by the Engineer. The PCMS will be diligently maintained and repaired by the Contractor throughout the project in accordance with the manufacturer‘s recommendations. When ownership is transferred to the City (at the end of the job), it must be demonstrated to be in good working condition, and meet the provisions of these specifications, including current registration. Add the following section: 206-9.4 Measurement and Payment. The PCMS shall be included in the contract unit price for Traffic Control and shall include full compensation for furnishing all labor, materials, tools, equipment and incidentals, and for doing all the work involved in furnishing, placing, operating, maintaining, repairing, replacing, transporting from location to location, and delivery of the signs to the City at the completion of the construction, in good working order, and as directed by the Engineer, and no other compensation will be made. SECTION 207 - PIPE Add the following section: 207-25 UNDERGROUND UTILITY MARKING TAPE. Add the following section: 207-25.1 Detectable Underground Utility Marking Tape: Detectable Underground Utility Marking Tape shall have a minimum 0.13 mrn (0.005”) overall thickness, with no less than a 35 gauge (AWG), 0.14 mm aluminum foil core. The foil must be visible from both sides. The layers shall be laminated together with the extrusion lamination process, not adhesives. No inks or printing shall extend to the edges of the tape. All printing shall be encased to avoid ink rub-off. Detectable Underground Utility Marking Tape shall conform to the properties listed in Tables 207-25(A) and 207- 25 (B). QRevised: 07/29/02 Contract No. 36871-A Page 95 of 152 Pages ~- ~.__ ~~ __ .. TABLE 207-25.1 (B) Color Red Yellow Orange Blue Green Brown Purple Utility Marked Electric power, distribution, transmission, and municipal electric systems. Gas and oil distribution and transmission, dangerous materials, product and steam. Telephone and telegraph systems, police and fire communications, and cable television. Water systems. Sanitary and storm sewer systems, nonpotable. Force mains. Reclaimed water lines. Add the following section: 207-25.2 Materials Approvals. requirements of each of the following agency/association publications. Detectable Underground Utility Marking Tape shall meet the A. Department of Transportation, Materials Transportation Bureau, Off ice of Pipeline Safety. USAS code for pressure piping B31.8, paragraph 192.321 (e). B. National Transportation Safety Board, Washington, DC, Special Study Prevention of Damage to Pipelines. Adopted June 7, 1974. Report NTSB-PSS-73-1. C. American Petroleum Institute (API). Recommended practice for marking buried liquid petroleum pipelines - APR RP 1109. D. General Services Administration, Washington, DC, Public Buildings Service Guide Specification for Mechanical and Electrical Equipment - PBS 4-1 501, Amendment 2, Page 501 -14, Paragraph 18, Subparagraph 18.1 , Clause 18.1 .l. E. Rural Electrification Authority (REA), U.S. Department of Agriculture, Washington, DC, National Electrical Safety Code for Underground Construction for remote and immediate hazards. - SECTION 209 - ELECTRICAL COMPONENTS 209 ELECTRICAL COMPONENTS. Modify as follows: Section 209, “Signals, Lighting and Traffic Electrical Systems”, herein, shall replace Section 209, “Electrical Components”, of the SSPWC in all matters pertaining to the specifications for measurement, payment, warranty, and materials and methods of construction for all elements of street lighting and traffic signals. For electrical components provided and installed in systems not including street lighting and traffic signals section 209 SSPWC is unmodified except as specified in sections other than section 209, “Signals, Lighting and Electrical Systems”, herein. For section 209, “Signals, Lighting and Electrical Systems”, for all elements of street lighting and traffic signals both construction materials and construction methods have been combined into a single section. SECTION 209 - SIGNALS, LIGHTING AND ELECTRICAL SYSTEMS 209-1 GENERAL 209-1.01 Description. Signals, lighting and electrical systems work shall consist of furnishing and installing, modifying or removing one or more traffic signals, traffic signal master controller assemblies and interconnection facilities, flashing beacon systems, lighting systems, sign illumination systems, traffic monitoring stations, communication systems, electrical equipment in structures, falsework lighting, provisions for future systems, or combinations thereof, all as shown on the plans, and as specified in these special provisions. - GRevised: 07/29/02 Contract No. 38871 -A Page 96 of 152 Pages The locations of signals, beacons, standards, lighting fixtures, signs, controls, services and ~ appurtenances shown on the plans are approximate and the exact locations will be established by the Engineer in the field. All systems shall be complete and in operating condition at the time of acceptance of the contract. 209-1.015 Definitions. The following definitions pertain only to Section 209, “Signals, Lighting and Electrical Systems.” Actuation.- The operation of any type of detector. Burn-In Procedure. -The procedure by which each LED signal module is energized for a minimum of 24 hours at operating voltage at a 100% duty cycle, and in an ambient temperature of 60QC (I 40QF). Candlepower Values. - Luminous intensity expressed in candelas (cd). Channel.- A discrete information path. Chromaticity (Color). - The color of the light emitted by a signal module, specified as x-y chromaticity coordinates on the chromaticity diagram according to the 1931 Commission lnternationale dEclairage standard observer and coordinate system. The measured chromaticity coordinates shall fall within the limits specified in VTCSH Section 8.04 “Limits of Chromaticity Coordinates.” Controller Assembly.- The complete assembly for controlling the operation of a traffic signal or other system, consisting of a controller unit, and all auxiliary equipment housed in a rainproof cabi- net. Controller Unit.- That part of the controller assembly which performs the basic timing and logic functions. Detector.- A device for indicating the passage or presence of vehicles or pedestrians. Duty Cycle. - The amount of illuminated on-time a signal module is energized, expressed as a percent of signal cycle time period. Electro1ier.- The complete assembly of lighting standard, luminaire, ballast and lamp. Flasher.- A device used to open and close signal circuits at a repetitive rate. Flashing Beacon Control Assembly.- A complete electrical mechanism for operating a warning beacon or intersection control beacon. Inductive Loop Vehicle Detector.-A detector capable of being actuated by the change of inductance caused by a vehicle passing over or standing over the loop. Integrating Photometer. - An instrument used in measuring the intensity of light that enables total luminous flux to be determined by a single measurement. LED Light Source. - An individual light emitting diode. LED Signal Module. - A sealed circular ball or arrow that includes the lens and utilizes LED devices as the light source. An LED signal module may directly replace an existing traffic signal lamp and lens combination. Lighting Standard.- The pole and mast arm which support the luminaire. Luminaire.- The assembly which houses the light source and controls the light emitted from the light source. Magnetic Vehicle Detector.- A detector capable of being actuated by the induced voltage caused by the passage of a vehicle through the earth’s magnetic field. Magnetometer Vehicle Detector.- A detector capable of being actuated by the magnetic disturbance caused by the passage or presence of a vehicle. Major Street.- The roadway approach or approaches at an intersection normally carrying the major volume of vehicular traffic. Minimum Intensity. - In accordance with the values in Table 1 of the existing “Vehicle Traffic Control Signal Heads”, hereinafter VTCSH standard, the minimum intensity values below which no LED signal modules will be released from the supplier. Minor Street.- The roadway approach or approaches at an intersection normally carrying the minor volume of vehicular traffic. Pedestrian Detector.- A detector, usually of the push button type, capable of being operated by hand. ~ - QRevised: 07/29/02 Contract No. 38871-A Page 97 of 152 Pages Plans. - For this Section (Section 209) plans shall include all documents listed in Section 2.5, “Plans and Specifications”, et seq. as well as the “STANDARD PLANS”, 1995 edition as promulgated by the State of California, Department of Transportation. Power Consumption. - The rms electrical power (watts) consumed by an LED signal module when operated at rated voltage. Pre-timed Controller Assembly.- A controller assembly for operating traffic signals in accordance with a pre-determined cycle length. Rated Initial Intensity. - The light intensity of a new LED signal module, operated at rated voltage, measured after the burn-in procedure with an integrating photometer. Rated Voltage. - The ac rms voltage at which light output performance and power consumption are specified (1 17 VAC at 60 Hz). Signal Face.-That part of a signal head provided for controlling traffic in a single direction and consisting of one or more signal sections. Signal Head.- An assembly containing one or more signal faces. Signal Indication.-The illumination of a signal section or other device, or of a combination of sections or other devices at the same time. Signal Section.-A complete unit for providing a signal indication consisting of a housing, lens, reflector, lamp receptacle and lamp. Sun Phantom. - The effect of an outside light source entering the signal assembly and being returned in such a manner as to present the appearance of the signal assembly being illuminated. Traffic-Actuated Controller Assembly.- A controller assembly for operating traffic signals in accordance with the varying demands of traffic as registered with the controller unit by detectors. Traffic Phase.- The right of way, change and clearance intervals assigned to a traffic movement or combination of movements. Vehicle.- Any motor vehicle normally licensed for highway use. VTCSH Standard. - The definitions and practices described in “Vehicle Traffic Control Signal Heads” published in the “Equipment and Materials Standards’’ of the Institute of Transportation - Engineers. 209-1.02 Regulations and Code. All electrical equipment shall conform to the standards of the National Electrical Manufacturers Association (NEMA), the Underwriters’ Laboratories Inc. (UL), the Electrical Testing Laboratories (ETL), the National Electrical Testing Association, Inc. (NETA), or the Electronic Industries Association (EIA), wherever applicable. In addition to the requirements of the plans, these special provisions, all materials and workmanship shall conform to the requirements of the National Electrical Code 1996 edition, hereinafter referred to as the Code; California Code of Regulations, Title 8, Chapter 4, Subchapter 5, Electrical Safety Orders; Rules for Overhead Electrical Line Construction, General Order No. 95 of the Public Utilities Commission; Standards of the American Society for Testing and Materials (ASTM); American National Standards Institute (ANSI); and any local ordinances which may apply. Wherever reference is made to any of the standards mentioned above, the reference shall be construed to mean the code, order, or standard that is in effect on the day the Notice to Contractors for the work is dated. 209-1.03 Equipment List and Drawings. Unless otherwise permitted in writing by the Engineer, the Contractor shall, within 15 days following award of the contract, submit to the Engineer for review a list of equipment and materials which the Contractor proposes to install as specified in Section 2-5.3, “Shop Drawings and Submittals.” The list shall be complete as to name of manufacturer, size and identifying number of each item. The list shall be supplemented by such other data as may be required, including schematic wiring diagrams and scale drawings of cabinets showing location and spacing of shelves, terminal blocks and equipment, including dimensioning. All of the above data shall be submitted, install as specified in Section 2-5.3, “Shop Drawings and Submittals”, for review. Where electrical equipment is constructed as detailed on the plans, the submission of detailed drawings and diagrams will not be required. .- a Revised: 07/29/02 Contract No. 38871 -A Page 98 of 152 Pages The Contractor shall furnish 5 sets of controller cabinet schematic wiring diagrams made by (1) wet blueprint, white background process using iron-sensitized paper, (2) the offset lithograph process, or (3) the electrostatic process. The diagrams shall show the location of the installation and shall list all equipment installed in each controller cabinet. In addition, for each signal installation, the Contractor shall furnish an intersection sketch showing poles, detectors, field wire connection terminals and phasing as shown on the plans. All schematic wiring diagrams of the controller units and auxiliary equipment, all cabinet diagrams, and all operation manuals shall be submitted at the time the controller assemblies are delivered for testing. The schematic wiring diagram shall show in detail all circuits and parts. All parts shown thereon shall be identified by name or number and in such manner as to be readily interpreted. All diagrams, plans and drawings shall be prepared using graphic symbols shown in ANSI publication Y32.2, entitled "IEEE Standard and American National Standard Graphic Symbols for Electrical and Electronic Diagrams." 209-1.04 Warranties, Guaranties and Instruction Sheets. Manufacturers' warranties and guaranties furnished for materials used in the work and instruction sheets and parts lists supplied with materials shall be delivered to the Engineer prior to acceptance of the project. 209-1.05 Maintaining Existing and Temporary Electrical Systems. Existing electrical systems (traffic signal, street lighting, flashing beacon, traffic monitoring, sign illumination and other facilities), or approved temporary replacements thereof, shall be kept in effective operation for the benefit of the traveling public during the progress of the work, except when shutdown is permitted, to allow for alterations or final removal of the systems. The traffic signal shutdowns shall be limited to normal working hours. Lighting system shutdowns shall not interfere with the regular lighting schedule, unless otherwise permitted by the Engineer. The Contractor shall notify the Engineer prior to performing any work on existing systems. The Contractor shall notify the local traffic enforcement agency prior to any operational shutdown of a traffic signal. - Where an existing system or temporary system is being modified, work not shown on the plans or specified in these special provisions and which is considered by the Engineer as necessary to keep all or any part of the system in effective operation will be paid for as extra work as provided in Section 3-3 "Extra Work.". The Agency will: 1 ) Continue the operation and maintenance of existing electrical facilities. 2) Continue to provide for electrical energy for the operation of existing electrical facilities. 3) Repair or replace existing facilities damaged by public traffic. 4) Pay the cost of electrical energy for the operation of existing or new facilities that are undergoing the functional tests described in Section 209-2.14C, "Functional Testing." The Contractor shall ascertain the exact location and depth of existing detectors, conduits, pull boxes and other electrical facilities before using any tools or equipment that may damage those facilities or interfere with any electrical system. Where damage is caused by the Contractor's operations, the Contractor shall, at the Contractor's expense, repair or replace damaged facilities promptly in accordance with these specifications. If any existing loop conductor, including the portion leading to the detector hand hole or termination pull box, is damaged by the Contractor's operations, the Contractor shall immediately notify the Engineer. The affected detectors shall be replaced at the Contractor's expense and as directed by the Engineer within 24 hours. If the Contractor fails to complete the repairs within this period, the repairs will be made by Agency forces at the Contractor's expense. Should the Contractor fail to perform the required repairs or replacements, the cost of performing the repairs or replacements will be deducted from any moneys due or to become due the Contractor. QRevised: 07/29/02 Contract No. 38871-A Page 99 of 152 Pages Where roadways are to remain open to traffic and existing lighting systems are to be modified, the lighting systems shall remain in operation and the final connection to the modified circuit shall be made so that the modified circuit will be in operation by nightfall of the same day. Temporary electrical installations shall be kept in effective operation until the temporary installations are no longer required for the traveling public. Removal of temporary installations shall conform to the provisions in Section 209-7, “Removing, Reinstalling or Salvaging Electrical Equipment.” These provisions will not relieve the Contractor in any manner of the Contractor’s responsibilities as provided in Sections 4-1.1 , ”General” and 4-1.2, “Protection of Work and Materials.” During traffic signal system shutdown the Contractor shall place “STOP AHEAD” and “STOP signs to direct vehicle and pedestrian traffic through the intersection. All signal faces shall be covered when the system is shut down overnight. Temporary “STOP AHEAD” and “STOP” signs shall be either covered or removed when the system is turned on. “STOP AHEAD and “STOP signs shall be furnished by the Contractor and shall conform to the provisions in Section 7-10.3, “Street Closures, Detours, Barricades.” Minimum size of “STOP signs shall be 750 mm (30). One “STOP AHEAD” sign and one “STOP” sign shall be placed for each direction of traffic. For two, or more, lane approaches, two “STOP” signs shall be placed for each direction of traffic. Location of the signs shall be as directed by the Engineer. 209-1.06 Scheduling of Work. No above ground work, except service equipment, shall be performed until the Contractor has all materials on hand to complete that particular signal location or lighting circuit. Work shall be so scheduled that each traffic signal, lighting and sign illumination system shall be completed and ready for operation prior to opening the corresponding section of the roadway to traffic. Traffic signals shall not be placed in operation for use by public traffic without the written approval of the Engineer. The Contractor shall obtain the written approval of the Engineer no less than three days prior to placing any traffic signal in operation. Traffic signals shall not be placed in operation for use by public traffic without the energizing of street lighting at the intersection to be controlled if street lighting exists or is being installed in conjunction with the traffic signals. Traffic signals shall not be placed in operation until the roadways to be controlled are open to public traffic, unless otherwise directed by the Engineer. Lighting and traffic signals shall not be placed in operation, including flashing operation, prior to commencement of the functional test period specified in Section 209-2:14, ‘Testing,’’ unless ordered otherwise by the Engineer. Conductors shall not be pulled into conduit until pull boxes are set to grade, crushed rock sumps installed, and metallic conduit bonded. The initial turn-on shall be made only between the hours of 9:00 a.m. and 2:OO p.m. and Tuesday through Thursday unless otherwise approved, in writing, by the Engineer. Prior to turn-on, all equipment as shown on the plans shall be installed and operable including pedestrian signals, pedestrian push buttons, vehicle detectors, lighting, signs and pavement delineation. All louvers, visors, and signal faces shall be directed to provide maximum visibility. Functional tests shall start on any working day except Friday, or the day preceding a legal holiday. 209-1.07 Safety Precautions. Attention is directed to Section 7-1 0.4.1, ‘Safety Orders.” Before starting work on existing series street lighting circuits, the Contractor shall obtain daily a safety circuit clearance from the serving utility. By-pass switch plugs shall be pulled and “Men at Work” signs posted at switch boxes before any work is done. aRevised: 07/29/02 Contract No. 38871-A Page 100 of 152 Pages 209-2 MATERIALS AND INSTALLATION . 209-2.01 Excavating and Backfilling. The excavations required for the installation of conduit, foundations, and other appurtenances shall be performed in such a manner as to avoid any unnecessary damage to streets, sidewalks, landscaping, and other improvements. The trenches shall not be excavated wider than necessary for the proper installation of the electrical appurtenances and foundations. Excavation shall not be performed until immediately before installation of conduit and other appurtenances. The material from the excavation shall be placed in a position that will not cause damage or obstruction to vehicular and pedestrian traffic nor interfere with surface drainage. Unless otherwise permitted in writing by the Engineer, all surplus excavated material shall be removed and disposed of, within 48 hours, outside the public right of way in accordance with the provisions in Sections 7-8.1, “Cleanup and Dust Control”, 300-1.3, “Removal and Disposal of Materials” and 302-6, “Surplus Material”, depending on the origin and nature of the materials to be removed and disposed. The excavations shall be backfilled in conformance with the provisions in Sections 300-3.5, “Structure Backfill” or 306-1.3, “Backfill and Densification,” depending on the nature of the structure or conduit that the excavation being backfilled accommodates. Excavations after backfilling shall be kept well filled and maintained in a smooth and well-drained condition until permanent repairs are made. All excavations shall be filled, and sidewalks, pavement, and landscaping restored at each intersection prior to excavating at any other intersection, unless otherwise permitted by the Engineer. Excavations in the street or highway shall be performed in such a manner that not more than one traffic lane is restricted at any time, unless otherwise approved by the Engineer. 209-2.02 Removing and Replacing Improvements. In addition to the requirements of sections 7-9, “Protection and Restoration of Existing Improvements” and 306-1.5, “Trench Resurfacing” Improvements such as sidewalks, curbs, gutters, portland cement concrete and asphalt concrete pavement, underlying material, lawns and plants, and any other improvements removed, broken or damaged by the Contractor’s operations, shall be replaced or reconstructed with the same kind of material as found on the work or with materials of equal quality. The new work shall be left in a serviceable condition. Whenever a part of a square or slab of existing concrete sidewalk, curb, gutter, or driveway is broken or damaged, the entire square, section or slab shall be removed and the concrete reconstructed as above specified. The outline of all areas to be removed in portland cement concrete sidewalks and driveways and in pavements shall be cut to a minimum depth of 50 mm (2”) with an abrasive type saw prior to removing the sidewalk, driveways and pavement material. Cuts shall be neat and true along score lines, with no shatter outside the removal area. 209-2.03 Foundations. Portland cement materials and construction methods shall conform to Section 201, “Concrete, Mortar and Related concrete Materials,” for Materials and Section 303, “Concrete and Masonry Construction,” for construction methods. Concrete foundations shall rest on firm ground. - GRevised: 07/29/02 Contract No. 38871-A Page 101 of 152 Pages Except when located on structures, foundations for posts, standards, and pedestals, not shown on the plans to have mortar pads, shall be placed “in the solid” and monolithic except for the top 50 mm (2) which shall be placed after the post, standard or pedestal is in proper position. After each post, standard, or pedestal on structures, and each standard shown on the plans to have mortar pads, is in proper position, mortar shall be placed under the base plate as shown on the plans. The exposed portions shall be formed to present a neat appearance. Mortar shall consist of one part by volume of portland cement and 3 parts of clean sand, shall contain only sufficient moisture to permit packing and shall be cured by keeping it damp for 3 days. Reinforced cast-in-drilled-hole concrete pile foundations for traffic signal and lighting standards shall conform to the provisions in Section 205-3.3, “Cast-in-Place Concrete Piles,” except that material resulting from drilling holes shall be disposed of as provided in Section 209-2.01, “Excavating and Backfilling.” The exposed portions of the foundation shall be formed to present a neat appearance. Forms shall be true to line and grade. Tops of foundations for posts and standards, except special foundations, shall be finished to curb or sidewalk grade or as directed by the Engineer. Forms shall be rigid and securely braced in place. Conduit ends and anchor bolts shall be placed in proper position and to proper height, and shall be held in place by means of a template until the concrete sets. Anchor bars or studs and nuts, except for Type 30 and Type 31 lighting standards, shall conform to ASTM Designation: A 307. Headed anchor bolts for foundations shall conform to the specifications of ASTM Designation: A 307, Grade B with S1 supplementary requirements. At the option of the Contractor, nonheaded anchor bolts for foundations shall conform either to the specifications of ASTM Designation: A 307, Grade C or to the provisions in AASHTO Designation: M 314, Grade 36 or 55 with SI supplementary requirements. When nonheaded anchor bolts conforming to the specifications of ASTM Designation: A 307, Grade C are furnished, the end of each fabricated anchor bolt shall be either coded by end stamping as required in ASTM Designation: A 307 or the end that projects from the concrete shall be permanently coded with a green color by the manufacturer. High strength anchor bolts, bars, or studs for Type 30 and Type 31 lighting standards shall conform to ASTM Designation: A 325, A 325M or A 449 and shall comply with the mechanical requirements of ASTM Designation: A 325 or A 325M after galvanizing. Nuts and washers for high strength anchor bolts shall conform to ASTM Designations: A 563 or A 563M, and F 476 or F 476M, respectively. In addition to the requirements of ASTM Designation: A 449, studs shall be marked on either end as required for bolt heads. All steel parts shall be galvanized in accordance with the provisions in Section 21 0-3.6, “Galvanizing for Traffic Signal Facilities.” - The upper threaded portion of all anchor bolts shall be provided with 2 nuts and 2 washers each. Anchor bars or studs shall be provided with 3 nuts and washers each. Welding shall not be performed on any portion of the body of high-strength anchor bolts, anchor bars, or studs. Plumbing of the standards shall be accomplished by adjusting the leveling nuts before placing mortar or before the foundation is finished to final grade. Shims, or other similar devices shall not be used for plumbing or raking of posts, standards or pedestals. Both forms and ground which will be in contact with the concrete shall be thoroughly moistened before placing concrete. Forms shall not be removed until the concrete has thoroughly set. Ordinary surface finish, as specified in Section 303-1.9.2, “Ordinary Surface Finish,” shall be applied to exposed surfaces of concrete. Where obstructions prevent the construction of a planned foundation, the Contractor shall construct an effective foundation as directed by the Engineer. The foundations shown on the plans shall be extended if conditions require additional depth, and the additional work, if ordered by the Engineer, will be paid for as extra work as provided in Section 3-2, “Changes Initiated By The Agency.” - @Revised: 07/29/02 Contract No. 38871 -A Page 102 of 152 Pages Unless otherwise specified or shown on the plans, foundations not to be reused shall be removed. The resulting hole shall be backfilled with material equivalent to the surrounding material. Unless othetwise shown on the plans, all standards to be relocated shall be provided with new foundations and anchor bolts of the proper type and size. Posts, poles, standards, pedestals, and cabinets shall not be erected until the foundation has set at least 7 days, and shall be plumbed or raked, as directed by the Engineer. In unpaved areas, a 1 .O m (3’) square, 100 mm (4”) thick or of the size shown on the plans, whichever is the larger, raised pad of portland cement concrete shall be placed in front of each controller cabinet. 209-2.04 Standards, Steel Pedestals and Posts. Standards for traffic signals and lighting, and steel pedestals for cabinets and other similar equipment shall be located as shown on the plans. Workmanship and finish shall be equal to the best general practice of metal fabrication shops. All welding shall conform to AWS D1.1, “Structural Welding Code,” and to the requirements in this Section 209-2.04. All welds joining the shafts of the standards and mast arms to their base plates shall be as shown on the plans, however, alternative weld joint details may be approved by the Engineer. Approval of alternative weld joint details will be contingent upon the proposed weld joint passing both weld procedure and nondestructive testing as deemed necessary by the Engineer. All costs of the supplemental testing shall be borne by the Contractor. All standards except Type 1, and all signal mast arms, shall have an aluminum identification plate, as noted on the plans, attached with stainless steel rivets or screws. Type 1 standards and steel pedestals for controller cabinets shall be constructed of 3 mm (.125”) or thicker galvanized steel; or 100 mm (4”) standard weight galvanized, steel pipe or Size 103, Type 1 conduit, with the top designed for post-top slip-fitter. Standard weight galvanized, steel pipe shall conform to the specifications of ASTM Designation: A 53. Materials and construction methods for all ferrous metal parts of standards, with shaft length of 4.6 m (15‘) and longer, shall conform to the details shown on the plans, the requirements of Sections 206, “Miscellaneous Metal Items,” for Materials and Section 304, “Metals Fabrication and Construction,” for construction methods except as otherwise noted, and the following requirements: 1) Except as otherwise specified, standards shall be fabricated from sheet steel of weldable grade having a minimum yield strength, after fabrication, of 276 Mpa (40,000 psi). Certified test reports which verify conformance to the minimum yield strength requirements shall be submitted to the Engineer. The test reports may be the mill test reports for the as-received steel or, when the as-received steel has a lower yield strength than required, the Contractor shall provide supportive test data which provides assurance that the Contractor’s method of cold forming will consistently increase the tensile properties of the steel to meet the specified minimum yield strength. Thesupportive test data shall include tensile properties of the steel both before and after cold forming for specific heats and thicknesses. 2) When a single-ply 8 mm (0.3125) thick pole is specified, a 2-ply pole with equivalent section modulus may be substituted. Standards may be fabricated of full-length sheets or shorter sections. Each section shall be fabricated from not more than 2 pieces of sheet steel. Where 2 pieces are used, the longitudinal welded seams shall be directly opposite one another. When the sections are butt-welded together, the longitudinal welded seams on adjacent sections shall be placed to form continuous straight seams from base to top of standard. 3) Butt-welded transverse joints shall be strengthened by inserting a metal sleeve at each joint. The sleeve shall be 3 mm (0.120) nominal thickness, or thicker, steel having the same chemical composition as the steel in the standard. When the sections to be joined have different specified minimum yield strengths, the steel in the sleeve shall have the same chemical composition as the higher minimum yield strength steel to be joined. The metal sleeve shall have a minimum length of 25 mm. The sleeve shall be centered at the joint and have the same taper as the standard with the outside of the sleeve in full contact with the inside of the standard throughout the sleeve length and circumference. All welds shall be continuous. The weld metal at the transverse joint shall extend to - @Revised: 07/29/02 Contract No. 38871-A Page 103 of 152 Pages the sleeve, making the sleeve an integral part of the joint. Longitudinal welds in steel tubular sections will be tested in accordance with California Test 664. The sampling frequency shall be as determined by the Engineer. The welds may be made by the electric resistance welding process. All exposed welds, except fillet and fatigue resistant welds and welds on top of mast arms, shall be ground flush with the base metal. 4) All exposed edges of the plates which make up the base assembly shall be finished smooth and all exposed corners of the plates shall be neatly rounded unless otherwise shown on the plans. Shafts shall be provided with slip-fitter shaft caps. Standards shall be straight, with a permissive variation not to exceed 25 mm (1“) measured at the midpoint of a 9 m (30’) or 11 m (36’) standard and not to exceed 20 mm (3/4(r) measured at the midpoint of a 5 m (17’) through 6 m (20’) standard. Variation shall not exceed 25 mm (1“) at a point 4.5 m (15‘) above the base plate for Type 35 and Type 36 standards. 5) All galvanized nuts, used on assemblies with a specified preload or torque, shall be lubricated in accordance with the requirements specified for galvanized Grade DH nuts in ASTM Designation: A 563 or A 563M. 6) Standards with an outside diameter of 300 mm (12“) or less shall be round. Standards with an outside diameter greater than 300 mm (12“) shall be round or multisided. Multisided standards shall have a minimum of 10 sides which shall be convex and shall have a minimum bend radius of 100 mm (4”). 7) Mast arms for standards, shall be fabricated from material as specified for standards and shall conform to the dimensions shown on the plans. 8) The cast steel option for slip bases shall be fabricated from material conforming to the requirements of ASTM Designation: A 27/A 27M, Grade 70-40. Other comparable material may be used if written permission is given by the Engineer. The casting tolerances shall be in accordance with the Steel Founder’s Society of America recommendations (green sand molding). One casting from each lot of 50 castings or less shall be subject to radiographic inspection, in accordance with the provisions in ASTM Designation: E 94. The castings shall comply with the acceptance criteria severity level 3 or better for all types and categories of discontinuities as specified in ASTM Designations: E 186 and E 446. If the one casting fails to pass the inspection, 2 additional castings shall be radiographed. Both of these castings shall pass the inspection or the entire lot of 50 will be rejected. Material certifications consisting of physical and chemical properties, and radiographic films of the castings shall be filed at the manufacturer’s office. These certifications and films shall be available for inspection upon request. 9) High-strength bolts, nuts and flat washers used to connect slip base plates shall conform to ASTM Designation: A 325 or A 325M and shall be galvanized as specified in Section 21 0-3.6, “Galvanizing for Traffic Signal Facilities.” 10) Plate washers shall be fabricated by saw cutting and drilling steel plate conforming to AIS1 Designation: 101 8, and be galvanized as specified in Section 21 0-3.6, “Galvanizing for Traffic Signal Facilities. ’’ 11) Prior to galvanizing, all burrs and sharp edges shall be removed and holes shall be chamfered sufficiently on each side to allow the bolt head to make full contact with the washer without tension on the bolt. 12) High-strength cap screws shown on the plans for attaching mast arms to standards shall conform to ASTM Designation: A 325, A 325M or ASTM Designation: A 449 and shall comply with the mechanical requirements of ASTM Designation: A 325 or A 325M after galvanizing. The cap screws shall be galvanized as specified in Section 21 0-3.6, “Galvanizing for Traffic Signal Facilities.” The threads of the cap screws shall be coated with a lubricant which is clean and dry to the touch. 13) The galvanized faying surfaces of the connections between signal or lighting mast arms and poles shall be free of surface imperfections, such as lumps, runs, and scum, which would prevent intimate, uniform contact between the faying surfaces. 14) Handholes in the base of standards shall conform to the details shown on the plans. All handholes shall be provided with covers. _. - @Revised: 07/29/02 Contract No. 38871 -A Page 104 of 152 Pages Standard Type Torque (Newton-meters) 15-58 200 30 200 31 275 36-20A 225 QRevised: 07/29/02 Torque Foot- Pounds 150 150 200 165 Contract NO. 3aa71-~ Page 105 of 152 Pages 209-2.05A Material. Conduit and conduit fittings shall be UL or ETL listed and shall conform to the following: Type 1. Hot-dip galvanized rigid steel conduit conforming to the requirements in UL Publication UL 6 for Rigid Metallic Conduit. The zinc coating will be tested in accordance with ASTM Designation: A 239. 2) Type 2. Hot-dip galvanized rigid steel conduit conforming to Type 1 above and coated with polyvinyl chloride or polyethylene. The exterior thermoplastic coating shall have a minimum thickness of 0.9 mm (35 mils). 3) Type 3. Rigid non-metallic conduit conforming to the requirements in the UL Standard for Rigid Non-Metallic Conduit (Publication UL 651). Type 3 conduit shall be installed at all underground locations. 4) Type 4. Liquid tight flexible metal conduit shall consist of conduit with a liquid tight, nan-metallic, sunlight-resistant jacket over an inner flexible metal core. Type 4 conduit shall be UL listed for use as the grounding conductor. 5) Type 5. Intermediate steel conduit (IMC) conforming to the requirements in UL Publication 1242 for Intermediate Metallic Conduit. Type 5 conduit shall only be used when specified. Bonding bushings to be installed on metal conduit shall be insulated and shall be the galvanized or zinc alloy type. All conduit installed underground shall be Type 3, rigid non-metallic conduit. Type 3 conduit shall be installed at underground locations only. 209-2.058 Use. Exposed conduit installed on a painted structure shall be painted the same color as the structure. Unless otherwise indicated, the minimum metric trade size of conduit shall be: 1 ) From an electrolier to the adjacent pull box shall be Size 41 (1 ’/;I dia). 2) From a pedestrian push button post to the adjacent pull box shall be Size 27 (1” dia). 3) From a signal standard to the adjacent pull box shall be Size 53 (2” dia). 4) From a controller cabinet to the adjacent pull box shall be Size 78 (3” dia). 5) For detector runs shall be Size 41 (l’/g dia . 6) Not otherwise specified shall be Size 41 (1 /; dia). I 209-2.05C Installation. Conduit shall be installed in conformance with the codes and regulations listed in Section 209-1.02, “Regulations and Code.” Conduit runs shown on the plans may be changed to avoid underground obstructions with written approval by the Engineer. The ends of all conduits, whether shop or field cut, shall be reamed to remove burrs and rough edges. Cuts shall be made square and true. Slip joints or running threads will not be permitted for coupling conduit. When a standard coupling cannot be used for coupling metal type conduit, a UL or ETL listed threaded union coupling shall be used. All couplings for metal type conduit shall be tightened to pro- vide a good electrical connection throughout the entire length of the conduit run. Conduit shall be tightened into couplings or fittings using strap wrenches or approved groove joint pliers. Conduit threads and damaged surfaces on metal conduit shall be painted with 2 applications of approved unthinned zinc-rich primer (organic vehicle type) conforming to the requirements in Section 21 0-3.6, “Galvanizing for Traffic Signal Facilities.” Aerosol cans shall not be used. The ends of conduit shall be threaded and shall be capped with standard pipe caps or “pennies” to protect the raceway against dirt and concrete until wiring is started. When caps or “pennies“ are removed, the ends of conduit and conduit fittings shall be provided with conduit bushings. Conduit terminating in pull boxes or foundations shall be provided with insulated bonding bushings. Conduit bends, except factory bends, shall have a radius of not less than 6 times the inside diameter of the conduit. Where factory bends are not used, conduit shall be bent, without crimping or flattening, using the longest radius practicable. GRevised: 07/29/02 Contract No. 38871 -A Page 106 of 152 Pages A No. 12 copper pull wire or a pull rope shall be installed in all conduits which are to receive future conductors. The pull rope shall be nylon or polypropylene with a minimum tensile strength of 2225 N (500 pounds). At least 0.6 m (2') of pull wire or rope shall be doubled back into the conduit at each termination. Existing underground conduit to be incorporated into a new system shall be cleaned with a mandrel or cylindrical wire brush and blown out with compressed air. Conduit shall be laid to a depth of not less than 460 mm (18) below grade in portland cement concrete sidewalk areas and curbed paved median areas, and not less than 750 mm (30) below finished grade in all other areas. Conduit may be laid on top of the existing pavement within new curbed medians being constructed on top of the existing pavement. Conduit couplings shall be located at least 150 mm (6) from face of foundation. 209-2.06 Pull Boxes. Pull boxes shall be installed at the locations shown on the plans or as specified. The Contractor may, as an option, at the Contractor's expense, use purl boxes of a larger standard size than that shown or specified. 209-2.06A Materials. Pull boxes, covers and extensions for installation in the ground or in sidewalk areas shall be of the sizes and details shown on the plans and shall be precast of reinforced portland cement concrete (PCC) I Covers shall be secured with 9 mm (3/;) bolts, cap screws, or studs, and nuts which shall be of brass, stainless steel or other non-corroding metal material. Stainless steel holddown bolts, cap screws or studs, and nuts and washers shall have a chromium content of not less than 18 percent and a nickel content of not less than 8 percent. All ferrous metal parts shall be galvanized in accordance with the provisions in Section 210-3.6, -. "Galvanizing for Traffic Signal Facilities." 209-2.066 Cover Marking. Covers for pull boxes, except covers for ceiling pull boxes, shall be marked as shown on the plans. Marking shall be clearly defined and uniform in depth and may be placed parallel to either the long or short sides of the cover. Marking letters shall be between 25 mm (1") and 75 mm (3") high. Marking shall be applied to each steel or cast iron cover prior to galvanizing by one of the following methods: (a) Cast iron strips, at least 6 mm ('/;) thick, with the letters raised a minimum of 1.5 mm ('/,$'). Strips shall be fastened to covers with 6 mm ('/;) flathead stainless steel machine bolts and nuts. Bolts shall be peened after tightening. (b) Sheet steel strips at least 0.7 mm (22 sa.) with the letters raised a minimum of 1.5 mm (Ill;) above the surrounding surface of the strips. Strips shall be fastened to covers b spot welding, tack welding or brazing, with 6 mm ('/.,") stainless steel rivets, or with 6 mm ( /4") roundhead stainless steel machine bolts and nuts. Bolts shall be peened after tightening. (c) Bead welding the letters on the covers. The letters shall be raised at least 2 mm (3/3;). 209-2.06C Installation and Use. Pull boxes shall be installed at the locations shown on the plans and, in conduit runs exceeding 60 m(200), shall be spaced at not over 60 m (200') intervals. The Contractor may, at the Contractor's expense, install additional pull boxes to facilitate the work. The bottoms of pull boxes installed in the ground or in sidewalk areas, shall be bedded in crushed rock as shown on the plans. 209-2.08 Conductors. Conductors shall be copper of the gage shown on the plans, unless specified otherwise. Copper wire shall conform to the specifications of ASTM Designations: B 3 and Y B a. QRevised: 07/29/02 Contract No. 38871-A Page 107 of 152 Pages ~ ~~~~~ Wire sizes, other than conductors used in loop detector lead-in cable, shall be based on American Wire Gage (AWG), except that conductor diameter shall be not less than 98 percent of the specified AWG diameter. Conductors for branch circuits shall be sized to prevent a voltage drop exceeding 3 percent at the furthest connected load, while drawing the combination of all connected loads capable of simultaneous operation. The maximum voltage drop for both feeders and branch circuits shall not exceed 5 percent at the furthest connected load, while drawing the combination of all connected loads capable of simultaneous operation. Conductors used in loop detector lead-in cable shall conform to the specifications of ASTM Designation: B 286. A Certificate of Compliance conforming to the provisions in Section 4-15 “Certification,” shall be submitted by the manufacturer with each type of cable to be used on a project. I (Note 6) 2,6 .................... 4,8 .................... 1,5 .................... 3,7 .................... 2p,6p ................ 4p,8p ................ lp,5p ................ 3p,7p ................ P-2,P-6 ............ P-4,P-8 ............ P-l.P-5 ............ 209-2.08A Conductor Identification. All single conductors in cables, except detector lead-in cables, shall have clear, distinctive and permanent markings on the outer surface throughout the entire length showing the manufacturer’s name or trademark, insulation type letter designation, conductor size, voltage rating and the number of conductors if a cable. Conductor insulation shall be of a solid color or of basic colors with a permanent colored stripe as detailed in the following table unless otherwise specified. Solid or basic colors shall be homogeneous through the full depth of insulation. Identification stripes shall be continuous over the entire length of the conductor. For conductor sizes No. 2 and larger, the insulation may be black and the ends of the conductors shall be taped with electrical insulating tape of the required color for a minimum of 500 mm (20). All single conductors in cables shall be marked as shown in Table 209-2.08A (A): Size (Note 11) 14 14 14 14 14 14 14 14 14 14 14 TABLE 209-2.08A (A) CON-2 ............. 40 band requirec Circuit I Signal Phase or Function 6 14 ,6 .................................... ,8 .................................... ,5 .................................... ,7 .................................... Vehicle Signals (Note 4) 40 band requirec ML1 ML2 .................. .................. ................................ Pedestrian Signals ................................ (Note 4) ................................ ................................ Pedestrian Push ................................ Buttons ................................ (Note 4) ................................ 14 10 10 c3p,7p ................................ Traffic Signal pngrounded between Service Controller Cabinet Bwitch & Cabinet .............. Highway Lighting Dngrounded-Line 1 .......... Pull Box to Luminaire (Note 9) Multiple Highway Lighting Lighting Control Multiple Service Sign Lighting (Note 8) - Jngrounded-Line 2 .......... 3rounded ......................... Jngrounded-Line 1 .......... Jngrounded-Line 2 .......... Jngrounded to Photoelectric Unit (PEU) Switching leg from PEU unit or SM transformer ......... Jngrounded-Line 1 (Signals) Jngrounded-Line 2 (Lighting) Ungrounded-Line 1 .......... Ungrounded-Line 2 .......... Base . Red, Yellow, Browr Red, Yellow, Browr Red, Yellow, Browr Red, Yellow, Browr Red, Brown Red, Brown Red, Brown Red, Brown Blue Blue Blue Blue Black Red Black Red White Black Red Black Red Black Red (Note 10) Black Red Stripe (Note 1) Black Orange None Purple Black Orange None Purple Black Orange None Purple None None None None None None None None None None None None None - P-3,P-7 ............I 14 CON-1 ............. I 6 .................... I l4 c1 ............ SL-1 ................. SL-2 ................. 10 QRevised: 07/29/02 Contract No. 38871 -A Page 108 of 152 Pages - Grounded & Common Interconnect ................................ ................................ Notes: 1. On overlaps, insulation is striped for first phase in designation, for example, a phase (2+3) conductor is striped as for phase 2. 2. Band for overlap and special phases as required. 3. Flashing beacons having separate service do not require banding. 4. These requirements do not apply to signal cable. 5. "S" if circuit is switched on line side of service equipment by utility. 6. Band conductors in each pull box and near ends of termination points. On signal light circuits, a single band may be placed around 2 or 3 ungrounded conductors comprising a phase. 7. Ungrounded conductors between service switch and flasher mechanism shall be black and banded as indicated in this column. 8. Conductors between ballasts and sign lighting lamps shall be No. 16 and color shall correspond to that of the ballast leads. 9. Both conductors between external H.I.D. ballast and lamp socket shall be black. 10. Black acceptable for size No. 2 and larger. Tape ends for 500 mm (20") with indicated color. 11. Wire sizes listed are minimums. Ampacity requirements of specific circuits or voltage drop may necessitate larger 209-2.08B Multiple Circuit Conductors. listed and rated for 600-volt operation. The insulation for No. 14 through No. 4 conductors shall be one of the following: I) Type TW polyvinyl chloride conforming to the requirements of ASTM Designation: D 221 9. 2) Type THW polyvinyl chloride. 3) Type USE, Type RHH or Type RHW cross-linked polyethylene. conductors. - Conductors for multiple circuits shall be UL or ETL . At any point, the minimum thickness of any Type TW, THW, USE, RHH or RHW insulation shall be 1 .O mm (40 mils) for conductor sizes No. 14 to No. IO, inclusive, and 1.3 mm (54 mils) for No. 8 to No. 2, inclusive. The insulation for No. 2 and larger conductors shall be one of the types listed above or shall be Type THWN. Conductors for wiring wall luminaires shall be stranded copper, with insulation rated for use at temperatures up to 125°C. Overhead lighting conductors shall be No. 8, or larger, medium hard drawn copper with weatherproof covering. 209-2.08C Series Circuit Conductors. Conductors for series circuits shall be No. 8, shall be rated for 5000-volt operation and shall be insulated with 3.7 mm (150 mils) minimum thickness polyvinyl chloride compound conforming to the specifications of ASTM Designation: D 221 9, or polyethylene conforming to the specifications of ASTM Designation: D 1351. #Revised: 07/29/02 Contract No. 38871-A Page 109 of 152 Pages 209-2.08D Signal Cable. Siqnal cable shall be installed. Individual conductors are not allowed. Signal cable shall conform to the following: The cable jacket shall be black polyethylene with an inner polyester binder sheath, and shall be rated for 600- volt and 75°C. All cables shall have clear, distinctive, and permanent markings on the outer surface throughout the entire length of the cable showing the manufacturer’s name or trademark, insulation designation, number of conductors, conductor sizes, and the voltage rating of the jacket. Filler material, if used, shall be polyethylene material. Individual conductors in the cable shall be solid copper with Type THWN insulation, and shall conform to the requirements in Section 209-2.08, “Conductors,” and ASTM Designation: B 286. The minimum thickness of Type THWN insulation, at any point, shall be 0.3 mm ( 13 mils) for conductor sizes No. 14 and No. 12, and 0.4 mm (1 8 mils) for conductor size No. 10. The minimum thickness of the nylon jacket shall be 0.1 mm (4 mils) at any point. Red yellow brown red/black stripe Three-Conductor Cable (SCSC). The 3-conductor signal cable shall consist of three No. 14 conductors. The cable jacket shall have a minimum average thickness of 1.1 mm (45 mils) and a minimum thickness at any point of 0.9 mm (36 mils). The nominal outside diameter of the cable shall not exceed 10 mm (0.10”). The color code of the conductors shall be blue/black stripe, blue/orange stripe, and white/black stripe. The 3 conductor cable shall be used for pedestrian push buttons and a spare. yellow/black stripe brown/black stripe black white/black stripe Five Conductor Cable (5CSC). The 5-conductor signal cable shall consist of five No. 14 conductors. The cable jacket shall have a minimum average thickness of 1.1 mm (45 mils) and shall have a minimum thickness at any point of 0.9 mm (36 mils). The nominal outside diameter of the cable shall not exceed 13 mm (0.50”). The color code of the conductors shall be red, yellow, brown, black, and white. Nine-Conductor Cable (9CSC). The 9-conductor cable shall consist of eight No. 14 conductors and one No. 12 conductor. The cable jacket shall have a minimum average thickness of .5 mm (60 mils) and shall have a minimum thickness at any point of 1.2 mm (48 mils). The nominal outside diameter of the cable shall not exceed 17 mm (0.70’). The color code for the No. 12 conductor shall be white. The color code for the No. 14 conductors shall be as Table 209-2.08D(A): Twelve-Conductor Cable (12CSC). The 12-conductor signal cable shall consist of eleven No. 14 conductors and one No. 12 conductor. The cable jacket shall have a minimum average thickness of 1.5 mm (60 mils) and shall have a minimum thickness at any point of 1.2 mm (48 mils). The nominal outside diameter of the cable shall not exceed 17 mm (0.70”). The color code for the No. 12 conductor shall be white. The color code and functional connections for the No. 14 conductors shall be as Table 209-2.08D(B), unless otherwise approved by the Engineer: GRevised: 07/29/02 Contract No. 38871 -A Page 1 10 of 152 Pages TABLE 209-2.08D(B) TWELVE -CONDUCTOR CABLE SIGNAL CABLE The 12-conductor cable shall be used for vehicle signals, pedestrian signals, spares and the signal common. Twenty Eight-Conductor Cable (28CSC). The 28-conductor signal cable shall consist of 27 No. 14 conductors and one No. 10 conductor. The cable jacket shall have a minimum average thickness of 2 mm (80 mils) and shall have a minimum thickness at any point of 1.6 mm (64 mils). The nominal outside diameter of the cable shall not exceed 23 mm (0.90”). The color code for the No. 10 conductor shall be white. The color code and functional connections for the No. 14 conductors shall be as Table 209-2.08D(C): @Revised: 07/29/02 Contract No. 38871 -A Page 11 1 of 152 Pages TWENTY I TABLE 209-2.08D(C) IGHT - CONDUCTOR CABLE SIGNAL CABLE Termination I Phase Color Code red/black stripe yellow/black stripe brown/black stripe red/orange stripe yellow/orange stripe browdorange stripe red/silver stripe yellow/silver stripe brown/silver stripe red/purple stripe yellow/purple stripe brown/purple stripe redl2 black stripes brown/2 black stripes red/2 orange stripes brown/2 orange stripes red/2 silver stripes brownl2 silver strbes red/2 purple stripes brown/;! purple stripes blue/black stripe blue/orange stripe b I u e/s i lve r s t ri pe blue/purple stripe white/black striDe blackhed stripe vehicle signal red 2or6 vehicle signal yellow 2or6 vehicle signal green 2or6 ~~ vehicle signal red I 4or8 vehicle signal yellow 4or8 vehicle signal green I 4or8 vehicle signal red 1 Or5 vehicle signal yellow 1 Or5 vehicle signal green 1 Or5 vehicle signal red 3or7 ped push button overlap B, D yellow 4 or 8 OLB(y), OLD(y) overlap A, C yellow OLA(y), OLC(y) ped push button common I railroad pre-emption 1) The signal commons in each 28-conductor cable shall be kept separate except at the signal controller. 2) Each 28-conductor cable shall be labeled in each pull box “Cl” or “C2”,. 3) The cable identified “C1” shall be used for signal Phases 1, 2, 3 and 4. The cable identified “C2” shall be used for signal Phases 5, 6, 7 and 8. 4) Each signal cable, except 28-conductor, shall be marked, in each pull box, showing the signal standard to which it is connected. 209-2.08E Signal Interconnect Cable (SIC). Signal Interconnect Cable shall consist of six or twelve No. 20, minimum, stranded tinned copper conductors as shown on the plans or required herein. Each conductor shall be insulated with 0.33 mm (0.013), minimum nominal thickness, color coded, polypropylene material. Conductors shall be in twisted pairs. Color coding shall distinguish each pair. Each pair shall be wrapped with an aluminum polyester shield and shall have a No. 22 or larger, stranded, tinned copper drain wire inside the shielded pair. The cable jacket shall be black, high density polyethylene, rated for a minimum of 300- volts and 60°C, and shall have a nominal wall thickness of 1.0 mm (40 mils), minimum. The cable jacket or the moisture-resistant tape directly under the outer jacket shall be marked with the manufacturer’s name, insulation type designation, number of conductors and conductor size, and voltage and temperature ratings. Splices shall be made only where shown on the plans or in controller cabinets. A minimum of one meter (3’) of slack shall be provided at each splice and 2 m (6‘) at each controller cabinet. Splices of conductors shall be insulated with heat-shrink tubing of the appropriate size and shall overlap the conductor insulation at least 15 mm (0.5”). The overall cable splice shall be covered with heat-shrink tubing, with at least 40 mm (1‘/2L() of overlap of the cable jacket. GRevised: 07/29/02 Contract No. 38871 -A Page 112 of 152 Pages 209-2.09 Wiring. All conductors shall be run in conduit, except overhead and temporary - installations and where conductors are run inside poles. Wiring shall be done in conformance with the regulations and code listed in Section 209-1.02, “Regulations and Code,” and the following additional requirements: 209-2.09A Circuitry. Sufficient traffic signal light conductors shall be provided to perform the functional operation of the signal and, in addition thereto, 3 spare conductors shall be provided in all conduits containing traffic signal light conductors, unless shown otherwise on the plans. Traffic signal light conductors shall not run to a terminal block on a standard unless they are to be connected to a signal head that is mounted thereon. Connection to each terminal of a pedestrian push button shall be by a single conductor. The common for pedestrian push button circuits shall be separate from the traffic signal light circuit grounded conductors. Where ballasts or transformers are used, series conductors shall be run from ballast to ballast, transformer to transformer, and from bal- last or transformer to service. 209-2.098 Installation. A UL or ETL listed inert lubricant shall be used in placing conductors in conduit. Conductors shall be pulled into conduit by hand and the use of winches or other power actuated pulling equipment will not be permitted. All conductors shall be pulled directlv from the spool into the conduit and shall not be draaaed on the around as to cause damaqe to the conductors. When new conductors are to be added to existing conductors in a conduit, all conductors shall be removed; the conduit shall be cleaned as provided in Section 209-2.050, “Installation”; and both old and new conductors shall be pulled into the conduit as a unit. Where traffic signal light conductors are run in lighting standards containing street lighting conductors from a different service point, either the traffic signal light conductors or the lighting conductors shall be encased in flexible or rigid metal conduit, to a point where the 2 types of conductors are no longer in the same raceway. Temporary conductors less than 3 m (IO‘) above grade shall be enclosed in flexible or rigid metal conduit. At least 0.3 m (1 ‘) of slack shall be left for each conductor at each signal or lighting standard, or combined standard, and at least one meter (3’) of slack at each pull box. At least one meter (3’) of slack shall be left for each conductor at each splice. Ends of spare conductors or conductors terminated in pull boxes shall be taped to provide a watertight seal. Conductors within fixtures or service cabinets shall be neatly arranged and shall be cabled together with self-clinching nylon cable ties, or other method approved by the Engineer. Traffic signal light conductors, interconnect conductors, service conductors, detector conductors and cables in controller cabinets and flashing beacon cabinets shall be neatly arranged, and shall be cabled together with self-clinching nylon cable ties, or enclosed in plastic tubing or raceway. Conductor identification shall be provided under the following conditions: - 1) Where signal phase or circuit are not clearly indicated by conductor insulation color and stripe as detailed in the conductor table in Section 209-2.08, “Conductors,” or when identification stripes are not available, marking shall be as detailed in the conductor table for special and overlap phases. 2) Where metered and unmetered conductors occupy the same pull box, the unmetered circuit conductors shall be identified, “UNMETERED-STREET LTG,” ”UNMETERED-COUNT STATION,” or as appropriate to describe the unmetered circuit. Conductors shall be permanently identified as to function. Identification shall be placed on each conductor, or each group of conductors comprising a signal phase, in each pull box and near the end of terminated conductors. Identification shall be by direct labeling, tags or bands fastened to the conductors in such a manner that they will not move along the conductors. Labeling shall be by mechanical methods. QRevised: 07/29/02 Contract No. 38871 -A Page 1 13 of 152 Pages .- 209-2.09C Connectors and Terminals. Conductors shall be joined by the use of UL or ETL listed crimp type connectors as shown on the plans. Connectors and terminals shall be applied with the proper type tool as recommended by the manufacturer of the connector or terminal being used. Finished connections and terminals shall comply with the requirements of Military Specification MIL- T-7928. All stranded conductors smaller than No. 14 shall be terminated in crimp style terminal lugs. All connectors and terminal lugs for conductor sizes No. 8 and smaller shall be soldered by the hot iron, pouring or dipping method. Open flame soldering will not be permitted. 209-2.09D Splicing and Terminations. Unless specified otherwise or permitted by the Engineer, splices shall conform to the details shown on the plans and will be permitted only in the following types of circuits at the following locations: 1) Grounded conductors in pull boxes. 2) Pedestrian push button conductors in pull boxes. 3) Multiple or series lighting conductors in the pull box adjacent to each electrolier or luminaire location or in the bases of Type 21 standards. Where electroliers are more than 120 m (400') apart, splices will be permitted in pull boxes at 120 m (400'), or greater, intervals. 4) When traffic signals are being modified, ungrounded traffic signal light conductors may be spliced in pull boxes at locations shown on the plans. 5) Ungrounded traffic signal light conductors to a terminal compartment or signal head on a standard may be spliced to through conductors of the same phase in the pull box adjacent to the standard. 6) All splices and terminal lugs for conductor sizes No. 8 and smaller shall be soldered by the hot iron, pouring or dipping method. Open flame soldering will not be permitted. 209-2.09E Splice Insulation. All splices shall be capable of satisfactory operation under continuous submersion in water. Multi-conductor cables shall be spliced and insulated to provide a watertight joint and to prevent absorption of moisture by the cable. Where more than one conductor enters the sleeve of a ballast installed in a pull box, the insulation and taping shall be applied between the conductors in such a manner as to provide a watertight joint. - Splice insulation shall conform to the details shown on the plans. Low-voltage tape shall be UL or ETL listed and shall be the following types: 1 ) Self-fusing, oil and flame-resistant, synthetic rubber. 2) Pressure-sensitive, adhesive, polyvinyl chloride, 0.1 5 mm (0.007") minimum thickness. Tape for insulating splices in high-voltage (over 600 V) circuits shall be designed for use on 5-kvolt circuits and shall be resistant to ozone, corona and water. Insulating pad shall be composed of a laminate of 2 mm (0.085") thickness of electrical grade polyvinyl chloride and a 3 mm (0.125) thickness of butyl splicing compound with removable liner. Heat-shrink tubing shall be medium or heavy wall thickness, irradiated polyolefin tubing containing an adhesive mastic inner wall. Minimum wall thickness prior to contraction shall be one millimeter (39 mils). When heated, the inner wall shall melt and fill all crevices and interstices of the object being covered while the outer wall shrinks to form a waterproof insulation. Each end of the heat shrink tube or the open end of the end cap of heat-shrink tubing shall, after contraction, overlap the conductor insulation at least 38 mm (1%"). Heat-shrink tubing shall conform to the requirements of UL Standard 468D and ANSI (319.1, for extruded insulated tubing at 600-V. All heat-shrink tubing shall also meet the requirements of Table 209-2.09E(A): QRevised: 07/29/02 Contract No. 38871 -A Page 1 14 of 152 Pages Property Shrinkage Ratio Dielectric Strength Resistivity Tensile Strength Operating Temperature Water Absorption 209-2.10 Bonding and Grounding. Metallic cable sheaths, metal pull box covers, metal conduit, equipment grounding conductors, ballast and transformer cases, service equipment, sign switches, and metal poles and pedestals shall be made mechanically and electrically secure to form a continuous system, and shall be effectively grounded. Bonding jumpers shall be copper wire or copper braid of the same cross sectional area as No. 6 for series lighting systems and No. 8 or larger for all other systems. The jumper size shall be increased to match the load or the circuit breaker size, or shall be as shown on the plans. Equipment grounding conductors shall be color coded to Code requirements or shall be bare. Requirement 33 percent, maximum, of supplied diameter when heated to 125°C and allowed to cool to 25°C. 140 kV per 10 mm, minimum. 1013 b. mm, minimum. 14 MPa, minimum. -40°C to 90°C (135°C Emergency). 0.5 percent, maximum. @Revised: 07/29/02 Contract No. 38871 -A Page 1 15 of 152 Pages ~~ ,- The bonding jumper in standards with handholes shall be attached by a 4.5 mm (3/1<) or larger brass bolt and shall be run to the conduit or bonding wire in the adjacent pull box. Standards without handholes shall be bonded by a jumper attached to all anchor bolts, and shall be run to the conduit or bonding wire in the adjacent pull box. Grounding jumper shall be visible after cap has been placed on foundation. Where slip base standards or slip base inserts are installed, the bonding jumper shall not intrude into the slip plane. Bonding shall be accomplished by a bonding strap to all anchor bolts or a 4.5 mm (3/16L1) or larger brass bolt installed in the bottom slip base plate. One side of the secondary circuit of series-multiple and step-down transformers shall be grounded. Grounding of metal conduit, service equipment and the grounded conductor at service point shall be accomplished as required by the Code and the serving utility, except that grounding electrode conductor shall be No. 6, or larger. For equipment grounding purposes in Type 3 conduit, a No. 6 copper wire shall be run continuously in circuits used for series lighting, and a No. 8, minimum, copper wire shall be run continuously in all other circuits. The bonding wire size shall be increased to match the circuit breaker size, or shall be as shown on the plans. Where Type 3 conduit is to be installed for future conductors, the copper wire may be omitted. Equipment bonding and grounding conductors are not required in conduits which contain only loop lead-in cable or signal interconnect cable or both. At each multiple service disconnect location, a ground electrode shall be furnished and installed. Ground electrodes shall be one-piece lengths of galvanized steel rod or pipe not less than 19 mm (3/4") in diameter, or of copper clad steel rod not less than 15 mm (5/81() in diameter. Ground electrodes shall be installed in accordance with the provisions of the Code. The service equipment shall be bonded to the ground electrode by use of a ground clamp or exothermic weld and No. 6 or larger copper wire, enclosed in a size 16 or larger diameter conduit. Ground clamp for service grounding and for grounding of equipment on wood poles shall be Size 16 galvanized, malleable iron conduit hub with swivel feature. On wood poles, all metallic equipment mounted less than 2.4 m (8') above ground surface shall be grounded. Bonding of metallic conduit in non-metallic pull boxes shall be by means of bonding bushings and bonding jumpers. Bonding of metallic conduit in metal pull boxes shall be by means of locknuts, one inside and one outside of the box. 209-2.1 1 Service. Electrical service installation and materials shall conform to the requirements of the serving utility. When the service equipment is to be installed on a utility-owned pole, the Contractor shall furnish and install conduit, conductors and all other necessary material to complete the installation of the service. The position of the riser and equipment will be determined by the utility. Service conduit shall conform to the requirements of the serving utility and shall be not less than Size 41 (1'/; dia.). Where a kilowatt-hour meter is required, a meter socket with sealing ring, as approved by the serving utility, shall be furnished and installed. Where a meter socket is installed, the meter enclosure shall be provided with factory installed test bypass facilities as required by the serving utility. Service equipment shall be installed as soon as possible to enable the utility to schedule its work well in advance of the completion of the project. 4m \#Revised: 07/29/02 Contract No. 38871 -A Page 116 of 152 Pages Each service shall be provided with a circuit breaker which shall simultaneously disconnect all - ungrounded service entrance conductors. All circuit breakers shall be quick-break on either automatic or manual operation. The operating mechanism shall be enclosed and shall be trip-free from the operating handle on overload. Circuit breakers shall be trip-indicating, shall have frame size plainly marked and shall have trip rating clearly indicated on the operating handle. Overload tripping of breakers shall not be influenced by an ambient temperature range of from -18°C to 50°C. Multiple-pole breakers shall be the internal trip type. All circuit breakers shall be listed by UL or ETL. Current rating of breakers shall be as shown on the plans. Circuit breakers used as service disconnect equipment shall have a minimum interrupting capacity of 10 000 A, rms. Circuit breakers shall be enclosed in a NEMA raintight enclosure with dead-front panel and hasp with a 11 mm (‘/,s‘3 hole for a padlock. The padlock will be furnished by others. Service equipment enclosures, except Types II and Ill, shall be galvanized. Types II and 111 service equipment enclosures shall be fabricated from galvanized sheet steel or fabricated from sheet steel and zinc or cadmium plated after fabrication, or shall be fabricated from aluminum. Fabrication of service equipment enclosures shall conform to the requirements of Section 209-3.04A, “Cabinet Construction.” Steel enclosures shall be painted in accordance with the provisions in Section 209-2.1 6, “Painting.” All overlapping exterior seams and doors shall meet the requirements for Type 3R enclosures specified in the NEMA Enclosure Standards. Except for falsework lighting and power for the Contractor’s operations, upon written request by the Contractor, the Engineer will arrange with the serving utility to complete service connections for both temporary and permanent installations and the Agency will pay all costs and fees required by the utility. The request shall be submitted not less than 15 days before service connections are required. Energy used prior to completion of the contract will be charged to the Contractor, except that the cost of energy used for public benefit, when an operation is ordered by the Engineer, will be at the expense of the Agency. Full compensation for furnishing and installing Agency-owned or permanent service poles, service equipment, conduit, conductors and pull boxes (including equipment, conduit, and conductors placed on utility-owned poles) shall be considered as included in the contract item of electrical work involved and no additional compensation will be allowed therefor. Where the service point is indeterminate and is shown on the plans as an “approximate location” or “service point not yet established, the labor and materials required for making the connection between the service point, when established, and the nearest pull box shown on the plans will be paid for as extra work as provided in Section 3-3, “Extra Work.” 209-2.12 Wood Poles. Wood poles for service or temporary installations shall be ANSI Class 5, or larger. Poles shall not have more than 180 degrees twist in grain over the full length. Sweep shall be no more than 100 mrn (4”). Tops of poles shall be beveled. Poles shall be placed in the ground to a depth of at least 1.8 rn (6’). The lengths of poles shall be 7.6 m (25‘) for service poles and 10.7 m (35‘) for other poles, unless otherwise specified. After each wood pole is set in the ground, the space around the pole shall be backfilled with selected earth or sand, free of rocks and other deleterious material, placed In layers approximately 100 mm (4”) thick. Each layer shall be moistened and thoroughly compacted. Mast arms for wood pole installations shall be fabricated from standard pipe, free from burrs. Each mast arm shall be provided with an insulated wire inlet and wood pole mounting brackets for mast arm and tie-rod cross arm. Tie rods shall be of structural steel and pipe. Mast arms for luminaires shall be mounted to provide a mounting height of 9.1 m (30’). Mast arms for traffic signals and flashing beacons shall provide a minimum vertical clearance of 5.2 m (17’) from bottom of equipment to the pavement. - GRevised: 07/29/02 Contract No. 38871-A Page 1 17 of 152 Pages Wood poles, not to be painted, shall be pressure treated after fabrication with creosote, pentachlorophenol (oil borne) or copper naphthenate as provided in Section 204-2, ‘Treatment With Preservatives.” All wood poles shall be pressure treated after fabrication with ammoniacal copper arsenate, chromated copper arsenate or ammoniacal copper zinc arsenate as provided in Section 204-2, “Treatment With Preservatives.” The minimum retention for water borne preservatives shall be that specified for posts. 209-2.13 Sign Control. Each sign illumination installation shall be provided with a disconnect circuit breaker mounted on the sign standard or structure, as shown on the plans. Where the sign lighting is served from a series lighting circuit through a series-multiple transformer, the circuit breaker shall be installed in the secondary circuit. Where the sign lighting is served through a multiple-multiple transformer, the circuit breaker shall be installed in the primary circuit. Circuit breakers shall meet the requirements for circuit breakers in Section 209-2.1 1 , “Service.” Enclosure for the circuit breaker shall be NEMA Type 3R, shall be galvanized or shall be cadmium plated, and shall be provided with dead front panel and a hasp with a 11 mm (7/16“) diameter hole for a padlock. Padlocks will be furnished by others. When the sign structure is to be painted, the circuit breaker or sign switch enclosure shall be painted the same color as the sign structure on which it is mounted. 209-2.14 Testing. Attention is directed to Section 4-1.4, “Test of Materials.” Testing shall conform to the following: 209-2.1 4A Materials Testing. Testing and quality control procedures for Model 170 and Model 2070 controller assemblies shall conform to the requirements in ‘Transportation Electrical Equipment Specifications,” and ‘Traffic Signal Control Equipment Specifications,” issued by the State of California, Department of Transportation, and to all addendums thereto current at the time of project advertising. Testing and quality control procedures for all other traffic signal controller assemblies shall conform to the requirements in the NEMA TS Standards for Traffic Control Systems. In the event equipment submitted for testing does not comply with specifications, the Contractor shall remove the equipment for repair within 5 working days after notification that the equipment is rejected. In the event the equipment is not removed within that period, it may be shipped to the Contractor at the Contractor’s expense. All testing subsequent to rejection of the equipment for failure to comply with specification requirements will be at the expense of the Contractor. Deductions to cover the cost of that testing will be made from any moneys due or which may become due the Contractor under the contract. The Contractor will be notified when testing of the equipment has been completed and it shall be the Contractor’s responsibility to deliver the equipment to the site of the work or, at the Contractor’s request and the Agency’s convenience, the Agency will pack and ship the equipment to the Contractor or to the site of work. The sum of $100 or the actual cost of packing and shipping, whichever amount is greater, will be deducted, for each unit of equipment shipped by the Agency, from any moneys due to the Contractor under the contract. 209-2.14B Field Testing. Prior to start of functional testing, the Contractor shall perform the following tests on all circuits, in the presence of the Engineer. 209-2.1 4B(1) Continuity. Each circuit shall be tested for continuity. 209-2.148(2) Ground. Each circuit shall be tested for grounds. GRevised: 07/29/02 Contract No. 38871 -A Page 11 8 of 152 Pages 209-2.146(3) Insulation Resistance. An insulation resistance test at 500 volts DC shall be made on each circuit between the circuit and a ground. The insulation resistance shall not be less than 10 MS1 on all circuits, except for inductive loop detector circuits which shall have an insulation resistance value of not less than 100 MS1. The insulation resistance test shall not be performed on magnetometer sensing elements. Splices in the pull box adjacent to the magnetometer sensing elements shall not be made prior to performing the test on the lead-in conductors between the pull box and the controller cabinet field terminals. 209-2.14C Functional Testing. Attention is directed to Section 209-1.06, “Scheduling of Work,” regarding requirements for test periods. A functional test shall be made in which it is demonstrated that each and every part of the system functions as specified. The functional test for each new or modified system shall consist of not less than 5 days of continuous, satisfactory operation. If unsatisfactory performance of the system develops, the condition shall be corrected and the test shall be repeated until the 5 days of continuous, satisfactory operation is obtained. Turn-on of new or modified traffic signals shall be made only after all traffic signal circuits have been thoroughly tested as specified above. Except for new or modified portions of existing lighting circuits and sign illumination systems, the Agency will maintain the system or systems during the test period and will pay the cost of electrical energy for the operation of all of the facilities that are undergoing testing. The cost of any necessary maintenance performed by the Agency on new circuits or on the portions of existing circuits modified under the contract, except electrical energy, shall be at the Contractor’s expense and will be deducted from any moneys due, or to become due, the Contractor. A shutdown of the electrical system resulting from damage caused by public traffic, from a power interruption or from unsatisfactory performance of Agency-furnished materials shall not constitute discontinuity of the functional test. 209-2.15 Galvanizing. Galvanizing shall be in accordance with the provisions in Section 21 0-3.6, “Galvanizing for Traffic Control Facilities,” except that cabinets may be constructed of material galvanized prior to fabrication in conformance with the specifications of ASTM Designation: A 525 or A 525M, Coating Designation G 90, in which case all cut or damaged edges shall be painted with at least 2 applications of approved unthinned zinc-rich primer (organic vehicle type) conforming to the requirements in Section 210-3.5, “Repair of Damaged Zinc Coating.” Aerosol cans shall not be used. Other types of protective coating shall be approved by the Engineer prior to installation. Iron or steel pipe standards and pipe mast arms shall be hot-dip galvanized after fabrication in conformance with the specifications of ASTM Designation: A 53. Galvanized surfaces shall have spurs removed. Tie-rods, bolts, nuts, washers, clamps and other miscellaneous ferrous parts shall be hot-dip galvanized after fabrication in accordance with the provisions in Section 21 0-3.6, “Galvanizing for Traffic Control Facilities.” Not less than 250 mm (IO) of the upper end of the anchor bolts, anchor bars, or studs, and all nuts and washers shall be galvanized in accordance with the provisions in Section 210-3.6, “Galvanizing for Traffic Control Facilities.” After galvanizing, the bolt threads shall accept galvanized standard nuts without requiring tools or causing removal of protective coatings. Galvanizing of existing materials in an electrical installation will not be required. QRevised: 07/29/02 Contract No. 38871-A Page 11 9 of 152 Pages 209-2.16 Painting. Painting of electrical equipment and materials shall conform to the provisions in Section 31 0, “Painting,” with the following additions and modifications. Paint materials for electrical installations, unless otherwise specified, shall conform to the provisions in Section 21 0, “Paint and Protective Coatings.” Factory or shop cleaning methods for metals will be acceptable if equal to the methods specified herein. In lieu of the temperature and seasonal restrictions for painting as provided in Section 310, “Painting,” paint may be applied to equipment and materials for electrical installations at any time permitted by the Engineer. All ungalvanized ferrous surfaces to be painted shall be cleaned prior to applying the prime coat. Blast cleaning will not be required. If an approved prime coat has been applied by the manufacturer, and it is in good condition, the first primer application by the Contractor will not be required. Existing equipment to be painted in the field, including Agency-furnished equipment, shall be washed with a stiff bristle brush using a solution of water containing 7.5 ml. of heavy duty detergent powder per liter (2 tablespoons per gallon). After rinsing, all surfaces shall be wire brushed with a coarse, cup shaped, power-driven brush to remove all poorly bonded paint, rust, scale, corrosion, grease or dirt. Any dust or residue remaining after wire brushing shall also be removed prior to priming. Immediately after cleaning, all galvanized surfaces and all non-ferrous metal surfaces shall be coated with one application of Primer (Wash) Pre-Treatment, Section 21 0-1.5 or wash primer conforming to the requirements of Military Specification MIL-P-15328D. The wash primer shall be applied by spraying or brushing to produce a uniform wet film on the surface. Galvanized equipment and wood poles for traffic signal or flashing beacon installations shall not be painted. New galvanized metal surfaces to be painted in the field shall be cleaned as specified for existing equipment before applying the prime coats specified. Wire brushing of new galvanized surfaces will not be required. After erection, all exterior surfaces shall be examined for damaged primer and the damaged surfaces shall be cleaned and spot coated with primer. Galvanized metal guard posts shall not be painted. Types II and Ill steel service equipment enclosures shall be painted with a polymeric or an enamel coating system conforming to Color No. 14672 (light green) of Federal Standard 5958. All coatings shall be commercially smooth, substantially free of flow lines, paint washout, streaks, blisters, and other defects that would impair serviceability or detract from general appearance. The coatings shall comply with the following requirements: 1) Coating Hardness - The finish shall have a pencil lead hardness of HB minimum using an Eagle Turquoise pencil. 2) Salt Spray Resistance - The undercutting of the film of the coating system shall not exceed 3 mm (1/8n) average, from lines scored diagonally and deep enough to expose the base metal, after 250 hours exposure in a salt spray cabinet in accordance with ASTM Designation: B 1 17. 3) Adherence - There shall be no coating loss when tested by California Test 645. Compliance of the coating system to the above requirements may be determined by the application of the coating, to 100 mm (4”) x 200 mm (8”) x 0.6 mm (0.0236”) test specimens of the same material as the cabinets, in the same manner as applied to the cabinets. A Certificate of Compliance shall be furnished in accordance with the provisions of Section 4-1.5, “Certification,” certifying that the coating system furnished complies in all respects with these requirements. Interior of metal signal visors, louvers and front faces of back plates shall be finished with 2 applications of lusterless black exterior grade latex paint formulated for application to properly prepared metal surfaces, except that factory finish in good condition will be acceptable. @Revised: 07/29/02 Contract No. 38871 -A Page 120 of 152 Pages Metal signal sections, signal head mountings, brackets and fittings, outside of visors, pedestrian - push button housings, pedestrian signal sections and visors, and back faces of back plates, shall be finished with 2 applications of lusterless black or dark olive green exterior grade latex paint formulated for application to properly prepared metal surfaces. Dark olive green color shall match Color Chip No. 68 on file at the CALTRANS Transportation Laboratory. Conduit and conduit fittings above ground shall be prepared and finished in the same manner as the adjacent standard or post. All paint shall be applied either by hand brushing or by spraying machines in the hands of skilled operators. The work shall be done in a neat and workmanlike manner. The Engineer reserves the right to require the use of brushes for the application of paint, should the work done by the paint spraying machine prove unsatisfactory or objectionable, as determined by the Engineer. 209-3 CONTROLLER ASSEMBLIES 209-3.Of Controller Assembly. A controller assembly shall consist of a complete mechanism for controlling the operation of traffic signals or other systems, including the controller unit and all necessary auxiliary equipment, mounted in a cabinet. All equipment required to provide the operation shown on the plans and as specified shall be provided. All field conductors No. 12 and smaller shall terminate with spade type terminals. All field conductors No. 10 and larger shall terminate in spade type or ring type terminals. 209-3.02 Type 90 Controller Assembly. Deleted 209-3.03 Model 170 and Model 2070 Controller Assemblies. Model 170 and Model 2070 (Model 170/2070) controller assemblies shall consist of a Model 170, 170E or 2070 controller unit, a wired cabinet and all auxiliary equipment required to control the system as shown on the plans, and as specified in these special provisions. Model 170/2070 controller assemblies shall conform to the requirements in ‘Transportation Electrical Equipment Specifications,” (TEES) and “Traffic Signal Control Equipment Specifications” (TSCES), issued by the State of California, Department of Transportation, and to all addendum thereto current at the time of project advertising. Unless otherwise specified or shown on the plans, controller assembly cabinets (housing) shall be Type I as shown in the TSCES. In addition to the requirements found in TEES and TSCES, Model 170/2070 controller assemblies shall conform to the following: 209-3.04 Controller Cabinets. Unless otherwise specified, controller cabinets for Model 170/2070 controllers shall conform to the following: 1) 2) 209-3.05 assembly for Model 170/2070 controllers: 1) 2) Controller cabinets shall be fabricated from aluminum sheet per the TSCES. Controller cabinets shall have a single front door equipped with a Best Company lock core and lock. No other manufacturers shall be accepted. Cabinet Accessories. The following accessories shall be furnish with each cabinet Controller cabinets shall have a pull-out type document tray. Each cabinet shall be provided with a fluorescent lighting fixture mounted on the inside top of the cabinet near the front edge. Fixture shall be provided with an F15T8, cool white lamp operated from a normal power factor UL or ETL listed ballast. The “on-off switch for the lighting fixture shall be a door-actuated switch that turns the light on when either door is open and off when either door is closed. - I @Revised: 07/29/02 Contract No. 38871-A Page 121 of 152 Pages .~ 3) An uninterruptible power system (UPS) shall be installed in each cabinet using a swing- away type mounting. The UPS shall be Clary SP 1000 series or approved equal and shall provide a minimum of eight (8) hours of continuous red flash operation at intersections using red LED signal indications and provide power conditioning to the controller. 209-5 DETECTORS 209-5.01 Vehicle Detectors. Vehicle detectors shall be the type or types shown on the plans. All sensor units, control units, and amplifiers shall meet the requirements of California Test 675. The units shall not be affected by transient voltages when tested in accordance with California Test 667. After a power interruption the units shall return to normal operation within one minute. Each unit shall be provided with a light or meter, for each output circuit, to indicate when the detector is detecting a vehicle. Each detector shall operate over the range of voltages from 100 volts to 135 volts at 60 Hz. Circuitry shall be solid-state except relays with normally closed contacts may be used for the output circuit. Units shall be designed to provide ease of maintenance with easily accessible electronic components. Each detector shall provide vehicle detection without readjustment from -1 8°C to 71 "C (0" to 160°F). Units shall use printed circuit boards designed to facilitate identification of components. This shall be done by either part identification markings or by providing a pictorial diagram showing physical location and identification of each component. Each printed circuit board shall have the following minimum quality requirements: NEMA FR-4 glass cloth base epoxy resin board, 1.5 mm minimum thickness, organic solder masking and old plated Printed circuit design shall be such that components may be removed and replaced without permanent damage to boards or tracks. Splices shall conform to the provisions in Section 209-2.09, "Wiring." contacts. lntercomponent wiring shall be copper track with a minimum mass of 600 g/m B (2 odff'). 209-5.01 A Inductive Loop Detectors. Inductive loop detectors shall conform to the following: 209-5.01 A(l) General. The term "inductive loop detector" applies to a complete installation consisting of a loop or group of loops installed in the roadway, as shown on the plans, lead-in cable and a sensor unit with power supply installed in a controller cabinet. 209-5.01 A(3) Sensor Unit Construction. "Card" type sensor units shall conform to the requirements in "Traffic Signal Control Equipment Specifications," issued by the State of California, Department of Transportation, and to all addendums thereto current at the time of project advertising. Shelf mounted sensor units shall conform to the requirements in Section 11 of the NEMA Standards Publication No. TS 1. Capacitors or inductors necessary for loop tuning shall not be mounted external to the sensor unit. 209-5.01 A(4) Construction Materials. Conductor for each inductive loop detector shall be continuous and unspliced and shall conform to one of the following: 1. Type 1 loop wire shall be Type RHW-USE neoprene-jacketed or Type USE cross-linked polyethylene insulated, No. 12, stranded copper wire. The minimum insulation thickness at any point shall be 1 .O mm (40 mils). Type 2 loop wire shall consist of a conductor inside of plastic tubing. The conductor shall be Type THWN or Type XHHW, No. 14, stranded copper wire. The tubing shall be polyethylene or vinyl, rated for use at 105"C, and shall be resistant to oil and gasoline. The tubing shall have a maximum outside diameter of 7 mm (0.27") and a minimum wall thickness of 0.71 mm (0.028"). The conductors shall not be spliced inside the tubing. 2. '3Revised: 07/29/02 Contract No. 38871 -A Page 122 of 152 Pages Conductors for loop detector lead-in cable shall be 2 No. 16 (19 x 29) stranded tinned copper. Loop detector lead-in cable shall conform to the calculated cross sectional area of ASTM Designation: B 286, Table 1. The lead-in cable shall conform to one of the following: 1. Type B lead-in cable shall be insulated with 0.5 mm (20 mils) of high-density polyethylene. The conductors shall be twisted together with at least 6 turns per meter and the twisted pair shall be protected with a copper or aluminum polyester shield. A No. 20, minimum, copper drain wire shall be provided and connected to the equipment ground within the cabinet. The cable shall be provided with a high-density polyethylene or high-density polypropylene outer jacket with a nominal thickness of 0.8 mm (35 mils). An amorphous interior moisture penetration barrier of nonhydroscopic polyethylene or polypropylene fillers shall be provided. Type C lead-in cable shall conform to International Municipal Signal Association (IMSA) Specification No. 50-2. A No. 20, minimum, copper drain wire shall be provided and connected to the equipment ground within the cabinet. 209-5.01A(5) Installation Details. Installation and tests shall conform to the details and notes shown on the plans. Unless shown othelwise each loop shall consist of 3 turns of conductor as specified in Section 209-5.01A(4), "Construction Materials." Slots cut in the pavement shall be washed clean, blown out and thoroughly dried before installing conductors. Residue resulting from slot cutting operations shall not be permitted to flow across shoulders or lanes occupied by public traffic and shall be removed from the pavement surface before any residue flows off of the pavement surface. Residue from slot cutting operations shall be disposed of outside the highway right of way in accordance with Section 7-8.1, "Cleanup and Dust Control." After conductors are installed in the slots cut in the pavement, the slots shall be filled with sealant to within 3 mm ('/;) of the pavement surface. The sealant shall be at least 25 mm (1") thick above the top conductor in the saw cut. Before setting, surplus sealant shall be removed from the adjacent road surfaces without the use of solvents. The sealant for filling slots shall conform to the following: 1. Hot-Melt Rubberized Asphalt Sealant.- Hot-melt rubberized asphalt shall be in solid form at room temperature and fluid at an application temperature of 190°C (375°F) to 205°C (400°F). Fumes from the material shall be non-toxic. Sealant shall be suitable for use in both asphalt coimete and portland cement concrete. Performance characteristics of the cured hot-melt rubberized asphalt shall be as per Table 209-5.01A(5)(8). 2. - TABLE 209-5.01A(5)(B) ASTM D 3407, Sec. 6 ,ASTM D 3407, Sec. 8 Property 5 mm, max. 25%, min. Cone ASTM D 113 ASTM D 92 ~~ Penetration Flow, 60°C 300 mm, min. 288 "C, min. ~ Resilience Softening Point, __ Ductility, Flash Point. COC, "C Viscositv. _____ Brookfield Thermcsel, -- CURED HOT-MELT RUBBERIZED ASP~ Measuring Standard (ASTM I Results Designation) I ASTM D 3407, Sec. 5 3.5 mm, max. I ASTM D 36 82 "C, min. I ASTM D 4402 2.5-3.5 Pas QRevised: 07/29/02 .T Conditions 25"C, 150 g, 5 s 25°C 25"C, 50 mm/min No. 27 Spindle, 20 rpm, 190"C, Contract No. 38871-A Page 123 of 152 Pages The hot-melt rubberized asphalt shall be melted in a jacketed, double boiler type melting unit. Temperature of the heat transfer medium shall not exceed 245°C (475°F). Application of the hot- melt sealant shall be made with a pressure feed applicator or pour pot. Sealant shall be applied when the pavement surface temperature is greater than 4°C (40°F). Hot-melt sealant shall be packaged in containers clearly marked “Detector Loop Sealant” and specifying the batch and lot number of the manufacturer. - Loop conductors shall be installed without splices and shall terminate in the nearest pull box. The loops shall be joined in the pull box in combination of series and parallel so that optimum sensitivity is obtained at the sensor unit. Final splices between loops and lead-in cable shall not be made until the operation of the loops under actual traffic conditions is approved by the Engineer. All loop conductors for each direction of travel for the same phase of a traffic signal system, in the same pull box, shall be spliced to a detector lead-in cable which shall be run from the pull box adjacent to the loop detector to a sensor unit mounted in the controller cabinet. All loop conductors for traffic monitoring shall terminate in a pull box or terminal strip in the traffic monitor station cabinet when a cabinet of that type is installed. Conductors for inductive loop traffic signal and traffic monitoring installations shall be identified and banded, in pairs, by lane, in the pull box adjacent to the loops and near the termination of the conductors in the controller or traffic monitoring station cabinet. Bands shall conform to the provisions in Section 209-2.09, ‘Wiring.” If asphalt concrete surfacing is to be placed, the loop conductors shall be installed prior to placing the uppermost layer of asphalt concrete. The conductors shall be installed, as shown on the plans, in the compacted layer of asphalt concrete immediately below the uppermost layer. Installation details shall be as shown on the plans, except the sealant shall fill the slot flush to the surface. .- 209-5.01 B Emergency Vehicle Pre-Emption Detector System. Each emergency vehicle pre- emption detector system shall conform to the details shown on the plans and these special provisions and shall consist of an optical emitter assembly or assemblies located on the appropriate vehicle and an optical detectorldiscriminator assembly or assemblies located at the traffic signal. Each system shall permit detection of Class I1 emergency vehicles. Class II emergency vehicles shall be capable of being detected at any range up to 2,500 feet from the optical detector. 209-5.01 B(l) Optical Emitter Assembly. Each optical emitter assembly shall consist of an emitter unit, an emitter control unit and connecting cables and shall conform to the following: Each optical emitter assembly, including lamp, shall be designed to operate over an ambient temperature range of -34’C to 749C at both modulation frequencies and to operate continuously at the higher frequency for a minimum of 3,000 hours at 25~C ambient before failure of lamp or any other component. Each emitter unit shall be controlled by a single, maintained-contact switch on the respective emitter control unit. The switch shall be capable of being positioned in a readily accessible location to the vehicle driver. The control unit shall contain a pilot light to indicate that the emitter power circuit is energized and shall be capable of generating only Class II modulating code. Functional Requirements. Each emitter unit shall transmit optical energy in one direction only. The signal from each emitter unit shall be capable of being detected at a distance of 2,500 feet when used with a standard optical detectioddiscriminator assembly. The modulation frequency for Class I1 signal emitters shall be 14.035 Hz f 0.003 Hz. The standard optical detection/discriminator assembly to be used in conducting the range tests shall be available from the manufacturer of the system. A certified performance report shall be furnished by the contractor with each assembly. - t The emitter unit shall be configured with a grating to provide precise directionality control. QRevised: 07/29/02 Contract No. 38871 -A Page 124 of 152 Pages Electrical Requirements. Each optical emitter assembly shall be capable of providing full light output with input voltages between 10 and 16 volts DC. An optical emitter assembly shall not be damaged by input voltages up to 7.5 volts DC about the supply voltage. The optical emitter assembly shall not generate voltage transient, on the input supply, which exceeds the supply voltage by more than 4 volts. Each optical emitter assembly shall not consume more than 100 watts at 17.5 volts DC and shall have a power input circuit breaker rated at 10 to 12 amperes, 12 volts DC. The design and circuitry of each emitter unit shall permit its use on vehicles with either negative or positive ground without disassembly or rewiring of the unit. Mechanical Requirements. Each emitter unit shall be housed in a weatherproof, corrosion- resistant housing. The housing shall be provided with facilities to permit mounting on various types of vehicles and shall have provision for proper alignment of the emitter unit and for locking of the emitter unit into proper alignment. Each emitter control unit shall be provided with appurtenant hardware to permit its mounting in or on an emergency vehicle or mass transit vehicle. Where required for certain emergency vehicles, the emitter control unit and all exposed controls shall be weatherproof. Each emitter shall include a multi-purpose port compliant with the SAE J1708 communication standard to enable unit configuration to be set into the emitter and read from the emitter. 209-5.01 B(2) Optical DetectiodDiscriminator Assembly. Optical detection/discriminator assembly shall consist of one or more optical detectors, connecting cable and a discriminator module and conform to the following: Each such assembly, when used with standard emitters, shall have a range of up to 2,500 feet for Class II signals. Standard emitters for Class II signals shall be available from the manufacturer of the system. Range measurements shall be taken with all range adjustments on the discriminator module set to “maximum”. 209-5.01 B(3) Optical Detector. Each optical detector shall be a waterproof unit capable of receiving optical energy from one or two separately aimable directions. The horizontal angle between the two directions shall be variable from 5 degrees to 180 degrees. The reception angle for each photocell assembly shall be a maximum of 8 degrees in all directions about the aiming axis of the assembly. Measurements of reception angle will be taken at a range of 2,500 feet for a Class II emitter. All internal circuitry shall be solid state and electrical power shall be provided by the associated discriminator module. Each optical detector shall be contained in a housing, which shall include one or two rotatable photocell assemblies, an electronic assembly and a base. The base shall have an opening to permit its mounting on a mast arm. Each optical detector shall weigh no more than 2.5 pounds and shall present a maximum wind load area of 36 square inches.’ The housing shall be provided with weep holes to permit drainage of condensed moisture. Each optical detector shall be installed, wired and aimed as specified by the manufacturer. - @Revised: 07/29/02 Contract No. 38871-A Page 125 of 152 Pages ~ ~ - 209-5.01 B(4) Optical Detector Cable. IPCEA-S-61-402/NEMA WC 5, Section 7.4, 600 volt control cable, 75*C, Type B and the following: Optical detector cable shall meet the requirements of The cable shall contain three conductors, each of which shall be AWG #20 (7x28) stranded, tinned copper with low-density polyethylene insulation. Minimum average insulation thickness shall be 25 mils. The insulation of individual conductors shall be color coded as follows: Yellow Detector Signal #I Blue Detector Signal #2 Orange Power (+) Bare (Drain) - Common or Ground The shield shall be either tinned copper braid or aluminized polyester film with a nominal 20 percent overlap. Where the film is used, a AWG #20 (7x28) standard, tinned, bare drain wire shall be place between the insulated conductors and the shield and in contact with the conductive surface of the shield The jacket shall be black polyvinyl chloride with a minimum rating of 600 volts and 80~C and a minimum average thickness of 45 mils. The jacket shall be marked as required by IPCENNEMA. The finished outside diameter of the cable shall not exceed 0.3 inches. The capacitance of the optical detector cable, as measured between any conductor and the other conductors and the shield, shall not exceed 14.3 microfarads per 1000 feet. The characteristic impedance of the optical detector cable shall be 0.6 ohms per 1000 feet. - 209-5.01 B(5) Discriminator Module. Each discriminator module shall be designed to be compatible and usable with Model 170 controller unit and to be mounted in the input file of a Model 332 controller cabinet, and shall conform to the requirements of Chapter 1 of the State of California, Department of Transportation, “Traffic Signal Control Equipment Specifications”, dated January 1989, and to all addenda thereto current at the time of project advertisement. Each discriminator module shall be capable of operating one or two channels and shall be capable of: 1. 2. 3. 4. Receiving Class II signals at a range of up to 2,500 feet. Decoding the signal on the basis of frequency at 14.035 Hz k 0.003 Hz for Class II signals. Establishing the validity of received signals on the basis of frequency and length of time received. A signal shall be considered valid only when received for more than 0.50 seconds. No combination of Class I signals shall be recognized as a Class II signal regardless of the number of signals being received, up to a maximum of ten signals. Once a valid signal has been recognized, its effect shall be held by the module in the event of temporary loss of the signal for a period adjustable from 4.5 seconds to 11 seconds in at least 2 steps at 5 f 0.5 seconds and 10 f 0.5 seconds. Providing an output for each channel that will result in “low” or grounded condition of the appropriate input of a Model 170 controller unit. For Class II signals the output shall be steady. Each discriminator module shall be powered from 115 volt (95 volts AC to 135 volts AC), 60 Hz mains and will contain an internal, regulated power supply that supports up to twelve optical detectors. Electric power, one detector input for each channel and one output for each channel, shall terminate at the printed circuit board edge connector pins listed below. Board edge connector pin assignments shall be as follows: t”s Revised: 07/29/02 Contract No. 38871 -A Page 126 of 152 Pages Pins A D E F H J K L M N - Function Ground Channel A primary detector input Detector 24 VDC power output Channel A output, collector (+) Channel A output, emitter (-) Channel B primary detector input Detector ground Earth ground AC - (in) AC + (in) Pins P R S T U V W X Y 2 - Function Not used Detector 24 VDC power output Not used Not used Not used Detector ground Channel B output collector (+) Channel B output emitter (-) Not used Not used Two auxiliary inputs for each channel shall enter each module through the front panel connector. Pin assignment for the connector shall be as follows: - Pins Function 13 Auxiliaw detector 2 input, Channel A 14 15 28 Auxiliary detector 1 input, Channel B Auxiliary detector 2 input, Channel B Auxiliary detector 1 input, Channel A Each channel output shall be an optically isolated NPN open collector transistor capable of sinking 50 milliamperes at 30 volts and shall be compatible with Model 170 controller unit inputs. Each discriminator module shall be provided with means of preventing transients received by the detector from affecting the Model 170 controller assembly. Each discriminator module shall have a single connector board, shall be capable of being inserted into the input file of a Model 332 cabinet and shall occupy one slot width of the input file. The front panel of each module shall have a handle to facilitate withdrawal and the following controls and indicators for each channel: 1. A Command (High) and Advantage (Low) solid-state LED indicator for each channel to display active calls. 2. A test switch for each channel to test proper operation of Command or Advantage priority. 3. A single confirmation light control output for each channel. These outputs shall be user configurable through software for a variety of confirmation light sequences. The front panel shall be provided with a single circular, bayonet-captured, multi-pin connector for two auxiliary detector inputs for each channel. Connector shall be a mechanical configuration equivalent to a D-Shell44-Pin front panel. Wiring for a Model 332 cabinet shall conform to the following: Slots 12 and 13 of the input file “J” shall be wired to accept a two-channel module. Field wiring for the primary detectors, except 24-volt DC power, shall terminate on either terminal board TB-9 in the controller cabinet or on the rear of input file “J”, depending on cabinet configuration. Where TB-9 is used, position assignments shall be as follows: QRevised: 07/29/02 Contract No. 38871-A Page 127 of 152 Pages Position Assiqnment 4 Channel A detector input, 1 st module (Slot J-12) 5 Channel B detector input, 1 st module (Slot J-12) 7 . Channel A detector input, 2nd module (Slot J-13) 8 Channel B detector input, 2nd module (Slot J-13) The 24 volt cabinet DC power shall be available at Position 1 of terminal board TB-1 in the controller cabinet. All field wiring for the auxiliary detectors shall terminate on terminal board TB-0 in the controller cabinet. Position assignments are as follows: Position Assinnment 7 +24VDC from (J-13E) 8 Detector ground from (J-l3K) 9 10 11 12 Channel A auxiliary detector input 1 Channel A auxiliary detector input 2 Channel B auxiliary detector input 1 Channel B auxiliary detector input 2 The contractor shall demonstrate that all of the components of the system will perform satisfactorily as a system. Satisfactory performance shall be determined using the following test procedure: 1. Each system to be used for testing shall consist of an optical emitter assembly, an optical detector, at least 200 feet of optical detector cable and a discriminator module. 2. The discriminator modules shall be installed in the proper input file slot of Model 332 controller cabinet. The controller cabinet, together with a Model 170 controller unit with the appropriate operating program, a Model 210 monitor unit and 120 volt AC power, will be available as shown on the plans and as indicated elsewhere in these special provisions. 3. One test shall be conducted using a Class II signal emitter and a distance of 2,500 feet between the emitter and the detector. All range adjustments on the module shall be set to “Maximum” for each test. 4. Each test shall be conducted for a period of one hour, during which the emitter shall be operated for 30 cycles, each consisting of a one minute “on” interval and a one minute “off” interval. During the total test period: (A) the emitter signal shall cause the proper response from the Model 170 controller unit during each “on” interval and (B) there shall be no improper operation of either the Model 170 controller unit or the monitor during each “off’ interval. 209-5.01C Video Detection System. The video detection system shall consist of one (1) video camera and one (1) video detection processor (VDP) for each vehicle approach, and a pointing device. The system shall include software that detects vehicles in multiple lanes using only the video image. Detection zones shall be defined using only a video menu and a pointing device to place zones on a video image. A minimum of 24 detection zones per camera shall be available. 209-5.01 C(1) Functional Requirements. The VDP shall process video from a single source. The source can be a video camera or a video tape player. The video shall be input to the VDP in RS170 format and shall be digitized and analyzed in real time. The VDP shall detect the presence of vehicles in up to 24 detection zones per camera. A detection zone shall be approximately the width and length of one car. Detection zones shall be programmed via a menu displayed on a video monitor and a pointing device connected to the VDP. The menu shall facilitate placement of the detection zones and setting of zone parameters. A separate computer shall not be required for programming detection zones or to view system operations. The VDP shall store up to three different detection zone patterns. The VDP shall be able to switch to any one of the three different detection zone patterns within one second of user request via menu selection with the pointing device. The VDP shall detect vehicles in real time as they travel across each detection zone. - @Revised: 07/29/02 Contract No. 38871 -A Page 128 of 152 Pages The VDP shall have an RS-232 port for communications with an external computer. The VDP shall accept new detector patterns from an external computer through the RS-232 port when that computer uses the appropriate communications protocol for downloading detector patterns. The VDP shall send its detector patterns to an external computer through the RS-232 port when requested when that computer uses the appropriate communications protocol for uploading detector patterns. A Windows-based software program designed for local or remote connection and providing video capture, real-time detection indication and detection zone modification capability shall be provided with the system. The camera system shall be able to transmit an NTSC video signal, with minimal signal degradation, up to 300m (1000 ft). The VDP shall default to a safe condition, such as a constant call to each active detection channel, in the event of unacceptable interference in the video signal. The system shall be capable of automatically detecting a low visibility condition such as fog and respond by placing all defined detection zones in a constant call mode. A user-selected output shall be active during the low Visibility condition that can be used to modify the controller operation if connected to the appropriate controller input modifier(s). The system shall automatically revert to normal detection mode when the low visibility condition no longer exists. 209-5.01C(2) Operational Requirements. A minimum of 24 detection zones per camera shall be supported and each detection zone can be sized to suit the conditions and the desired vehicle detection region. A single detection zone shall be capable of replacing multiple loops and the detection zone may be AND'ed or ORed together to indicate vehicle presence on a single phase of traffic movement. Placement of detection zones shall be done by using a pointing device and a graphical interface built into the VDP and displayed on a video monitor. No separate computer shall be required to program the detection zones. Up to three detection zone patterns shall be saved within the VDP memory and this memory shall be presetved during power outages. The selection of the detection zone pattern for current use shall be done through a menu system. It shall be possible to activate a detection zone pattern for a camera from VDP memory and have the detection zone pattern displayed within one second of activation. When a vehicle is detected crossing a detection zone, the detection zone will flash a symbol on the screen to confirm the detection of the vehicle. Detection shall be at least 98% accurate in good weather conditions and at least 96% accurate under adverse weather conditions (rain, snow or fog). Detector placement shall not be more distant from the camera than a distance of fifteen times the mounting height of the camera. The VDP shall provide up to eight channels of vehicle presence detection through a NEMA TSI port. The VDP shall provide dynamic zone reconfiguration (DZR) to enable normal detector operation of existing zones except the one being added or modified during the setup process. The VDP shall output a constant call on any detection channel when the corresponding zone is being modified. - Detection zone outputs shall be configurable to allow the selection of presence, pulse, extend and delay outputs. Timing parameters of pulse, extend, and delay outputs shall be user definable between 0.1 and 25.0 seconds. Up to six detection zones shall be capable of counting the number of vehicles detected. The count value shall be internally stored for later retrieval through the RS-232 port. The data collection interval shall be user definable in periods of five, fifteen, thirty or sixty minutes. GRevised: 07/29/02 Contract No. 38871-A Page 129 of 152 Pages 209-5.01C(3) Hardware Requirements. The VDP shall be housed in a durable metal enclosure suitable for shelf mounting in the side rails of the controller cabinet. The VDP enclosure shall not exceed 180mm (7.1 in) in length and 157mm (6.2 in) in depth. The VDP shall operate satisfactorily in a temperature range of -34°C to +74"C (-29°F to +165"F) and a humidity range of O%RH to 95% RH, non-condensing. The VDP shall be powered by 24 volts DC. VDP power consumption shall not exceed 10 watts. The VDP shall include an RS-232 port for serial communications with a remote computer. This port shall be a 9-pin "D" subminiature connector on the front of the VDP. The front of the VDP shall include one BNC video input connection suitable for RS170 video inputs. The video input shall include a switch-selectable 75-ohm or high impedance termination to allow camera video to be routed to other devices, as well as input to the VDP for vehicle detection. The front of the VDP shall include one BNC video output providing real time video output that can be routed to other devices. 209-5.01C(4) Video Detection Camera. The video camera shall be furnished by the VDP supplier and shall be qualified by the supplier to ensure proper system operation. The camera shall produce useable video image of the bodies of vehicles under all roadway lighting conditions, regardless of time of day. The minimum range of scene luminance over which the camera shall produce a useable video image shall be the minimum range of night time to day time but not less than the range of 0.1 lux to 10,000 lux. The camera shall use a CCD sensing element and shall output monochrome video with resolution of not less than 380 lines vertical and 380 lines horizontal. The camera shall include an electronic shutter control based upon average scene luminance and shall be equipped with a factory adjusted manual iris. The camera shall include a variable focal length lens with variable focus that can be adjusted, without opening the camera housing, to suit the site geometry by means of a portable interface device designed for that purpose and manufactured by the detection system supplier. The horizontal field of view shall be adjustable from 8.1" to 45.9". A single camera configuration shall be used for all approaches in order to minimize setup time and spares required by the user. The camera electronics shall include AGC to produce a satisfactory image at night. The camera shall be housed in a weather-tight sealed enclosure. The camera enclosure shall be able to rotate to allow proper alignment between the camera and the traveled road surface. The camera enclosure shall be equipped with a sun shield. The sun shield shall include a provision for water diversion to prevent water from flowing in the camera's field of view. The camera enclosure with sun shield shall be less than 170mm (6 in) in diameter, less than 380mm (15 in) long, and shall weigh less than 13.3kg (6 pounds) when the camera and lens are mounted inside the enclosure. The camera enclosure shall include a thermostatically controlled heater to assure proper operation of the lens at low temperatures and to prevent moisture condensation on the optical faceplate of the enclosure. When mounted outdoors in the enclosure, the camera shall operate satisfactorily in a temperature range of -34°C to +60"C (-29°F to +140"F) and .a humidity range of 0% RH to 100% RH. The camera shall be powered by 120/240 VAC, 50/60 Hz. Power consumption shall be 15 watts or less under all conditions. Recommended camera placement height shall be 10m (33 ft) above the roadway, and over the traveled way on which vehicles are to be detected. For optimum detection, the camera should be centered above the traveled roadway. The camera shall view approaching vehicles at a distance not to exceed 1 OOm (350 ft) for reliable detection (height:distance ration of 1O:lOO). Camera placement and field of view shall be unobstructed and as noted in the installation documentation provided by the supplier. The camera enclosure shall be equipped with separate, weather-tight connections for power and video cables at the rear of the enclosure. These connections may also allow diagnostic testing and viewing of the video signal at the camera while the camera is installed, using a lens adjustment module supplied by the VDP supplier. Video and power shall not be connected within the same connector. The video signal output by the camera shall be black and white in RS170 or CCIR format. The video signal shall be fully isolated from the camera enclosure and power cabling. -\vised: 07/29/02 Contract No. 38871 -A Page 130 of 152 Pages - 209-5.01C(5) Installation Requirements. The coaxial cable to be used between the camera and the VDP in the controller cabinet shall be Belden 8281 or a 75 ohm, precision video cable with 20 gauge solid bare copper conductor (9.9 ohms/M), solid polyethylene insulating dielectric, 98% (min) tinned copper double-braided shield and black polyethylene outer covering. The signal attenuation shall not exceed 0.78 dB per 30m (I00 ft) at 10 MHz. Nominal outside diameter shall be 8mm (0.304 in). The coaxial cable shall be a continuous, unbroken run from the camera to the VDP. This cable shall be suitable for installation in conduit or overhead with appropriate span wire. 75 ohm BNC plug connectors shall be used at both the camera and controller. The coaxial cable, BNC connector and crimping tool shall be approved by the supplier of the video detection system, and the manufacturer's instructions must be followed to ensure proper connection. The power cabling shall be 16 AWG three conductor cable. The cabling shall comply with the National Electric Code, as well as local electrical codes. Cameras may acquire power from the luminaire if necessary. The video detection system shall be installed by supplier factory certified installers and as recommended by the supplier and documented in the installation materials provided by the supplier. Proof of factory certification shall be provided. 209-5.01C(6) Warranty. The supplier shall provide a limited two year warrant on the video detection system. See supplier's standard warranty included in the Terms and Conditions of Sale documentation. During the warranty period, technical support shall be available from the supplier via telephone within four hours of the time a call is made by the user. This support shall be made available from factory certified personnel or factory certified installers. During the warranty period, updates to the VDP software shall be made available from the supplier without charge. 209-5.01C(7) Maintenance and Support. The supplier shall maintain an adequate inventory of parts to support maintenance and repair of the video detection system. These parts shall be made available for delivery within 30 days of placement of an acceptable order at the supplier's current pricing and terms of sale for said parts. The supplier shall maintain an ongoing program of technical support for the video detection system. This technical support shall be available via telephone, or via personnel sent to the installation site upon placement of an acceptable order at the supplier's current pricing and terms of sale for on site technical support services. Installation or training support shall be provided by a factory authorized representative. All product documentation shall be written in the English language. The contractor shall ensure the presence of a factory authorized representative at the time of traffic signal turn-on. 209-5.02 Pedestrian Push Button Assemblies. Where shown on the plans, pedestrian push button assemblies of substantial tamper-proof construction and signs shall be furnished and installed. The housing shall be either die-cast or permanent mold cast aluminum, or when specified shall be ultraviolet stabilized, self-extinguishing structural plastic. Plastic housings shall be black matching Color No. 17038, 27038 or 37038 of Federal Standard No. 5958, and shall be colored throughout. The assembly shall be rainproof and shall be shockproof in any weather condition. The pedestrian push button switch shall be a phenolic enclosed precision snap-acting type, single- pole, double-throw, switching unit, with screw type terminals, rated 15 A at 125 volts AC, and shall have the following characteristics: 1. Switching unit shall have a stainless steel plunger actuator and shall be provided with U-frame to permit recessed mounting in push button housing. 2. Switch shall have an operating force of 2.5 N (9 oz.) to 3.6 N (13 02.) and a minimum release force of one newton (4 02.). 3. Pretravel shall be 0.4 mm maximum. 4. Over travel shall be 6 mm (%;) minimum. 5. Differential travel shall be 0.01 mm (0.0004") to 0.05 mm (0.002"). 6. Actuator shall have a minimum diameter of 50 mm (2"). . aRevised: 07/29/02 Contract No. 38871-A Page 131 of 152 Pages Where a pedestrian push button is attached to a pole, the housing shall be shaped to fit the curvature of the pole and secured to provide a rigid installation. Saddles shall be provided to make a neat fit when required. Where a pedestrian push button is to be mounted on top of a Size 65 (2’/2”) diameter post, the housing shall be provided with a-slip-fitter fitting and screws for securing rigidly to the post. Pedestrian push button signs shall be porcelain enameled metal or structural plastic. Push button and sign shall be installed on the crosswalk side of the pole. Arrows on push button signs shall point in the same direction as the corresponding crosswalk. Where Type A push buttons are specified, each push button assembly shall be equipped with red and green indicator lamps. Lamps shall be so connected that, when the push button has been activated, the red lamp shall be energized and continue so until the next pedestrian walk interval, at which time the green lamp shall be energized in lieu of the red lamp. At the termination of the pedestrian walk interval, the lamps shall be de-energized until the next actuation of the push button. Lenses for the lamps shall have a visible diameter of approximately 32 mm (l’/;) and a length of approximately 22 mm (7/<). On the Type A or Type B push button assembly, the sign shall attach to and be securely supported by the framework. With Type C pedestrian push buttons, the instruction sign shall be mounted, using 2 straps and saddle brackets, on the same standard as the push button assembly. Straps and saddle brackets shall be as shown on the plans and shall be corrosion-resisting chromium nickel steel conforming to the specifications of ASTM Designation: A 167, Type 302. Bolts shall be stainless steel with a chromium content of at least 17 percent and a nickel content of at least 8 percent. Bolts shall NOT be theft-proof. 209-7 REMOVING, REINSTALLING OR SALVAGING ELECTRICAL EQUIPMENT 209-7.01 Removing Electrical Equipment. Attention is directed to Section 7-9, “Protection and Restoration of Existing Improvements.” Existing electrical equipment shown on the plans or specified in these special provisions to be removed and not reused or salvaged, and pull boxes, conduit and detector frames not reused, shall become the property of the Contractor and shall be removed from the street right of way in accordance with the provisions in 300-1, “Clearing and Grubbing,” except, if not interfering with other construction, underground conduit may be abandoned in place after all conductors have been removed. Care shall be exercised in salvaging equipment so that it will not be damaged or destroyed and will remain in its existing condition whenever possible. Mast arms shall be removed from standards. Luminaires, signal heads, and signal mounting assemblies shall be removed from standards and mast arms. Attention is directed to the provisions in Section 7-9, “Protection and Restoration of Existing Improvements” and 300-1.2, “Preservation of Property.” The Contractor will be required to repair or replace, at the Contractor’s expense, any electrical equipment to be salvaged which, as determined by the Engineer, has been damaged or destroyed by reason of the Contractor’s operations. Attention is directed to the provisions in Section 209-2.03, “Foundations,” regarding foundations to be abandoned or removed. Holes resulting from removing pull boxes and detector frames shall be filled with material equivalent to the surrounding material. 209-7.02 Reinstalling Removed Electrical Equipment. When removed electrical equipment is to be reinstalled, the Contractor shall furnish and install all necessary materials and equipment, including signal mounting assemblies, anchor bolts, nuts, washers and concrete as required to complete the new installation. All traffic signal and flashing beacon faces to be reinstalled or to be part of a modified system shall be cleaned and relamped. All luminaires and sign lighting fixtures to be reinstalled shall be cleaned and relamped. Existing materials required to be relocated and found to be unsatisfactory by the Engineer shall be replaced by new material and the cost therefor will be paid for as extra work as provided in Section 3-3, “Extra Work.” @Revised: 07/29/02 Contract No. 38871 -A Page 132 of 152 Pages 209-8 PAYMENT - 209-8.01 Payment. The contract lump sum price or prices paid for signal, flashing beacon, lighting, sign illumination, traffic monitoring station, closed circuit television systems, or combinations thereof; for modifying or removing those systems; for temporary systems; or the lump sum or unit prices paid for various units of those systems; or the lump sum or per meter price paid for conduit of the various sizes, types and installation methods listed in the Engineer’s Estimate shall include full compensation .ior furnishing all labor, materials, tools, equipment and incidentals, and for doing all the work involved in furnishing and installing, modifying, or removing the systems, combinations or units thereof, as shown on the plans, as specified in these special provisions, and as directed by the Engineer, including any necessary pull boxes (except when the type required is shown as a separate contract item); excavation and backfill; concrete foundations (except when shown as a separate contract item): pedestrian barricades: furnishing and installing illuminated street name signs; installing Agency-furnished sign panels on pedestrian barricades, on flashing beacon standards, and on traffic signal mast arms: restoring sidewalk, pavement and appurtenances damaged or destroyed during construction; salvaging existing materials; and making all required tests. Full compensation for all additional materials and labor, not shown on the plans or specified, which are necessary to complete the installation of the various systems, shall be considered as included in the prices paid for the systems, or units thereof, and no additional compensation will be allowed therefor, except as provided in Section 209-1.05, “Maintaining Existing and Temporary Electrical Systems.” When shown as a contract item, the contract price paid per meter for cast-in-drilled-hole concrete pile (signal foundation) shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in constructing reinforced concrete pile foundations of the size shown on the Engineer’s Estimate, including drilling holes, disposing of the material resulting from drilling holes, furnishing and placing anchor bolt assemblies and reinforcing steel, complete in place, as shown on the plans, and as specified in these special provisions and as directed by the Engineer. When shown as a contract item, non-reinforced portland cement concrete foundations will be measured and paid for in the manner as provided in Section 303-1 .I 1, ”Payment.” When shown as a separate contract item by the lump sum or per bid item linear measurement, interconnection conduit and conductor shall include all interconnection conductors, but shall only include conduit and pull boxes containing interconnection conductors and no other conductors. The quantity of interconnection conduit and conductor to be paid for by the lump sum bid or the bid item linear measurement shall be the length of that conduit. Compensation for conduit containing interconnection conductors and other conductors shall be considered as included in the contract price paid for the item requiring the other conductors. Full compensation for furnishing, installing, maintaining and removing falsework lighting equipment shall be considered as included in the contract prices paid for the items of work involved in the structure which requires the falsework lighting and no additional compensation will be allowed therefor. ~- GRevised: 07/29/02 Contract No. 38871-A Page 133 of 152 Pages SECTION 210 - PAINT AND PROTECTIVE COATINGS Surface to be Painted Temporary Railing type (K) 210-1 PAINT. Pre-reatment / Surface Primer Finish Coats Preparation Abrasive Blast Cleaning to a None Two coats white Acrylic Roughened, Textured Appearance Emulsion Paint (’I 21 0-1.5 Paint Systems. Add the following to Table 21 0-1.5(A) 21 0-1.6 Paint for Traffic Striping, Pavement Marking, and Curb Marking. Modify as follows: Paint for traffic lane lines, turn pocket lines, edge lines, channelizing lines, bike lane lines, chevrons, and curbs shall be rapid dry water borne conforming to CALTRANS Specification No. PTWB-01. Paint for pavement legends, pavement symbols, pavement arrows, cross walks, parking stall markings and stop bars shall be alkyd thermoplastic conforming to CALTRANS Specification No. 8010-19A. Glass beads shall be applied to the surface of the rapid dry water borne paint and the molten thermoplastic material and shall conform to the requirements of CALTRANS Specification No. 801 0-004 (Type 11). CALTRANS Specifications for water borne paint, thermoplastic material and glass beads may be obtained from the CALTRANS Transportation Laboratory, P.O. Box 19128, Sacramento, CA 9581 9, telephone number (91 6) 227-7000. SECTION 21 2 - LANDSCAPE AND IRRIGATION MATERIALS 212-2 IRRIGATION SYSTEM MATERIALS. 212-2.1.3 Plastic Pipe for Use with Solvent Weld Socket or Threaded Fittings, add the following: Except as provided in this section, all buried piping in the irrigation system shall be installed with underground utility marking tape conforming to the requirements of section 207-21 and identifying it as reclaimed water. Intermittent pressure lines (lines on the downstream side of a controller valve that will not be subject to constant pressure) will not require underground utility marking tape. All PVC pipe used for irrigation systems shall be colored purple by the addition of a dye integral to the PVC. Painted pipe will not be accepted. Pressure mainline piping for sizes 50 mm (2”) and larger shall be PVC having a pressure rating of 21 70 kPa (31 5 PSI), S.D.R. 13.5. Stenciled pipe is required for all irrigation system piping including portions not required to be marked with underground utility marking tape. All pipe shall have stenciling appearing on both sides of the pipe with the marking “Reclaimed Water” in 16 mm (5/<) high letters repeated every 300 mm (12“). PVC non-pressure buried lateral line piping shall be PVC Schedule 40. Add the following section: 212-2.1.7 Brass Pipe and Fittings. Brass pipe shall be IPS standard weight 125 LB 85 percent copper and 15 percent zinc, trade designation seamless red brass pipe conforming to the requirements of ASTM 843-91. Brass pipe fittings and connections shall be Standard 125 LB class 85 percent red brass fittings and connections. GRevised: 07/29/02 Contract No. 38871 -A Page 134 of 152 Pages 212-2.2.7 Valve Boxes. Add the following: All valve boxes shall be marked "RCV, "BV or "QC", "PB respectively. Remote control valves shall be marked with station numbers embossed on the valve cover with a brass tag. (RCV boxes shall have locking covers.) Other boxes such as pull boxes, etc., shall be marked with appropriate identification. Add the following section: 21 2-2.2.8 Ball Valves. Ball valves shall have bottom-loaded pressure-retaining stems, glass- reinforced seats, and reinforced TFE stem packing seals. Valves sizes 13 mm (E") to 50 mm (2) shall be pressure rated at 4140 kPa (600 PSI) WOG and 1030 kPa (150-PSI) saturated steam. Each valve shall be tested, air under water, in the opened and closed position by the manufacturer. Ball valve must conform to Federal Specification WW-V-35B, Type II, Class A, Style 3, End Connection A or C. Add the following section: 212-2.2.9 Pressure Regulator Valve Pressure regulator valve shall be bronze body with screw fitting. Add the following section: 212-2.2.9 Wye Strainers. Wye strainers shall have a cast iron or all-bronze body with a removable stainless steel or monel strainer. Wye strainers shall be capable of withstanding a cold water working pressure of 1034 kPa (150 psi). Wye strainers at backflow preventer assemblies shall be equipped with a gate valve at the outlet. All other wye strainers shall be equipped with a garden valve at the outlet. The strainer screen for the wye strainer in a backflow preventer assembly shall have an open area equal to at least 3 times the cross-sectional area of the pipe based on an iron pipe size and shall be woven wire fabric with 850-pm mesh or perforated sheet with 1.1 4 mm (0.045") diameter holes. All other wye strainers shall be equipped with 425-pm strainer screens. 212-2.4 Sprinkler Equipment. Add the following: All sprinkler heads are to have factory built-in check valves or a check valve under each head. Drip assemblies shall meet the following requirements: The drip emitter shall be Pepco Quadra or Rainbird XERI-Bird-8 or approved equal as called on drawings, with four ports. Drip tubing for emitter outlets shall be Rainbird (RBT-l60V), Salco, or approved equal. Drip tubing stakes shall be Rainbird No. RS-13, Salco, or approved equal. Bug cap for drip tubing shall be manufactured by Rainbird, Pepco, or approved equal. The drip pressure regulator shall be Rainbird, Netafim PVR, or approved equal. Drip emitter filter shall be Amiad, Rainbird, or approved equal. Drip emitter access boxes shall be Rainbird No. SEB-6X, Salco Subterranean Emitter Box, or approved equal. Check valves shall be of heavy-duty virgin PVC construction with FIP thread inlet and outlet. Internal parts shall be stainless steel and neoprene. Antidrain valves shall be field adjustable against drain out from 1.5 m to 12 m (5' to 40') of head. All sprinkler heads that are without valves in the heads are to have an antidrain valve feature and shall have an excess flow feature, which will automatically stop the flow of water when it exceeds the GPM preset by the manufacturer. Check valves shall be King Bros., Rainbird, or approved equal. 212-2.3 Backflow Preventer Assembly. Add the following: Backflow preventers shall be one of the approved reduced pressure principle devices listed by the California Department of Health Services, Division of Drinking Water and Environmental Management, 601 North 7th Street, Mailing Station (MS) 92, P.O. Box 942732, Sacramento, CA 94234-7320. Backflow preventers shall be factory assembled and shall include 2 check valves, one pressure differential relief valve, 2 shut-off valves and 4 test cocks. Backflow preventer and valves shall be the same size as the pipeline in which they are installed, unless otherwise shown on the plans. - - QRevised: 07/29/02 Contract NO. 38871 -A Page 135 of 152 Pages Backflow preventer shut-off valves shall be manufactured from iron or bronze and shall be either resilient wedged gate valves, resilient seated and fully ported ball valves, or resilient seated butterfly valves. Threaded type shut-off valves shall be provided with a union on one side of each valve. Unions shall be brass or malleable iron. Hose Size-Nominal (Millimeters) (Inches) "8 14 3 15 20 25 1 I Add the following section: 21 2-2.4.1 Additional Equipment. Contractor shall provide the following items to the Engineer: 1. Two control valve keys. 2. Two wrenches for removing each different type of sprinkler head. 3. Two quick coupler keys. The keys and hose ells shall be of the same manufacturer as 4. the coupling valve. 5. Five keys for opening and locking each automatic controller and enclosure. Minimum Wall Thickness* Range (Millimeters) (Inches) (Percent) 3.73 0.1 47 12 3.91 0.1 54 12 4.55 0.1 79 12 Add the following section: 212-2.5 Flexible Hose.- Flexible hose shall be nonrigid polyvinyl chloride (nonrigid PVC) hose conforming to the specifications of ASTM Designation: D 2287, Cell-type 6464500. Wall thicknesses of nonrigid PVC hose shall conform to Table 212-2.5(A) when determined in accordance with ASTM Designation: D 21 22. - Application of Geotextile Type Designation Separation of Soil and Street Structural Section 9ows Separation of Soil and Subsurface Aggregate Drain 180N Reinforcement of Street Structural Section 200w s 270WS Remediation and Separation of Soil Reinforcement of Soil 270WS Drainage at the Interface of Soil Structures NIA *as measured at any point on the cross section. The hose shall provide leak-free, non-separating connections suitable for the purpose intended when connected to the fittings specified herein. Fittings for flexible hose shall be injection molded PVC, Schedule 40, conforming to the specifications of ASTM Designation: D 2466. Fittings shall be solvent cemented type. Solvent cement for flexible hose and fittings shall be of commercial quality specifically manufactured for use with nonrigid PVC hose. Primer for flexible hose fittings shall be the same as specified for plastic pipe supply line fittings. SECTION 213 - ENGINEERING FABRICS 213-2 GEOTEXTILES. 213-2.1 General. Add the following: Geotextile types shall be used for the applications listed in Table 213-2.1 (A) Table 21 3-2.1 (A) 4m \#Revised: 07/29/02 Contract No. 38871 -A Page 136 of 152 Pages Application of Geotextile Drainage at the Interface of Soil and Structures Rock Slope Protection Fabric for Rock Sizes Below 225 kg (% Ton) Rock Slope Protection Fabric for Rock Sizes Including and Above 225 Type Designation N/A 180N 250N and 3 m (IO) Post Spacing I Erosion Control Fence with 1.8 m (6') Post Spacing and No Wire I 200ws kg (% Ton) Plant Protection Covering Erosion Control Fence with 14 AWG - 150 mm x 150 mm (6x6) Wire Add the following section: 213-3 EROSION CONTROL SPECIALTIES. Add the following section: 213-3 Gravel bags. Gravel bags for the use of temporary erosion control shall be burlap type, filled with no less than 23kg (50 Ibs) of 19 mm (?4") crushed rock and securely tied closed. Plastic bags are not acceptable. SECTION 214 PAVEMENT MARKERS 214-5 REFLECTIVE PAVEMENT MARKERS Add the following section: 214-5.1 Temporary Reflective Pavement Markers. Temporary pavement markers shown on the plans and required in the specifications shall be one of the types shown in Table 214-5.1 (A), or equal thereto. - TABLE 214-5.1IA\ 90N 9ows . . .- __ _ . . -. . TEMPORARY REFLECTIVE PAGEMENT MARKERS Type Manufacturer of Distributor I Stimsonite Chip SeaVTemporary Overlay Marker (Models 300 and 301) TFPM John C. Henberger Co., Traffic Safety and Control, San Diego, California, Telephone (619) 292-5772 DAPCO Davidson Plastics Company, 18726 East Valley Highway, Kent, Washington 98032, Telephone (206) 251 -81 40. QRevised: 07/29/02 Contract No. 38871-A Page 137 of 152 Pages _- Type Safe-Hit SH236MA Carsonite "Super Duck" SDF-436 Repo "The Replaceable Post" Manufacturer of Distributor Saf e-H it Corporation 1930 West Winton Avenue, Building #11 Hayward, CA 94545 Telephone (41 5) 783-6550 Carsonite International Corporation 2900LockheedWay Carson City, NV 89701 Telephone (702) 883-51 04 Western Highway Products P.O. Box 7 Stanton, CA 90680 Telephone (800) 422-4420 The Contractor shall provide the Engineer with a Certificate of Compliance in accordance with the provisions of Section 2-5.3.3 "Submittals". Said certificate shall certify that the permanent reflective channelizers comply with the plans and specifications and conform to the prequalified design and material requirements approved by the engineer and were manufactured in accordance with the approved quality control program. _- .I @Revised: 07/29/02 Contract No. 38871 -A Page 138 of 152 Pages SUPPLEMENTAL PROVISIONS TO STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION PART 3, CONSTRUCTION METHODS SECTION 300 - EARTHWORK 300-1 CLEARING AND GRUBBING. 300-1.1 General. add the following to the third paragraph: During surface clearing operations, the Contractor shall not cover or bury any plant growth or other objectionable materials. If the Contractor cannot successfully separate the plant growth from the surface soil and advertently or inadvertently mixes organic or other objectionable materials with the soil, the soil so contaminated shall be removed from the site by the Contractor. All costs, if any, associated with removing the soil mixed with organic or other objectionable materials and importing soil to replace said contaminated soil shall be borne by the Contractor and no additional payment therefor shall be made to the Contractor. 300-1.4 modify as follows: No separate payment shall be made for clearing and grubbing. Clearing and grubbing shall be considered incidental to the work. Payment. 300-2 UNCLASSIFIED EXCAVATION. 300-2.9 Payment. substitute the following: Payment for all unclassified excavation shall be paid for as incidental to the various items of work and no additional payment will be made therefore. 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 Delete the first paragraph and substitute the following: The Contractor shall compact the upper 300 mm (12) of subgrade beneath areas to be paved, have base or subbase material placed on them, or curb, gutter, curb and gutter, alley pavement, driveway or sidewalk constructed over them to no less than 95 percent maximum dry density as determined by ASTM test D-1557-91. 301-1.7 Payment. Modify the first paragraph as follows: Payment for subgrade preparation shall be included in the contract bid price for which the subgrade is prepared and shall include all labor, materials; including water, operations and equipment to scarify, adjust moisture, compact or recompact the subgrade, both in cut areas and in fill areas, and no further compensation will be allowed. Relative Compaction. @Revised: 07/29/02 Contract No. 38871-A Page 139 of 152 Pages 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. 302-5.2.3 Removal and Disposal of Material. During the milling operation, the contractor shall sweep the street with mechanical equipment and remove all loosened material from the Project site until the completion of the removal work. The removal crew shall follow within 50 feet of the milling machine unless otherwise directed by the Engineer. The Contractor shall take all necessary measures to avoid dispersion of dust. All material removed shall be considered the property of the Contractor and shall be disposed of by the Contractor at its expense. 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 approved by the Engineer. 302-5.4 Tack Coat. successive interfaces of existing pavement and new pavement. add the following: The Contractor shall place a tack coat between the -- 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. 302-5.6.1 General. modify as follows: Second paragraph, Part (2), add: Pinched joint rolling procedures shall be required, and vibratory rollers shall be limited to breakdown, unless otherwise directed by the Engineer. modify as follows: After last paragraph, add: Unless directed otherwise by the Engineer, the initial breakdown rolling shall be followed by a pneumatic-tired roller as described in this section. 302-5.8 Manholes (and other structures). delete the first paragraph and replace with the following: When placing the ARHM overlay the Contractor shall pave over appurtenances in the roadway which includes sanitary and storm access covers, water valve boxes, air vents, sewer dead end boxes and survey monument boxes. Each appurtenance shall be treated or covered to prevent adhesion of the overlay. Each appurtenance shall be located immediately after the overlay is placed and shall be thoroughly cleaned of any and all construction debris which may have entered due to the Contractor's operation. The contractor shall adjust all CMWD water valve boxes per CMWD Standard Drawing No. 811 or CMWD Standard Drawing No. W13. All City of Carlsbad sanitary sewer access covers shall be adjusted per CMWD Drawing No. S1. All storm sewer access covers shall be adjusted per SDRSD D-1 0. Riser rings or extensions shall not be used for the adjustment of these appurtenances. - Raising and adjusting to grade all appurtenances in the roadway shall be paid for at the contract unit price per each as shown in the Bid. Such price shall constitute full compensation for all labor, materials, and equipment necessary for completing the work as described in these specifications and plans. GRevised: 07/29/02 Contract No. 38871 -A Page 140 of 152 Pages 302-5.9 Measurement and Payment. add the following: Payment for asphalt concrete shall be at the unit price bid per ton. No additional payment shall be made for any tack coat. Add the following section: 302-11 ASPHALT PAVEMENT REPAIRS AND REMEDIATION Add the following section: 302-11.1 General. Asphalt pavement Repairs and Remediation shall consist of the repair and restoration of existing asphalt pavement. Repair of asphalt pavement shall consist of the saw cutting, removal and disposal of existing asphalt pavement in conformance with section 300-1.3, compaction of existing subgrade in conformance with section 301 -1, grading and compaction of base material in conformance with section 301-2, application of grade SS-I h emulsified asphalt and the placement of asphalt concrete base and wearing courses as specified herein. Add the following section. 302-11.2 Full Depth Asphalt Concrete Patch. Full depth asphalt concrete patch shall consist of removing asphalt concrete and/or aggregate basekubgrade to 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 basekubgrade shall be straight and vertical. The Contractor shall compact the upper 300mm (1') of subgrade to 95% relative compaction. A tack coat of SS-lh emulsified asphalt shall be applied uniformly to all asphalt to asphalt contact surfaces at a rate of 0.25 Urn2 to 0.45 UrnZ (0.05 to 0.10 gallons per square yard) in accordance with subsection 302-5.4, SSWPC. The Contractor shall fill and compact areas designated to be removed with 300 mm (1 .U) 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. 302-11.3 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% (475°F). Application of the hot-melt sealant shall be made with a pressure feed applicator or pour pot. Sealant shall be applied when the pavement surface temperature is greater than 4°C (40°F). Containers of hot-melt sealant shall be delivered to the job-site in unopened containers that are clearly marked with data showing the manufacturer's name, the product designation and the manufacturer's batch number and lot numbers. The level of the sealant shall be flush with the surface of the existing pavement. All excess sealant shall be removed from the crack with a minimum overlap onto adjacent pavement. Add the following section. 302-1 1.4. Measurement and Payment. Quantities of full depth asphalt concrete patch and crack sealing set forth in the bid item are for estimating purposes only, final quantity will be as designated and measured in the field. The Engineer will designate and mark the limits of the full depth asphalt concrete patch and crack sealant application areas. Payment for emulsion-aggregate slurry treatments shall include post emergent herbicide treatment of the areas to receive for emulsion- aggregate slurry treatment. Full compensation for conforming to the requirements of constructing full GRevised: 07/29/02 Contract No. 38871-A Page 141 of 152 Pages depth asphalt concrete patch shall include, but not be limited to, furnishing all labor, tools, equipment, and materials necessary for doing the work including, but not be limited to, saw cutting and removing 300 mm (1’) thick section of existing asphalt concrete, aggregate basehubbase and basement soil as designated by the engineer, placement of asphalt concrete, compaction of subbase and asphalt concrete, placement of SS-1 h asphalt emulsion and all other work incidental to full-depth asphalt concrete patch shall be considered as included in the contract unit price bid for full-depth asphalt concrete patch and no additional compensation will be allowed therefore. Full compensation for conforming to the requirements of crack sealing shall include, but not be limited to, furnishing all labor, materials, tools, equipment, and incidentals necessary to do the work. Crack cleaning, roadway cleanup, application of sealant, removal of excess sealant and all other work incidental to crack sealing shall be considered as included in the contract unit price bid an no additional compensation will be allowed therefore. Sewer Service Lateral Irrigation Water Lateral or Sleeve Street Light or Traffic Signal Pull Box SECTION 303 CONCRETE AND MASONRY CONSTRUCTION. S RW 303-1 CONCRETE STRUCTURES 303-1.6.2 Falsework Design. add the following: The Contractor shall provide all temporary bracing necessary to withstand all imposed loads during erection, construction, and removal of any falsework. The Contractor shall provide falsework drawings and calculations prepared by a registered professional engineer, civil or structural, that show provisions for resolution of all loads that may be imposed upon the falsework. Such plans and calculations shall include: 1. Resolution of all live, dead, wind, construction and impact loads that may be imposed on the 2. Temporary bracing or methods to be used during each phase of erection and removal of the 3. Concrete placement sequence. 4. Erection and removal sequence. 5. Deflection values for the falsework that include recommended methods to compensate for falsework. falsework. _- falsework deflections, vertical alignment, and anticipated falsework deflection. 303-5 CONCRETE CURBS, WALKS, GUTTERS, CROSS GUTTERS, ALLEY INTERSECTIONS, ACCESS RAMPS, AND DRIVEWAYS. 303-5.5.2 Curb. add the following: The Contractor shall stamp the curb face with 75 mm (3”) high block letters directly above the point that it is crossed by underground facilities with the marking specified in Table 303-5.5.2(A) TABLE 303-5.5.2(A) Curb Face Markings Type of underground facilities Marking Water Service Lateral W 303-5.9 Measurement and Payment. Delete 303-5.9 and add the following: Curb and gutter, and curb, shall be considered as continuing across driveways and access ramps when constructed adjacent thereto. Neither curb and gutter nor curb will be paid for across the length of local depressions, except that which occurs in gutter transitions at each side of an inlet. Payment for concrete curbs, walls, gutters, cross gutters, alley intersections, access ramps, and driveways will be considered as incidental to the work and no additional compensation will be made thereof. - GRevised: 07/29/02 Contract No. 38871 -A Page 142 of 152 Pages Add the following: 303-6 STAMPED CONCRETE (MEDIAN CONCRETE PAVING). 303-6.6 Random Stone Texture with Heavy Sandblast Finish to Expose Aggregate. Concrete shall be 560-C-3250. Use color application method "B" (integral color). Color shall be per Section 201 -1.2.4(a). The pattern shall be Bomacron "Random Slate" pattern or approved equal. The pattern shall be defined by clearly demarcated joints and detailed surface texture to simulate random stone paving. Concrete shall have a heavy sandblast finish to expose the aggregate within the concrete. Stamp pattern shall match the existing concrete paving along Alga Road. Prepare a 4x4 foot sample panel of pattern, color and finish including heavy sandblast finish for the approval of the Project Resident Engineer. Allow the sample to cure a minimum of 14 days prior to color review. An acceptable sample shall be approved prior to construction of the finished work. Add the following: 303-6.7 Measurement and Payment. Payment for colored, stamped concrete paving with random stone pattern and heavy sandblast finish to expose aggregate shall be will be considered as incidental to the work and no additional compensation will be made thereof. Said payment shall include compensation for all excavation, grading, backfill, permeable material, forming, reinforcing steel, concrete, integral color, texture sealers, and other material necessary to construct the specific paving. SECTION 306 - UNDERGROUND CONDUIT CONSTRUCTION 306-1 OPEN TRENCH OPERATIONS Add the following section: 306-1.1.7 Steel Plate Bridging -With a Non-Skid Surface. This section covers the use of steel plate bridging. The Contractor shall not employ the use or use steel plate bridging or trench plate that does not meet the requirements of this section both in application and circumstance of use. Add the following section: 306-1.1.7.1 Requirements for Use. Alternate construction methods that avoid the use of steel plate bridging shall be used by the Contractor unless otherwise approved by the Engineer. It is recognized that to accommodate excavation work, steel plate bridging may be necessary. All conditions for use of steel plate bridging set forth in the following requirements must be fulfilled as conditions of approval of the use of steel plate bridging. Consideration of steel plate bridging in the review process will take into account the following factors: I. Traffic volume and composition. 2. Duration of use of the steel plate bridging. 3. size of the proposed excavation. 3. Weather conditions. The following formula shall be used to score the permitted use of steel plate bridging: PS = [ + DAYS + 10 X WEEKEND + 5 X NIGHTS + 20 X WEATHER + SPEED (kmh) + SLOPE X 1001 X LANES 1 ow a PS = [ + DAYS + 10 X WEEKEND + 5 X NIGHTS + 20 X WEATHER + SPEED (mDh)+ SLOPE X 100) X LANES 1000 5 I where: PS = plate score. ADT = average daily traffic as defined in the CALTRANS Traffic Manual. QRevised: 07/29/02 Contract No. 38871-A Page 143 of 152 Pages - EWL - DAYS - WEEKEND = NIGHTS = WEATHER = SPEED = - - SLOPE - - LANES - equivalent wheel loads as defined in the CALTRANS Traffic Manual. total number of 24 hour periods during which the plates will be utilized at the site being considered. total number of Saturdays, Sundays and holidays that the plates will be utilized at the site being considered. total number of overnight periods that the plates will be in place, exclusive of Saturday, Sunday and holiday nights. total number of 24-hour periods that the plates will be utilized at the site being considered when the possibility of rain exceeds 40 percent. the design speed in kilometers per hour or miles per hour, as applicable in the formulae above, of the street where the plates are to be installed. This number shall not be reduced for construction zone speed reductions. the quotient of the vertical differential divided by the horizontal distance. The vertical and horizontal dimensions shall be measured at the locations spanning a distance of 15 m (50’) up and downstream of the position of the proposed steel plate bridging. the number of lanes where plates will be used. When the computed value of the plate score exceeds 50, steel plate bridging shall not be used unless, and at the sole discretion of the Engineer, the Engineer determines that no alternative method of construction is possible in lieu of using steel plate bridging or that other overriding considerations make the use of steel plate bridging acceptable. Alternatives considered to bridging shall include, but not be limited to, detouring traffic, construction detour routes, tunneling, boring and other methods of trenchless construction. Unless specifically noted in the provisions of the Engineer’s approval, the use of steel plate bridging at each location so approved shall not exceed four (4) consecutive working days in any given week. Add the following section: 306-1.1.7.2 Additional Requirements. In all cases when the depth of the trench exceeds the width of the steel plate bridging resting on each side of the pavement adjacent to the trench, safety regulations require or the Engineer determines that shoring is necessary to protect the health or safety of workers or the public the Contractor shall install shoring conforming to Section 7-10.4.1 of the Standard Specifications. The trench shoring shall be designed and installed to support the steel plate bridging and traffic loads. All approvals for design, substitution of materials or methods shall be submitted by the Contractor in accordance with all provisions of section 2-5.3 Shop Drawings and Submittals. The Contractor shall backfill and resurface excavations in accordance with section 306-1.5. Add the following section: 306-1.1.7.3 Installation. When backfilling operations of an excavation in the traveled way, whether transverse or longitudinal cannot be properly completed within a work day, steel plate bridging with a non-skid surface and shoring may be required to preserve unobstructed traffic flow. In such cases, the following conditions shall apply: a) Steel plate bridging when the plate score exceeds 50 is not allowed except when, at the b) Steel plates used for bridging must extend a minimum of 61 0 mm (2’) beyond the edges of c) Steel plate bridging shall be installed to operate with minimum noise. sole discretion of the Engineer, it is approved as specified hereinbefore. the trench. When the use of steel plate bridging and shoring is approved by the Engineer, the Contractor shall install using either Method (1) or (2) depending on the design speed of the portion of street where the steel plate bridging is proposed for use. @Revised: 07/29/02 Contract No. 38871 -A Page 144 of 152 Pages Maximum Trench Width ‘’I _. 0.3 m (IO) 0.6 m (23) __ 0.8 m (31”) 1 .O rn (41”) - -_ Minimum Plate Thickness 13 mm (’/;) 19 mm (V;) 22mm (’/;) 25 mm (1”) the Engineer for review and approval in accordance with section 2-5.3. Steel plate bridging shall be steel plate designed to support the HS20-44 truck loading per CALTRANS Bridge Design Specifications Manual. The Contractor shall maintain a nonskid surface on the steel plate with no less than a coefficient of friction of 0.35 as determined by California Test Method 342. If a different test method is used, the Contractor may utilize standard test plates with known coefficients of friction available from the CALTRANS District 11 Materials Engineer to correlate skid resistance results to California Test Method 342. In addition to all other required construction signing, the Contractor shall install Rough Road (W33) sign with black lettering on an orange background in advance of steel plate bridging. 1.6 m (63) GRevised: 07/29/02 32mm (1 W) Contract No. 38871-A Page 145 of 152 Pages Add the following section: 306-1.1.7.5 Measurement and Payment. Steel plate bridge materials including, but not limited to: steel plates, anchoring devices, cold milling, elastomeric sealant material, asphalt ramping and padding, signage, placing, installation, removal, relocation, preparation and processing of shop drawings and submittals to support the use of steel plate bridging and all other materials, labor, supervision, overhead of any type or description will be paid for as an incidental to the work that the bridging is installed to facilitate. No separate payment for steel plate bridging will be made. No extension to contract time will be allowed for, or because of, the use of steel plate bridging. 306-1.5 Trench Resurfacing. 306-1.5.1 Temporary Resurfacing. Delete the fourth and fifth paragraphs and substitute the following: Temporary bituminous resurfacing materials which are placed by the Contractor are for its convenience and shall be at no cost to the Agency. Temporary bituminous resurfacing materials shall be used in lieu of permanent resurfacing only when approved by the Engineer. When temporary bituminous resurfacing materials are used in lieu of permanent resurfacing it shall be removed and replaced with permanent resurfacing within 7 days of placement.’ No additional payment will be made for temporary bituminous resurfacing materials. The price bid for the associated conduit or structure shall include full compensation for furnishing, placing, maintaining, removing, and disposing of such temporary resurfacing materials. 306-1.5.2 Permanent Resurfacing. Add the following: Except as provided in section 306-1 5.1, “Temporary Resurfacing,” the Contractor shall perform permanent trench resurfacing within 24 hours after the completion of backfill and densification of backfill and aggregate base materials. - 306-5 ABANDONMENT OF CONDUITS AND STRUCTURES. Add the following: Unless otherwise noted on plans, the Contractor shall remove all existing abandoned pipelines and conduits of any type, or use, and pipelines and conduits of any type, or use, that are abandoned during the course of the work and shall replace said pipelines and conduits with properly compacted soils. Payment for removal and disposal of abandoned utilities shall be included in the lump-sum bid for Clearing and Grubbing, and no additional payment will be made. Add the following Section: SECTION 308 - LANDSCAPE AND IRRIGATION INSTALLATION 308-1 GENERAL During installation, Contractor shall observe safe practices in accordance with the City of San Diego Standard Specifications, and all appropriate federal, state, and local laws concerning safe job practices. 308-4.2 Protection and Storage. Add the following: 308-4.2.1 Existing Tree, Shrub, and Ground Cover Protection. The work is to be performed in areas of existing planting and irrigation. The Contractor shall take precautions to minimize the disturbance to adjacent planted areas and is required to replace in kind any irrigation or planting disturbed by the work. ”- Identify and protect from damage all individual plant and areas of planting to remain by appropriate means. The Contractor shall provide equivalent size replacement plants in the event that the death or decline of existing plants to remain is attributable to the Contractor’s negligence or lack of protection as determined by the Resident Engineer. aRevised: 07/29/02 Contract No. 38871 -A Page 146 of 152 Pages All plants to remain on-site shall be watered and irrigated as necessary during the entire construction contract to provide for the health of the plant. Any plants required to be removed, boxed and set aside for future installation shall be watered, and maintained by the Contractor in a healthy condition until replanted or until the end of the maintenance period. The pruning and trimming of the limbs and roots of plant materials to remain within the project scope shall be done by tradesmen experienced in this type of work. The removal of any limbs, branches, and roots shall be done only after conferring with the Resident Engineer and Landscape Advisor. 308-4.2.2 Excavation Adjacent to Existing Tree, Shrub and Groundcover to Remain. Trenching within the drip line of trees and shrubs shall be avoided. It is the intent of the plans that the Contractor provide an alternate routing of trenching to avoid cutting through roots of existing trees. Where it is necessary to excavate in close proximity to existing trees and shrubs, all possible caution shall be exercised to avoid injury to roots and trunks. In the event it is necessary to cut the roots of an existing tree, the tree shall be pruned prior to excavation to reduce the foliage volume by the same percentage as the approximate percentage of roots removed. Pruning of trees on private property shall not be done without written permission of the property owner. Excavation within the drip line of the tree shall be done by hand, tunneling under roots 1" in diameter and larger, and shall be done only on the approval of the Resident Engineer and Landscape Advisor. The exposed roots of trees shall be covered and shaded by moist burlap or canvas until the trench is backfilled. Within 24 hours of the cut, the Contractor shall paint the exposed end of the cut roots with an appropriate root pruning sealant. 308-4.5 Tree and Shrub Planting. Add the following: 308-4.5.1 General. Fertilizer planting tables [twenty-one (21) gram size], shall be placed with each plant at the following rates: One (1) tablet per one (1) gallon container; Two (2) tablets per five (5) gallon container: Four (4) tablets per fifteen (15) gallon container; One (1) tablet per each two inches (2") of box size container. All plants which settle deeper than specified shall be raised to correct level or replaced as directed by the Resident Engineer. Pruning shall be limited to the minimum necessary to remove injured twigs and branches, and to compensate for loss of roots during transplanting, but never to exceed one-tenth (1110) of the branching structure. Pruning may be done only with the approval of, and in the presence of, the Resident Engineer. GRevised: 07/29/02 Contract No. 38871 -A Page 147 of 152 Pages SECTION 310 - PAINTING 310-5 PAINTING VARIOUS SURFACES. 31 0-5.6 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 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 (’/<) in 3 m (10’) when measured parallel to the centerline of the street or more than 6 mm (l/4))) in 3 m (10’) when measured perpendicular to the centerline of the street. The use of any equipment that leaves ridges, indentations or other objectionable marks in the pavement shall be discontinued, and equipment capable of providing acceptable surface shall be furnished by the Contractor. This equipment shall meet all requirements of the air pollution control district having jurisdiction. 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 is not permitted. - The Contractor shall remove existing thermoplastic markings, legends and lines which are within the area to be resurfaced by wet grinding methods. Removal of such 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. GRevised: 07/29/02 Contract No. 38871 -A Page 148 of 152 Pages 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 IOOm (1/2 inch in 50 feet) from the specified alignment. The Contractor shall obliterate, straight stripes deviating more than 80mm per 1OOmm (I/ 2 inch in 50 feet) by wet grinding, and then correcting the markings. The Contractor shall lay out (cat track) immediately behind installation of surface course asphalt and as the work progresses. 310-5.6.8 Application of Paint. Modify the second paragraph as follows: The Contractor shall apply the first coat of paint immediately upon approval of striping layout by the Engineer. The Contractor shall paint the ends of each median nose yellow. Add the following to the eighth paragraph: The Contractor shall apply temporary traffic stripes in one coat. Temporary traffic stripes shall be maintained by the Contractor so that the stripes are clearly visible both day and night. 310-5.6.10 Measurement and Payment. Modify the first paragraph as follows: Final and temporary traffic striping, curb markings and pavement markings as shown on the plans and required by the specifications shall be included in the lump-sum price bid for 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 and shall include all labor, tools, equipment, materials, and incidentals for doing all work in installing the final and temporary traffic striping. SECTION 312 - PAVEMENT MARKER PLACEMENT AND REMOVAL 312-1 PLACEMENT. Add the following to the third paragraph: 4) When being installed on asphalt concrete pavement sooner than 14 days after placement of the asphalt concrete pavement course on which the pavement markers are to be placed. Add the following section: 312-1.1 Reflective Channelizer Placement and Removal. The Contractor shall place and remove reflective channelizers the same as for pavement marker placement and removal. The Contractor shall place the channelizers uniformly, straight on tangent alignment and on a true arc on curved alignment to the same tolerances of position as for application of paint in section 310-5.6.8. TheContractor shall perform all layout work necessary to place the channelizers to the proper alignment. If the channelizers are displaced or fail to remain in an upright position, from any cause, the channelizers shall immediately be replaced or restored to their original location, by the Contractor. When reflective channelizers are removed the pavement surface shall be restored to the same color and surface finish as the adjacent pavement. SECTION 31 3 - TEMPORARY TRAFFIC CONTROL DEVICES Add the following section: 313-1 TEMPORARY TRAFFIC PAVEMENT MARKERS. Add the following section: 313-1.1 General. The Contractor shall supply and install temporary traffic pavement markers, channelizers, 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. GRevised: 07/29/02 Contract No. 38871-A Page 149 of 152 Pages 31 3-1.2 Temporary Pavement Markers. Temporary reflective raised pavement markers shall be placed in accordance with the manufacturer’s instructions. Temporary reflective raised pavement markers shall be cemented to the surfacing with the adhesive recommended by the manufacturer, except epoxy adhesive shall not be used to place temporary reflective raised pavement markers in areas where removal of the markers will be required. Pavement striping, legends and markers which conflict with any traffic pattern shall be removed by grinding as determined by the Engineer. The Contractor shall use temporary reflective raised pavement markers for temporary pavement marking, except when the temporary pavement markers are used to replace patterns of temporary traffic stripe that will be in place for less than 30 days. Reflective pavement markers used in place of the removable-type pavement markers shall conform to the section 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 20/20. The channelizer bases shall be cemented to the pavement in the same manner as provided for cementing pavement markers to pavement in section 312-1, “Placement.” Channelizers shall be applied only on a clean, dry surface. Channelizers shall be placed on the alignment and location shown on the plans and as directed by the Engineer. The channelizers shall be placed uniformly, straight on tangent alignment and on a true arc on curved alignment. All layout work necessary to place the channelizers to the proper alignment shall be performed by the Contractor. If the channelizers are displaced or fail to remain in an upright position, from any cause, the channelizers shall immediately be replaced or restored to their original location, by the Contractor. The Contractor shall provide the Engineer with a Certificate of Compliance in accordance with the provisions of section 4-1 5, “Certification”. Said certificate shall certify that the channelizers comply with the plans and specifications and conform to the prequalified design and material requirements approved by the Engineer and were manufactured in accordance with a quality control program approved by the Engineer. Add the following section: 313-2 TEMPORARY TRAFFIC SIGNING. Add the following section: 31 3-2.1 General. The Contractor shall provide and install all temporary traffic control signs, markers, markings, and delineators at locations shown on plans and specified herein. Add the following section: 313-2.2 Maintenance of Temporary Traffic Signs. If temporary traffic signs are displaced or overturned, from any cause, during the progress of the work, the Contractor shall immediately replace the signs in their original approved locations. The Contractor shall maintain all temporary traffic signs used in the Work in a clean, reflective and readable condition. The Contractor shall replace or restore graffiti marked temporary traffic signs and posts used in the Work within 18 hours of such marking being discovered during non-working hours or, when the marking is discovered during working hours, within 2 hours of such discovery of marking. @Revised: 07/29/02 Contract No. 38871-A Page 150 of 152 Pages Add the following section: 313-3 TEMPORARY RAILING (TYPE K) AND CRASH CUSHIONS. Add the following section: 313-3.1 Temporary Railing and Crash Cushions. Temporary railing (Type K) shall consist 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 21 0-1.5 “Paint Systems” and 31 0 “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 (’//8”) thick plate welded on the upper end with a 5-mm (3/1:) fillet weld. The final surface finish of temporary railings (Type K) shall conform to the provisions in section 303-1.9.2 “Ordinary Surface Finish.” Exposed surfaces of concrete elements shall be cured by the water method, the forms-in-place method, or the pigmented curing compound method. The pigmented curing compound shall be type 2 curing compound. Temporary railing (Type K) may have the Contractor’s name or logo on each panel. The name or logo shall not be more than 100 mm in height and shall be located not more than 300 mm above the bottom of the rail panel. Add the following section. 313-3.1.3 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 (10) of a traffic lane shall have a reflector installed on top of the rail as directed by the Engineer. Reflectors and adhesive will be furnished by the Contractor. A Type P marker panel conforming to the requirements of the 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 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. QRevised: 07/29/02 Contract No. 38871-A Page 151 of 152 Pages - Add the following section: 31 3-3.2 Temporary Sand-Filled Crash Cushions. Temporary sand-filled crash cushion units shall be “Energite II I” 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: 31 3-4 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 crashcushions when not shown on the plans and requested by the Engineer shall be made per section 3-3, Extra Work, SSPWC. - em PISRevised: 07/29/02 Contract No. 38871 -A Page 152 of 152 Pages APPENDIX “A” RES1 DENT NOTIFICATION EXAMPLE I CITY OF CARLSBAD CONSTRUCTION WORK ABC CONTRACTORS OFFICE # (76O)XXX-XXXX FIELD # (76O)XXX-XXXX Dear resident: As a part of the City of Carisbad’s and Carlsbad Municipal Water District’s ongoing program to maintain its water and sewer facilities, your street will be closed to allow for pipeline construction. This construction will require the closing of your street to through traffic for X days. Your street, from XYZ St. to XYZAve. will be closed to through traffic on: from 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 your neighborhood that will not be impacted. ABC is the Contractor that will be performing the construction work for the city and you may call them at (76O)XXX-XXXX if you have any questions regarding the project. Mail delivery may be delayed if the postman cannot reach the mailbox that day. If you have a moving company scheduled for that day please call and inform the Contractor of the date. If you have any concerns which cannot be addressed by the Contractor, you may call the City’s Engineering Inspection Department at 438-1 161x4323. MON. TUE. WED. THU. FRI. DATE: Thank you for your cooperation as we work to make a better City of Carlsbad. APPENDIX B Geotechnical Investigation otechnical and Env GEOTECHNICAL EVALUATION REPORT RECYCLED WATER DISTRIBUTION PIPELINES ENCINA BASIN WATER RECLAMATION PROGRAM CARLSBAD, CALIFORNIA PREPARED FOR Mr. Robert Avera PBS&J 175 Calle Magdalena, Suite 10 1 Encinitas, California 92024 PREPARED BY: Ninyo & Moore Geotechnical and Environmental Sciences Consultants 5710 Ruffin Road San Diego, California 92 123 July 3 1,2002 (RevA;ec June 2,2003) Project No. 104693001 57 IO Ruffin Road = San Diego, California 92 123 9 Phone (858J 576-1 000 = Fax [858) 576-9600 Las Vegas = Salt Lake City . Phoenix San Diego = lrvine Ontario = Los Angeles Oakland The full report is available for purchase or review at the following location: CITY OF CARLSBAD PURCHASING DEPARTMENT 1635 FARADAY AVENUE CARLSBAD, CA 92008 Phone (760) 602-2460 _- APPENDIX C CALTRANS Permit TR-0120 (REV. 7/98) - compliance with (Check one): Permit No. 11 -02-NUX0701 DisUWRtePM 11 SD-5/R45.6 Date Your application of OCTOBER 7,2002 Utility Notice No. of Agreement No, of w 0 0 TO: APRIL 30,2003 Fee Paid Deposit $ NA $ NA $NA $NA Performance Bond Amount (1) Payment Bond Amount (2) Bond Company Bond Number (1) Bond Number (2) CITY OF CARLSBAD C/O PBS&J 175 CALLE MAGDALENA ENCINITAS, CA 92024 ATTN: ROBERT AVERA PHONE: (760) 753-1 120 X- 310 I The following attachments are also included as part of this permit (Check applicable): [z1 Yes No Utility Maintenance Provisions 0. Yes [x1 No Special Provisions . 0 Yes No A Cal-OSHA permit required prior to beginning Yes General Provisions work; 1 ,PERMITTEE In addition to fee, the permittee will be billed actual costs for: 0 Yes NO Review IXI Yes NO Inspection IXI Yes Field Work (If any Caltrans effort expended) and subject to the following, PERMISSION IS HEREBY GRANTED to: enter upon State Highway right of way in San Diego County, City of Carlsbad, on Route 5, post mile R45.6, to remove and install a water facility as shown on the attached plans, in accordance with the requirements and conditions contained herein and as furtha directed or approved by the State's Inspector, Mr. John Lyons, telephone number (619) 688-8644. The State's Inspector shall be notified seven working days prior to starting work. Working hours shall be 8:30 A. M. to 3:30 P. M., Monday through Friday, and as directed or approved by the State's Inspectors. No vehicles or equipment shall be parked within the highway right of way at any time, except for those vehicles or that equipment actually engaged in the work, during the working hours specified herein. (Continued) cc:Permits MNusz, Reg. Mgr. JLyons, Insp. Contractor Pewso-Delgado, Diqtrict Dhctor - Permittee - FM 91 1436 L . City of Carlsbad Page Two 11-02-NUX0701 Permittee's Contractor is responsible for actual cost of inspection, which may be more or less than the deposit. If required within this permit, Permittee's Contractor will also be responsible for the actual cost of mark-out by Caltrans personnel. A bill or refund shall be sent upon satisfactory completion of the work. Payment of any bill is a condition of the permit. The State of California, Department of Transportation makes no assurance or expressed warranty that the plans are complete or that the planned construction fits field conditions. Should additional work or modifications of the work be required in order to meet established Department Standards or in order to fit field conditions, the work shall be performed by Permittee as directed by the State's Inspector at no cost to the State. Notwithstanding General Provision No. 24, your contractor is required to apply for and obtain an encroachment permit prior to starting work. A permit inspection deposit fee of $480.00 will be required upon submittal of the application to perform the work. Also, your contractor must submit proof that they have obtained executed bonds in accordance with General Provision No. 24. - Traffic control when permitted or directed by the State's Inspector, shall consist of closing traffic lanes and ramps in accordance with the Department of Transportation publication entitled "Manual of Traffic Controls for Construction and Maintenance Work Zones", the provisions of Section 12, "Construction Area Traffic Control Devices," of the Standard Specifications, and these special provisions, including the attached TRAFFIC CONTROL SYSTEM, T-1 1. The Permittee shall retain a Civil Engineer, licensed to practice in California, who shall upon completion of the placement or regrading of materials requiring compaction, furnish to the State's Inspector, a report certifjmg that the compaction work has been accomplished in accordance with Caltrans Standard Specifications and Standard Plans. Compaction testing, in accordance with Caltrans testing procedures and policies, shall be performed by a certified testing laboratory. Copies of the test shall accompany the engineer's report. Permittee shall implement and maintain the attached WPCP, dated as approved November 7,2002, and as directed and approved by the State's Inspector. Pavement shall be sawcut a minimum of 60 mm (0.2 foot) deep prior to paving. All open trench within the improved area shall be backfilled, compacted and temporary repairs made to the surfacing before leaving the job site at the end of the working day. In lieu of temporary repairs, steel plate bridging may be allowed if approved by the State's Inspector prior to the start of work. Permanent paving shall be placed within five working days after completion of the above work. Permanent backfill and paving shall conform to the attached BACKFILL REQUIREMENTS. - City of Carlsbad Page Three 11-02-NUX0701 When steel plate bridging is used, the attached Steel Plate Bridging Special Provisions will apply in addition to the attached General Provisions. Upon completion of the work, the attached card shall be completed and returned. The following District Standard Special Provisions are generalizations of the Department Standard Specifications and are included only as a permittee convenience. Permittee's attention is directed to the current Department Standard Specifications for complete, unabridged, specification requirements. Once begun, that portion of the work within the State Highway right of way shall be prosecuted to completion as rapidly as possible. All personnel on foot within the State Highway right of way shall wear personal protective equipment, including orange vests or jackets, safety glasses, and hard hats. 1 The Permittee is responsible for locating and protecting all utilities both underground and aerial. Any costs incurred for locating and protecting andor relocating any utilities shall be borne by the Permittee. Five days prior to the start of work, trench excavation safety plans for any trench more than 1.5 m (5 feet) deep shall be submitted to the Permit Inspector for review by the District 11 Bridge Engineer. STATE OF CALJFORNLA, DFJ’ARTMENT OF TRANSPORTATION ENCROACHMENT PERMIT GENERAL PROMSIONS . I TR-0045 (REV. 6/2000) 1. . 2. 3. 4. 5. 6. - 7. 8. 9. . 10. 11. - AUTHORITY. The Department’s authority to issue encroachment permits is provided under, Div. 1, Chpt. 3, Art. 1, Sect. 660 to 734 of the Streets and Highways Code. REVOCATION: Encroachment permits are revocable on five days notice unless otherwise stated on the permit and except as provided by law for public corporations, franchise holders, and utilities. These General Provisions and the Encroachment Permit Utility Provisions are subject to modification or abrogation at any time. Permittees’ joint use agreements, franchise rights, reserved rights or any other agreements for operating purposes in State highway right of way are exceptions to this revocation. DENIAL FOR NONPAYMENT OF FEES: Failure to pay permit fees when due can result in rejection of future applications and denial of permits. ASSIGNDIENT: No party other than the permittee or permittee’s authorized agent is allowed to work under this permit. ACCEPTANCE OF PROYISIONS: Permittee understands and agrees to accept these General Provisions and all attachments to this permit, for any work to be performed under this permit. BEGINNING OF WORK: When traffic is not impacted (see Number 35), the pennittee shall notify the Department’s representative, two (2) days before the intent to start permitted work. Permittee shall notify the Department’s Representative if the work is to be interrupted for a period of five (5) days or more, unless otherwise agreed upon. All work shall be performed on weekdays during regular work hours, excluding holidays, unless otherwise specified in this permit. STANDARDS OF CONSTRUaION All work performed within highway right of way shall conform to recognized construction standards and current Department Standard Specifications, Department Standard Plans High and Low Risk Facility Specifications, and Utility Special Provisions. Where reference is ma& to “Contractor and Engineer,” these are amended to be read as “Permittee and Department representative.” PLAN CBANGES: Changes to plans, specifications, and permit provisions are not allowed without prior approval from the State representative. INSPECTION AND APPROVAL: All work is subject to monitoring and inspection. Upon completion of work, permittee shall request a final inspection for acceptance and approval by the Depaaent. The local agency permittee shall not give final construction approval to its contractor until final acceptance and approval by the Department is obtained. PERMIT AT WORKSITE: Permittee shall keep the permit package or a copy thereof, at the work site and show it upon request to any Department representative or law enforcement officer. If the permit package is not kept and made available at the work site, the work shall be suspended. CONFLICTING ENCROACHMENTS: Permittee shall yield start of work to ongoing, prior authorized, work adjacent to or within the limits of the project site. When existing encroachments conflict with new work, the permittee shall bear all cost for rearrangements, (e.g., relocation, alteration, removal, etc.). 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. PERMITS IFaROq OTHER AGENCIES: This permit is invalidated if the p&mittee has not obtained all permits necessary and required by law, from the Public Utilities Commission of the State of California (PUC), Califomia Occupational Safety and Health Administration (Cal-OW), or any other public agency having jurisdiction. PEDESTRIAN AND BICYCLIST SAFETY: A safe minimum passageway. of 4’ (1.21 meter) shall be maintained through the work area at existing pedestrian or bicycle facilities. At no time shall pedestrians be diverted onto a portion of the street used for vehicular traffic. At locations where safe alternate passageways cannot be provided, appropriate si,- and barricades shall be installed kt the limits of construction and in advance of the limits of construction at the nearest crosswalk or intersection to detour pedestrians to facilities across the street. PUBLIC TRAFFIC CONTROL: As required by law, the permittee shall provide traffic control protection warning signs, lights, safety devices, etc., and take all other measure necessary for traveling public’s safety. Day and night time lane closures shall comply with the Manuals of Traffic Controls, Standard Plans, and Standard Specifications for traffic control systems. These General Provisions are not intended to impose upon the permittee, by third parties, any duty or standard of care, greater than or different from, as required by law. MINIMUM INTERFERENCE WITH TRAFFIC: Permittee shall plan and conduct work so as to create the least possible inconvenience to the traveling public; traffic shall not be unreasonably delayed. On conventional highways, permittee shall place properly attired flagger(s) to stop or warn the traveling public in compliance with the Manual of Traffic Controls and Instructions to Raggers Pamphlet. STORAGE OF EQUIPMENT AND MATERIALS: Equipment and material storage in State right of way shall comply with Standard Specifications, Standard Plans, and Special Provisions. Whenever the permittee places an obstacle within 12’ (3.63 m) of the traveled way, the permittee shall place temporary railing (Type K). CARE OF DRAPNAGE:. Permittee ,shall provide alternate drainage for any work interfering with an existing drainage facility in compliance with the Standard Specifications, Standard Plans and/or as directed by the Department’s representative. RESTORATION AND REP- IN RIGHT OF WAY Permittee is responsible for restoration and repair of State highway right of way resulting from permitted work (State Streets and Highways Code, Sections 670 et. seq.). RIGHT OF WAY CLEAN W: Upon completion of work, permittee shall remove and dispose of all scraps, brush, timber, materials, etc. off the right of way. The aesthetics of the highway shall be as it was before work started. COST OF WOW Unless stated in the permit, or a separate written agreement, the permittee shall bear all costs incurred for work within the State right of way and waives all claims for ’ indemnification or contribution from the State. ACTUAL COST BILLING: When specified in the permit, the Department will bill the permittee actual costs at the currently set hourly rate for encroachment permits. K-26 , .* AS-BUILT PLANS: When required, permittee shall submit one (1) set of as-built plans within thirty (30) days after completion and approval of work in compliance with requirements listed as follows: 1. Upon completion of the work provided herein, the permittee shall send one vellum or paper set of As-Built plans, to the State representative. Mylar or paper sepia plans are not acceptable. 2. All changes in the work will be shown on the plans, as issued with the permit, including changes approved by Encroachment Permit Rider. 3. The plans are to be stamped or otherwise noted AS-BUILT by the permittee’s representative who was responsible for overseeing the work. Any origin;ll plan that was approved with a State stamp, or Caltrans representative signature, shall be used for producing the &Built plans. 4. If As-Built plans include signing or striping, the dates of signing or striping removal, relocation, or installation shall be shown on the plans when required as a condition of the permit. When the construction plans show signing. and striping for staged construction on separate sheets, the sheet for each stage shall show the removal, relocation or installation dates of the appropriate staged striping and 5. &Built plans shall contain the Permit Number, County, Route, Post Mile, and Kilometer Position on each sheet. 6. Disclaimer statement of any kind that differ from the obligations and protections provided by Sections 6735 through 6735.6 of the California Business and Professions Code, shall not be included on the As-Built plans. Such statements constitute non-compliance with Encroachment Permit requirements, and may result in the Department of Transportation retaining Performance Bonds or deposits until proper plans are submitted. Failure to comply may also result in denial of future permits, or a provision requiring a public agency to supply additional bonding. PERMlTS FOR RECORD PURPOSES ONLY When work in the right of way is within an am under a Joint Use Agreement (JUA) or a Consent to Common Use Agreement (CCUA), a fee exempt permit is issued to the permittee for the purpose of providing a notice and record of work. The Permittee’s prior rights shall be preserved without the intention of creating new or different rights or obligations. “Notice and Record Purposes Only” shall be stamped across the face of the permit. BONDING: The permittee shau file bond@), in advance, in the amount set by the Department. Failure to maintain bond($ in full force and effect will result in the Department stopping of all work and revoking permit(s). Bonds are not required of public corporations or privately owned utilities, unless permittee failed to comply with the provision and conditions under a prior permit. The surety company is responsible for any latent defects as provided in California Code of Civil Procedures, Section 337.15. Local agency permittee shall comply with requirements established as follows: In recognition that project construction work done on State property will not be directly funded and paid by State, for the purpose of protecting stop notice claimants and the interests of State relative to successll project completion, the locaI agency permittee agrees to require the construction contractor furnish both a payment and performance bond in the local agency’s name with both bonds complying with the requirements set forth in Section 3-1.02 of State’s current Standard Specifications before performing any project construction work. The local agency permittee shall defend, indemnify, and hold harmless the State, its officers and employees from all project construction related claims by contractors and all signing. 22 23. 24. 25. 26. 27. 28. stop notice or mechanic’s li’& ‘claimants. The local agency also agrees to remedy, $a timely manner and to State’s satisfaction, any latent defectS‘dchrring as a result of the project construction work. . FUTURE MOVING OF WSTAJLATIONS: Permittee understands and agrees to rearrange a permitted installation upon request by the Department, for State construction, reconstruction, or maintenance work on the highway. The permittee at his sole expense, unless under a prior agreement, JUA, or a CCUA, shdl comply with said request. ARCZIAEOLOGICAUHLWORTCAIS: If any archaeological or historical resources are revealed in the work vicinity, the permittee shall immediately stop work, notify the Department’s representative, retain a qualified archaeologist who shall evaluate the site, and make recommendations to the Department representative regarding the continuance of work. ’ .. PREVAILING WAGES: Work pedormed by or under a permit may require permittee’s contractors and subcontractors to pay appropriate prevailing wages as set by the Department of hdustrial Relations. Inquiries or requests for interpretations relative to enforcement of prevaiIing wage requirements are directed to State of California Department of Industrial Relations, 525 Golden Gate Avenue, San Francisco, California 94102. RESPONSIBIU[TY FOR DAMAGE: The State of California and all officers and employees thereof, including but not limited to the Director of Transportation and the Deputy Director, shall not be answemble or accountable in any manum for injury to or death of any person, including but not limited to the permittee, persons employed by the permittee, persons acting in behalf of the permittee, or for damage to property fi-om any cause. The pennittee shall be responsible for any liability imposed by law and for injuries to or death of any person, including but not limited to the permittee, persons employed by the permittee, persons actin;! in behalf of the permittee, or for damage to property arising out 01’ work, or other activity permitted and done by $e permittee undcr a permit, or arising out of the failure on the permittee’s part 10 perform his obligations under any permit in respect to maintenance or any other obligations, or resulting from defects or obstructions, or from any cause whatsoever during the progress of the work, or other activity or at any subsequent ,$me, work or other activity is being performed under the obligations provided by and contemplated by the permit. The permittee shall indemnify and save harmless the State of California, all officers, employees, and State’s contractors. thereof, including but not limited to the Director of Transportation and the Deputy Director, from all claims, suits or actions of every name, kind and description brought for or on account of injuries lo or death of any person, including but not limited to the permittee. persons employed by the permittee, persons acting in behalf of the permittee and the public, or damage to property resulting from the performance of work or other activity under the permit, or arising out of the failure on the permittee’s part to perform his obligations under any permit in respect to maintenance or any other obligations, or resulting from defects or obstructions, or from any cause whatsoever during the progress of the work, or other activity or at any subsequent time, work or other activity is being performed under the obligations provided by and contemplated by the permit, except as otherwise provided by statute. The duty of the permittee to indemnify and save harmless includes the duties to defend as set forth in Section 2778 of the Civil Code. The permittee waives any and all rights to any type of expressed or implied indemnity against the State, its officers, employees, md ’ K-27 State contractors. It is the intent of the parties that the permittee will indemnify and hold harmless the State, its officers, employees, and State’s contractors, from any and all claims, suits or actions as set forth above regardless of the existence or degree of fault or negligence, whether active or passive, primary or secondary, on the part of the State, the permittee, persons employed by the permittee, or acting on behalf of the permittee. For the purpose of this section, “State’s contractors” shall include contractors and their subcontractors under contract to the State of California performing work within the limits of this permit. NO PRECEDENT ESTABLISHED This permit is issued with the understanding that it does not establish a precedent. 29. 30. FEDERAL CIVIL RIGHTS REQurzzEMENTS FOR PUBLIC ACCOMMODATION: A. The permittee, for himself, his personal representative, successon in interest, and assigns as part of the consideration hereof, does hereby covenant and agree that: 1. No person on the grounds of race, color, or national origin shall be excluded from participation in, be denied the benefits of, or be otherwise subjected to discrimination in the use of said facilities. 2. That in connection with the construction of any improvements on said lands and the furnishings of services thereon, no discrimination shall be practiced in the selection and retention of first-tier subcontractors in the selection of second-tier subcontractors. 3. That such discrimination shall not be practiced against the public in their access to and use of the facilities and services provided for public accommodations (such as eating, sleeping, rest, recreation), and operation on, over, or under the space of the right of way. 4. That the permittee shall use the premises in compliance with all other requirements imposed pursuant to Title 15, Code of Federal Regulations, Commerce and Foreign Trade, Subtitle A. Office of the Secretary of Commerce, Part 8 (15 C3.R Part 8) and as said Regulations may be amended. 5.That in the event of breach of any of the above nondiscrimination covenants, the State shall have the right to terminate the permit and to re-enter and repossess said land and the land and the facilities thereon, and hold the same as if said permit had never been made or issued. 31. MAINTENANCE OF HIGHWAYS: The pennittee agrees, by acceptance of a permit, to properly maintain any encroachment. This assurance requires,the permittee to provide inspection and repair any damage, at permittee’s expense, to State facilities resulting from the encroachment. 32. SPECIAL EVENTS: In accordance with subdivision (a) of Streets and Highways ‘Code Section 682.5, the Department of Transportation shall not be responsible for the conduct or operation of the permitted activity, and the applicant agrees to defend, indemnify, and hold harmless the State and the city or county against any and all claims arising out of any activity for which the permit is issued. Permittee understands and agrees that it will comply with the obligations of Titles II and III of the Americans with Disabilities Act of 1990 in the conduct of the event, and fuaher agrees to indemnify and save harmless the State of California, all officers and employees thereof, including but not limited to the Director of Transportation, from any claims or liability arising out of or by virtue of said Act. State. The gifting ,of public property use and therefore public funds is prohibited adder the California Constitution, Article 16. 34. FIELD WORK REIMBURSEMENT: Permittee shall reimburse State for field work performed on permittee’s behalf to correct or remedy hazards or damaged facilities, or clear debris not attended to by the permittee. 35. NOTIFICATION OF DEPARTMENT AND TMC: The permittee shall notify the Department’s representative and the Transporntion Management Center (TMC) at least 7 days before initiating a lane closure or conducting an activity that may cause a traffic impact. A confinnation notification should occur 3 days before closure or other potential traffic impacts. In emergency situations when the corrective work or the emergency itself may affect traffic, TMC and the Department’s representative shall be notified as soon as possible. SUSPENSION OF TRAFFIC CONTROL OPERATION The permittee, upon notification by the Department’s representative, shall immediately suspend all lane closure operations and any operation that impedes the flow of traffic. All costs associated with this suspension shall be borne by the permittee. . 36. 37. UNDERGRQUND SERVICE ALERT WSN NOTIFICATION Any excavation requires compliance with the provisions of Government Code Section 4216 et. seq., including, but not limited to notice to a regional notification center, such as Underground Service Alert (USA). The permittee shall provide notification at least 48 hours before performing any excavation work within the right of way. 33. PRIVATE USE OF RIGHT OF WAY: Highway right of way shall not be used for private purposes without compensation to the K-28 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 tl . -L. 0 c z 0 v) fff I 185 STEEL PLATE SPECIAL PROVISIONS b 6 Steel plate bridging installations shall conform to the following: ,- Method 1 [For speeds more than 70 km/hr (45 mph)] The pavement shall be cold planed to a depth equal to the thickness of the plate and to a width and length equal to the dimensipns of the plate. 8. . .. .- . ?;*-”‘. 1. I < Method 2 For speeds 70 km/hr (45 mph) or less] Approach pl.ate(s) and ending the roadway by a minimum or2 dowels pre-drilled into the comers of the plate and drilled 50 mm (2”) into the pavement. other. slope 8.5% with a minimum 300 mm (12”) ta er to cover all edges of the steel {e backfilled with either graded fines of asphalt concrete mix, concrete_ slurry, or an equivalent slurry satisfactory fo the State’s representative. late (if longitudinal placement) shall be attached to Subsequent plates are butted to each Fine graded asphalt concrete shall be compacted to form ramps, maximum lates. When the steel plates are removed, t K e dowel holes in the pavement shall The permittee is responsible for the maintenance 6f the steel plates, shoring, and asphalt concrete ramps. Unless speaficaIly noted in the provisions of the permit, or approved by the State’s * representative, steel plate bridging should not exceed 4 consecutive workin’g days in any given week. of excavations shall be covered with a minimum 75 nun (3”) temporary layer of cold asphalt concrete. The following table shows the advisory minimal thickness of steel plate bridging needed for a given trench width (A36 grade designed for HS20-44 truck loading per Caltrans Bridge Design Specifications Manual): Backfillin Trench Width Minimum Plate Thickness 0.25 m (10”) 0.80 m (31” / 21-7”) 1.04 m .(41” / 3’-5”) 1.60 m (63” / 5’-3’’) 13 mm (1/2”) 22 mm (7/8”) 25 mm (1”) 32 mm (1 1/4”) 0.58 m (23” / 1’-11’’) 19 mm (3/4”) NOTE: For spans greater than 1.6 m (5’ -3”)) a structural design shall be prepared by a registered civil engineer. Steel plates used in the traveled portion of the highway shall have a surface that was manufactured with a minimum coefficient of friction equivalent to 0.35 as determined by California Test Method 342. If a different test method is used, the Kom each Caltrans’.District Materials Engineer to correlate skid resistance results to“ California Test Met od 342. Based on the test data, the permittee shall determine remove, test, o’r resurface an individual late. The tate representative ma have any untreated plate immediately rernovec? from traveled portions of the hig way, but ermittee may utilize standard test plates with known coefficients of friction available K l what amount of su R ace wear is acceptable, and inde endently ascertain when to ’:, is not responsible for evaluating surfaced plates. A Rough Road sign (W33), with black lettering on an orange background, may be used in advance of steel plate bridging. other required cm-struction signing. This sign is to be used along with any -. 4' BACKFILL REQUIREMENTS A. Backfill Within Existina or Proposed Paved Areas: I. Material for use as structure backfill shall have a sand equivalent of not less than 20. The percentage composition by weight as determined by laboratory sieves shall conform to the following grading: Controlled Low Strength Material (o shall be allowed for trench backfill if it meets Caltrans Standard Special Provisions 19-270-E and 19-27O-m. ' . Sieve Sizes Percentaae Passina Sieves 75mm (3') 100 35-1 00 - 20-100 Bad411 material shall be placed in horizontal, uniform layers not exceeding 200 mm (8 in.) in thickness, before compaction, and shall be brought up uniformly on all sides of the structure or facility. Each layer of backfill shall be compacted to a relative compadion of not less than 95 percent -* 2. The upper 200 mm (8 in.) shall consist of 150 mm (6 in.) Class 1 high early strength portland cement concrete (7 sack Type 111 cement) or Class 1 portland cement concrete (7 sack Type II with 2 percent calcium chloride by weight of cement) and 50 mm (2 in.) asphalt concrete extending outside the underiying trench a minimum distance of 150 mm (6 in.) on each side. Pavement shall be cut to a neat, straight line with saw, abrasive wheel, or spade bit Traffic shall not be allowed across the trench area until the PCC has been poured and has had reasonable time to set and permanent or temporary AC paving is in place. In cases where the trench width does not exceed 1.8 m (6 feet), requirement A2. may be waived and the following requirements substituted: the backfill material shall conform to A.l. above and shall be thoroughly mixed with 110 kg of portland cement per cubic meter (2 sacks per cubic yard). Placement and compaction shall conform to A.1. The upper portion shall consist of a tack coat of liquid asphalt and 100 mm (4 in.) asphalt concrete placed and compacted in two even lifts and rolled to a smooth even finish. Traffic shall not be allowed across the trench area until AC paving is in place. , 3. 4. For paved shoulders only, upon express permission of the State's Inspector, Provision A may be waived and Provision 3 backfill requirements shall apply. B. Backfdl in Paved Shoulder Areas: The bdll to within 300 mm (12 in.) of the existing or proposed profile grade shall conform to A. 1. above. The upper 300 mm (12 in.) shall consist of 200 mm (8 in.) Class 2 aggregate base compacted to a relative compaction of not less than 95 percent, covered with a tack coat of liquid asphalt and 100 mm (4 in,) asphalt concrete placed and compacted in two lifts and rolled to a smooth, even finish. Backfill in Unpaved Shoulder Areas: The backfill to within 300 mm (12 in.) ofthe existing or proposed profile grade shall conform to A.1, above. The upper 300 mm (12 in!) shall consist of Class 2 aggregate base compacted to not less than 95 percent - . .... C. D. Backfill Outside of Hiahwav Shoulders: The backfill material may consist of material from excavation, free from stones or lumps exceeding 75 mm (3 in.), vegetable matter, or other unsatisfactory material, and shall be compacted in lifts not exceeding 200 mm (8 in.) to a relative compaction of 90 percent. When the material from excavation is unsuitable for use as backfill, it shall be disposed of ad replaced with material meeting the above requirements of A.1. li' rc Excess material shall be disposed of outside the State right of way or at a location designated by the Department of Transportation's representative. * rd STATE OF CALIFORNIA DEPARTMENT OF TRANSp@TAnON .. CUSTOMER SEWWE QUESTlONMAllWE ,*.- PEF$MlT NUMBER ,* TR-0164 (REV 2/2001) I* Dear Customer, Our goal is to provide the best service possible to our customers, Please take a few minutes to complete this questionnaire. Your comments will enable us to see how we are doing overall and any areas which may need improvement. Please fax this comment sheet to (619) 688-6157. Pre-construction meeting set and held in a timely manner Inspector at job site frequently Inspector able to answer questions and deal with problems PLEASE TELL US MOW WE'RE DOING I Staff courteous and helpful I I I I - NAME (Optional) Staff quick and efficient Explanations and instructions clear DATE BUSlNESS PHONE NUMBER 1 I I Timely response I I ~- I Receiving infomation or answers Inspector courteous and helpful I I I What would you say is our overall performance? Is there a staff person you would like to commend? STAFPS NAME: ~ ~- COMMENTS: I I For individuals with sensov disabilities, this document is available in alternate Formats. Far information call (916) 654-6410 or,TfJD (916) 654-3880 wwrite Records and Forms Management, 1120 N Street, MS-89. Sacramento, CA 95814. ADA APPENDIX D SDG&E Work Order L 0 0 0 4 F a 0 * 0 PL W Z n a L - m - $ E E 0 0 i3 $ E P v) 3 e 8 c 0 y E 3 P c -2- \ \ \ I \ 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 ($1,000). Copies of such prevailing rate or per diem wage are on file at the City of Carlsbad 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 AVAILAl3LE (a) Each contractor and subcontractor shall keep an accurate payroll record, showing the name, address, social security number, work classification, and 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. (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. (2) A certified copy of all payroll records enumerated in subdivision (a) shall be made available for inspection or fiunished 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. (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) Each contractor 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. (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 in a manner so as to prevent disclosure of an individual's name, address, and social security number. The name and address of the contractor awarded the contract or performing the contract shall not be marked or obliterated. BP-0 March 17,2000 (0 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. - i (g) The contractor shall have 10 days in which to comply subsequent to receipt of written notice specifying in what respects the contractor must comply with this section. In the event that the contractor 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. (h) The body awarding the contract shall cause to be inserted in the contract stipulations to effectuate this section. These stipulations shall fix the responsibility for compliance with this section on the prime contractor. (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 Nothing in this chapter shall prevent the employment of properly registered apprentices upon public works. Every such apprentice shall be paid the standard wage paid to apprentices under the regulations of the craft or trade at which he or she is employed, and shall be employed only at the work of the craft or trade to which he or she is registered. Only apprentices, as defined in Section 3077, who are in training under apprenticeship standards and written apprentice agreements under Chapter 4 (commencing with Section 3070) of Division 3, are eligible to be employed on public works. The employment and training of each apprentice shall be in accordance with the apprenticeship standards and apprentice agreements under which he or she is training. When the contractor to whom the contract is awarded by the state or any political subdivision, or any subcontractor under him or her, in performing any of the work under the contract or subcontract, employs workers in any apprenticeable craft or trade, the contractor and subcontractor shall apply to the joint apprenticeship committee administering the apprenticeship standards of the craft or trade in the area of the site of the public work for a certificate approving the contractor or subcontractor under the apprenticeship standards for the employment and training of apprentices in the area or industry affected. However, approval as established by the joint apprenticeship committee or committees shall be subject to the approval of the Administrator of Apprenticeship. The joint apprenticeship committee or committees, subsequent to approving the subject contractor or subcontractor, shall arrange for the dispatch of apprentices to the contractor or subcontractor in order to comply with this section. Every contractor and subcontractor shall submit contract award information to the applicable joint apprenticeship committee which shall include an estimate of journeyman hours to be performed under the contract, the number of apprentices to be employed, and the approximate dates the apprentices will be employed. There shall be an affirmative duty upon the joint apprenticeship committee or committees administering the apprenticeship standards of the craft or trade in the area of the site of the public work to ensure equal employment and af€innative action in apprenticeship for women and minorities. Contractors or subcontractors shall not be required to submit individual applications for approval to local joint apprenticeship committees provided they are already covered by the local apprenticeship standards. The ratio of work performed by apprentices to journeymen who shall be employed in the craft or trade on the public work may be the ratio stipulated in the apprenticeship standards under which the joint apprenticeship committee operates, but, except as otherwise provided in this section, in no case shall the ratio be less than one hour of apprentices work for every five hours of labor performed by a journeyman. However, the minimum ratio for the land surveyor classification shall not be less than one apprentice for each five journeymen. Any ratio shall apply during any day or portion of a day when any journeyman, or the higher standard stipulated by the joint apprenticeship committee, is employed at the job site and shall be computed on the basis of the hours worked BP-1 March 17,2000 during the day by journeymen so employed, except for the land surveyor classification. The contractor shall employ apprentices for the number of hours computed as above before the end of the contract. 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 job site. Where an hourly apprenticeship ratio is not feasible for a particular craft or trade, the Division of Apprenticeship Standards, upon application of a joint apprenticeship committee, may order a minimum ratio of not less than one apprentice for each five journeymen in a craft or trade classification. The contractor or subcontractor, if he or she is covered by this section, upon the issuance of the approval certificate, or if he or she has been previously approved in the craft or trade, shall employ the number of apprentices or the ratio of apprentices to journeymen stipulated in the apprenticeship standards. Upon proper showing by the contractor that he or she employs apprentices in the craft or trade in the state 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 a journeyman, or in the land surveyor classification, one apprentice for each five journeymen, the Division of Apprenticeship Standards may grant a certificate exempting the contractor fiom the 140-5 hourly ratio as set forth in this section. This section shall 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) or 20 working days . 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 hourly ratio required by this section. "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 prescnied by the Apprenticeship Council. The joint apprenticeship committee shall have the discretion to grant a certificate, which shall be subject to the approval of the Administrator of Apprenticeship, exempting a contractor fiom the 1-to-5 ratio set forth in this section when it finds that any one of the following conditions is met: (a) Unemployment for the previous three-month period in the area exceeds an average of 15 percent . (b) The number of apprentices in training in such area exceeds a ratio of 1 to 5 . (c) 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. (d) Assignment of an apprentice to any work performed under a public works contract would create a condition which would jeopardize his or her life or the life, safety, or properly of fellow employees or the public at large or if the specific task to which the apprentice is to be assigned is of such a nature that training cannot be provided by a journeyman. When exemptions are granted to an organization which represents contractors in a specific trade fiom the 1-to-5 ratio on a local or statewide basis the member contractors will not be required to submit individual applications for approval to local joint apprenticeship committees, if they are already covered by the local apprenticeship standards. A contractor to whom the contract is awarded, or any subcontractor under him or her, who, in performing any of the work under the contract, employs journeymen or apprentices in any apprenticeable craft or trade and who is not contributing to a fund or funds to administer and conduct the apprenticeship program in any craft or trade in the area of the site of the public work, to which fund or funds other contractors in the area of the site of the public work are contributing, shall contribute to the fund or funds in each craft or trade in which he or she employs journeymen or apprentices on the public work in the same amount or upon the same basis and in the same manner as the other contractors do, but where the trust fund administrators are unable to accept the funds, contractors not signatory to the trust agreement shall pay a like amount to the California Apprenticeship Council. The contractor or subcontractor may add the amount of the contriiutions in computing his or her bid for the contract. The Division of Labor Standards Enforcement is authorized to enforce the payment of the contributions to the fund or funds as set forth in Section 227. The body awarding the contract shall cause to be inserted in the contract stipulations to effectuate this section. The stipulations shall fix the responsibility of compliance with this section for all apprenticeable occupations with the prime contractor. All decisions of the joint apprenticeship committee under this section are subject to Section 308 1. BP-2 March 17,2000 4- LABOR CODE SECTION 1810 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 control, 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 1813 PENALTY FOR OVERTIME ON ANY PUBLIC WORK CONTRACT The contractor 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 workman employed in the execution of the contract by the contractor or by any subcontractor for each calendar day during which such workman 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 therein 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 officer of the State or political subdivision who is authorized to pay the contractor money due him under the contract. 6- LABOR CODE SECTION 18 15 MINIMUM OVERTIME PAY Notwithstanding the provisions of Sections 18 10 to 18 14, 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), 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, Architectural, 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) at the location of such potential cultural resources find. The Engineer shall issue a “Stop Work Order” directing the Contractor to cease all construction operations BP-3 March 17,2000 .- 2) Such “Stop Work Order” shall be effective until such time as a qualified archeologist can be called to assess the value of these potential cultural resources and make recommendations to the State Water Resources Control Board Cultural Resources Officer. Any “Stop Work Order” shall contain the following: a) b) c) d) e) A clear description of the work to be suspended; Any instructions regarding issuance of further orders by the Contractor for material services; Guidance as the action to be taken on subcontracts; Any suggestions to the Contractor as to minimization of his costs; Estimated duration of the temporary suspension. If the archeologist determines that the potential find is a bonafide cultural resource, at the direction of the State Water Resources Control Board Cultural Resources Officer, 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. 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 Equipment 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, Equipment 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. 4 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. March 17,2000 BP-4 10 - STATE MBWE PROVISIONS CONTRACT PROVISIONS OF THE STATE WATER RESOURCES CONTROL BOARD (SWRCB) DMSION OF CLEAN WATER PROGRAMS RELATIVE TO THE UTILIZATION OF MINORITY BUSINESS ENTERPRISE (MBE) AND WOMEN BUSINESS ENTERPRISE (WBE) 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 EnterpriseNomen Business Enterprise Information” (Attachment B) with the bid shall cause the bid to be rejected as a non-responsive bid. DEFINITIONS BONA FIDE MINORITY BUSINESS ENTERPRISE (BE) MEANS: An MBE that has submitted a “Minority Business EnterpriseNomen Business Enterprise Self Certification“ (Attachment A) to, and been accepted as, a bona fide MBE by the owner. In addition, the following requirements apply: 1. An independent business concern which is at least 5 1% owned and controlled by minority group member(s) (see definition of Minority Group Member). Ownership and control can be measured by: a. Responsibility for performance of contract work. b. Management responsibility. c. At least 5 1 % share of profits and risk. d. Other data (such as voting rights) that may be related to ownership andor control. 2. 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. BONA FIDE WOMEN BUSINESS ENTERPRISE WBE) MEANS: A WBE that has submitted Attachment A to, and been accepted as, a bona fide WBE by the owner. In addition, the following requirements apply: 1. An independent business which is at least 51% owned by a woman or women who also control and operate it. a. Ownership. Determination of whether a business is at least 51% owned by a woman or women shall be made without regard to community property laws. For example, an otherwise qualified WBE 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 which is 51% owned by a married man and 49% by an unmarried woman will not become a qualified WBE by virtue of his wife’s 50% interest in his share of the business. BP-5 March 17,2000 b. Control and operation. "Control" means exercising the power to make policy decisions and "operatell means being actively involved in the day-to-day management of the business. - JOINT VENTURE (JV) A business enterprise formed by a combination of fm under a JV agreement. To qualify as a bona fide MBE/WBE, the minority-ownedwoman or women owned and controlled firms in the JV must: 1. Satisfy all requirements for bona fide MBE/WBE participation in their own rights. In cases where a minority woman or women-owned fm participates in a JV, the percentage may be credited towards MBE participation or as WBE participation, or allocated, but may not be credited fully to both. 2. Share a clearly defined percentage of the ownership, management responsibilities, risks, and profits of the JV. Only this percentage will be credited towards the MBE/WBE goal. MINORITY GROUP MEMBERS A minority group member is an individual who is a citizen of the United States and one of the following: 1. Native Americans consist of American Indian, Eskimo, Aleut, and native Hawaiian. 2. Black Americans consist of U.S. citizens, other than Hispanic, having origins in any of the black racial groups of Africa. Asian Pacific Americans consist of U.S. citizens 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, the 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, Sikkim. and Bhutan. 3. 4. Hispanic Americans consist of U.S. citizens 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. BROKERAGE MEANS Buying and selling for others on commission of other fee basis without maintaining a warehouse or other similar inventory storage facilities (supplier and wholesale arrangements may also fall into this business enterprise category). CONSTRUCTION MEANS Erection, building, alteration, remodeling, improvement or extension of buildings, structures, or other property. REOUIREMENTS A. Positive Effort Documentation The bidder must take affmtive steps prior to bid opening to assure that MBEs and WBEs are used whenever possible as sources of supplies, construction and services. Failure to take such steps vrior to bid oDening and to submit Attachment B with the bid shall cause the bid to be reiected as non-responsive. Affirmative steps shall be as follows: 1. Including qualified MBEs and WBEs on solicitation lists. BP-6 March 17,2000 2. 3. 4. 5. The bidder must document that it requested assistance from the Small Business Administration gnJ the Office of Minority Business Enterprise MBE/WBE assistance centers and that this request for assistance was received by the MBE/WBE assistance centers at least five (5) working days prior to the need for referrals (see affirmative step no. 5). Assure that MBEs and WBEs are solicited whenever they are potential sources. The bidder must document that it has provided invitations to MBE/WBE bidders at least seven (7) working days prior to the need of a bid response. The bidder must document that invitations were sent to at least three (3) (or all if less than three) MBWE contractors/suppliers for each item of work referred by the MBENBE assistance center(s). The invitations must adequately specify the item(s) for which sub-bids were requested. The documentation of the bidder's effort to show positive efforts must indicate a real desire for a positive response; i.e., certified letter with return receipt requested or telephone call documentation. A regular letter or an unanswered telephone call is not adequate positive effort. The bidder must submit to the owner documentation consisting of a list of all sub-bidders for each item of work that MBEs or WBEs were solicited including dollar amounts for both MBE/WBE and non-MBE/WBE sub-bidders. Divide total requirements, when economically feasible, into small tasks or quantities to permit maximum participation of MBEs and WBEs. A bidder must document that it gave consideration to dividing the contract into small proprietary portions (paving, electrical, landscaping, etc.). If this was not done, documentation must be submitted explaining why it could not be done. Establish delivery schedules, where the requirements of the work permit, which will encourage participation by MBEs and WBEs. The bidder must document that it gave consideration to establishing a project schedule which would allow MBEs and WBEs to bid the work as subcontractors or suppliers. If this is not done, document reasons why the project schedule, or portions thereof, cannot be modified so as to accommodate interested MBEs and WBEs. Use of the services and assistance of the Small Business Administration and the Office of Minority Business Enterprise of the U. S. Department of Commerce, as appropriate. The bidder must present documentation that contact was made with both of the offices listed below. Their services are provided at no cost to the bidder. Do not write. The internet web site contains local SBA and MBDA centers. The local center may provide the bidder with a listing of MBE/WBE firms. If a list was not provided, bidder must explain why it was not and describe what MBE/WBE solicitation list was used. Small Business Administration: <http://www.sba.gov> Office of Minority Business Enterprise: Regional Office U.S. Dept. of Commerce <http://www.mbda.gov> Government Contracting Office 455 Market Street, Suite 600 San Francisco, CA 94105 Telephone: (415) 744-8429 Minority Business Development Agency (MBDA) San Francisco, CA 94 105 Telephone: (415) 744-3001 In addition, the bidder is encouraged to procure supplies and services from labor surplus area firms. BP-7 March 17,2000 B. Other Requirements 1. The apparent successful low bidder must submit documentation showing that, prior to bid opening, all required positive efforts were made. This documentation must be received by the owner within ten (IO) working days following bid opening (except Attachment B which is to be submitted with the bid). Failure to submit Attachment B with the bid will cause the bid to be reiected as non-resuonsive. 2. If the apparent successful low bidder has rejected or considered as non-responsible andor non- responsive any low MBE or WBE sub-bidder, a complete explanation must be provided to the owner. Each MBEMrBE firm to be utilized must complete the Attachment A, which is to be with the documentation submitted to the owner by the apparent successful low bidder. 3. 4. If additional MBE/WBE subcontracts become necessary after the award of the prime contract, Attachment B must be provided to the owner by the Prime Contractor within ten (IO) working days following the award of each new subcontract. 5. Any deviation from the information contained in Attachment B shall not result in a reduction of MBE/WBE participation without prior approval of the owner. 6. When brokerage type arrangements are utilized, only the amount of commission or fee will be eligible for MBENBE consideration. 7. Failure of the apparent low bidder to perform the five affirmative steps prior to bid opening andor to submit Attachment B with its bid will lead to its bid being declared non-responsive by the owner. The owner may then award the contract to the next low responsive, responsible bidder meeting the requirements of these contract provisions. The owner also may rebid the contract. C. State’s “Fair Share” Obiectives - The SWRCB has established the following fair share objectives for this construction contract: 20 % of the total bid dollar amount of this contract for MBE. 10 % of the total bid dollar amount of this contract for WBE. (The owner may contact the SWRCB, Division of Clean Water Programs, Design Review Unit at (916) 227-4588 for questions on the state’s fair share objectives.) D. LocalRegional Objectives The owner may have established 1ocaVregional objectives and those requirements may be attached if appropriate. BP-8 March 17,2000 ATTACHMENT A MINORITY BUSINESS ENTERF'RISE/WOMEN'S BUSINESS ENTERPRISE (MBENBE)' SELF CERTIFICATION STATE WATER RESOURCES CONTROL BOARD DIVISION OF CLEAN WATER PROGRAMS Firm Name: Phone: Address: Principal Service or Product: 0- MBE 0- WBE 0- Prime Contractor 0- Subcontractor 0- Supplier of MateriaYService 0- Broker I I 0- Sole Ownership 0- Corporation 0- Partnership 0- Joint Venture I I Names of Owners Percent MBE- WBE Ownership Ethnic Identity' Additional proofs may be required upon written challenge of this certification by any person or agency. Falsification of this certification by a fm selected to perform Federally funded work may result in a determination that the firm is non-responsible and ineligible for future contracts. Certified Title: by: (Signature) Name: Date: ' Refer to definitions on the next page. BP-9 March 17,2000 -DEFINITIONS- MINORITY BUSINESS ENTERF’RISE/WOMEN’S BUSINESS ENTERPRISE MENBE) An MBE or WE is a business which is at least 5 1 percent owned and controlled by minority group members or by woman or women. Owners must exercise actual day-to-day management. MINORITY GROUP MEMBERS American Indians Persons having origins in any of the original peoples of North America. To qualify in this group, a person must be a citizen of the United States and meet one or more of the following: (1) Be at least one-fourth Indian descent (as evidenced by registration with the Bureau of Indian Affairs). (2) Characteristic Indian appearance and features. (3) Characteristic Indian name. (4) Recognition in the community as an Indian. (5) Membership in a tribe, band or group of American Indians (recognized by the Federal Government), as evidenced by a tribal enrollment number or similar indication. Black Americans U.S. citizens, other than Hispanic, having origins in any of the black racial groups of Afiica. Asian Americans U.S. citizens having origins in any of the original peoples of the Far East, Southern Asia, the Indian subcontinent or the Pacific Islands. This area includes, for example, China, Japan, Korea, the Philippine Islands and Samoa. The Indian subcontinent takes in the countries of India, Pakistan, Bangladesh, Sri Lanka, Nepal, Sikkim, and Bhutan, Hispanic Americans U.S. citizens of Mexican, Puerto Rican, Cuban, or other Spanish culture or origin, regardless of race. 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, the category does not include persons from Portugal, who should be classified according to race. American Eskimos and Americy Aleuts March 17,2000 BP-IO LOAN RECIPIENTS NAME PROJECT DESCRIPTION CONTRACT NO. OR SPECIFICATION NO. PROJECT LOCATION NAME AND ADDRESS (Include ZIP Code, DOB, & SSN) PHONE ~~ PRIME CONTRACTOR INFORMATION 0 WBE 0 MBE AMOUNT OF CONTRACT 0 SUBCONTRACTOR 0 JOINTVENTURE NAME AND ADDRESS (Include ZIP Code, DOB, & SSN) 0 SUBCONTRACTOR 0 SUPPLIEWSERVICE 0 JOINTVENTURE 0 BROKER AMOUNT OF CONTRACT PHONE 0 SUPPLIEWSERVICE 0 BROKER WORK TO BE PERFORMED AMOUNT OF CONTRACT 0 MBE PHONE 0 WBE 0 SUBCONTRACTOR 0 JOINT VENTURE 1 NAME AND ADDRESS (Include ZIP Code, DOB, & SSN) 0 SUPPLIEWSERVICE 0 BROKER AMOUNT OF CONTRACT NAME AND ADDRESS (Include ZIP Code, DOB, & SSN) 0 SUBCONTRACTOR 0 SUPPLIEWSERVICE 0 JOINT VENTURE 0 BROKER I AMOUNT OF CONTRACT PHONE PHONE WORK TO BE PERFORMED TOTAL MBE AMOUNT: $ TOTAL WBE AMOUNT: $ ACTUAL MBE PARTICIPATION % ACTUAL WBE PARTICIPATION % MBE GOAL: % WBE GOAL: % SIGNATURE OF PERSON COMPLETING FORM: TITLE: PHONE: DATE: IKM 41w-B (rev mu) BP-11 March 17,2000 11 - THE SUBLETTING 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 Contracts Code. 12 - 40 CFR 60-8.4(b) - EQUAL OPPORTUNITY CLAUSE (in relevant part) 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. (2) The contractor will, in all solicitations or advertisements for employees placed by or on behalf of the contractor, state that all qualified applicants will receive considerations for employment without regard to race, color, religion, sex, or national origin. (3) The contractor will send, to each labor union or representative of workers with which he has a collective 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 11246 of September 24,1965, and of the rules, regulations, and relevant orders of the Secretary of Labor. (5) The contractor will knish 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. (6) In the event of the contractor’s noncompliance with the nondiscrimination clauses of this contract or with any of the said rules, regulations, or orders, this contract may be canceled, terminated, or suspended in whole or in part, and the contractor may be ineligible for further Government contracts or federally assisted construction contracts in accordance with procedures authorized in Executive Order 11246 or September 24, 1965, and such other sanctions may be imposed and remedies invoked a s provided in Executive Order 11246 of September 24,1965, or by rule, regulation, or orders of the Secretary of Labor, or as otherwise provided by law. March 17,2000 BP-12 (7) The contractor will include 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. 13 - NONDISCRIMINATION CLAUSE NONDISCRIMINATION CLAUSE 1. ' During the performance of this contract, contractor and its subcontractors shall not unlawfully discriminate against any employee or applicant for employment because of race, religion, color, national origin, ancestry, physical handicap, medical condition, marital status, age (over 40) or sex. Contractors and subcontractors shall insure that the evaluation and treatment of their employees and applicants for employment are free of such discrimination. Contractors and subcontractors shall comply with the provisions of the Fair Employment and Housing Act (Government Code Section 12900 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, set forth in Chapter 5 of Division 4 of Title 2 or the California Administrative Code are incorporated into this 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. This contractor shall include the nondiscrimination and compliance provisions of this clause 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: SIGNATURE: DATE: March 17,2000 BP-13 14 - 41 CFR 60-4.2 CONSTRUCTION CONTRACTORS--AFFIRMATIVE ACTION REOUIREMENTS fin relevant art) 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 (Agency to insert start and 16.9% 6.9% end dates of contract) (Contact SWRCB, Division of Clean Water Programs, at (916) 227-4586 for assistance with the minority goal and timetables. E-mail <musialr@cwp.swrcb.ca.gov>: Office of Federal Contract Compliance Programs' web site for compliance issues and preaward registry is <http://www.dol.gov/doYesa/public/ofcp-erg>) 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. rt 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 within 10 working days of award of any construction subcontract in excess of $10,000 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). Q 60-4.3 Equal opportunity clauses (in relevant part) Standard Federal Equal Employment Opportunity Construction Contract Specifications (Executive Order 11 246) BP-14 March 17,2000 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 Employe<s Quarterly Federal Tax Return, U.S. Treasury Department Form 94 1. 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 U.S. Department of Labor in the covered area either individually or through an association, its affinnative 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 1 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. BP-15 March 17,2000 7. The Contractor shall take specific aff'tive 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 fblly, 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 therefor, 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. BP-16 March 17,2000 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. 1 1. The Contractor shall not enter into any Subcontract with any person or fm 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 11246, 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. BP-17 March 17,2000 14. The Contractor shall designate a responsible official to monitor all employment related activity to ensure that the company EEO policy is being canied 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.& those under the Public Works Employment Act of 1977 and the Community Development Block Grant Program). 15 - ELIMINATION OF SEGREGATED FACILITIES NOTICE TO PROSPECTIVE 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. BP-18 March 17,2000 16 - CERTIFICATION OF NON-SEGREGATED FACILITIES Environmental Protection Agency Region IX 75 Hawthorne Street San Francisco, California 94 105 CERTIFICATION OF NON-SEGREGATED FACILITIES (Applicable to federally assisted construction contracts and related subcontracts exceeding $10,000 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 $10,000 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. March 17,2000 BP-19 17 - DRUG-FREE WORKPLACE CERTIFICATION DRUG-FREE WORKPLACE CERTIFICATION CONTRACTOWA.PPLICANT 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. OFFICIAL’S NAME: DATE EXECUTED: EXECUTED IN COUNTY OF: CONTRACTOWAPPLICANT SIGNATURE: TITLE: March 17,2000 BP-20 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 agencyk 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 CFR part 9, subpart 9.4, suspended, debarred, ineligible, or voluntarily excluded from participation in this March 17,2000 BP-2 1 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)@) 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 andor 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. March 17,2000 BP-22 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 from 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 and/or 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 42 15 (in relevant art) 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. (1974) 20 - SUBMITTING OF BIDS AND AGREEING TO ASSIGN GOVERNMENT CODE SECTION 4552 (in relevant part) 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 Carhvright 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) March 17,2000 BP-23 2 1 - NON-COLLUSION AFFIDAVIT PUBLIC CONTRACTS CODE SECTION 7106 NON-COLLUSION AFFIDAVIT TO BE EXECUTED BY BIDDER AND SUBMITTED 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 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 fn 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 CoIporation, partnership, company association, organization, bid depository, or to any member or agent thereof the 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) islare subscribed to the within instrument and acknowledged to me that he/she/they executed the same in his/her/their authorized capacity(ies), and that by his/her/their 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) March 17,2000 BP-24 Minority Participation Goals for California Affirmative Action/Equal Employment opportunity for Construction Contractors Aggregate Work Force Standard Metropolitan Statistical Area (SMSA) 41 CFR $60 - 4.6 All areadall trades Female participation goal 6.9% Area minority participation Goal (%) 174 Redding: Non-SMSA 6.8 Lassen; Modoc; Plumas; Shasta; Siskiyou; Tehema 175 Eureka: Non-SMSA Counties 6.6 Del Norte; Humboldt; Trinity 176 San Francisco-Onkland-San Jose: SMSA Counties: 7120 Salinas-Seaside-Monterev 28.9 Monterey 7360 San Francisco-Oakland 26.6 Alameda; Contra Costa; Marin; San Francisco; San Mateo 7400 San Jose 19.6 Santa Clara 7485 SantaCruz 14.9 santa cruz 7500 SantaRosa 9.1 Sonoma. 8720 Valleio-Fanfield-NaDa 17.1 Napa; Solano Non-SMSA Counties 23.2 - Lake; Mendocino; San Benito 177 Sacramento: SMSA Counties: 6920 Sacramento 16.1 Placer; Sacramento; Yolo Non-SMSA Conuties 14.3 Butte; Colusa; El Dorado; Glenn; Nevada; Sierra; Sutter; Yuba 178 Stockton-Modesto: SMSA Counties: 5170 Modesto 12.3 8120 Stockton 24.3 Stanislaus San Joaquin Non-SMSA Counties 19.8 Alpine; Amador; Calaveras; Mariposa; Merced; Tuolumne Area minority participation Goal (YO) 179 Fresno-Bakersfield: SMSA Counties: 0680 Bakersfield 19.1 2840 Fresno 26.1 Fresno Non-SMSA Counties 23.6 Kings; Madera; Tulare Kelll 180 Los Angeles: SMSA Counties: 0360 Anaheim-Santa Ana-Garden Grove 11.9 4480 Los Andes-Lone Beach 26.3 6000 Oxnard-Simi Vallev-Ventura 21.5 6780 Riverside-San Bemardino-Ontario 19.0 7480 Santa Barbara-Santa Maria-Lomuoc 19.7 Orange Los Angeles Ventura. Riverside; San Bernardino. Santa Barbara Non-SMSA Counties 24.6 Inyo; Mono; San Luis Obisbo 181 San Diego: SMSA Counties: 7320 SanDiezo 16.9 San Diego Non-SMSA Counties 16.2 Imperial BP-25 March 17,2000 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 stones high or the equivalent height. (3) The demolition of any building, structure, falsework, or scaffold more than three stories 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 - 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. PUBLIC CONTRACT CODE SECTION 71 05 (a) Construction contracts of public agencies shall not require the contractor to be responsible for the (b) For the purposes of this section: (1) "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) (1) Where authority to contract is vested in any public agency, excluding the state, the authority shall BP-26 (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) Contracts of public agencies may include provisions for termination for environmental considerations at the discretion of the public agencies. 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-26 Technical Specifications SECTION 01025 - MEASUREMENT AND PAYMENT PART 1 -- GENERAL 1.1 1.2 1.3 DESCRIPTION A. The items listed below beginning with Paragraph 1.5, refer to and are the same pay items listed in the Bid Form. They constitute all of the pay items for the completion of the WORK. No direct or separate payment will be made for providing miscellaneous temporary or accessory works, plant, sewices, CONTRACTOR'S or ENGINEER'S field offices, layout surveys, job signs, sanitary requirements, testing, safety devices, approval and record drawings, water supplies, power, maintaining traffic, removal of waste, watchmen, bonds, insurance, and all other requirements of the CONTRACT DOCUMENTS. Compensation for all such services, materials, and items shall be included in the prices stipulated for the lump sum and extra work unit price pay items listed herein. Work not listed in the Bid Schedule, costs for related work and appurtenances which are required and/or implied by the General Provisions, Technical Specifications, Special Provisions and Plans and are not listed as a separate bid item but are necessary to complete the project shall be included in the appropriate bid items or items within the proposal. The lump sum bid price will be deemed to include an amount considered by CONTRACTOR to be adequate to cover CONTRACTOR'S overhead and profit for each separately identified item. B. C. SCOPE A. Payment shall include all compensation to be received by the CONTRACTOR for furnishing all tools, equipment, supplies, and manufactured articles, and for all labor, operations, and incidentals appurtenant to the items of WORK being described, as necessary to complete the various items of the WORK all in accordance with the requirements of the CONTRACT DOCUMENTS, including all appurtenances thereto, and including all costs of compliance with the regulations of public agencies having jurisdiction, including Safety and Health Requirements of the California Division of Industrial Safety and the Occupational Safety and Health Administration of the US. Department of Labor (OSHA). BREAKDOWN OF CONTRACT PRICE OF LUMP SUM CONTRACTS A. Prior to execution of a lump sum contract, CONTRACTOR shall submit a detailed price breakdown showing the allocated portion of the total bid price to the various items of work. CONTRACTOR must submit a preliminary price breakdown for the review and amroval of the ENGINEER. The ENGINEER reserves the riaht to reiect anv breakdown submitted by the CONTRACTOR which the ENGlNfER judges is nit sufficient to allow for the preparation of accurate monthlyprogress payment estimates. The detailed price breakdown shall be listed by specification section number and shall include a separate cost item for all items of equipment or work. The price breakdown shall typically be a unit price type breakdown and shall include quantities, unit prices and total bid cost for each cost item. Where a unit price breakdown is judged impractical, ENGINEER may allow a breakdown by lump sum for certain cost items. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 01025 - 1 SECTION 01025 - MEASUREMENT AND PAYMENT This information will be used by ENGINEER in preparing monthly progress payment estimates. Items for which quantities are indicated "LUMP SUM", or "LS" shall be paid for at the price indicate in the Bid. Such payment shall be full compensation for the items of WORK and all WORK appurtenant thereto. B. 1.4 UNIT PRICE A. Items for which quantities are indicated as "UNIT PRICE" (e.g. LF) shall be paid for at the priced indicated in the bid. The quantity indicated in the bid schedule may vary from rf: 25% without any additional compensation due to the CONTRACTOR, unless otherwise noted. BID SCHEDULE A - PIPELINE AND PRESSURE REDUCING STATION (Excluding the Work Described in Schedules B, and C) A. 1.5 Sheeting, Shoring, and Bracing (Bid Item No. 1) Lump Sum Payment for temporary sheeting, shoring, and bracing or equivalent method will be made at the lump-sum price named in the Bid Schedule(s) under Item No. 1, which price shall constitute full compensation for completion of all planning, design, engineering fees, furnishing and constructing, and removal and disposal of such temporary sheeting, shoring, and bracing as a lump-sum item, complete, as required under the provisions of any permits, and in accordance with the requirements of OSHA and the Construction Safety Orders of the State of California, pursuant to the provisions of Section 6705 of the California Labor Code. Mobilization and Demobilization (Bid Item No. 2) Lump Sum Payment for mobilization/demobilization shall be made at the contract lump sum price named in the bid schedule complete and in accordance with the CONTRACT DOCUMENTS, and based on the project progress defined in Section 9-3.4.1 of the Supplemental Provisions. The contract price shall include, but is not limited to the following items in addition to all items identified in the Supplemental Provisions Section 9-3.4.1 : mobilizing labor force, equipment and construction facilities onto site; provide storage yard; securing construction water supply, providing on-site sanitary facilities; posting OSHA requirements and establishing safety programs; project cleanup and closeout. This Bid Item includes all other work necessary to complete this item of WORK. Construction Schedule (Bid Item No. 3) Lump Sum Payment for the construction schedule shall be made at the contract lump sum price named in the bid schedule as stipulated in the supplemental provisions section 6-1 .E. The contract price shall include, but is not limited to the preparation, revision, updates and submittals of the construction schedule as required and in conformance with the CONTRACT DOCUMENTS, per section 6-1 of the supplemental provisions. This Bid Item includes all other work necessary to complete this item of WORK. B. C. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 01 025 - 2 SECTION 01025 - MEASUREMENT AND PAYMENT D. Storm Water Pollution Prevention Plan (SWPPP) (Bid Item No. 4) Lump Sum The contract lump sum price paid for the SWPPP shall constitute full compensation for the SWPPP including all labor, material, equipment, and incidentals complete in place, including but not limited to the preparation, submittal, implementation, maintenance and removal of the erosion and sedimentation control measures defined by the approved SWPPP, as required, complete in place as specified in the CONTRACT DOCUMENTS. This Bid Item includes all other work necessary to complete this item of WORK. Pressure Reducing Station (PRS) (Bid Item No. 5) Lump Sum The contract lump sum price paid for the PRS (Not including the related work under Bid Item No. 26, Electrical & Instrumentation) shall constitute full compensation for the installation of the PRS including all labor, material, tools, equipment, and incidentals complete in place, including but not limited to precast concrete vault, backfill, hatches, ladders, vents, sump, sump pump and controls, grating and vault appurtenances: all ductile iron pipe and steel pipe and pipe specials, in-vault and buried including but not limited to, appurtenances, connections to existing pipelines, pipe supports, flexible couplings, wall penetrations, pressure gage assemblies, pressure sensing tubing and appurtenances, pressure reducing valves and appurtenances, pressure relief valves and appurtenances, discharge piping, all isolation valves with operator, valve box and valve appurtenances; and appurtenant work including but not limited to, field survey, welding, trench excavation, PRS vault excavation, bedding, backfill, compaction, pavement replacement, pressure testing, disinfection, cleanup and restoration, complete in place as shown on the Drawings and as specified in the specifications. Work Within CalTrans Right-of-way (Bid Item No. 6) Lump Sum The contract lump sum price paid for the WORK within CalTrans Right-of-way (Not including the related work under Bid Item No. 25, Traffic Control and Bid Item No. 7, new 14-inch Expansion Joints) shall constitute full compensation for the installation and WORK required within CalTrans right-of-way including all labor, coordination, material, tools, equipment and incidentals complete in place, including but not limited to performance of the work conforming to the CalTrans permit regulations: accessing, inspection and evaluation of the four existing 14-inch expansion joints (double-ball flex tends) per the CONTRACT DOCUMENTS; the removal and replacement of the existing 14-inch butterflyvalves, including but not limited to the removal of the existing 14-inch butterfly valves and furnishing and installing the new 14-inch butterfly CL 250 valves and assemblies, including but not limited to, valve extension, valve can, AC pavement demo, excavation, backfill, compaction, spoil removal, AC pavement repair, and connections, complete and in place as shown on the Drawings and as specified in the specifications. E. F. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 01 025 - 3 SECTION 01025 - MEASUREMENT AND PAYMENT G. New 14-inch Expansion Joints (Bid Item No. 7) Each The contract unit price paid for the installation of each 14-inch expansion joint (double ball flex-tend) shall be made at the unit price named in the Bid Schedule under Item No. 7, which shall constitute full compensation for the installation and work required for each 14-inch expansion joint including all labor, coordination, material, tools, equipment and incidentals complete in place; including but not limited to the removal and salvage of the existing expansion joints, installation of the new expansion joints and appurtenances, disinfection, testing, and pipe connections, complete in place, and as required for the satisfactory completion of the WORK. 24-inch Pipeline WSP (Bid Item No. 8) Linear Feet The Contract unit price paid for the 24-inch Pipeline WSP shall constitute full compensation to furnish and install the 24-inch diameter cement mortar-lined, tape wrapped with rock shield welded steel pipe in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, specials, miscellaneous pipe, connections and appurtenances, labor, supplies, and equipment required to install the pipe, fittings, thrust blocks, adapters, backfill, compaction, pavement, cathodic protection, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including but not limited to traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians, as required, trench plating, and resurfacing; complete in place as shown on the drawings and specified in the specifications. 12-inch Pipeline CL 200 PVC (Bid Item No. 9) Linear Feet The contract unit price paid for the 12-inch Pipeline CL 200 PVC shall constitute full compensation to furnish and install the AWWA C-900 12-inch CL 200 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including but not limited to traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing; complete in place as shown on the Drawings and specified in the specifications. 12-inch Pipeline CL 150 PVC (Bid Item No. IO) Linear Feet The contract unit price paid for the 12-inch Pipeline CL 150 PVC shall constitute full compensation to furnish and install the 12-inch AWWAC-900 CL150 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including, but not limited to, traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing; complete in place as shown on the Drawings and specified in the specifications. H. 1. J. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D" TANKS - REACHES I AND 3 PAGE 01025 - 4 SECTION 01025 - MEASUREMENT AND PAYMENT K. 6-inch Pipeline CL 200 PVC (Bid Item No. 11) Linear Feet The Contract unit price paid for the 6-inch Pipeline CL 200 PVC shall constitute full compensation to furnish and install the 6-inch AWWA C-900 CL 200 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, the steel specials, the miscellaneous pipe, the fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including, but not limited to, traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing; complete in place as shown on the Drawings and specified in the specifications. 6-inch Pipeline CL 150 PVC (Bid Item No. 12) Linear Feet The Contract unit price paid for the 6-inch Pipeline CL 150 PVC shall constitute full compensation to furnish and install the 6-inch AWWA C-900 CL 150 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, the steel specials, the miscellaneous pipe, the fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including, but not limited to, traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing; complete in place as shown on the Drawings and specified in the specifications. 4-inch Pipeline CL 200 PVC (Bid Item No. 13) Linear Feet The Contract unit price paid for the 4-inch Pipeline CL 200 PVC shall constitute full compensation to furnish and install the 4-inch AWWA C-900 CL 200 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, the steel specials, the miscellaneous pipe, the fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including, but not limited to, traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing; complete in place as shown on the Drawings and specified in the specifications. 24-inch Butterfly Valves, CL 250 (Bid item No. 14) Each The Contract unit price paid for the 24-inch Butterfly Valves, CL 250, shall constitute full compensation to furnish and install 24-inch Butterfly CL 250 valve assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install valves, valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. L. M. N. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 01025 - 5 SECTION 01 025 - MEASUREMENT AND PAYMENT 0. 24-inch Butterfly Valves, CL 150 (Bid item No. 15) Each The Contract unit price paid for the 24-inch Butterfly Valves, CL 150, shall constitute full compensation to furnish and install 24-inch CL 150 butterfly valve assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install valves, valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. 12-inch Gate Valves (Bid item No. 16) Each The Contract unit price paid for the 12-inch Gate Valves shall constitute full compensation to furnish and install 12-inch gate valve assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor,'supplies and equipment required to install valves, valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. 6-inch Gate Valves (Bid item No. 17) Each The Contract unit price paid for the 6-inch Gate Valves shall constitute full compensation to furnish and install 6-inch gate valve assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install valves, valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. 4-inch Gate Valve (Bid item No. 18) Each P. 0. R. The Contract unit price paid for the 4-inch Gate Valves shall constitute full compensation to furnish and install 4-inch gate valve assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install valves, valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. S. 2-inch Air Release and Vacuum Valve (Bid Item No. 19) Each The Contract unit price paid for the 2-inch Air Release and Vacuum Valve shall constitute full compensation to furnish and install 2-inch combination air release and air vacuum assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install the air vacuum/air release valve, shut-off valves, piping, cathodic protection, air valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D"TANKS - REACHES 1 AND 3 PAGE 01025 - 6 SECTION 01025 - MEASUREMENT AND PAYMENT T. 2-inch Blow-Off Valve (Bid Item No. 20) Each The Contract unit price paid for the 2-inch Blow-Off Valve shall constitute full compensation to furnish and install the 2-inch blow off assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install the valves, piping, cathodic protection, thrust blocks, backfill, compaction, pavement, and testing to provide a complete operable system. 2-inch Manual Air Release Assembly (Bid Item No. 21) Each The Contract unit price paid for the 2-inch Manual Air Release Assembly shall constitute full compensation to furnish and install the 2-inch manual air release assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install the valves, piping, cathodic protection, concrete supports, backfill, compaction, pavement, and testing to provide a complete operable system. 2-inch Irrigation Service (Bid Item No. 22) Each The Contract unit price paid for the 2-inch Irrigation Service shall constitute full compensation to furnish and install the 2-inch irrigation service in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install the meter, valves, piping, cathodic protection, valve boxes, thrust blocks, backfill, compaction, pavement, and testing to provide a complete operable system. 4-inch Blow Off Assembly (Bid Item No. 23) Each The Contract unit price paid for the 4-inch Blow-Off Valve shall constitute full compensation to furnish and install the 4-inch blow off assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install the valves, piping, cathodic protection, thrust blocks, backfill, compaction, pavement, and testing to provide a complete operable system. U. V. W. . X. Traffic Signal Video Detection (Bid Item No. 24) Lump Sum The Contract lump sum price paid for the Traffic Signal Video Detection shall constitute full compensation for the Traffic Signal Video Detection including all labor, material, equipment, and incidentals complete in place, including but not limited to hardware, cameras, cable, appurtenances, and reprogramming as required complete in place as shown on the drawings and as specified in the specifications. Traffic Control (Bid item No. 25) Lump Sum The Contract lump sum price paid for the Traffic Control shall constitute full compensation for the Traffic Control including all labor, material, equipment, and incidentals complete in place, including but not limited to the signage, striping, protection devices, flagging, cleanup and restoration and all other WORK necessary to complete this item of WORK, complete in place as shown on the Drawings and as specified in the specifications. Y. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 01 025 - 7 SECTION 01025 - MEASUREMENT AND PAYMENT Z. Electrical/lnstrumentation (Bid Item No. 26) Lump Sum The Contract lump sum price paid for the Electricalllnstrumentation shall constitute full compensation for the Electricalllnstrumentation including all labor, material, equipment, and incidentals complete in place, including but not limited to the WORK required to conform to the SDG&E Service Order, pull boxes, conduit and wire forthe signal, power and pressure sensing lines, meter and pedestal, SDG&E meter fees, signal and power panels, panel mounting, instruments and appurtenances and all appurtenant work including but not limited to, potholing, trenching, bedding, backfill, compaction, pavement replacement, cleanup, restoration and resurfacing, as required complete in place as shown on the Drawings and as specified in the specifications. 1.6 BID SCHEDULE B - ALDERWOOD DRIVE (Sta. 1+00 to Sta. 12+40.58), BATIQUITOS DRIVE (Sa. 1+00 to Sta. 18+97.46) A. Sheeting, Shoring, and Bracing (Bid Item No. 1) Lump Sum Payment for temporary sheeting, shoring, and bracing or equivalent method will be made at the lump-sum price named in the Bid Schedule(s) under Item No. 1, which price shall constitute full compensation for completion of all planning, design, engineering fees, furnishing and constructing, and removal and disposal of such temporary sheeting, shoring, and bracing as a lump-sum item, complete, as required under the provisions of any permits, and in accordance with the requirements of OSHA and the Construction Safety Orders of the State of California, pursuant to the provisions of Section 6705 of the California Labor Code. Construction Schedule (Bid Item No. 2) Lump Sum Payment or the construction schedule shall be made at the contract lump sum price named in the bid schedule as stipulated in the supplemental provisions section 6-1.8. The contract price shall include, but is not limited to the preparation, revision, updates and submittals of the construction schedule as required and in conformance with the CONTRACT DOCUMENTS, per section 6-1 of the supplemental provisions. This Bid Item includes all other work necessary to complete this item of WORK. Storm Water Pollution Prevention Plan (SWPPP) (Bid Item No. 3) Lump Sum The Contract lump sum price paid for the SWPPP shall constitute full compensation for the SWPPP including all labor, material, equipment, and incidentals complete in place, including but not limited to the preparation, submittal, implementation, maintenance and removal of the erosion and sedimentation control measures defined by the approved SWPPP, as required, complete in place as specified in the CONTRACT DOCUMENTS. This Bid Item includes all other work necessary to complete this item of WORK. B. C. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 01 025 - 8 SECTION 01025 - MEASUREMENT AND PAYMENT D. 8-inch Pipeline CL 200 PVC (Bid Item No. 4) Linear Feet The Contract unit price paid for the 8-inch Pipeline CL 200 PVC shall constitute full compensation to furnish and install the 8-inch AWWA C-900 CL 200 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including, but not limited to, traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing; complete in place as shown on the Drawings and specified in the specifications. 8-inch Pipeline CL 150 PVC (Bid Item No. 5) Linear Feet The Contract unit price paid for the 8-inch Pipeline CL 150 PVC shall constitute full compensation to furnish and install the 8-inch AWWA C-900 CL 150 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including, but not limited to, traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing; complete in place as shown on the Drawings and specified in the specifications. 6-inch Pipeline CL 200 PVC (Bid Item No. 6) Linear Feet The Contract unit price paid for the 6-inch Pipeline CL 200 PVC shall constitute full compensation to furnish and install the 6-inch AWWA C-900 CL 200 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including, but not limited to, traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing; complete in place as shown on the Drawings and specified in the specifications. E. F. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D"TANKS - REACHES 1 AND 3 PAGE 01 025 - 9 SECTION 01025 - MEASUREMENT AND PAYMENT G. 6-inch Pipeline CL 150 PVC (Bid Item No. 7) Linear Feet The Contract unit price paid for the 6-inch Pipeline CL 150 PVC shall constitute full compensation to furnish and install the 6-inch AWWA C-900 CL 150 PVC Pipeline in complete accordance with the Contract Documents. The work includes, but is not limited to, all materials, labor, supplies, and equipment required to install the pipe, fittings, thrust blocks, adapters, backfill, compaction, pavement, testing, and disinfection of pipeline to provide a complete operable system. Work also includes, but is not limited to, restoration to original condition of all damaged surface improvements including, but not limited to, traffic loops and striping, cross gutters, curb and gutter, brick and stamped decorative concrete including medians as required, trench plating, and resurfacing: complete in place as shown on the Drawings and specified in the specifications. 8-inch Gate Valves (Bid item No. 8) Each The Contract unit price paid for the 8-inch Gate Valves shall constitute full compensation to furnish and install 8-inch gate valve assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install valves, valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. 6-inch Gate Valve (Bid item No. 9) Each The Contract unit price paid for the 6-inch Gate Valves shall constitute full compensation to furnish and install 6-inch gate valve assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install valves, valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. 2-inch Air Release and Vacuum Valve (Bid Item No. 10) Each The Contract unit price paid for the 2-inch Air Release and Vacuum Valve shall constitute full compensation to furnish and install 2-inch combination air release and air vacuum assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install the air vacuum/air release valve, shut-off valves, piping, cathodic protection, air valve can and cover, concrete supports, anchor blocks, backfill, compaction, pavement, and testing to provide a complete operable system. 2-inch Blow-Off Valve (Bid Item No. 11) Each The Contract unit price paid for the 2-inch Blow-Off Valve shall constitute full compensation to furnish and install the 2-inch blow off assemblies in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install the valves, piping, cathodic protection, thrust blocks, backfill, compaction, pavement, and testing to provide a complete operable system. H. I. J. K. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE01025-10 SECTION 01025 - MEASUREMENT AND PAYMENT L. 2-inch Irrigation Service (Bid Item No. 12) Each The Contract unit price paid for the 2-inch Irrigation Service shall constitute full compensation to furnish and install the 2-inch irrigation service in complete accordance with the Contract Documents. The work includes, but is not limited to all materials, labor, supplies and equipment required to install the meter, valves, piping, cathodic protection, valve boxes, thrust blocks, backfill, compaction, pavement, and testing to provide a complete operable system. Traffic Signal Video Detection (Bid Item No. 13) Lump Sum The Contract lump sum price paid for the Traffic Signal Video Detection shall constitute full compensation for the Traffic Signal Video Detection including all labor, material, equipment, and incidentals complete in place, including but not limited to hardware, cameras, cable, appurtenances, and reprogramming as. required complete in place as shown on the drawings and as specified in the specifications. Traffic Control (Bid item No. 14) Lump Sum The Contract lump sum price paid for the Traffic Control shall constitute full compensation for the Traffic Control including all labor, material, equipment, and incidentals complete in place, including but not limited to the signage, striping, protection devices, flagging, cleanup and restoration and all other WORK necessary to complete this item of WORK, complete in place as shown on the Drawings and as specified in the specifications. M. N. 1.7 BID SCHEDULE C - ASPHALT PAVEMENT OVERLAY A. Traffic Control (Bid Item No. 1) Lump Sum The Contract lump sum price paid for the Traffic Control shall constitute full compensation for the Traffic Control including all labor, material, equipment, and incidentals complete in place, including but not limited to the signage, striping, protection devices, flagging, cleanup and restoration and all other Work necessaryto complete this item of Work, complete in place as shown on the Drawings and as specified in the Specifications. Mobilization and Demobilization (Bid Item No. 2) Lump Sum Payment for mobilization/demobilization shall be made at the contract lump sum price named in the bid schedule complete and in accordance with the CONTRACT DOCUMENTS, and based on the project progress defined in Section 9-3.4.1 of the Supplemental Provisions. The contract price shall include, but is not limited to the following items in addition to all items identified in the Supplemental Provisions Section 9-3.4.1 : mobilizing labor force, equipment and construction facilities onto site; provide storage yard; securing construction water supply, providing on-site sanitary facilities; posting OSHA requirements and establishing safety programs; project cleanup and closeout. This Bid Item includes all other work necessary to complete this item of WORK. B. JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 01 025 - 11 SECTION 01025 - MEASUREMENT AND PAYMENT C. D. E. F. G. H, I. JULY 2003 CWRF PIPE1 Full Depth Asphalt Concrete Patch (Bid Item No. 3) Tons The Contract unit price paid for the Full Depth Asphalt Concrete Patch, shall constitute full compensation including all labor, material, equipment, disposal, and incidentals complete in place, including but not limited to saw cutting, removal, excavation, disposal, pavement replacement, restoration and resurfacing as required and as shown on the Drawings and as specified in the specifications. Asphalt Rubber Hot Mix (ARHM) overlay (Bid Item No. 4) Tons The Contract unit price paid for Asphalt Rubber Hot Mix (ARHM) overlay shall constitute full compensation including all labor, material, equipment, and incidentals complete in place, including but not limited to the placement of asphalt rubberized hot mix overlay as required and as shown on the Drawings and as specified in the specifications. Cold Milling 5' Width (Bid Item No. 5) Linear Feet The Contract unit price paid for Cold Milling 5' Width shall constitute full compensation including all labor, material, equipment, and incidentals complete in place, including but not limited to the grinding and the cold milling as required and as shown on the Drawings and as specified in the specifications. Cold Milling IO' Wide Header Cut (Bid Item No. 6) Linear Feet The Contract unit price paid for Cold Milling 1O'Wide Header Cut shall constitute full compensation including all labor, material, equipment, and incidentals complete in place, including but not limited to the grinding and the cold milling as required and as shown on the Drawings and as specified in the specifications. Full Raise of Sewer & Stormdrain Manholes (Bid Item No. 7) Each The Contract unit price paid for Full Raise of Sewer & Stormdrain Manholes shall constitute full compensation including all labor, material, equipment, and incidentals complete in place, including but not limited to the locating, evaluating and adjusting to finish grade as necessary all manholes affected by the overlay as required and as shown on the Drawings and as specified in the specifications. Full Raise of Valve Boxes, Monument Boxes, ect. (Bid Item No. 8) Each The Contract unit price paid for Full Raise of Valve Boxes, Monument Boxes, ect. shall constitute full compensation including all labor, material, equipment, and incidentals complete in place, including but not limited to the locating, evaluating and adjusting to finish grade as necessary all utility, valve boxes, vaults, sewer cleanouts, storm drain grates, inlets, survey monuments and other surface improvements affected by the overlay as required and as shown on the Drawings and as specified in the specifications. Pavement Delineation (Bid Item No. 9) Lump Sum The Contract unit price paid for Pavement Delineation shall constitute full compensation including all labor, material, equipment, and incidentals complete in MEASUREMENT AND PAYMENT -INE TO "D" TANKS - REACHES 1 AND 3 PAGE 01 025 - 12 SECTION 01025 - MEASUREMENT AND PAYMENT place, including but not limited to all striping, signage, stop limits, reflective markers, pavement markings, crosswalks, pavement arrows, pavement legends, including removal of markings by grinding and repainting, cleanup and disposal all as required and as shown on the Drawings and as specified in the specifications END OF SECTION JULY 2003 MEASUREMENT AND PAYMENT CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 01025 - 13 SECTION 02140 - DEWATERING PART 1 - GENERAL 1 .I 1.2 1.3 1.4 DESCRIPTION A. This section includes design, materials, installation, maintenance, operation and removal of temporary dewatering systems, and disposal of pumped water. RELATED WORK SPECIFIED ELSEWHERE A. Section 02200 "Earthwork" B. REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. California Regional Water Quality Control Board General Waste Discharge Requirements for Groundwater Remediation and Dewatering Waste Discharges, Order Number 90-31 and 91-10, Copies of the Waste Discharge Requirements may be obtained from the ENGINEER upon request. Section 02601 "Buried Piping Installation". B. NOT USED. C. NOT USED. DESIGN CRITERIA A. A Civil Engineer registered in the State of California shall design the dewatering systems to perform as follows: 1. Effectively reduqe the hydrostatic pressure and lower the groundwater levels below the excavation; 2. Develop a substantially dry and stable subgrade for prosecution of construction operations; Prevent damage to adjacent properties, building, structures, utilities and other WORK; and Assure that, after 12 hours of initial pumping, no soil particles will be present in the discharge. 3. 4. 6. Methods of dewatering may include sump pumping, single or multiple stage well point systems, educator and ejector type systems, deep wells, and combinations thereof. C. Locate dewatering facilities where they shall not interfere with utilities and construction WORK to be performed by others. 0. Modify dewatering procedures which cause, or threaten to cause, damage to new or existing facilities, so as to prevent further damage. Install settlement gauges, as JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 DEWATERING PAGE 02140 - 1 SECTION 02140 - DEWATERING 1.5 necessary, to monitor settlement of critical structures or facilities adjacent to areas of dewatering. Control the rate of dewatering to avoid all objectionable settlement and subsidence. Comply with Regional Water Quality Control Board Waste Discharge requirements under Orders 92-25 and 96-41. Obtain a permit and comply with the proper requirements specified therein. The CONTRACTOR shall furnish, install, and operate all pumps, pipes, and equipment of sufficient capacity to remove the groundwater. The CONTRACTOR shall take extreme care to prevent the pumping of fine material by his dewatering methods. If the quantity of fines being removed is determined by the ENGINEER to be excessive the CONTRACTOR must alter his dewatering method or utilize a different dewatering method. If the CONTRACTOR elects to use dewater wells, the location of the wells are subject to the approval of the City of Carlsbad. The slotted steel cassions for the dewater wells must have openings which are not greater than 0.0030 inches. Backfill material around the outside of the cassion shall be No. 12 silica sand or approved equal. In some cases, the approximate depth to groundwater or estimate groundwater elevation may be shown on the Drawings or included within the Specifications. The City does not guarantee these groundwater elevations and the information is provided only as a general indications of past experience within the City. Should the CONTRACTOR desire additional groundwater information prior to bid, he shall perform exploratory excavations at his own expense in accordance with the information and instruction for bidders. The CONTRACTOR shall make exploratory excavations prior to construction to determine the elevation of the groundwater. The CONTRACTOR shall be responsible for all damages which may result from his dewatering operations, including any surface subsidence that may occur from the pumping of excess fine material. E. F. G. H. I. Full compensation for furnishing all labor, materials, tools, equipment and incidentals, and for doing all the WORK involved in dewatering, as specified herein, and as directed by the ENGINEER shall be considered as included in the contract priced paid for the various items of WORK, and no additional compensation will be allowed therefore. SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. B. Shop Drawings shall, at a minimum, indicate the following: 1. The proposed type of dewatering system: 2. Arrangement, location, and depths of systems components; JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 DEWATERING PAGE 02140 - 2 SECTION 02140 - DEWATERING 3. Complete description of equipment and instrumentation to be used with installation, operation and maintenance procedures; Types and sizes of filters; Design calculations demonstrating adequacy of the proposed system and equipment; and Methods of disposal,of pumped water. 4. 5. 6. PART 2 - MATERIALS 2.1 MATERIALS AND EQUIPMENT A. Fumish all materials, tools, equipment, facilities and services as required for providing the necessary dewatering WORK and facilities. Provide back-up equipment as necessary for replacement and for unanticipated emergencies. Provide piezometer for monitoring groundwater levels and other instruments and measuring devices as required. B. PART 3 - EXECUTION 3.1 DEWATERING A. Perform dewatering in accordance with approved Shop Drawings. Keep the ENGINEER advised of any changes made to accommodate field conditions and, on completion of the dewatering system installation, revise and resubmit Shop Drawings as necessary to indicate the installed configuration. Organize dewatering operations to lower the groundwater level in excavations as required for prosecution of the WORK, and to provide a stable, dry subgrade for the prosecution of construction operations. Maintain water level at lower elevations, so that no danger to structures can occur because of buildup of excessive hydrostatic pressure, and provide for maintaining the water level a minimum of 2 feet below the subgrade, unless othetwise permitted by the ENGINEER. The extent of dewatering may be reduced for structures designed to withstand hydrostatic uplift pressure, provided such water level does not result in uplift pressures in excess of 80 percent of the downward pressure produced by the weight of the structure and backfill in place. Maintain groundwater level a minimum of 5 feet below the prevailing level Of backfill being placed. B. C. D. E. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 DEWATERING PAGE 02140 - 3 SECTION 02140 - DEWATERING F. Dispose of water in such a manner as to cause no injury or nuisance to public or private property, or be a menace to the public health. Dispose of the water in accordance with the requirements contained in the California Regional Water Quality Control Board General Waste Discharge Requirements, Order Numbers 90-31 and 91-10, Do not drain trench water through the pipeline under construction. The dewatering operation will be continuous, so that the excavated areas shall be kept free from water during construction, while concrete is setting and achieves full strength, and until backfill has been places to a sufficient height to anchor the WORK against possible flotation. Prevent disposal of sediments from the soils to adjacent lands or wateways by employing whatever methods are necessary, including settling basins. Furnish temporaly drainage facilities to convey and dispose of surface water falling on or passing over the site. G. H. I. 3.2 RECORDS A. Observe and record the average flow rate and time of operation of each pump used in the dewatering system. Where necessary provide appropriate devices, such as flow meters, for observing the flow rates. Submit the data during the period that the dewatering system is in operation. Observe and record the elevation of the groundwater during the period that the dewatering system is in operation. B. END OF SECTION JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 DEWATERING PAGE 02140 - 4 SECTION 02200 - EARTHWORK PART 1 - GENERAL 1.1 THE REQUIREMENT A. The WORK of this section includes all earthwork required for construction of the WORK. Such earthwork shall include, but not be limited to, the loosening, removing, loading, transporting, depositing, and compacting in its final location of all materials wet and dry, as required for the purposes of completing the WORK specified in the CONTRACT DOCUMENTS, which shall include, but not be limited to, the furnishing, placing, and removing of sheeting and bracing necessary to safely support the sides of all excavation; all pumping, ditching, draining, and other required measures for the removal or exclusion of water from excavation; 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; borrow of materials to make up deficiencies for fills; and all other incidental earthwork, all in accordance with the requirements of the CONTRACT DOCUMENTS. No classification of excavated materials will be made. Excavation includes all materials regardless of type, character, composition, moisture or condition thereof. 1.2 CONTRACTOR SUBMITTALS B. A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. B. Trenchina Plans. 1. The CONTRACTORS attention is directed to the provisions for "Shoring and Bracing Drawings" in Section 6705 of the California Labor Code. The CONTRACTOR, prior to beginning any trench or structure excavation 5 feet deep or over shall submit to the OWNER and shall be in receipt of the OWNERS written acceptance of the CONTRACTORS detailed plan showing design of all shoring, bracing, sloping of the sides of excavation. or other provisions for worker protection against the hazard of caving ground during the excavation of such trenches or structure excavation. The plans shall be prepared by a civil or structural engineer licensed in the State of California. As a part of the plan, a note shall be included stating that the registered civil or structural engineer certifies that the plan complies with the CALOSHA Construction Safety Orders. If. however, the plan does not comply with the Safety Orders, the plan shall include a note stating that the registered civil or structural engineer certifies that the plan is not less effective than the shoring, bracing, sloping, or other provisions of the Safety Orders. Each copy of the plan shall have an original seal and "wet" signature of a civil or structural engineer registered in the State of California across the seal. 2. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 1 SECTION 02200 - EARTHWORK 3. If the CONTRACTORS trench protection system includes the use of a shield, the shield design shall be approved by the Division of Industrial Safety. Structural details shall indicate the maximum pressure the shield can safely withstand, the trench configuration and supporting calculations indicating the maximum pressure against the shield. In portions of the trench near critical existing facilities and areas of dry granular soils, the CONTRACTOR shall use sheeting as required by the ENGINEER in lieu of a shield. 4. The OWNER, the ENGINEER, the consulting engineer, or their consultants may have made investigations of subsurface conditions in areas where the WORK is to be performed. If so, these investigations are identified in the specifications and the records of such investigations are available for inspection at the offices of the OWNER. The detailed plan showing the design of the shoring, etc., which the CONTRACTOR is required to submit to the ENGINEER in advance of excavation will not be accepted by the ENGINEER if the plan is based on subsurface conditions which are more favorable than those revealed by the investigations made by the OWNER, the ENGINEER, the consulting engineer, or their consultants; nor will the plan be accepted if it is not based on soils-related design criteria set forth in the report on the aforesaid investigations of the subsurface conditions. The detailed plan showing the design of the shoring etc., shall include surcharge loads for nearby embankments and structures, for spoil banks, and for construction equipment and other construction loadings. The plan shall indicate for all trench conditions the minimum horizontal distances from the side of the trench at its top to the near side of the surcharge loads. Nothing contained in the section shall be construed as relieving the CONTRACTOR of the full responsibility for providing shoring, bracing, sloping, or other provisions which are adequate for worker protection. Nothing in this section is intended to relieve the CONTRACTOR of his responsibility to carefully examine the contract documents and the site where the WORK is to be performed; to familiarize himself with all the local conditions and federal, state, and, local laws, ordinances, rules, and regulations that may affect the performance of any WORK; to study all surveys and investigation reports about subsurface and latent physical conditions pertaining to the site; to perform any additional surveys and investigations as the CONTRACTOR deems necessary to complete the WORK at his bid price: and to correlate the results of all such data with the requirements of the contract documents. 5. 6. 7. C. Samples of backfill materials described in paragraph 2.4C subparagraphs 3b, 5, 7, 9, IO. and 12 shall be submitted for testing. D. NOT USED JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 2 SECTION 02200 - EARTHWORK E. A list and description of compaction equipment intended for use by the CONTRACTOR shall be submitted to the ENGINEER for approval in accordance with the requirements of this section. F. The CONTRACTOR shall submit a dewatering plan if necessary. The dewatering plan shall clearly identify the dewatering system proposed to be employed by the CONTRACTOR. G. Storm Water Pollution Prevention and Monitoring Plan: Comply with the requirements of Section 7-8.6, Water Pollution Control. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of the SPECIFICATIONS, all WORK specified herein shall conform to the local Grading Codes of the City and/or County having jurisdiction, Chapter 70 of the Uniform Building Code, or exceed the applicable requirements of the following documents to the extent that the provisions of such documents are not in conflict with the requirements of this section. 1. Commercial Standards: JULY 2003 CWRF PIPELINE TO ASTM D 422 ASTM D 1140 ASTM D 1556 ASTM D 1557 ASTM D 1633 ASTM D 2419 ASTM D 2487 ASTM D 2901 "D TANKS - REACHES 1 AND 3 Method for Particle-Size Analysis of Soils. Test Method for Amount of Material in Soils Finer than the No. 200 (75- um) Sieve. Test Method for Density of Soil in Place by the Sand-Cone Method. Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft- Ibf/ft) Test Method for Compressive Strength of Molded Soil-Cement Cylinders. Test Method for Sand Equivalent Value of Soils and Fine Aggregate. Classification of Soils for Engineering Purposes. Test Method for Cement Content of Freshly-Mixed Soil-Cement. EARTH WORK PAGE 02200 - 3 SECTION 02200 - EARTHWORK ASTM D 4318 ASTM D 3017 ASTM D 2922 AASHTO T 224 Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils. Test Method for Moisture Content of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth). Test Method for Density of Soil and Soil Aggregate in Place by Nuclear Methods. Correction for Coarse Particles in the Soil Compaction Test. B. All work herein shall also conform to the following documents incorporated into this specification herein by reference. 1. "Geofechnical Evaluation - Recycled Water Distribution Pipelines - Carlsbad, Ca/ifomia"revised June 2, 2003 by Ninyo & Moore. 1.4 QUALITY ASSURANCE A. General: All soils testing will be done by a testing laboratory of the OWNERs choice and at the OWNERs expense. Where soil material is required to be compacted to a percentage of maximum density, the maximum density at optimum moisture content will be determined in accordance with ASTM D 1557. Field density in-place tests will be performed in accordance with ASTM D 1556, ASTM D 2992 or by such other means acceptable to the ENGINEER. In case the tests of the fill or backfill show non-compliance with the required density, the CONTRACTOR shall accomplish such remedy as may be required to insure compliance. Subsequent testing to show compliance shall be by a testing laboratory selected by the OWNER and shall be at the CONTRACTORS expense. B. C. D. Particle size analysis of soils and aggregates will be performed using ASTM D 422. E. F. Unified Soil Classification System. References in these SPECIFICATIONS to soil classification type and standards set forth in ASTM D 2487 shall have the meanings and definitions indicated in the Unified Soil Classification System. The CONTRACTOR shall be bound by all applicable provisions of said ASTM D 2487 in the interpretation of soil classifications. Determination of sand equivalent value will be performed using ASTM D 2419. JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 4 SECTION 02200 - EARTHWORK G. ComDaction Testinq. Field tests of the moisture content and degree of compaction of the fill soils will be performed at the direction of the ENGINEER based on field conditions encountered. However, in general, the tests should be taken at approximate intervals of 2 feet in vertical rise and/or 1,000 cubic yards of compacted till soils. In addition, on slope faces, as a guideline, approximately one test should be taken for each 5,000 square feet of slope face andlor each 10 feet of vertical height of slope. PART 2 - PRODUCTS 2.1 SUITABLE FILL AND BACKFILL MATERIAL REQUIREMENTS A. General. Fill, backfill, embankment materials shall be suitable selected or processed clean, fine earth, rock or sand, free from grass, roots, brush, or other vegetation. Fill and backfill materials to be placed within 6 inches of any structure or pipe shall be free of rocks or unbroken masses of earth materials having a maximum dimension larger than 3 inches. Suitable Materials. Soils not classified as unsuitable as defined in Paragraph entitled, "Unsuitable Material" herein, are defined as suitable materials and may be used in fills, backfilling, and embankment construction subject to the specified limitations. Suitable materials may be obtained from onsite excavations, may be processed onsite materials, or may be imported. If imported materials are required to meet the requirements of this section or to meet the quantity requirements of the PROJECT, the CONTRACTOR shall provide the imported materials at no additional expense to the OWNER. The following types of suitable materials are designated and defined as follows: 1. Tvpe: Not Used. 2. m: Not Used. 3. B. C. D. E. TvDe C: Sand with 100 percent passing a 3/8-inch sieve, at least 90 percent passing a Number 4 sieve, and a sand equivalent value of not less than 30 or having a coefficient of permeability greater than 35mm per hour (1.4 incheslhour). TvDe D: (3/4-inch by No. 4 aggregate) Crushed rock or gravel with 100 percent passing a I-inch sieve and not more than 5 percent passing a Number 4 sieve. Tvpe: (Pea gravel) Crushed rock or gravel with 100 percent passing a 112-inch sieve and not more than 10 percent passing a Number 4 sieve. 4. 5. JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 5 SECTION 02200 - EARTHWORK 6. Type F: Crushed rock or gravel meeting the following gradation requirements: Sieve Size Percentage Passinq 2-inch 1-112-inch I-inch 3/4-inch 100 94 - 96 20 - 40 4-8 7. Tvpe G: (Class II Aggregate Base) Crushed rock aggregate base material of such nature that it can be compacted readily by watering and rolling to form a firm. stable base for pavements. At the option of the CONTRACTOR, the grading for either the 1-112 inch maximum size or 3/4-inch maximum size shall be used. The sand equivalent value shall be not less than 22, and the material shall meet the following gradation requirements. Class II aggregate base shall be in accordance with the State of California Department of Transportation Standard Specifications, Section 2b-1. Sieve Size Percentage Passinq 1-1/2 inch Max. 3/4-inch Max. l-1/2-inch 90 - 100 100 1 -inch - 100 3/4-inch 50 - a5 90 - 100 No. 4 25 - 45 35- 55 No. 30 10 - 25 10- 30 No. 200 2-9 2- 9 8. m: Not Used. 9. m: Any other suitable material as defined in Paragraph 2.2, herein. For materials to be placed beneath structures, said material shall have at least 40 percent of material smaller than 1/4-inch in size and shall have an expansion index of 30 or less when tested in accordance with UBC Standard 29-2. 10. Type J: (Cement treated base) Material which consist of Type H material, or any mixture of Types B, C, G, and H materials which has been cement-treated so that the cement content of the material is not less than 5 percent by weight when tested in accordance with ASTM D 2901. The ultimate compressive strength at 28 days shall be not less than 400 psi when tested in accordance with ASTM D 1633. TvDe K: Stockpiled topsoil material which has been obtained at the site by removing soil to a depth not exceeding 2 feet. Removal of the topsoil shall be done after the area has been stripped of vegetation and debris as specified. 11. JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 6 SECTION 02200 - EARTHWORK 12. Cement Slum Backfill: Cement slurry shall have a cement to sand ratio of 1-1/4 sacks of cement to 1 cubic yard of sand, with a water content of approximately 65 gallons of water. The sand material shall have a sand equivalent of not less than 60. 2.2 UNSUITABLE MATERIAL A. Unsuitable soils for fill material shall include soils which, when classified under the standard method for "Classification of Soils for Engineering Purposes," ASTM D 2487, fall in the classifications of Pt, OH, CH, MH, or OL. In addition, any soil containing organic (brush, root, sod or other deleterious material) matter, having a plastic limit of less than 8 percent when tested in accordance with the requirements of ASTM D 4318 and containing more than 25 percent of material, by weight, passing the Number 200 sieve when analyzed according to the requirements of ANSVASTM D 1140; or any soil which cannot be compacted sufficiently to achieve the percentage of maximum density specified for the intended use, shall be classed as unsuitable material. Oversize: Oversize material, defined as rock or other irreducible material with a maximum dimension greater than 6 inches, shall not be buried or placed in fills, unless the location, materials, and disposal methods are specifically approved by the ENGINEER. Oversize disposal operations must be such that nesting of oversize material does not occur, and such that the oversize material is completely surrounded by compacted or densified fill. Oversize material should not be placed within 10 feet vertically of finish grade, within 2 feet of future utilities or underground construction, or within 15 feet horizontally of slope faces. B. C. 2.3 USE OF FILL, BACKFILL, AND EMBANKMENT MATERIAL TYPES A. The CONTRACTOR shall use the types of materials as designated herein for all required fill, backfill, and embankment construction hereunder. Where these SPECIFICATIONS conflict with the requirements of any local agency having jurisdiction, or with the requirements of a material manufacturer, the ENGINEER shall be immediatelv notified. In case of conflict therewith. the B. CONTRACTOR shall use the most itringent requirement, as determined by the ENGINEER. C. Fill and backfill types shall be used in accordance with the following provisions: 1. Not Used. 2. Pipe bedding backfill as defined under "Pipe and Utility Trench Backfill" within paragraph 3.12 of this section, shall consist of Type C materials. Pipe zone backfill, as defined under "Pipe and Utility Trench Backfill" within paragraph 3.12 of this section, shall consist of the following materials for each pipe material listed below. 3. JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 7 SECTION 02200 - EARTHWORK 4. 5. 6. 7. 8. 9. IO. 11. 12. a. Plastic pipe, and asbestos-cement pipe shall be provided Type C pipe zone backfill material. Perforated plastic pipe ductile iron and vitrified clay pipe shall be backfilled with Type E pipe zone backfill material. Steel pipe shall be backfilled with Type C pipe zone backfill material. b. C. Trench zone backfill for pipelines as defined under "Pipe and Utility Trench Backfill" within 3.12 of this Section shall be Type I backfill material. Final backfill material for pipelines under paved areas or areas to be paved, as defined under "Pipe and Utility Trench Backfill" within paragraph 3.12 of this section shall be Type G backfill material. Final backfill under areas not paved shall be the same material as that used for trench backfill except that Type K material shall be used for final backfill in agricultural or landscaped areas, unless otherwise noted. Trench backfill and final backfill for pipelines under structures shall be the same material as used in the pipe zone, except where concrete encasement is required by the CONTRACT DOCUMENTS. Aggregate base materials under pavements shall be Type G material constructed to the thicknesses shown or specified. Backfill around structures shall be Type I material, or Tvpes A throuqh Tvpe H materials, or any mixture thereof. The top 6 inches of landscaped trench fills shall consist of Type K material, topsoil. Backfill used to replace pipeline trench over-excavation shall be Type F material for wet trench conditions or the same material as used for the pipe zone backfill if the trench conditions are not wet. Where required by the CONTRACT DOCUMENTS, pea gravel shall be Type E material. Backfill behind berms or similar structures shall be Type K materials. PART 3 - EXECUTION 3.0 SECTION INCLUDES A. Structure and Roadway Excavation B. Pipeline and Utility Trench Excavation JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 8 SECTION 02200 - EARTHWORK C. D. E. F. G. H. I. J. K. L. M. Over-Excavation not Ordered, Specified, or Shown Excavation in Vicinity of Trees NOT USED NOT USED Disposal of Excess and Unsuitable Excavated Material Backfill - General Placing and Spreading of Backfill Materials Compaction of Fill, Backfill, and Embankment Materials Pipe and Utility Trench Backfill Embankment Construction Erosion Control 3.1 GENERAL A. The WORK of this Section includes all earthwork required for construction of the WORK. Such earthwork shall include, but not be limited to, the loosening, removing, loading, transporting, depositing, and compacting in its final location of all materials wet and dry, as required for the purposes of completing the WORK specified in the CONTRACT DOCUMENTS, which shall include, but not be limited to, the furnishing, placing, and removing of sheeting and bracing necessary to safely support the sides of all excavations; all pumping, ditching, draining, and other required measures for the removal or exclusion of water from excavation; 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; borrow of materials to make up deficiencies for fills; and all other incidental earthwork, all in accordance with the requirements of the CONTRACT DOCUMENTS. 3.2 STRUCTURE AND ROADWAY EXCAVATION A. General. Except when specifically provided to the contrary, excavation shall include the removal of all materials of whatever nature encountered, including all obstructions of any nature that would interfere with the proper execution and completion of the WORK. The removal of said materials shall conform to the lines and grades shown or ordered. Unless otherwise provided, the entire construction site shall be stripped of all vegetation and debris, and such material shall be removed from the site prior to performing any excavation or placing any fill. Holes resulting from removal of buried obstructions which extend below finished site grades should be replaced with suitable compacted fill material. JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 9 SECTION 02200 - EARTHWORK The CONTRACTOR shall furnish, place, and maintain all supports and shoring that may be required for the sides of the excavations, and all pumping, ditching, or other approved measures for the removal or exclusion of water, including taking care of storm water, groundwater, and wastewater reaching the site of the WORK from any source so as to prevent damage to the WORK or adjoining property. Excavations shall be sloped or otherwise supported in a safe manner in accordance with applicable State safety requirements and the requirements of OSHA Safety and Health Standards for Construction (29CFR1926). B. Excavation Beneath Structures. Except where otherwise specified for a particular structure or ordered by the ENGINEER, excavation shall be carried to the grade of the bottom of the footing or slab. Where shown or ordered, areas beneath structures or fills shall be over-excavated. When such over-excavation is shown on the CONTRACT DRAWINGS, both over-excavation and subsequent backfill to the required grade shall be performed by the CONTRACTOR at its own expense. When such over-excavation is not shown but is ordered by the ENGINEER, such over-excavation and any resulting backfill will be made in accordance with the negotiated price. After the required over-excavation has been completed, the exposed surface shall be scarified to a depth of 6 inches, brought to optimum moisture content, and rolled with heavy compaction equipment to the densities specified in paragraph 3.1 1 of this section. Additional requirements for allowable types of compaction equipment are detailed in paragraph 3.13 of this section. Excavation Beneath Paved Areas. Excavation under areas to be paved shall extend to the bottom of the aggregate base. After the required excavation has been completed, the exposed surface shall be scarified, brought to optimum moisture content, and rolled with heavy compaction equipment to 95 percent of maximum density. Removal of Existinq Pavements and Surface Imwovements. 1. C. D. Removal of existing asphalt pavement and concrete pavement and surface improvements shall conform to SSPWC Section 300-1.3.2 except as modified below. All portland cement concrete pavement surfaces shall be scored with concrete sawing equipment; provided, that any portland cement concrete base under an asphaltic mix surface will not be required to be scored by sawing. Asphaltic-concrete pavement shall be removed to clean straight lines by means of a cutting wheel. Impact cutting will not be acceptable. If a strip of existing pavement less than 4 feet is left between the trench and a gutter, it shall be removed and new pavement placed in its stead. In cutting or breaking up street surfacing, the CONTRACTOR shall not use equipment which will damage the adjacent pavement. The existing A.C. pavement on major and primary arterials shall be sawcut to a minimum depth of 3 inches as directed by the ENGINEER. 2. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 10 SECTION 02200 - EARTHWORK 3. Use of asphalt-grinding equipment will be permitted for use in asphaltic- concrete pavement removal only with the provision that dust-abatement procedures are strictly observed as specified in Section 01560 of these Specifications. E. Notification of EnQineer. The CONTRACTOR shall notify the ENGINEER in writing at least 3 days in advance of completion of any structure excavation and shall allow the ENGINEER a review period of at least one day before the exposed foundation excavation is scarified and compacted or is covered with backfill or with any construction materials. 3.3 PIPELINE AND UTILITY TRENCH EXCAVATION A. General. Unless otherwise shown or ordered, excavation for pipelines and utilities shall be vertical open-cut trenches. Trench widths shall be kept as narrow as is practical for the method of pipe zone densification selected by the CONTRACTOR, but shall have a minimum width at the bottom of the trench equal to the outside diameter of the pipe plus 24 inches for mechanical compaction methods and 18 inches for water consolidation methods and a maximum width at the top of the pipe equal to the outside diameter of the pipe plus 36 inches. Trench Bottom. Except when pipe bedding is required, the bottom of the trench shall be excavated uniformly to the grade of the bottom of the pipe. The trench bottom shall be given a final trim, using a string line for establishing grade, such that each pipe section when first laid will be continually in contact with the ground along the extreme bottom of the pipe. Rounding out the trench to form a cradle for the pipe will not be required. Own Trench. Except by permission of the ENGINEER the maximum amount of open trench permitted in any one location shall be 500 feet, or the length necessary to accommodate the amount of pipe installed in a single day, whichever is greater. All trenches shall be fully backfilled at the end of each day, or in lieu thereof, shall be covered by heavy steel plates adequately braced and capable of supporting vehicular traffic in those locations where it is impractical to backfill at the end of each day. The above requirements for backfilling or use of steel plate will be waived in cases where the trench is located further than 100 feet from any traveled roadway or occupied structure. In such cases, however, barricades and warning lights meeting OSHA requirements shall be provided and maintained. B. C. D. Trench Over-Excavation Where Shown. Where the DRAWINGS indicate that trenches shall be over-excavated, they shall be excavated to the depth shown, and then backfilled to the grade of the bottom of the pipe. WORK specified in this Paragraph shall be performed by the CONTRACTOR at its own expense. E. Over-Excavation When Ordered. When ordered by the ENGINEER, whether indicated on the CONTRACT DRAWINGS or not, trenches shall be over- excavated beyond the depth shown. Such over-excavation shall be to the depth ordered. The trench shall then be backfilled to the grade of the bottom of the JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES I AND 3 EARTHWORK PAGE 02200 - 11 SECTION 02200 - EARTHWORK 3.4 3.5 3.6 3.7 3.8 3.9 pipe. All WORK specified in this section shall be performed by the CONTRACTOR at its own expense when the over-excavation ordered by the ENGINEER is less than 6 inches below the limits shown. When the over- excavation ordered by the ENGINEER is 6 inches or greater below the limits shown, additional payment will be made to the CONTRACTOR for that portion of the WORK which is located below said 6-inch distance. Said additional payment will be made in accordance with a negotiated price. F. NOT USED OVER-EXCAVATION NOT ORDERED, SPECIFIED, OR SHOWN A. Any over-excavation carried below the grade ordered, specified, or shown, shall be backfilled to the required grade with the specified material and compaction. Such WORK shall be performed by the CONTRACTOR at its own expense. EXCAVATION IN VICINITY OF TREES A. Except where trees are indicated within the CONTRACT DOCUMENTS to be removed, trees shall be protected from injury during construction operations. No tree roots over 2 inches in diameter shall be cut without the written permission of the ENGINEER. Trees shall be supported during excavation as may be directed by the ENGINEER. NOT USED NOT USED DISPOSAL OF EXCAVATED MATERIAL A. Material removed from the excavations which' does not conform to the requirements for fill and excess excavated materials shall be hauled away from the project site and disposed of in compliance with ordinances, codes, laws and regulations at no additional cost to the District. The CONTRACTOR shall utilize highway legal trucks for the export of material from the project site and to a site secured by the CONTRACTOR. No earth moving equipment or special construction equipment, as defined in Section 565, of the California Vehicle Code, will be allowed for hauling material on public streets. BACKFILL - GENERAL A. Backfill shall not be dropped directly upon any structure or pipe. Backfill shall not be placed around or upon any structure until the concrete has attained sufficient strength to withstand the loads imposed and a minimum of seven days has lapsed since the concrete was placed. B. Except for gravelhock materials being placed in over-excavated areas or trenches, backfill shall not be placed until after all water is removed from the excavation. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 12 SECTION 02200 - EARTHWORK 3.10 PLACING AND SPREADING OF BACKFILL MATERIALS A. Backfill materials shall be placed and spread evenly in level layers at all times. When compaction is achieved using mechanical equipment the layers shall be evenly spread in &inch thick loose lifts. Flooding and jetting methods of compaction will only be allowed upon written approval from the ENGINEER and will be restricted to grading operations entailing the disposal of over-size rock material. During spreading each layer shall be thoroughly mixed as necessary to promote uniformity of material in each layer. Pipe zone backfill materials shall be manually spread around the pipe so that when compacted the pipe zone backfill will provide uniform bearing and side support. Where the backfill material moisture content is below the optimum moisture content water shall be added before or during spreading until the proper moisture content is achieved. Where the backfill material moisture content is too high to permit the specified degree of compaction the material shall be dried until the moisture content is satisfactory. Where indicated on the plans or directed by the ENGINEER, a cement-slurry backfill shall be required. B. C. D. E. 3.1 I COMPACTION OF FILL, BACKFILL, AND EMBANKMENT MATERIALS A. Each layer of Types C, G, H. I, and K backfill materials as defined in Paragraph 2.2E, herein, where the material is graded such that at least 10 percent passes a Number 4 sieve, shall be mechanically compacted to the specified percentage of maximum density. Equipment that is consistently capable of achieving the required degree of compaction shall be used and each layer shall be compacted over its entire area while the material is at the required moisture content. Each layer of Type D, E, F, and J backfill materials shall be compacted by means of at least 8 passes from a flat plate vibratory compactor, except when such materials are used for pipe zone, backfill vibratory compaction shall be used at the top of the pipe zone or at vertical intervals of 24 inches, whichever is least. A minimum of eight passes shall be made by the compaction equipment. This may be subject to change based on the actual field conditions at the discretion of the ENGINEER. Flooding, ponding, and jetting compaction methods shall not be used to achieve specified compaction unless approved in writing by the ENGINEER and utilize to compact around oversize rock material. Backfill and compaction around newly poured concrete structures, cement-slurry backfill, concrete pipe encasements and similar structures shall not proceed until after 7 days after the concrete pour. Moisture conditions will only be allowed at the borrow site. B. C. D. NOT USED JULY 2003 CWRF PIPELINE TO “D” TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 13 SECTION 02200 - EARTHWORK E. Pipe zone backfill materials that are granular may be compacted by a combination of flooding and vibration using concrete vibrators or by jetting, when acceptable to the ENGINEER. Pipeline trench zone backfill materials, containing 5 percent or less of material passing a No. 200 sieve, may be compacted using flooding and jetting or vibration if the CONTRACTOR uses effective procedures that yield the specified compaction test results. Flooding and jetting shall not be done in such a manner that nearby utilities are damaged, or in areas of poorly draining or expansive soils. Approved jet pipes or immersible vibrators shall be used so that each backfill layer is saturated and consolidated to its full depth before the next layer is placed. Jet pipes shall be kept at least 6 inches away from the pipe where the backfill is being consolidated and 2 feet away from other pipes or utilities. F. G. NotUsed. H. Not Used. I. ComDaction Reouirements: The following compaction test requirements apply to Type C, D, G, H, I, and K materials. Type E. F, and J materials do not require testing. Where agency or utility company requirements govern, the highest compaction standards shall apply. ASTM D 1557 shall be used to determine the maximum density and optimum moisture relationship of non-granular materials ASTM D 1556 or ASTM D 2922 shall be used to determine the in-place maximum density and optimum moisture relationship density of granular fill materials. Percentage of Maximum Density Location or Use of Fill Pipe zone backfill portion 90 above bedding for flexible pipe. Pipe zone backfill bedding and 95 over-excavated zones under bedding/ pipe for flexible pipe. Pipe zone backfill portion 90 Pipe zone backfill bedding and above bedding for rigid pipe. 90 over-excavated zones under bedding/ pipe for rigid pipe. Final backfill. beneath paved areas or structures. 95 Final backfill, not beneath 90 JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 14 SECTION 02200 - EARTHWORK paved areas or structures. Trench zone backfill. 90 Backfill around structures. 90 Topsoil (Type K material) 80 95 Aggregate base (Type G material) J. Trench Backfill Reauirements. The pipe has been structurally designed based upon the trench configuration specified in Section 3.3A. herein. The CONTRACTOR shall maintain the indicated trench cross section up to a horizontal plane lying 12 inches above the top of the pipe. The CONTRACTOR shall not slope the trench walls or othenvise increase the trench width beyond the tolerances indicated in the CONTRACT DOCUMENTS, without prior written permission from the ENGINEER. At any location under said horizontal plane (3.11.K) that the CONTRACTOR slopes the trench walls or exceeds the maximum trench widths indicated in the CONTRACT DOCUMENTS, the pipe zone backfill shall be "improved" or the pipe class increased at no additional cost to the OWNER. "Improved" backfill shall mean sand-cement backfill or other equivalent method acceptable to the ENGINEER. If the allowable deflection specified for the pipe is exceeded, the CONTRACTOR shall expose and reround or replace the pipe, repair all damaged lining and coating, and reinstall the pipe zone material and trench backfill as specified at no additional expense to the OWNER. PIPE AND UTILITY TRENCH BACKFILL A. K. L. M. 3.12 PiDe Zone Backfill. The pipe zone is defined as the trench cross-sectional area between a line 6 inches below the bottom of the pipe, Le., the subgrade, to a level line 12 inches above the top of the pipe. The bedding for flexible pipe is defined as the portion of pipe zone backfill material between the subgrade and the bottom of the pipe. The bedding for rigid pipe is defined as that portion of the pipe zone backfill material between the subgrade and a level line which varies from the bottom of the pipe to the springline as shown on the CONTRACT DRAWINGS. B. NOTUSED C. After compacting the bedding the CONTRACTOR shall perform a final trim using a stringline for establishing grade, such that each pipe section when first laid will be continually in contact with the bedding along the extreme bottom of the pipe. The pipe zone shall be backfilled with the specified backfill material. The CONTRACTOR shall exercise care to prevent damage to the pipeline coating, JULY 2003 EARTHWORK D. CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02200 - 15 SECTION 02200 - EARTHWORK cathodic bonds, or the pipe itself during the installation and backfill operations. Backfill and compaction over cement-slurry, or concrete pipe encasement shall not proceed until 7 days after the concrete or cement-slurry has been placed. Trench Zone Backfill. After the pipe zone backfill has been placed as specified above, and after all excess water has completely drained from the trench, backfilling of the trench zone may proceed. The trench zone is the trench cross- sectional area that extends from 12 inches above the top of the pipe to a level line 18 inches below finished surface grade, or if the trench is under pavement, 18 inches below the subgrade. Flooding, ponding, or jetting will not be allowed to compact trench zone backfill. Final Backfill. Final backfill is all backfill in the trench cross-sectional area within 18 inches of finished grade, or if the trench is under pavement, all backfill within 18 inches of the subgrade. Fill or Backfill Below Structures. All fill or backfill below any structures, including all backfill zones within a pipe trench shall be compacted to 95 percent relative compaction. This requirement shall extend for a horizontal distance beyond the outside face of the structure footing equal to the depth of the excavation or pipe trench below the footing. Cement Slurrv Backfill. Where specified in the drawings, the middle zone and upper zone of pipeline trenches shall be backfilled with an imported cement-sand slurry mix. The cement-sand slurry backfill shall be provided and placed by the CONTRACTOR, at his own expense. The slurry mix is to have a cement to sand ratio of 1 1/4 sack of cement to 1 cubic yard of sand with a water content of approximately 65 gallons of water. The sand material shall have a sand equivalent of not less than 60. The cement-sand slurry backfill shall be placed in layers not exceeding 3 feet in thickness and each layer shall be vibrated to obtain maximum density. E. F. G. H. 3.13 NOTUSED 3.14 EROSION CONTROL A. During all phases of construction, the CONTRACTOR shall perform the WORK in a manner which will minimize soil erosion and water and air pollution. The CONTRACTOR shall minimize erosion, turbidity and siltation on the WORK site by proper scheduling of WORK and careful construction practices; by trapping sedimentation in temporary debris basins where sediment is caused by construction operations; and by employing erosion control measures and temporary site drainage structures where significant erosion would occur during the winter periods. After grading operations are completed, the OWNER shall provide erosion protection for the surfaces of all areas disturbed by his operations that are not to be paved or otherwise covered. B. C. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 16 SECTION 02200 - EARTHWORK 3.15 NOTUSED 3.16 IMPORTED FILL A. Imported fill shall be tested in accordance with this specification prior to its acceptance as backfill. Imported fill shall be required to meet the requirements specified for its intended use. 3.17 EXCAVATION IN LAWN AREAS A. Where pipeline excavation occurs in lawn areas, the sod shall be carefully removed and stockpiled to preserve it for replacement. Excavated material from the trench may be placed on the lawn provided a drop cloth or other suitable method is employed to protect the lawn from damage. The lawn shall not remain covered for more than 72 hours. Immediately after completion of backfilling and testing of the pipeline, the sod shall be replaced in a manner so as to restore the lawn as near as possible to its original conditions. 3.18 CONTROL OF RUNOFF AND DRAINAGE A. The CONTRACTOR, at his expense, shall take care to control all normal or abnormal runoff in the vicinity of the construction site and surface and subsurface drainage entering the site from whatever source. All water shall be controlled to prevent damage to cut slopes, fills, trenches or other features of the construction site or adjacent properly. The CONTRACTOR shall construct and maintain all necessary channels, diversion and protective works required to fulfil the requirements of this section and shall be responsible for all damage to the construction project or adjacent property due to any failure for inadequacy of the water control measures taken. 3.19 TRENCH RESURFACING A. Unless otherwise specified, all trenches within paved areas shall be repaved with asphaltic concrete per SDRSD G-24, Type A, except that the new asphalt paving shall be I-inch greater in thickness than the existing paving. The minimum repair shall consist of 4 inches of asphaltic concrete over 4 inches of aggregate base. The minimum width of trench resurfacing shall be 6 feet. Trench patches shall to the greatest extent possible be of a uniform even width, shall be neat in appearance and shall be smooth. Trenches within major and primary arterials shall be repaved per SDRSD G-24, Type A, with a minimum of 5-inches and 6-inches, respectively of asphalt concrete placed on the minimum 6-inch aggregate base. Poinsettia Lane is a major arterial. In all streets or alleys in which the surface is removed, broken, or damaged by equipment, or in which the ground has caved in, heaved or settled, due to the installation of improvements, the CONTRACTOR shall restore the surface to the original grade and cross section. This requirement applies to areas beyond the actual limits of the trench which have been damaged by equipment or by the B. C. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 EARTH W 0 RK PAGE 02200 - 17 SECTION 02200 - EARTHWORK diversion of vehicles from their usual traffic lanes because of the CONTRACTORS operations. All restoration WORK shall match the appearance and drainage patterns of the existing improvements. The finished pavement shall not deviate from the original grade, and shall be free from ruts, depressions and irregularities. In street or alleys which are not paved but are travelled by traffic, the surface of the area disturbed by the CONTRACTORS operations shall be replaced to a depth of at least 6 inches with compacted decomposed granite. Temporary resurfacing shall be replaced with permanent resurfacing within 20 working days following the substantial completion and testing of any individually designated section of water or sewer line. This may require the CONTRACTOR to perform final paving operations at certain locations prior to completion of the entire Contract. D. E. F. END OF SECTION JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 EARTHWORK PAGE 02200 - 18 SECTION 02601 - BURIED PIPING INSTALLATION PART 1 -GENERAL 1 .I RELATED SECTIONS A. Section 02200 "Earthwork". E. NOTUSED C. NOTUSED D. E. F. F. G. NOTUSED H. I. NOT USED. Section 02646 - Plastic (PVC) Pressure Pipe (AWWA C 900). Section 02651 Steel Pipe - Cement Mortar Lined and Coated. Section 02653 Steel Pipe - Fabricated Specials. Section 02666 "Water Pipeline Testing and Disinfection". Section 15020 "Valves and Appurtenances ". 1.3 REFERENCES A. 8. C. D. E. F. G. H. I. J. K. L. NOT USED NOT USED NOT USED AWWA C206 - Field Welding of Steel Water Pipe. NOT USED AWWA C606 - Grooved and Shouldered Joints. AWWA C651 - Disinfecting Water Mains. NOT USED AWWA M11 - Steel Pipe - A Guide for Design and Installation. NOT USED NOT USED NOT USED JULY 2003 BURIED PIPING INSTALLATION CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 02601 - 1 SECTION 02601 - BURIED PIPING INSTALLATION M. NOTUSED N. NOT USED 1.3 SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. Manufacturer's Product Data. CONTRACTOR shall submit manufacturer's product data detailing material and dimensional data for fi products to be incorporated into the new piping system, including, but not limited to: 1. B. All piping and fittings as required by this and any other sections of these specifications. Supports, Restraints and Thrust Blocks. All jointing and gasketing materials, specials, flexible couplings, mechanical couplings, harnessed and flanged adapters, sleeves, tie rods, and all other items required to provide a complete and workable piping system. 2. 3. 1.4 QUALITY ASSURANCE A. All pipe, fittings, valves, gaskets, and appurtenances shall be the product of a single manufacturer for that particular item (Le.. fittings by same manufacturer; valves by same manufacturer). Materials shall be compatible for the use intended and shall be in conformance with the appropriate sections of these specifications. Dissimilar materials shall be properly insulated to prevent galvanic action and so as to not cause any deterioration or failure of service. 1.5 REQUIREMENT A. The CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown; specified, or required to install and test all buried piping, fittings, and appurtenances. The WORK includes, but is not limited to, the following: 1. All types and sizes of buried piping except those specified under other sections. Supports, restraints, and thrust blocks. 2. 3. Pipe encasement. 4. 5. Testing. 6. Cleaning and Disinfecting Work on or affecting existing piping JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 BURIED PIPING INSTALLATION PAGE 02601 - 2 SECTION 02601 - BURIED PIPING INSTALLATION 7. All jointing and gasketing materials, specials, flexible couplings, mechanical couplings, harnessed and flanged adapters, sleeves, tie rods, and all work required for a complete and workable buried piping installation. Incorporation of valves, meters, and special items shown or specified into the piping system as required and as specified. 8. PART 2 - PRODUCTS 2.1 GENERAL A. All piping, fittings, and appurtenances shall be of the types shown on the CONTRACT DOCUMENTS and shall conform to the applicable sections of these specifications. 2.2 NOTUSED 2.3 NOTUSED 2.4 NOTUSED PART 3 - EXECUTION 3.1 INSTALLATION A. Installation of buried piping shall conform to the provisions of the applicable sections of these specifications. All trench excavations shall be inspected by ENGINEER prior to laying of pipe. ENGINEER shall be notified in advance of excavation, bedding, and pipe laying operations. All earthwork and trenching shall conform to Section 02200 "Earthwork" of these specifications. Minimum depth of cover over piping shall be fifty-four-inches (54) except where shown or directed by ENGINEER. Pipe, fittings, and appurtenances that are cracked, damaged, or in poor condition or have damaged linings or coatings will be rejected. In order to prevent accumulations of air and to enable the pipeline to be drained, piping shall not have high or low points except where shown. B. C. D. E. F. G. NOTUSED JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 BURIED PIPING INSTALLATION PAGE 02601 - 3 SECTION 02601 - BURIED PIPING INSTALLATION 3.2 ALIGNMENT OF PIPING A. Alignment shown on the CONTRACT DOCUMENTS shows the general alignment along which the pipelines are to be installed. The actual alignment may be varied in the field by the ENGINEER from this general alignment as required to clear all existing underground facilities. All variations in alignment shall be approved by the ENGINEER prior to construction. B. The information shown on the CONTRACT DOCUMENTS as to location of existing water and utility lines represents the most accurate data available at the time of preparation of these Contract Documents, but in no case is to be construed as guaranteeing that the data shown is correct. The OWNER does not expressively or by implication agree, represent, or imply that the actual locations conform exactly to that shown on the CONTRACT DOCUMENTS. The OWNER has located, to the extent possible without excavation, all conflicting water, storm drain and sewer lines. The CONTRACTOR shall, at his expense, perform exploratory excavations and potholing sufficiently in advance of pipe laying operations to enable the alignment or profile to be revised to clear existing utilities such that delays or reconstruction will be avoided. C. 3.3 CONNECTION TO EXISTING WATER PIPELINES A. General. At the locations shown on the CONTRACT DOCUMENTS, the CONTRACTOR shall make the required connections to existing pipelines. All water system shut downs shall be done in accordance with Part 3.14 of this Section. New pipelines shall not be connected to existing pipelines until the new pipeline has been successfully pressure tested, and has been disinfected and passed the bacteriological tests. Connections shall be performed in conformance these specifications. Where in conflict, the more stringent requirement shall apply. B. Existina PiDinq. The information shown on the CONTRACT DOCUMENTS concerning the size and type of pipe of the existing lines to which connections are to be made represents the most accurate data available at the time of preparation of the Contract Documents, but is in no case to be construed as guaranteeing that the data shown is correct. The OWNER does not expressly or by implication, agree, represent, or imply that the actual size and type of pipe conforms exactly to that shown on the CONTRACT DOCUMENTS or in these specifications. CONTRACTOR must assume all responsibility for deductions or conclusions as to size and type of pipe to which the connections are to be made. As a part of the CONTRACTORS initial exploratoly excavation and potholing requirements under the Contract, the CONTRACTOR must determine the actual size, type of pipe and location of all existing piping to which connections are to be made. C. NOTUSED D. Disinfection. Extreme caution shall be observed by the CONTRACTOR when cutting into existing water mains to avoid contamination. The connection and existing main shall be disinfected in accordance with AWWA Standard C651. JULY 2003 BURIED PIPING INSTALLATION CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 02601 - 4 SECTION 02601 - BURIED PIPING INSTALLATION 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.1 1 NOT USED CONCRETE THRUST ANCHORAGE A. Concrete thrust blocks shall be constructed at all water pipeline fittings, valves and fire hydrants. Thrust blocks shall conform to the details shown on the CONTRACT DOCUMENTS and shall have a five square foot minimum bearing area. If special thrust block details are not shown in the CONTRACT DOCUMENTS, thrust blocks shall conform to the details shown in the San Diego Regional Standard Drawings with five square foot minimum bearing area. Thrust blocks shall be placed against undisturbed soil and shall be placed in such a manner as not to disturb the joints, alignment or grade. Forms to confine the concrete and shape it to the required lines shall be used wherever necessary and shall be removed prior to backfilling. E. CROSSING OF WATER AND SEWER MAINS A. Water and sewer main crossings, as shown on the Drawings, shall be constructed in accordance with the criteria established by the State of California - Department of Health Services for the separation of recycled water mains and sanitary sewers. NOT USED INSULATION OF CONNECTIONS A. Insulating bushings, unions, couplings, and flanges, as appropriate, shall be used for joining pipes of dissimilar metals, and for piping systems where corrosion control and cathodic protection are involved, or where shown, all in accordance with Section 16641 - Sacrificial Anode Cathodic Protection. PREVENTION OF PIPE UPLIFT A. All necessary precautions shall be taken to prevent uplift or floating of the pipe prior to the completion of the backfilling operation. The CONTRACTOR shall assume full responsibility for any damage due to this cause and shall, at his own expense, restore and replace the pipe to its specified conditions and grade if it is displaced due to floating. NOT USED PRODUCT DELIVERY, STORAGE, AND HANDLING A. 8. Deliver materials to the site to ensure uninterrupted progress of the WORK. Handle all pipe, fittings, specials, and accessories carefully with approved handling devices. Do not drop or roll material off trucks. Do not othewise drop, roll, or skid piping. Materials cracked, gouged, chipped, dented, or otherwise damaged will not be acceptable and shall be removed from the site immediately. JULY 2003 BURIED PIPING INSTALLATION CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02601 - 5 SECTION 02601 - BURIED PIPING INSTALLATION C. Unload pipe, fittings, and specials opposite to or as close to the place where they are to be installed as is practical to avoid unnecessary handling. Keep pipe interior completely free from dirt and foreign material. All steel piping shall have plastic caps over the ends of each pipe and caps shall not be removed until installed. D. 3.12 NOTUSED 3.13 MAINTAINING WATER SERVICES A. While installing a new pipeline to replace an existing pipeline providing water service to users along the line, the service to a given user shall not be interrupted except for the required period to transfer that service from the old line to the new line. Where required, the CONTRACTOR shall make provisions necessary to keep the old main in service until the new main has been completed and is ready for service transfers. Transfers shall not be made until the new line has been installed, disinfected, tested and placed in service. At the CONTRACTOR'S option, highlines may be installed, maintained and removed to provide uninterrupted service to the users while the new pipeline is being constructed in lieu of making individual connections and shutting down one user at a time. If highlines are not used, the CONTRACTOR shall notify each user where service is to be connected at least 24 hours prior to cutting of the service line. The highline pipe shall be a minimum of 2 inches in diameter. The CONTRACTOR shall submit a plan of all proposed highline facilities for approval by the ENGINEER prior to installation. Proper disinfection practices shall be maintained at all times as required by the State Health Department. Adequate fire protection facilities shall be maintained at all times. B. 3.14 SHUT DOWN OF EXISTING WATER MAINS A. General. All shut downs of existing water mains shall be performed by the CONTRACTOR. Should the CONTRACTOR wish to have an existing water main shut down, a formal written request will be made to the OWNERs Operations Supervisor, one week in advance of the time of the requested shut down. The OWNER will allow a shut down only when such shut down will cause a minimum of disturbance to the normal delivery of water to customers. The OWNER will have the sole discretion as to approval of schedules for requested shut downs and may require rescheduling if in the OWNERs opinion the requested time for shut down will adversely affect the proper functioning of the water distribution system. Notification Of Shut Down. A minimum of 48 hours prior to initiating shut down of existing water mains, the CONTRACTOR shall distribute written notification to all users whose water service will be interrupted by the shut down. In some instances the shut down of existing water mains may affect a large portion of the water system and will require extensive notification. However, this will not reduce the CONTRACTORS responsibility to notify all affected users. The forms of written B. JULY 2003 BURIED PIPING INSTALLATION CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 02601 - 6 SECTION 02601 - BURIED PIPING INSTALLATION notice shall be reviewed and approved by the ENGINEER prior to distribution. The OWNER will assist the CONTRACTOR with determination of which services will be affected by the shut down. C. Additional Reauirements. Shutdown of water main shall be performed in accordance with City of Carlsbad standards. 3.15 TEMPORARY RESURFACING A. Immediately after placing the backfilling of any section of pipeline in a paved area, temporary resurfacing at least 2-inches in thickness shall be placed over the backfilled' trench and maintained by the CONTRACTOR at his own expense. Upon completion of substantial parts of the project, but not before the pipeline is tested, the temporary resurfacing shall be replaced with permanent resurfacing. 3.16 NOTUSED 3.17 NOTUSED END OF SECTION JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 BURIED PIPING INSTALLATION PAGE 02601 - 7 SECTION 02646 - PLASTIC (PVC) PRESSURE PIPE (AWWA CSOO) PART I - GENERAL 1.1 SECTION INCLUDES A. Plastic (PVC) pressure pipe. B. C. Deflection couplings. D. Restraining devices. Cement mortar lined ductile iron fittings. 1.2 RELATED SECTIONS A. Section 02200 "Earthwork". B. C. D. Section 10900 "Miscellaneous Specialties". E. Section 02601 "Buried Piping Installation". Section 02666 "Pipeline Testing and Disinfection". Section 15020 "Valves and Appurtenances". 1.3 REFERENCES A. AWWA C900 - Polyvinyl Chloride (PVC) pressure pipe, 4 in. through 12 in., for water. AWWA CllO - Ductile-Iron and Gray-Iron Fittings, 3 in. through 48 in.. for water and other liquids. AWWA C104 - Cement Mortar Lining for Ductile-Iron Pipe and Fittings for water. AWWA C153 - Ductile-Iron Compact Fittings, 3 in. through 12 in. for water and other liquids. AWWA M-23 - PVC Pipe Design and Installation. AWWA Clll - Rubber - Gasket Joints for Ductile-Iron and Gray-Iron Pressure Pipe and Fittings. B. C. D. E. F. I .4 SUBMllTALS A. Submittals shall be in accordance with Section 2-5.33 of the latest edition of the SSPWC. PLASTIC (PVC) PRESSURE PIPE JULY 2003 (AWWA CSOO) CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02646 - 1 SECTION 02646 - PLASTIC (PVC) PRESSURE PIPE (AWWA CSOO) 1.5 1.6 B. Manufacturer's Product Data. CONTRACTOR shall submit manufacturer's product data and certificate of compliance with specified standards for all items to be installed in the WORK under this specification, including 1) PVC Pressure Pipe 2) Ductile-Iron Fittings Contractor shall submit layout drawings for all the pipelines. C. QUALITY ASSURANCE A. Products installed under the requirements of this specification shall be obtained from the same manufacturer throughout the project life unless granted written permission by ENGINEER. PRODUCT DELIVERY, STORAGE AND HANDLING A. Delivery of Materials: Piping materials shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. Handling of the PVC pipe shall be done in accordance with manufacturer's instructions to ensure that the pipe is not damaged in any manner during loading, unloading and installation. Storage: Piping materials shall be carefully stored in a manner that will prevent damage and in an area that is protected from sunlight and other harmful elements. B. C. PART 2 - PRODUCTS 2.0 GENERAL A. Polyvinyl Chloride pipe shall be of the diameter and class indicated on the plans, and shall conform to the AWWA Standard Specifications for Polyvinyl Chloride Water Pipe C-900; Polyvinyl Chloride pipe design and installation Manual, M23; and the UNI-BELL Polyvinyl Chloride Pipe Association handbook for design and construction. 2.1 PLASTIC (PVC) PRESSURE PIPE A. High Pressure Pipe (Class 150 Pipe and Higher). PVC pressure pipe shall conform to the requirements of AWWA Standard C900. Pipe shall be pressure Class 150 (DR18) unless a higher pressure class is indicated on the CONTRACT DOCUMENTS. Pipe dimensions shall conform to Table 2 of AWWA C900 for PVC pipe with cast iron equivalent O.D. Provide one elastomeric gasket for each bell end. PVC pipe for Recycle Water (RW) shall be purple color. Acceptable PVC pipe shall have common profiles for interchangeability between rough-barrel dimensions, couplings, ends, and elastomeric gaskets so as to B. PLASTIC IPVC) PRESSURE PIPE JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 ~ , ~~~~ ~ (AWWA C900) PAGE 02646 - 2 SECTION 02646 - PLASTIC (PVC) PRESSURE PIPE (AWWA CSOO) 2.2 2.3 2.4 2.5 facilitate future repairs. When assembled, the pipe shall have only one gasket per bell and spigot end, and/or two gaskets per coupling. Acceptable PVC pipe shall be provided in standard 20-foot lengths, unless otherwise specified, detailed, or required on the approved plans. Random lengths shall not be permitted. The pipe and couplings shall be carefully inspected for defects. Any length of pipe, coupling, or elastomeric gasket found to be defective in workmanship or materials, or so damaged as to make repairs and use questionable, shall be rejected and not delivered to the jobsite. The opinion of the ENGINEER shall be final. Acceptable PVC pipe shall be stored in suppliers' yards per the manufacturer's recommendations. PVC pipe which has been subjected to excessive ultraviolet radiation from the sun shall not be used. The determination as to the acceptability of PVC pipe faded by the sun's radiation shall rest solely with the ENGINEER. C. D. E. CEMENT MORTAR LINED DUCTILE IRON FllTlNGS A. Fittings for use with PVC pipe shall be cement mortar lined ductile iron designed specifically for use with PVC pressure pipe, and shall conform to AWWA Standards CllO or C153. Cement lining shall be double thickness conforming to AWWA Standard C104. Fittings shall have an asphaltic coating and polyethylene sheet encasement conforming to AWWA standard C105. DOUBLE BELL DEFLECTION COUPLINGS A. Use PVC couplings with two elastomeric gaskets which are designed to allow a maximum of 2 degrees deflection at each gasket. The deflection shall be one-half of manufacturers maximum deflection allowed. PVC double bell deflection couplings shall be used only where specified, and shall be 1. Certainteed 2. Vinyl-Iron, or 3. An approved equivalent product. B. RESTRAINING DEVICES A. Restraining devices shall be UNI-Flange Series 1300 and 1350, or approved equivalent. REPAIR COUPLINGS A. Use PVC couplings with two elastomeric gaskets which are designed to connect plain ends of straight pipe. These couplings shall not be used to obtain deflection of the pipe joint. Use of these couplings shall only be permitted upon the approval of the ENGINEER or as required on the approved plans. PLASTIC (PVC) PRESSURE PIPE JULY 2003 (AWWA CSOO) CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 02646 - 3 SECTION 02646 - PLASTIC (PVC) PRESSURE PIPE (AWWA CSOO) 2.6 HIGH DEFLECTION COUPLINGS A Use high deflection couplings and plain end pipe for curved alignments in both horizontal and vertical directions. Do not bend pipe between couplings. Saw cut integral bell end of standard pipe and bevel end for use with couplings. Use 19- foot plain end pipe lengths with deflection couplings for all radii between 270 feet to 560 feet. For radii greater than 560 feet, use an integral bell end pipe length joined together with a 19-foot plain end pipe length to form a chord. Use deflection couplings on each end of the chord and continue this combination through the curved alignment. Joint lengths shorter than 9 feet will not be used on projects unless specifically authorized by the District's Representative. High deflection couplings shall be: 1. Certainteed or 2. An approved equivalent product PART 3 - EXECUTION 3.1 INSTALLATION A. General. 1. The CONTRACTOR shall install all the pipe closure sections, fittings, valves, and appurtenances shown on the approved plans, including bolts, nuts, gaskets, and joining materials. At all times when the WORK of installing pipe is not in progress, all openings into the pipe and the ends of the pipe in the trenches shall be kept tightly closed to prevent the entrance of animals and foreign materials. The CONTRACTOR shall maintain the interior of the pipe clean, sanitary, and free from foreign materials. Where pipe sections less than the standard 20-foot pipe lengths are required, the pipe sections shall be installed in accordance with the 2. 3. manufacturer's'installation guide and shall only be used with the approval of the ENGINEER. 4. Store PVC pipe in the field by supporting the pipe uniformly per AWWA Manual M23. Do not stack pipe higher than four (4) feet or stack the pipe with weight on the bell ends. Cover stored PVC pipe to protect it from the sun's ultraviolet radiation. Overly faded pipe, which is determined by the ENGINEER to be of suspect quality shall not be used and shall be removed from the project site immediately. Pipe which has been contaminated with any petroleum products (inside or outside) shall not be installed. PLASTIC (PVC) PRESSURE PIPE JULY 2003 (AWWA C900) CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02646 - 4 SECTION 02646 - PLASTIC (PVC) PRESSURE PIPE (AWWA CSOO) 5. PVC pipe which has been gouged shall not be used. PVC pipe which has received minor scratches during handling may be used solely at the discretion of the ENGINEER. B. Installation. 1. Proper care shall be used to prevent damage in handling, moving, and placing the pipe. Tools and equipment satisfactory to the ENGINEER shall be provided and used by the CONTRACTOR. All pipe, fittings, valves, and other pipeline materials shall be lowered into the trench in a manner that prevents damage. The pipe shall not be dropped, dragged, or handled in a manner that will cause bruises, cracks, or other damage. Any material damaged in the course of installation shall be identified and removed from the job site. The pipe shall be installed by mechanical means in the trench to true alignment and grade in accordance with the approved plans. Installation tolerances for the pipe shall not vary more than 0.15 foot horizontally or 0.1 foot vertically from the alignment and elevations shown on the approved plans. Pipe installation for horizontal or vertical curve alignments shall be as described below. In no case shall the pipe be bent between the couplings, nor shall deflection be made at a joint without the use of a deflection coupling. a. 2. 3. Use integral bell-end pipe for straight alignments and for radii greater than 1,150 feet. Use an integral bell-end pipe length joined together with a 19 foot plain end pipe length to form a chord. Use deflection couplings on each end of the chord and continue this combination through the curved alignment for all radii between 560 feet to 1 ,I 50 feet. Use 19 foot plain end pipe lengths with deflection couplings for all radii between 270 feet to 560 feet. Use 9.5-foot plain end pipe lengths with deflection couplings for all radii between 140-feet to 270-feet. Pipe lengths shorter than 9 feet shall not be used on radii unless specifically authorized by the ENGINEER. b. c. d. 4. Install PVC pipe in the trench using bell holes at each joint to prevent the pipe from being supported by the bell end or coupling. All connecting parts of pipe, rings, coupling and castings shall be clean before assembly. Assembly of the couplings and rings shall be in accordance with the manufacturer's recommendations. Lubricant and 5. PLASTIC (PVC) PRESSURE PIPE JULY 2003 (AWWA C900) CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02646 - 5 SECTION 02646 - PLASTIC (PVC) PRESSURE PIPE (AWWA C900) 3.2 3.3 3.4 rubber rings shall be supplied by the pipe manufacturer. The use of excessive lubricant will not be permitted. Insert the spigot end into the bell or coupling to the proper insertion mark. Check that the elastomeric ring has not left the groove during assembly by passing a feeler gauge around the completed joint. Saddles shall be located a minimum of 2-feet from any pipe joint, and from other saddles or fittings. Multiple saddles installed on the same side of a single pipe length shall be staggered 30 degrees so as not to form a weak line in the pipe. Tapping tools and shell cutters of the kind and type recommended by the manufacturer shall be used. Tapping saddles shall be installed a minimum of 3-feet from the edge of the saddle to any other saddle, pipe joint or other fitting. Multiple taps of 6 inches or larger shall not be made in the same joint of pipe without the approval of the ENGINEER. Concrete thrust blocks shall be installed at all fittings and valves, as specified in Section 02601 of these specifications. Cutting and milling shall be accomplished with tools intended for such use to create a machined end equal in workmanship to the milled ends of the pipe as furnished by the manufacturer. Milling shall not result in undercutting the wall thickness and must be approved by the ENGINEER prior to installation. 6. 7. 8. 9. 10. BEARING A. Bearing shall be obtained in accordance with procedures as defined in Section 02200, to provide a firm, stable, and uniform support for the full length of the pipe. Bell holes shall be provided at each joint to permit proper joint assembly and pipe support. Trench bottom shall bring the pipe to true line and grade as shown on the approved plans. CLEAN I NG A. A cleaning tool, satisfactory to the ENGINEER, shall be pulled through the pipe during installation to remove dirt, rocks, or foreign materials. The tool shall be designed to fit closely without damaging the pipe during the cleaning operation. The tool shall be examined as it is pulled to avoid damage to the pipe by the collected debris and to avoid jamming. At the end of cleaning or other installation operations, the end of pipeline shall be sealed to protect the pipe from the intrusion of groundwater or any other foreign material at all times. WARNINGIIDENTIFlCATlON TAPE A. Provide and install waming/identification tape per CMWD Standard D-4 PLASTIC (PVC) PRESSURE PIPE JULY 2003 (AWWA C900) CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PAGE 02646 - 6 SECTION 02646 - PLASTIC (PVC) PRESSURE PIPE (AWWA CSOO) END OF SECTION PLASTIC (PVC) PRESSURE PIPE JULY 2003 (AWWA CQOO) CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02646 - 7 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED PART I - GENERAL 1 .I THE REQUIREMENT A. The CONTRACTOR shall furnish and install mortar-lined and tape coated steel pipeline, complete in place, all in accordance with the requirements of the Contract Documents. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. B. C. D. E. F. G. H. I. J. K. Section 02200 ”Earthwork”. Section 02601 ”Buried Piping Insulation”. Section 02653 “Steel Pipe-Fabricated Specials”. Section 02666 “Water Pipeline Testing and Disinfection”. NOT USED Section 05500 “Miscellaneous Metalwork” for valve supports, flange bolts, and anchor bolts. Section 09800 “Protective Coatings” for exposed steel surfaces. Section 15020 “Valves and Appurtenances”. NOT USED NOT USED Section 09810 “Tape Coating for Steel Pipe”. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of these specifications, all work specified herein shall conform to or exceed the applicable requirements of the referenced portions of the following documents to the extent that the requirements therein are not in conflict with the provisions of this Section. 1. Commercial Standards: ANSI B16.5 Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys Electric-Fusion (Arc) -Welded Steel Pipe (Sizes 4-in. and Over), Specification for Liquid Penetrant Inspection, Methods for ANSllASTM A 139 ANSVASTM E 165 JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED 8 COATED PAGE 02651 - 1 SECTION 02651 -STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED ANSIIAWS D1.l ANSIIAWWA C200 ANSIIAWWA C205 ANSIIAWWA C206 ANSIIAWWA C207 ANSIIAWWA C208 ANSIIAWWA C208 ANSIIAWWA C 209 ANSIIAWWA C214 ANSIIAWWA C602 ASTM A 36 ASTM A 283 ASTM A 307 ASTM A 325 ASTM A 570 ASTM A 572 Structural Welding Code - Steel Steel Water Pipe 6-Inches and Larger Cement-Mortar Protective Lining and Coating for Steel Water Pipe - 4-inches and Larger, Shop Applied Field Welding of Steel Water Pipe Steel Flanges for Water Works Service, 4- inches through 144-inch Fabricated Steel Water Pipe Fittings, Dimensions for Fabricated Steel Water Pipe Fittings, Dimensions for (Supplement to ANSIIAWWA C208) Cold Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines Tape Coating Systems for the Exterior of Steel Water Pipelines Cement-Mortar Lining of Water Pipelines 4- inch (1 00 mm) and Larger - In Place Specification for Structural Steel Specification for Low and Intermediate Tensile Strength Carbon Steel Plates, Shapes and Bars Specification for Carbon Steel Externally Threaded Standard Fasteners Specification for High Strength Bolts for Structural Steel Joints Specification for Hot- Rolled Carbon Steel Sheet and Strip, Structural Quality Specification of High- Strength Low Alloy Columbian-Vanadium Steels of Structural Quality JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED B COATED PAGE 02651 - 2 SECTION 02651 -STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED ASTM C150 Specification for Portland Cement ASTM D 2000 Classification System for Rubber Products in Automotive Applications AWWA M-11 Steel Water Pipe -A Guide for Design and Installation 1.4 SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest eddition of the SSPWC. Shop Drawinas. The CONTRACTOR shall submit shop drawings of pipe and fittings in accordance with the requirements of ANSVAWWA C200, C205, C209, and C214 the following supplemental requirements as applicable: 1. 2. B. Certified dimensional drawings of all valves, fittings, and appurtenances Joint and pipe/fitting wall construction details which indicate the type and thickness of cylinder; the position, type, size, and area of wire or reinforcement; manufacturing tolerances; and all other pertinent information required for the manufacture of the product. 3. Fittings and specials details such as elbows, wyes. tees, outlets, connections, test bulkheads, and nozzles or other specials where shown on the Drawings which indicate amount and position of all reinforcement. All fittings and specials shall be properly reinforced to withstand the internal pressure, both circumferential and longitudinal, and the external loading conditions as indicated in the Contract Documents. Design calculations of each critical section of pipe wall, girth joints, and specials - all sufficient to ascertain conformance of pipe and fittings with the Specifications. 5. Material lists and steel reinforcement schedules which includes and 4. describes all materials to be utilized. Line layout and marking diagrams in accordance with AWWA C207 which indicate the specific number of each pipe and fitting and the location of each pipe and the direction of each fitting in the completed line. In addition, the line layouts shall include: the pipe station and invert elevation at all changes in grade or horizontal alignment; the station and invert elevation to which the bell end of each pipe will be laid; all elements of curves and bends, both in horizontal and vertical alignment; and the limits of each reach of restrained and/or welded joints, or of concrete encasement. 6. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED 8 COATED PAGE 02651 - 3 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED 7. Full and complete information regarding location, type% size, and extent of all welds shall be shown on the shop drawings. The shop drawings shall distinguish between shop and field welds. Shop drawings shall indicate by welding symbols or sketches the details of the welded joints and the preparation of parent metal required to make them. Joints or groups of joints in which welding sequence or technique are especially important shall be carefully controlled to minimize shrinkage stresses and distortion. 8. Complete diagrams and details of the pipe strutting and bracing assemblies. C. Certifications. The CONTRACTOR shall furnish a certified affidavit of compliance for all pipe and other products or materials furnished under this Section of the Specifications. as specified in ANSVAWWA C200, C205, C209 and C214 respectively, and the following supplemental requirements; 1. Physical and chemical properties of all steel. 2. Hydrostatic test reports 3. All expenses incurred in making samples for certification of tests shall be bome by the CONTRACTOR. Results of production weld tests. D. 1.5 QUALITY ASSURANCE A. Inspection. All pipe shall be subject to inspection at the place of manufacture in accordance with the provisions of ANSVAWWA C200, C205, C209 and C214 respectively, as supplemented by the requirements herein. The CONTRACTOR shall notify the ENGINEER in writing of the manufacturing starting date not less than 14 calendar days prior to the start of any phase of the pipe manufacture. During the manufacture of the pipe, the ENGINEER shall be given access to all areas where manufacturing is in process and shall be permitted to make all inspections necessaty to confirm compliance with the Specifications. Tests. Except as modified herein, all materials used in the manufacture of the pipe shall be tested in accordance with the requirements of ANSVAWWA C200, C205, C209 and C214 as applicable. 1. 6. C. After the joint configuration is completed and prior to lining with cement- mortar, each length of pipe of each diameter and pressure class shall be shop-tested and certified to a pressure of at least 80 percent of the yield strength of the pipe steel. In addition to the tests required in ANSVAWWA C200, weld tests shall be conducted on each 5,000 feet of production welds and at any other times 2. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED & COATED PAGE 02651 - 4 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED there is a change in the grade of steel, welding procedure, or welding equipment. D. The CONTRACTOR shall perform said material tests at no additional cost to the OWNER. The ENGINEER shall have the right to witness all testing conducted by the CONTRACTOR; provided, that the CONTRACTORS schedule is not delayed for the convenience of the ENGINEER. In addition to those tests specifically required, the ENGINEER may request additional samples of any material including mixed concrete and lining and tape coating samples for testing by the OWNER. The additional samples shall be furnished at no additional cost to the OWNER. Welding Requirements. All welding procedures used to fabricate pipe shall be prequalified under the provisions of ANSVAWS D1 .l. Welding procedures shall be required for, but not necessarily limited to, longitudinal and girth or spiral welds for pipe cylinders, spigot and bell ring attachments, reinforcing plates and ring flange welds, and plates for lug connections. All welding shall be done by skilled welders, welding operators, and tackers who have had adequate experience in the methods and materials to be used. Welders shall be qualified under the provisions of ANSVAWWA D1.l by an independent local, approved testing agency not more than 6 months prior to commencing work on the pipeline. Machines and electrodes similar to those used in the WORK shall be used in qualification tests. The CONTRACTOR shall furnish all material and bear the expense of qualifying welders. E. F. G. PART 2 - PRODUCTS 2.1 GENERAL A. Mortar lined and tape coated steel pipe shall conform to ANSVAWWA C200, C205, C209 and C214 subject to the following supplemental requirements. The pipe shall be of the diameter and class shown, shall be furnished complete with welded joints, as indicated in the Contract Documents, and all specials and bends shall be provided as required under the Contract Documents. Markinas. The CONTRACTOR shall legibly mark all pipes and specials in accordance with the laying schedule and marking diagram. Each pipe shall be numbered in sequence and said number shall appear on the laying schedule and marking diagram in its proper location for installation. All special pipe sections and fittings shall be marked at each end with top field centerline. The word "top" shall be painted or marked on the outside top spigot end of each pipe section. Handling. The pipe shall be handled by use of wide slings, padded cradles, or other devices acceptable to the ENGINEER, designed and constructed to prevent damage to the pipe coating/exterior. The use of chains, hooks, or other equipment which might injure the pipe coating/exterior will not be permitted. All other pipe B. C. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED &COATED PAGE 02651 - 5 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED D. E. F. G. H. I. J. K. handling equipment and methods shall be approved by the ENGINEER. The CONTRACTOR shall be fully liable for the cost of replacement or repair of pipe which is damaged. Stockpiled pipe shall be supported on sand or earth berms free of rock exceeding 3 inches in diameter. The pipe shall not be rolled and shall be secured to prevent accidental rolling. Struttinq. Adequate strutting shall be provided on all specials, fittings, and straight pipe so as to avoid damage to the pipe, the mortar lining, or tape coating of the steel pipe. The following requirements shall apply: 1. The strutting shall be placed as soon as practicable afler the mortar lining has been applied and shall remain in place while the pipe is loaded, transported, unloaded, installed and backfilled at the jobsite. The strutting materials, size and spacing shall be adequate to support the earth backfill plus any greater loads which may be imposed by the backfilling and compaction equipment. Any pipe damaged during handling, hauling, storage, or installation due to improper strutting shall be repaired or replaced. The details of the strutting assembly shall be submitted for review by the ENGINEER prior to the start of pipe manufacture. 2. 3. 4. Lavina Lengths. Maximum pipe laying lengths shall be 40 fl. with shorter lengths provided as required by the Drawings. Offset Tolerances. For pipe wall thicknesses of 3/8- inch or less, the maximum radial offset (misalignment) for submerged arc and gas metal arc welded pipe shall be 0.1875 times the pipe wall thickness or l/ls-inch, whichever is larger. Finish. The pipe shall have smooth dense interior surfaces and shall be free from fractures, excessive interior surface crazing and roughness. Closures and Correction Pieces. Closures and correction pieces shall be provided as required so that closures may be made due to different headings in the pipe laying operation and so that corrections may be made to adjust the pipe laying to conform to pipe stationing shown on the Drawings. The location and number of said items shall be approved by the ENGINEER. Nominal Diameter. For pipe 14 inches in diameter and larger, the inside diameter afler lining shall not be less than the nominal diameter specified or shown. Pipe smaller than 14 inches in diameter may be furnished in standard outside diameters. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED & COATED PAGE 02651 - 6 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED 2.2 PIPE DESIGN CRITERIA A. Pipe lining and coating shall be the product of one company in the business of designing and manufacturing cement-mortar lined, tape wrapped and mortar coated steel pipe. Use of Subcontractors or subcontracts to apply the lining and coating of the steel pipe is not allowed. Cylinder Thickness. The thickness of the steel pipe cylinder shall be as shown on the plans. Where the pipe cylinder thickness is not shown on the plans, the thickness shall conform to the requirements of AWWA M-11, subject to the following minimum thicknesses: 1. 6. For buried piping with inside diameter (D). the minimum pipe cylinder thickness (t) shall be given by: a) b) c) For exposed piping with inside diameter (D), the minimum pipe cylinder thickness (t) shall be given by: a) b) Pipe that transitions from exposed to buried shall have a minimum pipe thickness conforming to the exposed condition for a minimum of two (2) pipe diameters, or 2 feet, whichever is greater or at the nearest sleeve type coupling, on the buried side of the transition. t = 0.10 inches for D = 28-inches and less, t = D/288 for 28 <D 5 54 inches, and t = (D+20)/400 for D> 54 inches. 2. t = 0.25 inches for D = 48 inches and less, and t = DI192 for D> 48 inches 3. 2.3 MATERIALS A. Cement. Cement for mortar shall conform to the requirements of ANSVAWWA C205; provided, that cement for mortar coating shall be Type 11, and mortar lining shall be Type II or V. A fly ash or pozzolan shall not be used as a cement replacement. Admixtures containing chlorides shall not be used. Steel for Cvlinders and Fittinqs. Pipe manufactured under ANSVAWWA C200 shall be fabricated from sheet conforming to the requirements of ASTM A 570. Grades 33, 36, or 40, or from plate conforming to the requirements of ASTM A 36, A 283, Grades C, or A 572, Grade 42, or coil conforming to the requirements of ASTM A 139, Grades C. All longitudinal and girth seams, whether straight or spiral, shall be joined by full penetration butt joint welds, using an approved electric-fusion-weld process. All steel used for the fabrication of pipe shall have a maximum carbon content of 0.25 percent and shall have a minimum elongation of 22 percent in a 2-inch gage length. 6. C. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED & COATED PAGE 02651 - 7 SECTION 02651 -STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED 2.4 2.5 2.6 SPECIALS AND FllTlNGS A. Unless otherwise required under the requirements of the Contract Documents, all specials and fittings shall be in accordance with Section entitled "Steel Pipe - Fabricated Specials" 02653 and shall conform to the dimensions of ANSVAWWA C208. DESIGN OF PIPE A. General. The pipe furnished shall be steel pipe, mortar-lined and tape coated, with field welded joints as shown. The pipe shall consist of a steel cylinder, shop-lined with portland cement-mortar and an exterior tape coating. B. The pipe shall be designed, manufactured, tested, inspected, and marked according to applicable requirements previously stated and except as hereinafter modified, shall conform to ANSVAWWA C200. Pioe Dimensions. The pipe shall be of the diameter and class shown. The minimum steel cylinder thickness for each pipe size shall be as specified or shown. Fittinq Dimensions. The fittings shall be of the diameter and class shown. Joint Desiqn. The standard field joint for steel pipe shall be a single-welded lap joint for all pipe sizes. Mechanically coupled, or flanged joints shall be required where shown. Butt-strap joints shall be used only where required for closures or where shown. The joints furnished shall have the same or higher pressure rating as the abutting pipe. Lap joints prepared for field welding shall be in accordance with ANSVAWWA C200. The method used to form, shape and size bell ends shall be such that the physical properties of the steel are not substantially altered. Unless otherwise approved by the ENGINEER, bell ends shall be formed by an expanding press or by being moved axially over a die in such a manner as to stretch the steel plate beyond its elastic limit to form a truly round bell of suitable diameter and shape. No process will be permitted in which the bell is formed by rolling. Faying surfaces of the bell and spigot shall be essentially parallel, but in no case shall the bell slope vary more than 2 degrees from the longitudinal axis of the pipe. Shop-applied interior linings and tape coatings shall be held back from the ends of the pipe as shown on the Drawings or as otherwise acceptable to the ENGINEER. C. D. E. F. G. CEMENT-MORTAR LINING A. Cement-Mortar Lininq for Shoo ADDlication. Except as otherwise provided herein, interior surfaces of all steel pipe, fittings, and specials shall be cleaned and lined in the shop with cement-mortar lining applied centrifugally in conformity with ANSUAWWA C205. During the lining operation and thereafter, the pipe shall be maintained in a round condition by suitable bracing or strutting. The lining JULY 2003 STEEL PIPE - CEMENT MORTAR LINED & COATED CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02651 - a SECTION 02651 -STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED machines shall be of a type that has been used successfully for similar work and shall be approved by the ENGINEER. Every precaution shall be taken to prevent damage to the lining. If lining is damaged or found faulty at the delivery site, the damaged or unsatisfactory portions shall be replaced with lining conforming to these Specifications at no additional cost to the OWNER. The minimum lining thickness shall be as follows, with a tolerance of plus or minus 25 percent: B. Nominal Pipe Diameter (in) 4-12 13-16 17 - 24 Over 25 Lining Thickness 511 6 318 112 314 C. The pipe shall be left bare where field joints occur. Ends of the linings shall be left square and uniform. Feathered or uneven edges will not be permitted. Defective linings, as determined by the ENGINEER, shall be removed from the pipe wall and shall be replaced to the full thickness required. Defective linings shall be cut back to a square shoulder in order to avoid feather edged joints. The progress of the application of mortar lining shall be regulated in order that all handwork, including the repair of defective areas, is cured in accordance with the provisions of ANSVAWWA C205. Cement-mortar for patching shall be the same materials as the mortar for machine lining, except that a finer grading of sand and mortar richer in cement shall be used when field inspection indicates that such mix will improve the finished lining of the pipe. Cement-Mortar Linina for Field Apolication. The materials and design of in-place cement-mortar lining shall be in accordance with ANSIIAWWA C602 and the following supplementary requirements: 1. 2. 3. 4. The minimum lining thickness shall be as specified for shop-applied cement-mortar lining and finished inside diameter after lining shall be as shown on the Drawings. D. E. F. Portland cement shall conform to Type II of ASTM C 150. Pozzolanic material shall not be used in the mortar mix. Admixtures shall contain no calcium chloride G. Protection of Pipe Lininqllnterior. For all pipe and fittings with plant-applied concrete or cement mortar linings, the CONTRACTOR shall provide a polyethylene or other suitable bulkhead on the ends of the pipe and on all special JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED 8 COATED PAGE 02651 - 9 SECTION 02651 -STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED openings to prevent drying out of the lining. All bulkheads shall be substantial enough to remain intact during shipping and storage until the pipe is installed. 2.7 EXTERIOR COATING OF PIPE A. Exterior Coatina of Exposed Pioing. The exterior surfaces of pipe which will be exposed to the atmosphere inside structures or above ground shall be thoroughly cleaned and then given a shop coat of rust-inhibitive primer conforming to the requirements of Section 09800, "Protective Coatings", and shall be coated after installation in conformance with Section 09800. "Protective Coatings". Exterior Coatina of Buried Piping. All pipe for buried service, including bumped heads, shall be coated with an 80 mil minimum thickness of tape coating in conformance with ANSVAWWA C209 and C214 and Section 09810 - Tape Coating For Steel Pipe. Unless otherwise shown on the Drawings, exterior surfaces of pipe or fittings passing through structure walls shall be tape coated from the center of the wall or from the wall flange to the end of the underground portion of pipe or fitting. B. 2.8 PIPE APPURTENANCES A. Flanaes. Flanges shall conform to either ANSVAWWA C207 or ANSI B16.5 specifications. Flanges shall conform to Class 150 (AWWA Class D) ratings unless otherwise shown or if working pressures exceed Class 150 rating. Flanges shall have flat faces and shall be attached with bolt holes straddling the vertical axis of the pipe unless otherwise shown. Attachment of the flanges to the pipe shall conform to the applicable requirements of ANSVAWWA C207. The machined faces of all flanges shall be shop-coated with rust-preventative compound, Houghton "Rust-Veto 344" or Rust-Oleum "R-9." Edges and back faces of attached flanges shall be shop-coated with Kopper's "Bitumastic Mill Undercoat." All surfaces of blind flanges, except the machined surfaces and surfaces exposed to water during pipeline operation, shall be shop-coated with Kopper's "Bitumastic Mill Undercoat." The inside of blind flanges shall be cement- mortar lined, the thickness to be the same as the cement-mortar lining for pipe as stated herein. Blind flanges shall be in accordance with ANSVAWWA C207. B. C. Not Used. D. Gaskets for flanges shall be 118-inch ring-type, full face, Garlock No. 3200 compressed non-asbestos sheet packing, or equivalent. lnsulatina Flanae Sets. Insulating flange sets shall be provided where shown on the Drawings. Each insulating flange set shall consist of an insulating gasket, insulating sleeves and washers and a steel washer. Insulating flange kits shall be designed for use with standard bolts and bolt holes. E. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED 8 COATED PAGE 02651 - 10 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED F. lnsulatina Flanae Gaskets. Insulating gaskets shall be JM Red Devil Type E full- face gasket, or equivalent. Insulating sleeves and washers shall be one piece when flange bolt diameter is 1-112 inch or smaller and shall be made of acetal resin. For bolt diameters larger than 1-1/2 inch, insulating sleeves and washers shall be 2-piece and shall be made of polyethylene or phenolic. Steel washers shall be in accordance with ASTM A 325. Flanae Bolts. All-thread studs shall be used on all valve flange connections and shall be in accordance with ASTM A 307, Grade B, with heavy hex nuts. Machine bolts may be used on all other flanged connections and shall be in accordance with ASTM A 307, Grade A, with hex nuts. Studs and bolts shall extend through the nuts a minimum of 1/4-inch. All nuts and bolts shall be uncoated steel unless specified otherwise. Mechanical Couolinqs. The ends of the pipe, where specified or shown, shall be prepared for flexible steel couplings, such as Dresser, Rockwell, Romac, or equivalent. Plain ends for use with couplings shall be smooth and round for a distance of 12 inches from the ends of the pipe, with outside diameter not more than 1164-inch smaller than the nominal outside diameter of the pipe. The middle ring shall be tested by cold-expanding a minimum of one percent beyond the yield point to proof-test the weld to the strength of the parent metal. The weld of the middle ring shall be subjected to air test for porosity. The followers shall be single- piece contoured mill section welded and cold expanded as required for the middle rings. They shall be of sufficient strength to accommodate the number of bolts necessary to obtain adequate gasket pressures without excessive rolling. The shape of the follower shall be of such design as to provide positive confinement of the gasket. Gaskets shall be rubber-compound material that will not deteriorate from age or exposure to air under normal storage or use conditions. The rubber in the gasket shall meet the following specifications: 1. Color - Jet Black 2. Surface - Non-blooming 3. 4. 5. The gaskets shall be immune to attack by impurities normally found in water. All gaskets shall meet the requirements of ASTM D 2000, AA709Z, meeting Suffix 813 Grade 3, except as noted above. Restrained Joints. Where shown on the Drawings, restrained joints shall be field- welded joints. Designs shall include considerations of stresses induced in the steel cylinder, the joint rings, and any field welds caused by thrust at bulkheads, bends, G. H. I. Durometer Hardness - 74 f 5 Tensile Strength - 1000 psi Minimum Elongation - 175 percent Minimum J. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED 8 COATED PAGE 02651 - 11 SECTION 02651 -STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED reducers, and line valves resulting from the design working pressure. For field welded joints, design stresses shall not exceed 50 percent of the specified minimum yield strength of the grade of steel utilized, or 18,000 psi, whichever is less, for the part being examined when longitudinal thrust is assumed to be uniformly distributed around the circumference of the joint. At the CONTRACTOR'S option, the steel cylinder area may be progressively reduced from the point of maximum thrust to the end of the restrained length. All joints to be field welded for thrust restraint shall have the joint rings attached to the cylinder with double fillet welds. PART 3 - EXECUTION 3.1 INSTALLATION OF PIPE A. Handlinq and Storaae. All pipe, fittings, and any other components of the piping system subject to the requirements of this section shall be carefully handled and protected against damage to lining and coatinglinterior and exterior surfaces, impact shocks, and free fall. All pipe handling equipment shall be acceptable to the ENGINEER. 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 trench site or elsewhere. Pipe shall be handled and stored at the trench site in accordance with Paragraphs 2.1C and 2.1E, herein. No pipe shall be installed where the lining or coatinglinterior or exterior surfaces show cracks that may be harmful as determined by the ENGINEER. Such damaged lining and coatinglinterior and exterior surfaces, shall be repaired, or a new undamaged pipe shall be furnished and installed. All pipe damaged prior to project completion shall be repaired or replaced by the CONTRACTOR. Damaged pipe that can be repaired shall be repaired prior to laying in the pipe trench, using materials and methods acceptable to the ENGINEER. 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. 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. 6. C. D. E. Not Used. F. Pipe shall be laid directly on the bedding material in accordance with the City of Carlsbad Recycled Water Standard Specifications. 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 JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED & COATED PAGE 02651 - 12 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED pipe to prevent point loading at the bells or couplings. 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 coating on field joints. Each section of pipe shall be laid in the order and position shown on the laying schedule. In laying pipe, it shall be laid to the setline and grade, within approximately one inch plus or minus. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the 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, if joint deflection is selected, in no case shall the deflection in the joint exceed the maximum deflection recommended by the pipe manufacturer. No joint shall be misfit any amount which 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, or prior to applying in-place mortar lining, shall be the controlling factor. Except for short runs which may be permitted by the ENGINEER, pipes shall be laid uphill on grades exceeding IO percent. Pipe which is laid on a downhill grade shall be blocked and held in place until sufficient support is furnished by the following pipe to prevent movement. All bends shall be properly installed as shown on the Drawings. After the backfill has been placed, the struts shall be removed and shall remain the property of the CONTRACTOR. Cold Weather Protection. No pipe shall be installed upon a foundation into which frost has penetrated or at any time that there is a danger of freezing. No pipe shall be laid unless it can be established that the trench will be backfilled before the formation of ice and frost occurs. Pipe and Specials Protection. The openings of all pipe and specials where the pipe and specials have been cement 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 so 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. At all times, means shall be provided to prevent the pipe from floating. G. H. I. J. K. L. M. PiDe Cleanup. As pipe laying progresses, the CONTRACTOR shall keep the pipe interior free of all debris. The CONTRACTOR shall completely clean the interior of the pipe of all sand, dirt, mortar splatter and any other debris following completion of pipe laying, pointing of joints and any necessary interior repairs prior to testing and disinfecting the completed pipeline. JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED & COATED PAGE 02651 - 13 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED 3.2 WELDED JOINTS A. B. General. Field welded joints shall conform with ANSVAWWA C206. / Where exterior welds are performed, adequate space shall be provided for welding and inspection of the joints. During installation of welded steel pipe in either straight alignment or on curves, the pipe shall be laid so that at any point around the circumference of the joint there is a minimum lap of 1/2-inch and a minimum space of 3/4-inch plus the thickness of the steel pipe wall between the spigot end of the pipe and the nearest tangent to a bell radius. Butt straps, where used or required, shall be a minimum of 6 inches wide, the same thickness as the pipe wall and shall provide for a minimum of 3/4-inch lap at each pipe joint. After the pipe and pipe joint are properly positioned in the trench, the length of pipe between joints shall be backfilled to at least one foot above the top of the pipe. Care shall be exercised during initial backfilling to prevent movement of the pipe and to prevent any backfill material from being deposited on the joint. Prior to the beginning of the welding procedure, any tack welds used to position the pipe during laying shall be removed. Any annular space between the faying surfaces of the bell and spigot shall be equally distributed around the circumference of the joint by shimming, jacking, or other suitable means. The weld shall then be made in accordance with ANSVAWWA C206. Where more than one pass is required, each pass except the first and final one shall be peened to relieve shrinkage stresses; and all dirt, slag, and flux shall be removed before the succeeding bead is applied. As soon as practicable after the welding of each joint, all field-welded joints shall be tested by the liquid penetrant inspection procedure conforming to the requirements of ANSVASTM E165 under Method "B. All defects shall be chipped out, rewelded and retested. Upon retest, the repaired area shall show no leaks or other defects. C. D. E. F. G. H. Following testing of the joint, the exterior joint spaces shall be coated in accordance with these specifications after which backfilling may be completed. Qualifications of Procedures and Welders. All welding procedures used to install pipe shall be prequalified under provisions of ANSVAWS D1.l. Welding procedures shall be required for field attachments and field welded joints. Joints. 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 shown on the Drawings. I. J. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED & COATED PAGE 02651 - 14 SECTION 02651 -STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED 3.3 JOINT COATING AND LINING General. The interior and exterior joint recesses shall be thoroughly wiped clean and all water, loose scale, and dirt; and other foreign material shall be removed from the inside surface of the pipe. The cement for the joint grout and mortar shall be portland cement acceptable under ASTM C 150. Joint Coatinq. After the pipe has been laid, sufficient backfill has been placed between the joints to hold the pipe securely in place, and the joint has been taped in conformance with Section 09810 - Tape Coating for Steel Pipe the outside annular space between pipe sections shall be completely filled with grout formed by the use of heavy- duty diapers. The grout shall be composed of one part cement to not more than 2 parts sand, thoroughly mixed with water to a consistency of thick cream. The grout space prior to filling shall be flushed with water so that the surface 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, and 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 3 joints of the pipe being laid. Grout Bands (DiaDers). The grout bands or heavy-duty diapers shall be fabric with steel strapping of sufficient strength to hold the fresh mortar, resist rodding ,of the mortar and allow excess water to escape. The fabric backing shall be cut and sewn into 9-inch wide strips with slots for the steel strapping on the outer edges. The heavyduty diaper 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 cement grout, the flaps shall be closed and overlapped in a manner that fully encloses the grout. The grout band shall remain in position on the pipe joint. Joint Lininq. After the pipe zone backfill has been completed the interior joint recess shall be filled with mortar of stiff consistency mixed in proportions of one part cement to 2 parts sand. The mortar shall be tightly packed into the joint recess and troweled flush with the interior surface, and all excess shall be removed. At no point shall there be an indention or projection of the mortar exceeding 1/16 inch. (With pipe smaller than 24 inches in diameter, before the spigot is inserted into the bell, the bell shall be daubed with mortar containing one part cement to 2 parts sand. The spigot end then shall be forced to the bottom of the bell and excess mortar on the inside of the joint shall be swabbed out.) A. B. C. D. E. F. JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED & COATED PAGE 02651 - 15 SECTION 02651 - STEEL PIPE CEMENT MORTAR LINED AND TAPE COATED 3.4 INSTALLATION OF PIPE APPURTENANCES A. Protection of Aoourtenances. Where the joining pipe is tape coated with a rock shield, buried appurtenances shall be coated with the same coating. Installation of Valves. All valves shall be handled in a manner to prevent any injury or damage to any part of the valve. All joints shall be thoroughly cleaned and prepared prior to installation. The CONTRACTOR shall adjust all stem packing and operate each valve prior to installation to insure proper operation. All buried valves shall be coated and protected in accordance with Section 09800 entitled "Protective Coatings". All valves shall be installed so that the valve stems are plumb and in the locations shown on the Drawings. Installation of Flanaed Joints. Before the joint is assembled, the flange faces shall be thoroughly cleaned of all foreign material with a power wire brush. The gasket shall be centered and the connecting flanges drawn up watertight without unnecessarily stressing the flanges. All bolts shall be tightened in a progressive diametrically opposite sequence and torqued with a suitable, approved and calibrated torque wrench. All clamping torque shall be applied to the nuts only. All buried flanges shall be coated and protected in accordance with Section 09800 entitled "Protective Coatings". Flexible COUDled Joints. When installing flexible couplings, care shall be taken that the connecting pipe ends, couplings and gaskets are clean and free of all dirt and foreign matter with special attention being given to the contact surfaces of the pipe, gaskets and couplings. The couplings shall be assembled and installed in conformity with the recommendation and instruction of the coupling manufacturer. Wrenches used in bolting couplings shall be of a type and size recommended by the coupling manufacturer. Coupling bolts shall be tightened so as to secure a uniform annular space between the follower rings and the body of the pipe with all bolts tightened approximately the same amount. Diametrically opposite bolts shall be tightened progressively and evenly. Final tightening shall be done with a suitable, approved and calibrated torque wrench set for the torque recommended by the coupling manufacturer. All clamping torque shall be applied to the nut only. Upon completion of the coupled joint, the coupling and bare metal of the pipe shall be cleaned, primed and protected in accordance with the requirements of Section 09800, "Protective Coatings". B. C. D. E. F. G. H. I. END OF SECTION JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 STEEL PIPE - CEMENT MORTAR LINED & COATED PAGE 02651 - 16 SECTION 02653 -STEEL PIPE FABRICATED SPECIALS PART 1 -GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall fabricate, install, and test all bends, reducers, wyes. tees, outlets, and other steel plate specials, complete in place all in accordance with the requirements of the Contract Documents. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section 02200 "Earthwork". B. C. D. E. NOT USED F. Section 02601 "Buried Piping Installation". Section 02651 "Steel Pipe, Cement Mortar Lined and Coated". Section 02666 "Water Pipeline Testing and Disinfection". Section 05500 "Miscellaneous Metalwork" for valve supports, flange bolts, and anchor bolts. Section 09800 "Protective Coatings" for exposed steel surfaces. Section 15020 "Valves and Appurtenances". G. H. I. NOT USED J. NOT USED REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. 1.3 Without limiting the generality of other requirements of these specifications, all WORK specified herein shall conform to or exceed the applicable requirements of the referenced portions of the following documents to the extent that the requirements therein are not in conflict with the provisions of this Section. 1. Commercial Standards: ANSIIAWWA C200 ANSIIAWWA C208 Steel Water Pipe 6-inches and larger. Fabricated Steel Water Pipe Fittings, Dimensions for. ASTM A234lA234M Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures. JULY 2003 STEEL PIPE FABRICATED SPECIALS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 02653 - 1 SECTION 02653 - STEEL PIPE FABRICATED SPECIALS ANSIIAWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe - 4- inches and Larger, Shop Applied. ANSIIAWWA C602 AWWA M-I 1 Cement-Mortar Lining of Water Pipelines 4-inch (I00 mm) and Larger - In Place. Steel Water Pipe - A Guide for Design and Installation. 1.4 SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. B. ShoD Drawinqs. The CONTRACTOR shall submit shop drawings and laying diagrams of all pipe, joints, bends, reducers, wyes. tees, crosses, outlets, manifolds, and other steel plate specials. Design calculations shall be submitted to the ENGINEER for review prior to manufacture of pipe specials. Certifications. A certified affidavit of compliance shall be furnished for all steel plate specials and other products or materials furnished under this section of the specifications. C. D. 1.5 QUALITY ASSURANCE A. Shop Testing of Steel Plate SDecials. Upon completion of the welding, but prior to lining and coating, each steel plate special shall be bulkheaded and tested under a hydrostatic pressure of 1-112 times the design pressure; provided, that if straight pipe used in fabricating the specials has been previously tested and meets the requirements of the applicable specifications, no further hydrostatic testing will be required; or provided, that all other welded seams are tested by the liquid penetrant inspection procedure conforming to ASTM E 165, under Method "B" or where applicable by the soap and compressed air method at an air pressure of 25 psi. Any pin holes or porous welds which may be revealed by the test shall be chipped out and rewelded and the pipe or fitting retested. No outside mortar shall be applied over a seam prior to testing; however, mortar lining may be applied over a seam prior to hydrostatic testing, but under such con- ditions said pressure test shall be held on the pipe or fitting for a period of not less than 30 minutes. Field Testinq. Field testing shall conform to the requirements of Section 02666. B. C. JULY 2003 STEEL PIPE FABRICATED SPECIALS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02653 - 2 SECTION 02653 -STEEL PIPE FABRICATED SPECIALS PART 2 - PRODUCTS 2.1 GENERAL A. Specials are defined as fittings, closure pieces, bends, reducers, wyes, tees, outlets, and other steel plate specials wherever located, and all piping above ground or in structures. 2.2 DESIGN A. m. Except as otherwise provided herein, materials, fabrication and shop testing of straight pipe shall conform to the requirements of ANSVAWWA C200. and shall conform to the dimensions of ANSVAWWA C208. The minimum thickness of plate for pipe from which specials are to be fabricated shall be the greater of that determined by the following 2 formulas: where T = Plate thickness in inches D = P,., = Pt = Y = Outside diameter of steel cylinder in inches Design working pressure in psi Design transient pressure in psi Yield point of steel in psi S,., = St = Safety factor of 2.5 at design working pressure Safety factor of 1.875 at design transient pressure B. In no case shall the design stress at design working pressure (Y/S,) for mortar- coated steel pipe exceed 16,500 psi or 22,000 psi at design transient pressure (Y/S,), nor shall plate thickness be less than the thickness of adjacent mainline pipe or the following: Pipe Manifolds Elbows Nominal Pipe Piping Above Ground Bends Diameter (in) Pipinq in Structures Reducers 24 and under 3/16-inch 10-gage 25 to 48 1/4-inch 1/4-inch JULY 2003 STEEL PIPE FABRICATED SPECIALS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02653 - 3 SECTION 02653 - STEEL PIPE FABRICATED SPECIALS C. Pipe installed on saddle supports shall be designed to limit the longitudinal bending stress to a maximum of 10,000 psi. Design shall be in accordance with the provisions of Chapter 7 of AWWA M-1 1. 2.3 FABRICATION AND MATERIALS A. General. Reinforcement for wyes, tees, outlets, and nozzles shall be designed in accordance with AWWA Manual M-11. Reinforcement shall be designed for the design pressure specified or shown and shall be in accordance with the details shown on the Drawings. Specials and fittings shall be equal in pressure design strength and shall have the same lining and coating as the adjoining pipe. Unless otherwise shown on the Drawings, the minimum radius of elbows shall be 2.5 times the pipe diameter and the maximum miter angle on each section of the elbow shall not exceed 11-114 degrees. Specials and fittings that cannot be mechanically lined and coated shall be lined and coated by hand- application, using the same materials as are used for the pipe and in accordance with the applicable AWWA or ASTM Standards. Coating and lining applied in this manner shall provide protection equal to that specified for the pipe. Fittings may be fabricated from pipe that has been mechanically lined and/or coated. Areas of lining and coating that have been damaged by such fabrication shall be repaired by hand-applications in accordance with applicable AWWA or ASTM Standards. B. C. Not Used. D Moderate deflections and long radius curves may be made by means of beveled joint rings, by pulling standard joints, by using short lengths or pipe, or a combination of these methods; provided that pulled joints shall not be used in combination with bevels. The maximum total allowable angle for beveled joints shall be 5 degrees per pipe joint. Bevels shall be provided on the bell ends. Mitering of the spigot ends will not be permitted. The maximum allowable angle for pulled joints shall be in accordance with the manufacturer's recommendations or the angle which results from a 3/4-inch pull out from normal joint closure, whichever is less. All horizontal deflections or fabricated angles shall fall on the alignment. All vertical deflections shall fall on the alignment and at locations adjacent to underground obstructions, points of minimum earth cover, and pipeline outlets and structures, the pipe angle points shall meet the angle point shown on the Drawings. Outlets, Tees, Wves. and Crosses. Outlets 12-inch and smaller may be fabricated from Schedule 40 or heavier steel pipe in the standard outside diameter, Le., 12- 3/4 inch, 10-3/4 inch, 8-518 inch, 6-5/8 inch, and 4- 112 inch. The design of outlet reinforcement shall be in accordance with the procedures of AWWA Manual M-11, except that the design pressure, P, used in the M-11 procedure shall equal the greater of 1.25 Pw or 0.9375 Pt. Unless otherwise - c. F. G. JULY 2003 STEEL PIPE FABRICATED SPECIALS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02653 - 4 SECTION 02653 -STEEL PIPE FABRICATED SPECIALS shown on the Drawings, outlets 2-inches in diameter and smaller need not be reinforced. In lieu of saddle or wrapper reinforcement as provided by the design procedure in Manual M-11, pipe or specials with outlets may be fabricated in their entirety of steel plate having a thickness equal to the sum of the pipe wall plus the required reinforcement. Where required by the M-I 1 design procedure, crotch plate reinforcement shall be furnished. H. I. J. K L. M. N. 0. P. JULY 2003 CWRF PIPEL Steel Weldina Fittinas. Steel welding fittings shall conform to ASTM A 234. Ends for Mechanical-Type Couolinas. Except as otherwise provide herein, where mechanical-type couplings are indicated, the ends of pipe shall be banded with Type C collared ends using double fillet welds. Where pipe 12-inch and smaller is furnished in standard schedule thicknesses, and where the wall thickness equals or exceeds the coupling manufacturer's minimum wall thickness, the pipe ends may be grooved. Lininq. All requirements pertaining to thickness, application and curing of lining specified for straight pipe shall apply to specials, with the following provisions. If the special cannot be lined centrifugally, it shall be lined by hand. Where specials must be mortar lined by hand, the lining shall be reinforced with 2-inch by 4-inch by No. 12 welded wire fabric positioned approximately in the center of the lining. The wires spaced 2-inch on centers shall extend circumferentially around the pipe with the fabric securely fastened to the pipe. Splices shall be lapped 4-inches and the free ends tied or looped to assure continuity. Cement Mortar Lininq for Shop Application. Steel pipe specials shall be cleaned and lined in the shop with cement-mortar lining applied centrifugally in conformity with ANSVAWWA C205. During the lining operation and thereafter, the pipe shall be maintained in a round condition by suitable bracing or strutting. The lining machines shall be of a type that has been used successfully for similar WORK and shall be approved by the ENGINEER. Every precaution shall be taken to prevent damage to the lining. If lining is damaged or found faulty at the delivery site, the damaged or unsatisfactory portions shall be replaced with lining conforming to these Specifications at no additional cost to the OWNER. The minimum cement mortar lining thickness shall conform to the requirements of Section 02651-2.6. The pipe shall be left bare where field joints occur. Ends of the linings shall be left square and uniform. Feathered or uneven edges will not be permitted. Defective linings, as determined by the ENGINEER, shall be removed from the pipe wall and shall be replaced to the full thickness required. Defective linings shall be cut back to a square shoulder in order to avoid feather edged joints. STEEL PIPE FABRICATED SPECIALS .INE TO "D TANKS - REACHES 1 AND 3 PAGE 02653 - 5 SECTION 02653 -STEEL PIPE FABRICATED SPECIALS 0. The progress of the application of mortar lining shall be regulated in order that all hand work, including the repair of defective areas, is cured in accordance with the provisions of ANSI/AWWA C205. Cement-mortar for patching shall be of the same material as the mortar for machine lining, except that a finer grading of sand and richer-mortar cement shall be used when field inspection indicates that such mix will improve the finished lining of the pipe. Cement-Mortar Linina for Field Awlication. The materials and design of in-place cement-mortar lining shall be in accordance with ANSVAWWA C602 and the following supplementary requirements: 1. 2. 3. 4. The minimum lining thickness shall be as specified for shop-applied cement-mortar lining and finished inside diameter after lining shall be as shown on the Drawings. R. Portland cement shall conform to Type II of ASTM C 150. Pozzolanic material shall not be used in the mortar mix Admixtures shall contain no calcium chloride. S. Protection of Pipe Lininallnterior. For all pipe and fittings with plant-applied concrete or cement mortar linings, the CONTRACTOR shall provide a polyethylene or other suitable bulkhead on the ends of the pipe and on all special openings to prevent drying out of the lining. All bulkheads shall be substantial enough to remain intact during shipping and storage until the pipe is installed. Coatinq. All requirements pertaining to thickness, application and curing of coating specified for straight pipe shall apply to specials. Unless otherwise shown, the mortar coating on the buried portion of a pipe section passing through a structure wall shall extend to the center of the wall, or to the wall flanges, if one is indicated. Pipe above ground or in structures shall be field-painted as specified in the Section entitled "Protective Coatings", 09800. Markinq. A mark indicating the true vertical axis of the special shall be placed on the top and bottom of the special. T. U. PART 3 - EXECUTION 3.1 GENERAL A. Unless otherwise provided, the CONTRACTOR shall fumish and install all fittings. closure pieces, bends, reducers, wyes, tees, crosses, outlets, manifolds, and other steel plate specials, bolts, nuts. gaskets, jointing materials, and all other appurtenances as shown and as required to provide a complete and workable installation. Where pipe support details are shown, the supports shall conform thereto and shall be placed as indicated: provided, that the support for all exposed piping shall be complete and adequate regardless of whether or not supporting JULY 2003 STEEL PIPE FABRICATED SPECIALS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 02653 - 6 SECTION 02653 - STEEL PIPE FABRICATED SPECIALS devices are specifically shown. Where shown, concrete thrust blocks and welded joint?, shall be provided. At all times when the WORK of installing pipe is not in progress, all openings into the pipe and the ends of the pipe in trenches or structures shall be kept tightly closed to prevent entrance of animals and foreign materials. The CONTRACTOR shall take all necessary precautions to prevent the pipe from floating due to water entering the trench from any source, shall assume full responsibility for any damage due to this cause and shall at its own expense restore and replace the pipe to its specified condition and grade it is displaced due to floating. The CONTRACTOR shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the OWNER. 3.2 LAYING A. Trenches shall be in a reasonable dry condition when the pipe special is laid. Necessary facilities including slings shall be provided for lowering and properly placing the pipe sections in the trench without damage. The pipe and specials shall be laid to the line and grade shown and they shall be closely jointed to form a smooth flow line. Immediately before placing each section of pipe in final position for jointing, the bedding for the pipe shall be checked for firmness and uniformity of surface. END OF SECTION JULY 2003 STEEL PIPE FABRICATED SPECIALS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 02653 - 7 SECTION 02666 - WATER PIPELINE TESTING AND DISINFECTION PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall perform all pipeline flushing, testing, and disinfection, complete, for the recycled water distribution system, including conveyance of test water from designated source to point of use, and including all disposal thereof, all in accordance with the requirements of the CONTRACT DOCUMENTS. 1.2 SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. 0. Pressure Testinq. 1. Submit test bulkhead locations and design calculations, pipe attachment details such as temporary vents, backflow preventors, flow meters. valves and drains, and methods to prevent excessive pipe wall stresses. Submit six copies of the hydrostatic test records to the ENGINEER upon completion of the testing. Provide a recent record of pressure gauge calibrations. The CONTRACTOR shall submit a minimum 7-day advance written notice of its proposed testing schedule for review and concurrence of the ENGINEER. The CONTRACTORS proposed plans for water conveyance control, and disposal shall also be submitted in writing. 2. 3. 4. C. Disinfection. 1. Submit a plan for the proposed disinfection and dechlorination methods and procedures, including equipment used to inject the chlorine solution, gauges and/or scales to measure the rate at which chlorine is injected, qualifications of the personnel performing the disinfection, chlorine injection, testing locations, testing schedule, source of potable water, and water disposal locations. Personnel performing the disinfection shall demonstrate a minimum of five (5) years experience in the chlorination and dechlorination of large diameter pipelines. Qualifications of certified testing laboratory. Six copies of bacteriological test results to the ENGINEER upon completion of each test. Approvals of local agencies regulating chlorination facilities. 2. 3. 4. 5. Emergency Response PlanFransportation Plan. JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02666 - 1 SECTION 02666 - WATER PIPELINE TESTING AND DISINFECTION 1.3 1.4 1.5 6. Prior to the discharge of water used in the disinfection process, submit a plan which describes the proposed method of dechlorination, including equipment used to measure the introduction of chemicals to neutralize the chlorine, the concentration of neutralizing solution, the discharge flow rate, testing methods, and a discharge schedule. Provide a daily record of the average flow rates and chlorine residual, as measured at the sample points for all discharge water and receiving waters from draining and flushing the pipeline. 7. RELATED SECTIONS A. Section 02200 “Earthwork”. B. C. REFERENCES A. Section 02601 “Buried Piping Installation”. Section 15020 Valves and Appurtenances”. American Water Works Association (AWWA). 1. 2. 3. SSPWC 306 - Underground Pipeline Construction (with supplements) AWWA 8300 - Standard for Hypochlorites. AWWA 8301 - Standard for Liquid Chlorine. AWWA C651 - Disinfecting Water Mains. B. JOB CONDITIONS A. Discharge of chlorinated water into watercourses or surface waters is regulated by the California Regional Water Quality Control Board, San Diego Region, under the National Pollutant Discharge Elimination System (NPDES). Schedule and coordinate rates of flow and locations of discharge of disinfection and flushing water with the ENGINEER and cognizant state and local regulatory agencies to ensure compliance with all applicable rules and regulations. Use potable water for chlorination. Submit request for use of potable water from waterlines of OWNER two (2) working days in advance. Disinfection operations shall be scheduled by the CONTRACTOR as late as possible during the contract time period so as to assure the maximum degree of sterility of the facilities at the time the WORK is accepted by the OWNER. Bacteriological testing shall be performed by a certified testing laboratory approved by the OWNER and at the expense of the CONTRACTOR. Results of the bacteriological testing shall be satisfactory with the State Department of Health. B. C. D. JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PAGE 02666 - 2 SECTION 02666 -WATER PIPELINE TESTING AND DISINFECTION I .6 PRESSURE TESTING RECORDS A. The CONTRACTOR shall submit a minimum 48-hour advance written notice of its proposed testing schedule for review and concurrence of the ENGINEER. The CONTRACTORS proposed plans for water conveyance, control and disposal shall also be submitted in writing and shall include: - Dateof test - - Identification of pipeline material. - Identification of pipe specification. - Testfluid. - Test pressure. - Remarks: Leaks identified (type and location), types of repairs, or correction made. - Certification by CONTRACTOR that the leakage rate measured conformed to the specifications. Identification of pipeline, or pipeline section, tested or retested. - Test duration. - Allowable losses. - Actual losses. PART 2 - PRODUCTS 2.1 PRESSURE TESTING A. Vents and Drains for Above Ground Pioinq. Install vents on the high points of above ground piping, whether shown on the CONTRACT DOCUMENTS or not. Install drains on low points of above ground piping, whether shown on the CONTRACT DOCUMENTS or not. Provide a valve at each vent or drain point. Valves shall be 314 inch for piping 3 inches and larger and 1/2 inch for piping smaller than 3 inches. 0. Manual Air-Release Valves for Buried Pioina. Where necessary, provide temporary manual air-release valves for pipeline test. Construct the pipe outlet in accordance with San Diego Regional Standard Drawings or District Standards. After use, seal with a pipe cap, or plug and coat equal to the adjacent pipe. JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02666 - 3 SECTION 02666 - WATER PIPELINE TESTING AND DISINFECTION C. Test Bulkheads. Design and fabricate test bulkheads per Section Vlll of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. Materials shall comply with Part UCS of said code. Design pressure shall be at least 2.0 times the specified test pressure for the section of pipe containing the bulkhead. Limit stresses to 70 percent of yield strength of the bulkhead material at the bulkhead design pressure. Include air-release and water drainage connections. Testina Fluid. For potable water pipelines, obtain and use only potable water for hydrostatic testing. D. E. Testina EauiDment. Provide new, calibrated, 6 inch diameter face pressure gauges and a chart recorder, pipes, bulkheads, pumps, and calibrated meters to perform the hydrostatic testing. Use laboratory calibrated test gauges and meters, which shall be calibrated by a certified laboratory prior to the test. 2.2 DISINFECTION A. Form of Chlorine. Use calcium hypochlorite, sodium hypochlorite, or liquid chlorine conforming to AWWA 8300 and 8301. Calcium hypochlorite tablets shall not be used for disinfecting pipes larger than 24-inches in diameter. Chlorine Residual Test Kit. For measuring chlorine concentration, supply and use a medium range, drop count, titration kit or an orthotolidine indicator comparator with wide range color discs: Range to match chlorine concentration limits. Products: Hach Chemical or Hellige. Maintain kits in good working order available for immediate test of residuals at point of sampling. B. PART 3 - EXECUTION 3.1 GENERAL A. Water for testing and disinfecting recycled water pipelines will be furnished by the OWNER at no cost to the CONTRACTOR. The CONTRACTOR shall make all necessary provisions and bear all costs associated with conveying the water from the source to the points of use. All pressure pipelines shall be tested. Disinfection shall be accomplished by chlorination. Chlorine dosages shall be as computed by the ENGINEER. All chlorinating and testing operations shall be performed by qualified professionals in the presence of the ENGINEER. The CONTRACTOR shall perform the WORK of this Section exercising the utmost care to conserve water. B. C. 3.2 PRESSURE TESTING A. Testina PreDaration. JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02666 - 4 SECTION 02666 - WATER PIPELINE TESTING AND DISINFECTION 1. Install AWWA approved reduced pressure-principle backflow preventers and turbine flow meters at each water supply connection. Place and anchor pipes before commencing pressure testing. Conduct pressure tests on exposed and above ground piping after the piping has been installed and attached to the pipe supports, hangers, anchors, expansion joints, valves, and meters. Conduct pressure tests of buried pipeline after the trench has been completely backfilled. Provide any temporary piping needed to carry the test fluid to the piping that is to be tested. After the test has been completed and demonstrated to comply with the specification, disconnect and remove temporary piping. Provide temporary drain lines needed to carry testing fluid away from the pipe being tested. Remove such temporary drain lines after completing the pressure testing. 2. 3. 4. 5. 6. B. Cleaninq. 1, In pipelines less than 24 inches in diameter, before conducting hydrostatic test, flush pipes with water to remove dirt and debris. Maintain a flushing velocity of at least 3 fps for water testing. Flush pipes for the minimum time period as given by the formula below and as required to thoroughly clear the pipeline of dirt and debris. T =a 3 in which: T = flushing time (seconds) L = pipe length (feet) 2. In pipes 24 inches or larger in diameter, clear the pipe using high-pressure water jet, sweeping, scrubbing, or equally effective means. All water, sediment, dirt, and foreign material accumulated during this cleaning operation shall be discharged, vacuumed, or otherwise removed from the pipe. C. NOT USED D. Lencrth of Test Section for Buried PiDinq. The maximum length of the test section for buried pipe of 12 inches or smaller in diameter is 2,500 feet; for buried pipe larger than 12 inches, submit for approval by the ENGINEER any test lengths in excess of 1 mile. Initial PiDeline Fillincr for Hvdrostatic Testinq. Control maximum rate of filling to E. JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02666 - 5 SECTION 02666 -WATER PIPELINE TESTING AND DISINFECTION prevent water velocity in pipeline from exceeding 1 fps maximum velocity which may otherwise be required for disinfection by the slug method. Filling may be facilitated by removing automatic air valves and releasing air manually. Hydrostatic Testinq of Above Ground or Exoosed Pioinq. Open vents at high points of the piping system to purge air while the pipe is being filled with water. Venting during system filling may also be provided by temporarily loosening flanges. Subject the piping system to the test pressure specified herein. Maintain the test pressure for a minimum of 24 hours. Examine joints, fittings, valves, and connections for leaks. The piping system shall show zero leakage or weeping. Correct leaks and retest until zero leakage is obtained. Air and vacuum valves shall be in place and working in case of pipe failure during testing. Hydrostatic Testing of Buried Pioinq. 1. F. G. Where any section of the piping contains concrete thrust blocks or encasement, do not pressure test until at least 10 days after the concrete has been poured. When testing cement mortar lined piping, fill the pipe to be tested with water and allow it to soak for at least 48 hours to absorb water before conducting the pressure test. Apply and maintain the test pressure by means of a hydraulic force pump. Maintain the test pressure for the following duration by restoring it whenever it falls an amount of 5 psi: 2. 3. Pipe Diameter (inches) 18 and less 4 20 to 36 8 Greater than 36 24 4. 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 rate is defined by the formula: L = HND (P) 1/2 C in which: H = specified test period (hours) L = allowable leakage (gallons) N = number of rubber-gasketed joints in the pipe tested D = diameter of the pipe (inches) P = specified test pressure (psig) C = 7,400 JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 02666 - 6 SECTION 02666 -WATER PIPELINE TESTING AND DISINFECTION a. b. The allowable leakage for welded steel pipe shall be zero gallons. The allowable leakage for buried piping having threaded, gasketed, brazed, or welded (including solvent welded) joints shall be zero gallons. 5. Repair and retest any pipes showing leakage rates greater than that allowed in the above criteria. Repair and retest any pipes showing leakage rates greater than that allowed in the above criteria. 6. H. Test Pressure. The field hydrostatic test pressure in pounds per square inch is the field hydrostatic test HGL minus the pipe invert elevation multiplied by 0.433. Repetition of Test. If the actual leakage exceeds the allowable, locate and correct the faulty WORK and repeat the test at the CONTRACTORS expense. Restore the WORK and all damage resulting from the leak and its repair. Eliminate visible leakage. Bulkhead and Test Facility Removal. After a satisfactory test, remove test bulkheads and other test facilities, restore the pipe lining and coatings, and fill the pipeline section tested with water and maintain it in a full condition until all disinfection and hydrostatic testing of the entire pipeline length has been completed. The CONTRACTOR shall assume all responsibility for any damage to the pipeline as a result of pressure imposed during the operations of filling the pipeline with water and conducting the tests. I. J. 3.3 DISINFECTION A. General. Fill and disinfect the new pipeline simultaneously, in accordance with AWWA C651 and this specification, utilizing either the continuous feed method or the slug method. Disinfect the connections to the existing facilities by the swabbing method prior to refilling the pipeline. 0. Methods. The methods used for disinfection of the pipelines shall be in C. accordance with AWWA C651. Disinfection Of Valves And ADDurtenances. During the period that the chlorine solution or slug is in the section of pipeline, open and close valves to obtain a chlorine residual at pipeline appurtenances. D. Confirmation of Residual. 1. Afler the chlorine solution applied by the continuous feed method has been retained in the pipeline for 24 hours, confirm that a chlorine residual of not less than 10 mgll exists along the pipeline by sampling at air valves and other points of access. JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02666 - 7 SECTION 02666 -WATER PIPELINE TESTING AND DISINFECTION 2. With the slug method, confirm by sampling as the slug passes each access point and as it leaves the pipeline. E. Bacterioloqic Tests. 1. After final flushing and before connection to a distribution system, two consecutive sets of acceptable samples shall be taken at least 24 hours apart. All sampling and testing shall be done by a certified laboratory which has been approved by the Engineer. At least one set of samples shall be collected from all ends including branches and every 2000 feet of the pipeline or as directed by the Engineer. Test all samples for bacteriological quality in accordance with Standard Methods for the Examination of Water and Wastewater, and shall show the absence of coliform organisms. 2. F. Repetition Of Procedure. If the initial chlorination fails to produce required residuals and bacteriologic tests, repeat the chlorination and retesting until satisfactory results are obtained. G. Pipeline Flushing. 1. After confirming the chlorination the chlorine residual, flush the excess chlorine solution from the pipeline until the chlorine concentration in the water leaving the pipe is within 2.0 mgll of the replacement water. Pipeline flushing shall be performed to remove any excess lubricants within the pipeline. Constructed mains that have not been filled, or filled mains that have remained stagnant shall be reflushed prior to being integrated with the City water system. 2. H. Disposal and Dechlorination of Water. 1. CONTRACTOR shall provide suitable means for disposal and dechlorination of test, disinfection and flushing water so that no damage results to facilities or waterways. Means for dechlorination of test, disinfection and flushing water shall be subject to the approval of ENGINEER, local governing authorities, regulatory agencies, NPDES requirements and AWWA C691 Appendix B. CONTRACTOR shall be responsible for any damage caused by his water disposal operations. 2. 3. I. Test Facilitv Removal. After satisfactory disinfection, replace air valves, restore the pipe coating, and complete the pipeline where temporary disinfection or test facilities were installed. JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 02666 - 8 SECTION 02666 - WATER PIPELINE TESTING AND DISINFECTION J. Connections To Existino Pipelines. To prevent contamination of the new or existing pipeline, disinfect pipeline closure sections, fittings, valves, and other appurtenances used to perform the permanent connections to an existing water system by swabbing the interior of all surfaces with a one percent solution of chlorine just prior to installation. END OF SECTION JULY 2003 WATER PIPELINE TESTING AND DISINFECTION CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PAGE 02666 - 9 - , SECTION 03400 - PRECAST CONCRETE VAULTS PART 1 -GENERAL 1 .I DESCRIPTION A. w: 1, CONTRACTOR shall furnish all labor, materials, equipment and incidentals required to provide precast concrete vaults as shown on the drawings and specified in the schedule attached at the end of this section. All precast concrete vault sections shall be manufactured in a plant especially designed for the purpose. All units will conform to the design shown on the drawings, and all work shall be done under strict plant controlled supervision. 2. B. Coordination: 1. Review applicable installation procedure under other Sections and coordinate the installation of items that must be installed in the precast concrete trough units. Notify other CONTRACTORS in advance of the precasting to provide them with sufficient time to advise of items required in their work that must be installed in the units. 2. C. Related Work Specified Elsewhere: 1. "Earthwork." 02200 2. 3. 4. "Miscellaneous Metalwork." 05500 "Plastic (PVC) Pressure Pipe, AWWA C900." 02646 "Steel Pipe - Cement Mortar Lined and Coated." 02651 D. Classes of Concrete: 1. 1.2 QUALITY ASSURANCE Conform to the mix designs for Class A concrete. A. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1. ACI 318. Building Code Requirements for Reinforced Concrete, which includes referenced ASTM Standards. Comply with local building code requirements where more stringent than ACI 318. JULY 2003 PRECAST CONCRETE VAULTS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 03400 - 1 SECTION 03400 - PRECAST CONCRETE VAULTS 2. ACI 21 1.3. Recommended Practice for Selecting Proportions for No-Slump Concrete. ACI 517, Recommended Practice for Atmospheric Pressure Steam Curing of Concrete. PCI MNL 116, Manual for Quality Control for Plants and Production of Precast Prestressed Concrete Products. 3. 4. B. Fabricator Qualifications: Fabricated by a firm regularly engaged in the manufacture of precast units. Source Qualitv Control: Make cylinder tests of concrete quality in accordance with ASTM C 192, for each mix design, for each day of production, or for each 25 cubic yards of concrete. C. 1.3 SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. . ShoD Drawinas: Submit for approval the following: 1. B. Shop Drawings showing all dimensions, openings, jointing, camber, inserts, reinforcing, prestressing, design calculations, and method of handling. Include manufacturer's setting plans and anchorage details. Show all conditions at openings, including size, location, topping and grout details, fasteners, etc., locations and dimensions. Copies of all concrete cylinder test reports. Manufacturer's literature and installation instructions. Certificates of material conformance with Specifications, and ASTM C857 and c85a. 2. 3. 4. 1.4 PRODUCT DELIVERY, STORAGE AND HANDLING A. Deliverv and Handlinq: Transport precast concrete vaults units with proper equipment to protect units from dirt and damage. B. Storaae: Store units off ground and on firm surfaces to avoid warping and cracking. Protect vaults from damage and discoloration. Stack so that lifting devices are accessible and undamaged. Separate stacked members by battens across full width of each bearing. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PRECAST CONCRETE VAULTS PAGE 03400 - 2 SECTION 03400 - PRECAST CONCRETE VAULTS PART 2 - PRODUCTS 2.1 2.2 2.3 2.4 2.5 GENERAL A. Precast concrete vaults and risers shall be manufactured by: 1. Brooks Products, Inc. 2. Associated Concrete Products, Inc., 3. Or approved equal. Precast concrete vault shall comply with ASTM C858 except as modified herein. Minimum wall thickness shall be 6-inches. Design vault to withstand site soil conditions and H-20 traffic loading. Vault shall be designed to have sufficient weight to prevent "floating" due to buoyancy forces caused by groundwater. Provide openings in precast vaults for piping and access. Provide cast-in-place inserts in the roof shell and wall at the locations as shown on the drawings. B. C. PRECAST CONCRETE RISERS A. Precast concrete risers, grade ring, and cone shall comply with ASTM C478 except that the wall thickness shall be 5-inches minimum. NOT USED. NOT USED. MATERIALS A. Concrete. 1. All cement shall be Portland Cement conforming to ASTM C150, Type V. Cement content shall be sufficient to produce minimum strength of 3,000 PSI. or other design strengths required. All aggregates, fine and coarse, other than lightweight aggregate shall conform to Specifications outlined by ASTM C-33. Lightweight aggregates fine and coarse shall conform to the Specifications outlined by ASTM C- 330. Aggregates shall be free of deleterious substances causing reactivity with oxidized hydrogen sulfide. Both types of aggregate shall be graded in a manner so as to produce a homogenous concrete mix. All materials are to be accurately weighed at a central batching facility for mixing. Chemical admixtures shall conform to ASTM C494. Calcium chloride shall not be used. Water shall be free from foreign materials in amounts harmful to concrete. 2. 3. 4. Reinforcina Steel. All reinforcing shall be sufficiently tied to withstand any displacement during the pouring operation. All bars shall be intermediate or hard B. JULY 2003 PRECAST CONCRETE VAULTS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 03400 - 3 SECTION 03400 - PRECAST CONCRETE VAULTS grade billet steel conforming to ASTM A-615lA-706. Bars other than 114" round, or smaller, shall be deformed in accordance with ASTM A306. All forms used in placing concrete shall be of metal and sufficiently designed and braced to maintain their alignment under pressure of the concrete during placing. D. Miscellaneous Grout Materials 1. m. Ordinary grout shall consist of one part portland cement to two parts sand with sufficient water to permit placing or pouring as required. Sand shall pass the No. 16 sieve. TODDinq Grout and Concrete Fill. a. 2. Grout for topping of slabs and concrete fill for built-up surfaces of tank and 'basin bottoms shall be composed of cement, fine aggregate, coarse aggregate, water and admixtures proportioned and mixed as herein specified. All materials and procedures specified for normal concrete shall apply except as noted otherwise herein. The concrete topping shall be portland cement conforming to Type II of ASTM C 150. Fine aggregate shall conform to the specifications and grading for fine aggregate in concrete. Coarse aggregate shall conform to the specifications for coarse aggregate in concrete and shall be graded as follows: b. U.S. STANDARD SIEVE SIZE 112 318" No. 4 No. 16 No. 30 NO. a PERCENT BY WEIGHT PASSING 100 90-1 00 20-55 5-30 0-1 0 0 C. Final mix desian shall be as determined bv trial mix desian under supervision of-the approved testing laboraiory. Slump &all be 2- inch maximum. d. Strenqth. Minimum compressive strength of topping grout and concrete fill at the end of 28 days shall be 3000 psi. 2.6 MIXES A. Measurements of concrete mix materials shall be within the following limits: 1. Cement: Plus or minus 1 percent. JULY 2003 PRECAST CONCRETE VAULTS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 03400 - 4 SECTION 03400 - PRECAST CONCRETE VAULTS 2. Water. Plus or minus 1 percent. The cement shall be Portland Cement Type V B. 2.7 DESIGN AND FABRICATION A. Desiqn Loads. 1. Design loads shall consist of dead load, impact, and in addition, loads due to water table, and any other loads which may be imposed upon the structure, and shall comply with ASTM C857. Live loads shall be for H-20 and/or H-20-SI6 per AASHTO Standard Specifications for Highway Bridges with revisions. Design wheel load shall be 16 kips. The live load shall be that loading which produces the maximum shears and bending moments in the structure. 2. B. Furnish units which are free from voids and honeycomb, with straight true edges and surfaces. Provide units of a uniform color and free from stains or discoloration. Top surface to have a float finish free from holes. Design calculations, drawings, and details shall be stamped and signed by a Registered Civil Engineer in the State of California. C. 2.8 SEALANTS AND GROUT A. Fill joints between precast sections with either a plastic sealing compound or mortar. Plastic sealing compound shall comply with Federal Specification SS-S- 00210. Mortar shall comply with ASTM C387, Type S. 2.9 NOTUSED 2.10 EXTERIOR COATING A. Exterior coating shall conform to the requirements of Section 09800 of these Specifications. 2.11 HATCHES A. Hatches shall be rated for H-20 loading and shall conform to the requirements of Section 05500 of these Specifications. .PART 3 - EXECUTION 3.1 INSPECTION A. Examine the areas and conditions under which the vaults are to be installed. Notify the ENGINEER in writing of the conditions detrimental to the proper and JULY 2003 PRECAST CONCRETE VAULTS CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PAGE 03400 - 5 SECTION 03400 - PRECAST CONCRETE VAULTS timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions have been corrected in a manner acceptable to the ENGINEER. 3.2 INSTALLATION A. Excavate for the vault and install a crushed rock base, 1 foot thick. Crushed rock base material shall extend a minimum 6-inches beyond the outside edge of the concrete vault base and shall be compacted to 90% relative density. Set each precast concrete vault section or riser plumb on a bed of sealant or cement grout at least 1/2-inch thick to make a watertight joint with the preceding unit. B. C. Lift, place, and secure the vaults in accordance with manufacturer's printed instructions and approved Shop Drawings. Vaults having any dimension smaller or greater than required, or that are outside the specified tolerance limits, will be rejected if the appearance or function of the structure is adversely affected. Vaults that are constructed of concrete not meeting the specified strength shall be removed and replaced. D. E. F. Level vaults accurately, align and level to approved tolerance by methods, procedures, and equipment as recommended by the manufacturer. The ENGINEER shall have access to the manufacturer's plant at all times during and after fabrication to inspect all precast vaults at the manufacturer's plant prior to delivery to the jobsite. During progress of the Work, not less than 6 test cylinders shall be made for each day's casting. Two cylinders shall be tested at the time of prestress, two at age 28 days and two held in reserve. Do not cut reinforcing without approval of manufacturer and as acceptable to the ENGINEER. Repair damaged exposed surfaces. Leave units in a condition acceptable to the ENGINEER and ready to receive subsequent work. G. H. I. END OF SECTION JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PRECAST CONCRETE VAULTS PAGE 03400 - 6 SECTION 05500 - MISCELLANEOUS METALWORK PART 1 -GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish, fabricate, and install miscellaneous metalwork and appurtenances, and complete, all in accordance with the requirements of the CONTRACT DOCUMENTS. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Painting and protective coating of metalwork and fabricated items shall, unless otherwise specified herein, be performed in accordance with the requirements of Section 09800, "Protective Coatings." 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of these specifications, all WORK specified herein shall conform to or exceed the requirements of the Building Code and the applicable requirements of the following documents to the extent that the provisions of such documents are not in conflict with the requirements of this Section: 1. 2. American Welding Society (AWS). 3. 4. 5. References herein to "Building Code" or UBC shall mean the Uniform Building Code of the International Conference of Building Officials (ICBO). The latest edition of the codes, as adopted as of the date of award by the agency having jurisdiction, shall apply to the WORK herein. American Society for Testing and Materials (ASTM). American Institute of Steel Construction (AISC). American Iron and Steel Institute (AISI). Occupational Safety and Health Administration (OSHA) B. 1.4 SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. B. Shop drawings of all miscellaneous metalwork shall be submitted to the ENGINEER for review in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. Wherever power-driven pins will be utilized for anchorage or support, complete information describing pin capacity. connections, and proposed use locations shall be furnished to the ENGINEER. C. JULY 2003 MISCELLANEOUS METALWORK CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 05500 - 1 SECTION 05500 - MISCELLANEOUS METALWORK PART 2 - PRODUCTS 2.1 2.2 2.3 2.4 2.5 2.6 GENERAL REQUIREMENTS A. All structural steel shapes, plates, bars, and their products shall conform to the requirements of ASTM A 36, "Specifications for Structural Steel." Unless otherwise shown, .miscellaneous metalwork of fabricated steel shall be coated in accordance with Section entitled "Protective Coatings" and shall not be galvanized prior to coating. All other miscellaneous metalwork shall be hot-dip galvanized after fabrication as specified herein. B. NOT USED NOT USED NOT USED LADDERS A. Ladders shall be of galvanized steel, hot-dip galvanized after fabrication, and shall be manufactured by: 1. 2. Or approved equal. Alhambra Foundry Model No. A-3400. VAULT HATCHES A. General. Vault hatches shall be of the design, sizes and types shown. Aluminum in contact with other metal or concrete shall be shop-painted with 1 coat of zinc chromate and 2 coats of approved aluminum metal-and-masonry paint. Hatches shall be as manufactured by: 1. Bilco, Type J-4AL 2. Or approved equal. Vault Hatches. Hatches shall be of aluminum as shown on the contract drawings. Hatches shall be 1/4-inch steel diamond pattem plate designed to withstand H20 traffic live loading. Channel frame shall be 1/4-inch steel with an anchor flange around the perimeter. Leaf shall be equipped with heavy stainless steel hinges, stainless steel pins, spring operators for easy operation, and an automatic hold- open arm with release handle. Leaf shall be equipped with a recessed hasp for padlock. Recess shall have a flush cover of same material as leaf. Cover shall be retained by a single flat head screw. A 1-1/2 inch drainage coupling shall be located in the front right corner of the channel frame. Hardware shall be 304 stainless steel. Frame and leaf shall be mill-flush with a bituminous coating applied to the exterior of the frame. B. JULY 2003 MISCELLANEOUS METALWORK CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 05500 - 2 SECTION 05500 - MISCELLANEOUS METALWORK 2.7 PIPE COLUMNS A. Pipe column steel shall conform to the requirements of ASTM A 53, "Specifications for Welded and Seamless Steel Pipe," Grade B. 2.8 NOTUSED 2.9 NOTUSED 2.10 NOTUSED 2.11 NOTUSED 2.12 BOLTS AND ANCHORS A. Except where otherwise shown or specified, all bolts, anchor bolts, and nuts shall be steel, galvanized after fabrication as specified herein. Threads on galvanized bolts and nuts shall be formed with suitable taps and dies such that they retain their normal clearance after hot-dip galvanizing. Except as otherwise provided herein, steel for bolts, anchor bolts and cap screws shall be in accordance with the requirements of ASTM A 307 "specifications for Carbon Steel Externally and Internally Threaded Standard Fasteners," Grade B or threaded parts of ASTM A 36 and shall meet the following additional requirements: 1. 2. B. The nut material shall be free-cutting steel, and The nuts shall be capable of developing the full strength of the bolts. Threads shall be Coarse Thread Series conforming to the requirements of the American Standard for Screw Threads. All bolts and cap screws shall have hexagon heads and nuts shall be Heavy Hexagon Series. C. Unless otherwise shown, all bolts, anchor bolts and nuts which are buried, submerged, or below the top of the wall inside any hydraulic structure shall be of Type 316 stainless steel. Unless otherwise shown, expanding-type anchors shall be steel expansion type Phillips Drill Company "Red Head" anchors, McCullock Industries "Kwick-Bolt," or equivalent. Lead caulking anchors will not be permitted. Size shall be as shown. Expansion type anchors which are to be embedded in grout may be steel. Non- embedded buried or submerged anchors shall be Type 316 stainless steel. D. 2.13 NOTUSED JULY 2003 MISCELLANEOUS METALWORK CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 05500 - 3 SECTION 05500 - MISCELLANEOUS METALWORK PART 3 - EXECUTION 3.1 FABRICATION AND INSTALLATION REQUIREMENTS A. Fabrication and Erection. Except as otherwise shown, the fabrication and erection of structural steel shall conform to the requirements of the American Institute of Steel Construction "Manual of Steel Construction." Steel Railinas. Field welding of steel pipe handrail joints will be permitted only if approved in writing by the ENGINEER, and then only in accordance with the instructions of the ENGINEER. Stainless steel shall not be field welded under any circumstances. Vault Hatches. Unless otherwise shown, the CONTRACTOR shall furnish and install a 112 inch PVC drain line to daylight 4-inches beyond the outside wall face or to an inside drain, or curb. B. C. D. NOTUSED 3.2 WELDING A. 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. Qualification of welders shall be in accordance with the AWS Standards governing same. B. In assembly and during welding, the component parts shall be adequately ctamped, 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 which is to be painted or coated shall be ground to a minimum of 1/32-inch on the flat. 3.3 GALVANIZING A. All structural steel plates, shapes, bars and fabricated assemblies required to be galvanized shall, afler the steel has been thoroughly cleaned of rust and scale, be galvanized in accordance with the requirements of ASTM A 123, "Specification for Zinc (Hot-Galvanized) Coating on Products Fabricated from Rolled, Pressed and Forged Steel Shapes, Plates, Bars and Strip." Any galvanized part that becomes warped during the galvanizing operation shall be straightened. Bolts, anchor bolts, nuts and similar threaded fasteners, afler being properly cleaned, shall be galvanized in accordance with the requirements of ASTM A 153 "Specifications for Zinc Coating (Hot-Dip) on Iron or Steel Hardware." Field repairs to galvanizing shall be made using "Galvinox," "Galvo-Weld," or equivalent. 3.4 ROTUSED END OF SECTION JULY 2003 MISCELLANEOUS METALWORK CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 05500 - 4 SECTION 09800 - PROTECTIVE COATINGS PART 1 - GENERAL 1.1 1.2 THE REQUIREMENT A. The WORK of this Section shall include the protective coating of all specified surfaces including all surface preparation, pretreatment, coating application, touch- up of factory-coated surfaces, protection of surfaces not to be coated, cleanup, and appurtenant work, all in accordance with the requirements of the CONTRACT DOCUMENTS. The following surfaces shall not be protective coated hereunder unless shown on the plans, by this Section, or elsewhere in the CONTRACT DOCUMENTS. 1. Concrete 2. Stainless steel 3. Machined surfaces 4. Equipment nameplates 5. Manhole frames and covers 6. Fiberglass Reinforced Plastic Surfaces B. REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of these specifications, all cleaning, surface preparation, coating, and appurtenant work shall conform to the applicable requirements of the referenced portions of the standards specified herein. References herein to "SSPC Specifications" or "SSPC shall mean the published standards of the Steel Structures Painting Council, 4400 Fifth Avenue, Pittsburgh. PA 15213. References herein to "NACE shall mean the published standards of the National Association of Corrosion Engineers, P.O. Box 986, Katy, TX 77450. All products shall conform to all current local air quality regulations in effect at the B. C. D. time of application as dictated by the San Diego Air Pbllution Control District (APCD). E. All products intended for immersion in potable water shall conform to all national, state and local water quality regulations in effect at the time of application, including, but not limited to, NSF 61. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PROTECTIVE COATINGS PAGE 09800 - 1 SECTION 09800 - PROTECTIVE COATINGS 1.3 SUBMllTALS A. Samples. Upon request of the ENGINEER, the CONTRACTOR shall be prepared to submit samples of all paint, finishes, and other coating materials specified herein. Coatina Materials List. The CONTRACTOR shall provide 8 copies of a coating materials list which indicates the manufacturer and the coating number, keyed to the coating schedule herein, for the approval of the ENGINEER prior to or at the time of submittal of samples. 6. C. Paint Manufacturer's Information. For each paint system to be used the CONTRACTOR shall submit, the following listed data at least 30 days prior to painting. 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. Colors available for each product (where applicable). Compatibility of shop and field applied coatings (where applicable). Material safety data sheet for each product used. Two sets of color samples to match each color selected by the ENGINEER from the manufacturer's standard color sheets. If custom mixed colors are required by this Section, the color samples shall be made using color formulations prepared to match the color samples furnished by the ENGINEER. The color formula shall be shown on the back of each color sample. 3. 4. 5. 6. D. Manufacturer's Certification. For submerged and severe service coating systems, the CONTRACTOR shall require the paint manufacturer to attest to the following: 1. The coating systems supplied are in conformance with these specifications. Each element is compatible with the other elements in the system, and the system is suitable for its intended use. The CONTRACTOR shall submit all such certificates to the ENGINEER within 10 days of completion of each paint system. ADDliCatOr'S Certificate. For submerged and severe service coating systems, the CONTRACTOR shall require the applicator of the protective paint coatings to certify to the following: 1. Immediately before painting, surfaces conformed to the specified preparation; they were in suitable condition; and were clean, dry, and free of dust, rust, and mill scale. E. F. JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 09800 - 2 SECTION 09800 - PROTECTIVE COATINGS 2. Surface preparation and coating use. mixing, application, and curing were done in accordance with the current printed instructions and recommendations of the protective coating manufacturer, and these Specifications. The products specified were used. A listing of the names of the products and their manufacturer shall be provided. The products were used within the shelf-life dates, stating the shelf-life dates of each container of each product used. The specified dry film thickness of coatings are on the items. The quantities of each product used with copies of paint manufacturer's invoice. Compatible paints were used where shop or field applied coatings are applied over previously-applied coatings. 3. 4. 5. 6. 7. G. The applicator's certificate shall list the dates and locations that the coating work was completed for the various surfaces coated, and shall also list the dry film thickness obtained for each coat. The CONTRACTOR shall submit said paint applicator's certificates to the ENGINEER within 10 days after completion of each paint system. Comoliance With VOC Reaulations. The paint manufacturer shall submit to the ENGINEER certification that all coatings used on the job comply with local air pollution regulations limiting the amount of volatile organic compounds (VOC) contained in industrial coatings. This includes compliance with rule 67.0 of the San Diego County APCD for coatings applied in the field and 67.3 for shop applied coatings. H. 1.4 QUALITY ASSURANCE A. The CONTRACTOR shall give the ENGINEER a minimum of 3 days advance notice of the start of any field surface preparation for coating applications, and a minimum of 7 days advance notice of the start of any shop surface preparation. All such field surface preparation shall be performed only in the presence of the ENGINEER, unless the ENGINEER has granted prior approval to perform field surface preparation in its absence. Inspection by the ENGINEER, or the waiver of inspection of any particular portion of the WORK, shall not relieve the CONTRACTOR of its responsibility to perform the WORK in accordance with these CONTRACT DOCUMENTS. Where protective coatings are to be applied by a subcontractor, said subcontractor must possess a valid state license as required for performance of the painting and coating called for in this specification and must provide 5 references which show that the painting subcontractor has previous successful experience with the JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 09800 - 3 B. C. D. SECTION 09800 - PROTECTIVE COATINGS specified or comparable coating systems. Include the name, address, and the telephone number of the owner of each installation for which the painting subcontractor provided the protective coating. InsDection Devices. The CONTRACTOR shall furnish, until final acceptance of such coatings, inspection devices in good working condition for the detection of holidays and measurement of dry-film thicknesses of protective coatings. Dry-film thickness gages shall be made available for the ENGINEERS use at all times while coating is being applied, until final acceptance of such coatings. The CONTRACTOR shall provide the service of a trained operator of the holiday detection devices until the final acceptance of such coatings. Holiday detection devices shall be operated only in the presence of the ENGINEER. Holidav Testinq. The CONTRACTOR shall holiday test all coated ferrous surfaces and other surfaces which will be submerged in water or other liquids, or surfaces which are enclosed in a vapor space in such structures. Areas which contain holidays shall be marked and repaired or recoated in accordance with the coating manufacturer's printed instructions and then retested. 1. Coatings With Thickness Exceeding 20 Mils: For surfaces having a total dry film coating thickness exceeding 20 mils: Pulse-type holiday detector, Tinker & Rasor Model AP-W, D.E. Steams Co., Model 14/20 or equal, adjusted to operate at the voltage required to cause a spark jump across an air gap equal to twice the specified coating thickness. Coatings With Thickness of 20 Mils or Less: For surfaces having a total dry film coating thickness of 20 mils or less: Tinker and Rasor Model M-1 nondestructive type holiday detector, K-D Bird Dog or equivalent shall be used. The unit shall operate at less than 75-volts. For thicknesses between 10 and 20 mils, a non-sudsing type wetting agent, such as Kodak Photo-Flo, or equivalent, shall be added to the water prior to wetting the detector sponge. E. F. 2. G. Film Thickness Testinq. On ferrous metals, the dry film coating thickness shall be measured in accordance with the SSPC "Paint Application Specification No. 2" using a magnetic-type dry film thickness gage such as Mikrotest model FM, Elcometer model lll/lEZ, or equal. Each coat shall be tested for the correct thickness. No measurements shall be made until at least 8 hours after application of the coating. On non-ferrous metals and other substrates, the coating thicknesses shall be measured at the time of application using a wet film gage. Surface Preparation. Evaluation of blast cleaned surface preparation will be based upon comparison of the blasted surface with the standard samples available from the NACE standard TM-01-70. H. 1.5 MANUFACTURER REPRESENTATIVE A. At the request of the ENGINEER, the CONTRACTOR shall require the protective coating manufacturer to furnish a qualified technical representative to visit the project site for technical support as may be necessary to resolve field problems JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 09800 - 4 SECTION 09800 - PROTECTIVE COATINGS attributable or associated with the manufacturer‘s products furnished under this contract of the application thereof. 1.6 SAFETY AND HEALTH REQUIREMENTS A. General. In accordance with requirements of OSHA Safety and Health Standards for Construction (29CFR1926) and the applicable requirements of regulatory agencies having jurisdiction, as well as manufacturer‘s printed instructions, appropriate technical bulletins, manuals, and material safety data sheets, the CONTRACTOR shall provide and require use of personnel protective and safety equipment for persons working in or about the project site. Head and Face Protection and Respiraton, Devices. The CONTRACTOR shall require all persons to wear protective helmets 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, halfmask or mouthpiece respirators with appropriate filters. Barrier creams shall be used on any exposed areas of skin. B. C. Ventilation. Where ventilation is used to control hazardous exposure, all equipment shall be explosion-proof. Forced air ventilation shall be provided to reduce the concentration of air contaminants to the degree such that a hazard does not exist and to assist in the proper curing of the coating applied in a confined area. Air circulation and exhausting of solvent vapors shall be continued until coatings have fully cured. D. Sound Levels. Whenever the occupational noise exposure exceeds maximum allowable sound levels, permitted under OSHA regulations, 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 ENGINEER, the CONTRACTOR shall provide additional illumination to cover all areas to be inspected. The level of illumination for inspection purposes shall be determined by the ENGINEER. E. F. Ventilation. Forced air ventilation, in accordance with the requirements of Paragraph 1.6.C herein is required for the application and curing of coatings on the interior surfaces of steel reservoirs and enclosed hydraulic structures. During curing periods air shall be continuously exhausted from the lowest level of the structure using portable ducting. After all interior coating operations have been completed the final curing period shall be a minimum of 10 days, during which the forced air ventilation system shall operate continuously. TemDoraw Access. All temporary ladders and scaffolding shall conform to applicable safety requirements. Scaffolding shall be erected where requested by the ENGINEER to facilitate inspection and shall be moved by the CONTRACTOR to locations as requested by the ENGINEER. G. JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PROTECTIVE COATINGS PAGE 09800 - 5 SECTION 09800 - PROTECTIVE COATINGS 1.7 MAINTENANCE A. Warrantv InsDection. A warranty inspection may be conducted during the eleventh month following completion of all coating and painting. The CONTRACTOR and a representative of the coating material manufacturer shall attend this inspection. All defective WORK shall be repaired in accordance with these specifications and to the satisfaction of the OWNER. The OWNER may, by written notice to the CONTRACTOR, reschedule the warranty inspection, or may cancel the warranty inspection altogether. If a warranty inspection is not held, the CONTRACTOR is not relieved of its responsibilities under the CONTRACT DOCUMENTS. Provision of Maintenance Paintina Materials. Upon completion of the WORK, the CONTRACTOR shall provide two gallons of each color used for both the Industrial Coating Systems and the Architectural Coating Systems. B. PART 2 - PRODUCTS AND COATING SYSTEMS 2.1 GENERAL A. Definitions. The ten "paint," "coatings," or "finishes" as used herein, shall include surface treatments, emulsions, enamels, paints, epoxy resins, and all other protective coatings, excepting galvanizing or anodizing, whether used as a pretreatment, primer, intermediate coat, or finish coat. The term "DFT" means minimum dry film thickness. General. Coating materials shall be sealed in containers that plainly show the designated name, formula or specification number, batch number, color, date of manufacture, manufacturer's directions, and name of manufacturer, all of which shall be plainly legible at the time of use. The CONTRACTOR shall use coating materials suitable for the intended use and recommended by their manufacturer for the intended service. Comoatibility. In any coating system only compatible materials from a single manufacturer shall be used in the WORK. Particular attention shall be directed to compatibility of primers and finish coats. Colon. All colors and shades of colors of all coats of paint shall be as selected or specified by the ENGINEER. Each coat shall be of slightly different shade, as directed by the ENGINEER, to facilitate inspection of the surface coverage of each coat. Finish colors shall be as selected from the manufacturer's standard color samples by the ENGINEER. B. C. D. E. . F. Protective Coatina Materials. Products shall be standard from recognized manufacturers regularly engaged in production of such materials for essentially identical facilities, and with previous successful experience in such manufacture for comparable applications. Where requested, the CONTRACTOR shall provide the ENGINEER with the names of not less than 10 successful applications of the JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PROTECTIVE COATINGS PAGE 09800 - 6 SECTION 09800 - PROTECTIVE COATINGS proposed manufacturer's products demonstrating compliance with these specification requirements. G. Coatinq Manufacturers. Except as otherwise indicated herein, materials specified are from the catalogs of the companies listed herein. Materials by other manufacturers approved by the ENGINEER are acceptable provided that they are established to the satisfaction of the ENGINEER as being compatible with and of equivalent quality to the coatings of the companies listed. The CONTRACTOR shall provide satisfactory documentation from the firm manufacturing the proposed material that the material meets the specified requirements and is equivalent or better than the listed materials in the following properties: 1. Quality 2. Durability 3. 4. Life expectancy 5. Ability to recoat in future 6. Solids content by volume 7. 8. Compatibility with other coatings 9. IO. Resistance to chemical attack 11. 12. 13. Ease of application 14. 15. Stability of colors The cost of all testing and analyzing of the proposed substitute materials that may be required by the ENGINEER shall be paid by the CONTRACTOR. If the proposed substitution requires changes in the WORK, the CONTRACTOR shall bear all such costs involved and the costs of allied trades affected by the substitution. Materials Sources. Each of the following manufacturers is capable of supplying many of the industrial coating materials specified in this Article. Where manufacturers and paint numbers are listed, it is to show the type and quality of JULY 2003 PROTECTIVE COATINGS Resistance to abrasion and physical damage Dry film thickness per coat Suitability for the intended service Temperature limitations in service during application Type and quality of recommended undercoats and topcoats Ease of repairing damaged areas H. I. CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 09800 - 7 SECTION 09800 - PROTECTIVE COATINGS 2.2 coatings that are required. Proposed substitute materials must be shown to satisfy the material descriptions and to equal or exceed the properties of the listed materials as required in Paragraph 2.1.G. 1. Ameron 2. Kop-CoaffCarboline Co. 3. Dupont Company 4. Corchem Corporation 5. Tnemec Company 6. Valspar Corporation Unless otherwise directed, paint all piping, vents, conduits, items of equipment, miscellaneous fixtures, appurtenances and the like, to match the color of adjacent wall and ceiling surfaces. Paint interior surfaces of ducts behind grilles and diffusers, where duct is visible, flat black. J. K. L. Surface preparation and coating application shall be in accordance with manufacturer‘s recommendations. Product information and application instructions shall be submitted to the ENGINEER two weeks prior to application. The CONTRACTOR shall notify the ENGINEER 24 hours in advance of any coating application. All coatings to be used where exposed within potable water systems shall be certified under the requirements of standard NSF 61. M. INDUSTRIAL COATING SYSTEMS A. NOT USED B. NOT USED C. NOT USED D. Svstem 10 - Acrvlic. Three coats of an approved latex acrylic paint, equivalent to Amerguard 220, TNEMEC series 6 Tneme-Cry1 or approved equivalent, shall be applied by brush, spray or roller to completely cover any exposed exterior tank wall surface, downspouts, and roof edge. Downspouts shall be painted before installation. Svstem 11 - Buried Concrete Walls. Three coats of Koppers Bitomastic Super Setvice Black or an approved equivalent, shall be applied by brush. spray or roller to completely cover the underground wall at the manufacturets recommended usage rate. E. JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PAGE 09800 - 8 SECTION 09800 - PROTECTIVE COATINGS 1. Topcoat, (2 coats at 14 mils DFT each, 28 mils total). 2.3 SUBMERGED AND SEVERE SERVICE COATING SYSTEMS A. Materials Sources. The manufacturers’ products listed in this paragraph are materials which satisfy the material descriptions of this paragraph and have a documented successful record for long term submerged or severe service conditions. If the products proposed by the CONTRACTOR are not listed below the requirements of Paragraph 2.1.G apply. In addition, submit for consideration a list of at least 10 installations with similar service conditions for which the proposed products have shown satisfactory performance for at least several years. Include the name, address, and phone number of the OWNER of each installation. Svstem 100 - EDOW. High build, amine cured, straight epoxy resin with a solids content of at least 80 percent by volume, and suitable for long-term immersion service in potable water. 1. B. Prime coat and finish coat (2 coats at 7 mil DFT each, 14 mils total), Amercoat 395FD, or equivalent. C. Svstem 106 - Fusion Bonded EDO~. The coating material shall be a 100 percent powder epoxy applied in accordance with the ANSVAWWA C213 “AWWA Standard for Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines,” except that the surface preparation shall be as specified in the coating system schedule of this Section. Apply the coating using the fluidized bed process. 2.4 SPECIAL COATING SYSTEMS A. Svstem 200 - PVC TaDe. Prior to wrapping the pipe with PVC tape, the pipe and fittings first shall be primed using a primer recommended by the PVC tape manufacturer. After being primed, the pipe shall be wrapped with a 20-mil adhesive PVC tape, half-lapped, to a total thickness of 40 mils. Svstem 201 - Rich Portland Cement Mortar. Rich portland cement mortar coating to minimum thickness of l/&inch, followed by enclosure in an 8-mil thick polyethylene sheet with all joints and edges lapped and sealed with tape. B. C. Svstem 205 - Polvethvlene Encasement. Application of polyethylene encasement in accordance with ANSYAWWA C105 “American National Standard for Polyethylene Encasement for Ductile-Iron Piping for Water and Other Liquids,” using Method C. Svstem 209 - Non-Oxide Grease. Apply one coat of NO-OX-ID as manufactured by Dearborne Chemical Company or approved equal. Tightly wrap with 8 mil thick polyethylene sheet with all joints and edges lapped by at least 6 inches and taped with JM Pipe Tape, 10 mil (pipe wrap). D. JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PROTECTIVE COATINGS PAGE 09800 - 9 SECTION 09800 - PROTECTIVE COATINGS E. System 210 - Petroleum TaDe Coatinq. A cold-applied wax or petroleum tape coating shall be provided in accordance with AWWA Standard C217. A non- hardening mastic filler shall be used to provide a smooth profile for subsequent tape wrapping. A water impermeable self-adhesive PVC overwrapping tape shall be applied over the petroleum tape coating. Coating system shall be manufactured by Denso. Inc. (Houston, Texas), Trenton Corporation (Ann Arbor, MI) or approved equivalent. Coating system shall be applied in strict accordance with the manufacturer's instructions and recommendations. PART 3 - EXECUTION 3.1 SAFETY REQUIREMENTS A. The CONTRACTOR shall provide and require the use of protective and safety equipment for workers in accordance with the requirements of the Construction Safety Orders of State of California Division of Industrial Safety, and the OSHA Safety and Health Regulations 29CFR 1926. The CONTRACTOR shall comply with the manufacturer's printed instructions, technical bulletins, manuals, and material safety data sheets in the handling of potentially hazardous or harmful materials. All workers shall wear protective helmets, eye and face protection devices, air purifying mask or mouthpiece respirators, and barrier creams on exposed skin areas as required to comply with the regulatory agency or manufacturer's safety instructions. Where forced ventilation is used to control hazardous exposure, explosion-proof equipment shall be used. Adequate illumination shall be provided while work is in progress. Lighting and electrical equipment shall be explosion-proof. Cloths and cotton waste that might constitute a fire hazard shall be placed in fire- resistant closed metal containers until removed from the work site or destroyed at the end of each day. B. C. D. E. F. 3.2 STORAGE, MIXING, AND THINNING OF MATERIALS A. Protection of Materials. All material shall be delivered to the work site in their original unopened containers bearing the manufacturer's name, brand and batch number. Manufacturer's Recommendations. Unless otherwise specified herein, the coating manufacturer's printed recommendations and instructions for thinning, mixing, handling, applying, and protecting its coating materials, for preparation of surfaces for coating, and for all other procedures relative to coating shall be strictly 6. JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 09800 - 10 SECTION 09800 - PROTECTIVE COATINGS observed. No substitutes or other deviations will be permitted without written permission of the ENGINEER. The CONTRACTOR shall supply the ENGINEER with copies of each manufacturer’s instructions in accordance with the requirements of Section 01300 entitled, “Submittals.” C. All protective coating materials shall be used within the manufacturer‘s recommended shelf life. Storage and mixing of paint or other coating materials shall be performed only in those areas designated by the ENGINEER. Storaoe and Mixinq. Coating materials shall be protected from exposure to cold weather, and shall be thoroughly stirred, strained, and kept at a uniform consistency during application. Coatings of different manufacturers shall not be mixed together. D. E. 3.3 PREPARATION FOR COATING A. General. All surfaces to receive protective coatings shall be cleaned as specified herein prior to application of said coatings. The CONTRACTOR shall examine all surfaces to be coated, and shall correct all surface defects before application of any coating material. All marred or abraded spots on shop-primed and on factory- finished surfaces shall receive touch-up restoration prior to any coating application. B. Protection of Surfaces Not to be Coated. Surfaces which are not to receive protective coatings shall be protected during surface preparation, cleaning, and coating operation. C. All hardware, lighting fixtures, switchplates, machined surfaces, couplings, bearings, nameplates on machinery, and other surfaces not to be painted shall be removed, masked or otherwise protected. Drop cloths shall be provided to prevent coating materials from falling on or marring adjacent surfaces. 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 not to damage adjacent WORK during blast cleaning operations. 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 WORK or adjoining property occurring from blast cleaning or coating operations. Protection of Painted Surfaces. Cleaning and coating shall be so programmed that dust and other contaminants from the cleaning process will not fall on wet, newly- coated surfaces. p. Items of equipment or surfaces with existing coatings which are required to be coated with the materials specified in this section are listed in the coating system schedules. D. E. F. JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PROTECTIVE COATINGS PAGE 09800 - 11 SECTION 09800 - PROTECTIVE COATINGS 3.4 SURFACE PREPARATION STANDARDS A. The following referenced surface preparation specifications of the Steel Structures Painting Council shall form a part of this specification: 1. 2. 3. 4. 5. 6. 7. Solvent Cleaning (SSPC-SP1): Removal of oil, grease, dirt, soils, salts, contaminants by cleaning with solvent, vapor, alkali, emulsion, or steam. Hand Tool Cleaning (SSPC-SP2): Removal of loose rust, loose mill scale, and loose paint to the degree specified by hand tool chipping, scraping, sanding, and wire brushing. Power Tool Cleaning (SSPC-SP3): Removal of loose rust, loose mill scale, and loose paint to the degree specified by power tool chipping, descaling, sanding, wire brushing, and grinding. White Metal Blast Cleaning (SSPC-SPS): Removal of all visible rust, mill scale, paint, and foreign matter by blast cleaning with wheel or nozzle (dry or wet) using sand, grit, or shot. Commercial Blast Cleaning (SSPC-SP6): two-thirds of each element of surface area is free of all visible residues. Brush-off Blast Cleaning (SSPC-SP7): Blast cleaning of all except tightly adhering residues of mill scale, rust, and coatings, exposing numerous evenly distributed flecks of underlying metal. Near-White Blast Cleaning (SSPC-SPIO-63): Blast cleaning nearly to White Metal Cleanliness, until at least 95 percent of each element of surface area is free of all visible residues. Blast cleaning until at least 8. The CONTRACTOR shall note that the definition of Near White Metal Blast Cleaning, SSPC-SP10, is from the 1963 version of the SSPC standard, and requires that 95 percent of "each element'' of surface area be free of all visible residues. The other surface preparation standards shall be the most recent versions published by the SSPC. 3.5 METAL SURFACE PREPARATION (UNGALVANIZED) A. The minimum abrasive blasting surface preparation shall be as specified in the coating system schedules included at the end of this Section. Where there is a conflict between these specifications and the coating manufacturer's printed recommendations for the intended service, the higher degree of cleaning shall apply. B. Workmanship for metal surface preparation shall be in conformance with the current SSPC Standards and this Section. Blast cleaned surfaces shall match the standard samples available from the National Association of Corrosion Engineers, NACE Standard TM-01-70. JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 09800 - 12 SECTION 09800 - PROTECTIVE COATINGS C. D. E. F. G. H. I. J. K. L. M. N. All oil, grease, welding fluxes and other surface contaminants shall be removed by alkaline cleaning per SSPC-SP1 prior to blast cleaning. All sharp edges shall be rounded or chamfered and all burrs, and surface defects and weld splatter shall be ground smooth prior to blast cleaning. The type and size of abrasive shall be selected to produce a surface profile that meets the coating manufacturer's recommendation for the particular coating and service condition. The abrasive shall not be reused unless otherwise approved by the ENGINEER. For automated shop blasting systems, clean oil-free abrasives shall be maintained. The CONTRACTOR shall comply with the applicable federal, state and local air pollution control regulations for blast cleaning. Compressed air for air blast cleaning shall be supplied at adequate pressure from well maintained compressors equipped with oil/ moisture separators which remove at least 95 percent of the contaminants. 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 painting. Enclosed areas and other areas where dust settling is a problem shall be vacuum cleaned and wiped with a tack cloth. Damaged or defective coating shall be removed by the specified blast cleaning to meet the clean surface requirements before recoating. If the specified abrasive blast cleaning will damage adjacent work, the area to be cleaned is less than 100 square feet, and the coated surface will not be submerged in service, than SSPC-SP2. hand tool cleaning or SSPC-SP3. power tool cleaning, will be permitted. Shop applied coatings of unknown composition shall be completely removed before the specified coatings are applied. Valves, castings, ductile or cast iron pipe, and fabricated pipe or equipment shall be examined for the presence of shop-applied temporary coatings. Temporary coatings shall be completely removed by solvent cleaning per SSPC-SP1 before the SSPC-SP2 or SSPC-SP3 work has been started. Shop primed equipment shall be alkaline cleaned in the field before finish coats are applied. 3.6 ALUMINUM SURFACE PREPARATION A. Remove oil, grease or soap film with a neutral detergent or emulsion cleaner; treat with Alodine 1200, Alumniprep (Ameron, Protective Coatings Division) or JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 09800 - 13 SECTION 09800 - PROTECTIVE COATINGS 3.7 3.8 3.9 3.10 equivalent product or blast lightly with a fine abrasive as recommended by the manufacturer. CONCRETE SURFACE PREPARATION A. All concrete or shotcrete surfaces shall be thoroughly cleaned of all oil, laitance, and other deleterious materials before coating or painting. All cracks and voids shall be repaired and the surfaces shall be cleaned and acceptable for painting and coating as recommended by the coating manufacturer. B. SURFACE PREPARATION FOR GALVANIZED FERROUS METAL A. Alkaline clean or solvent clean galvanized ferrous metal per SSPC-SP-1 to remove oil, grease, and other contaminants detrimental to adhesion of painting system to be used. Prepare the alkaline cleaner by adding 1/2 to 1 pound of trisodium phosphate and 2 to 4 ounces of detergent to each gallon of hot water. Apply the cleaner generously and scrub the surfaces thoroughly with brushes. After scrubbing, wash the surfaces thoroughly with hot fresh water under pressure. Use pretreatment coatings for galvanized surfaces as recommended by the coating manufacturer. B. SURFACE PREPARATION OF FERROUS SURFACES WITH EXISTING COATINGS A. General. Remove all grease, oil, heavy chalk, dirt or other contaminants by solvent or detergent cleaning prior to abrasive blast cleaning. Determine the generic type of the existing coatings by laboratory testing. Abrasive Blast Cleaninq. Provide the degree of cleaning specified in the coating system schedule for the entire surface to be coated. If cleaning is not specified in the schedule, remove deteriorated coatings by abrasive blast cleaning to SSPC- SP-6, Commercial Blast Cleaning. Clean areas of tightly adhering coatings to SSPC-SP-7, Brush-off Blast Cleaning. IncomDatible Coatincs. If coating to be applied is not compatible with existing coating system, apply an intermediate coating after abrasive blast cleaning per the paint manufacturer's recommendation. As an alternate to the intermediate coating the existing coating may be completely removed by abrasive blast cleaning. Conduct a small trial application for compatibility prior to painting large areas. Unknown Coatinas. Completely remove coatings of unknown composition prior to application of new coatings. B. C. D. PLASTIC, FIBERGLASS AND NONFERROUS METALS SURFACE PREPARATION A. Lightly sand fiberglass surfaces and then solvent clean with a chemical compatible with the coating system primer. JULY 2003 CWRF PIPELINE TO "D' TANKS - REACHES 1 AND 3 PROTECTIVE COATINGS PAGE 09800 - 14 SECTION 09800 - PROTECTIVE COATINGS B. Solvent clean nonferrous metal surfaces per SSPC-SP-1 and then sand or brush blast. Surfaces shall be clean and dry prior to coating. C. 3.11 NOTUSED 3.12 NOTUSED 3.13 NOTUSED 3.14 WORKMANSHIP A. B. Skilled craftsmen and experienced supervision shall be used on all work. Clean drop cloths shall be used. All damage to surfaces resulting from the WORK hereunder shall be cleaned, repaired, and refinished to the complete satisfaction of the ENGINEER at no cost to the OWNER. All coatings shall be applied under dry and dust-free conditions. Coating shall be applied in a workmanlike manner so as to produce an even film of uniform thickness. Edges, corners, crevices, and joints shall receive special attention to insure that they have been thoroughly cleaned and that they receive an adequate thickness of coating material. The finished surfaces shall be free from runs, drops, ridges, waves, laps, brush marks, and variations in color, texture, and finish. The hiding shall be so complete that the addition of another coat would not increase the hiding. Special attention shall be given to insure that edges, comers, crevices, welds, and similar areas receive a film thickness equivalent to adjacent areas, and installations shall be protected by the use of drop cloths or other approved precautionary measures. C. 3.15 SHOP COATING REQUIREMENTS 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. All items of equipment, or parts and surfaces of equipment which are submerged when in service, with the exception of valves, shall have all surface preparation and coating work performed in the field. For certain pieces of equipment it may be undesirable or impractical to apply finish coatings in the field. Such equipment may include 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 in the shop and then repaired in the field with the identical material after installation. The CONTRACTOR shall require the manufacturer of each such piece of equipment to B. C. JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PROTECTIVE COATINGS PAGE 09800 - 15 SECTION 09800 - PROTECTIVE COATINGS certify as part of its shop drawings that the surface preparation is in accordance with these specifications. The coating material data sheet shall be submitted with the shop drawings for the equipment. 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 drawing submittals. Shop painted surfaces shall be protected during shipment and handling by suitable provisions including padding, blocking, and the use of canvas or nylon slings. Primed surfaces shall not be exposed to the weather for more than 6 months before being topcoated. or less time if recommended by the coating manufacturer. Damage to shop-applied coatings shall be repaired in accordance with this Section and the coating manufacturers printed instructions. The CONTRACTOR shall make certain that the shop primers and field topcoats are compatible and meet the requirements of this Section. Copies of applicable coating manufacturer's data sheets shall be submitted with equipment shop drawings. 3.16 APPLICATION OF COATINGS D. E. F. G. A. B. C. D. E. F. G. The application of protective coatings to steel substrates shall be in accordance with "Paint Application Specification No. 1, (SSPC-A-l), "Steel Structures Painting Council." Cleaned surfaces and all coats shall be inspected prior to each succeeding coat. The CONTRACTOR shall schedule such inspection with the ENGINEER in advance. Blast cleaned ferrous metal surfaces shall be painted before any rusting or other deterioration of the surface occurs. Blast cleaning shall be limited to only those surfaces that can be completed in the same working day. Coatings shall be applied in accordance with the manufacturer's instructions and recommendations, and these specifications. If direction differs, the most stringent requirements shall be followed. Thinning shall be performed in accordance with all air quality requirements and manufacturer's recommendations. Special attention shall be given to edges, angles, weld seams, flanges, nuts and bolts, and other places where insufficient film thicknesses are likely to be present. Use stripe painting for these areas. Finish coats, including touch-up and damage repair coats shall be applied in a manner which will present a uniform texture and color matched appearance. Coatings shall not be applied under the following conditions: JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 09800 - 16 SECTION 09800 - PROTECTIVE COATINGS 1. Temperature exceeding the manufacturer's recommended maximum and minimum allowable. Dust or smoke laden atmosphere. 2. 3. Damp or humid weather. 4. 5. When the temperature is less than 5 degrees F. above dewpoint. When air temperature is expected to drop below 40 degrees F. or less than 5 degrees F. above the dewpoint within 8 hours after application of coating. Dewpoint shall be determined by use of a sling psychrometer in conjunction with U.S. Department of Commerce, Weather Bureau psychrometric tables. Steel piping shall be abrasive blast cleaned and primed before installation. The finish coat on all WORK shall be applied after all concrete, masonry, and equipment installation is complete and the work areas are clean and dust free. H. I. J. 3.17 CURING OF COATINGS A. The CONTRACTOR shall provide curing conditions in accordance with the conditions recommended by the coating material manufacturer or by these specifications, whichever is the highest requirement, prior to placing the completed coating system into service. In the case of enclosed areas, forced air ventilation, using heated air if necessary. may be required until the coatings have fully cured. B. 3.18 CLEANUP A. Upon completion of the WORK, remove all staging, scaffolding and containers from the site. Remove coating spots and oil or stain that is upon adjacent surfaces and clean the job site. Dispose of all waste materials in a manner which conforms to all local and regional environmental regulations. Repair and clean all damage to adjacent surfaces or facilities resulting from the work performed under the contract to restore the adjacent surfaces to their original condition. 3.19 COATING SYSTEM SCHEDULES - FERROUS METALS A. Coatinq Svstem Schedule, Ferrous Metal - Not Galvanized Item Surface Prep. Svstem No. All exDosed surfaces Commercial blast cleanina (4) Aliohatic - ., . indoors and outdoors, SSPC-SP6 polyurethane except those included below All Valves (100) Amine Cured Epoxy JULY 2003 PROTECTIVE COATINGS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 09800 - 17 SECTION 09800 - PROTECTIVE COATINGS Buried ductile iron pipe Per AWWA '2105 and C110 (205) polyethylene encasement Buried couplings, valves, Solvent cleaning SSPC-SP1 (210) Mastic and wax and flanged joints tape coating Ferrous surfaces of White metal blast cleaning (106) fusion bonded sleeve-type couplings SSPC-SP5 epoxy 3.20 NOT USED. 3.21 COATING SYSTEM SCHEDULE -CONCRETE Item Surface Prep. Svstem No. - No. c- 1 Exterior Walls Concrete Per Paragraph 3.7 (10) c-2 Buried concrete Per Paragraph 3.7 (11) - walls END OF SECTION JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PROTECTIVE COATINGS PAGE 09800 - 18 SECTION 09810 -TAPE COATING FOR STEEL PIPE PART I -GENERAL 1 .l 1.2 1.3 I .4 THE REQUIREMENT A. The WORK of this Section includes providing a prefabricated, cold-applied, multilayer, polyethylene tape coating system for steel pipe. Except as described in this Section, the coating system shall be in accordance with ANSIIAWWA C214 for straight pipe sections and ANSIIAWWA C209 for fittings, specials, and field joints. 6. RELATED SECTIONS A. . The WORK of the following Section applies to the WORK of this Section. Other Sections of the Specification, not referenced below, shall also apply to the extent required for proper performance of this WORK. 1. Section 02651 Steel Pipe Cement Mortar Lined and Tape Coated 2. Section 02653 Steel Pipe Fabricated Specials SPECIFICATIONS AND STANDARDS A. Except as otherwise indicated, the current editions of the following apply to the WORK of this Section. References herein to "SSPC SDecifications" or "SSPC" shall mean the Dublished B. standards of the Steel Structures Painting Council, 4400 Fifth Avenue, Pittsburgh, PA 15213. C. Commercial Standards: ANSIIAWWA C200 ANSIIAWWA C209 Steel Water Pipe 6 inches and larger Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines Tape Coating Systems for the Exterior of Steel Water Pipelines ANSIIAWWA C214 SUBMITTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. B. Coating Materials List: The CONTRACTOR shall submit a list of the tape coating materials which indicates the manufacturer, product numbers, and thickness of the materials. Materials Information: For each material, the CONTRACTOR shall submit technical data sheets which itemize technical and performance information that indicates C. JULY 2003 TAPE COATING FOR STEEL PIPE CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 09810-1 SECTION 09810 -TAPE COATING FOR STEEL PIPE compliance with this Section. Samples: Samples of the materials shall be submitted fortesting bythe ENGINEER. Each sample shall be clearly identified for catalog number, size, color, and other information required for testing. D. 1.5 FACTORY AND FIELD INSPECTION AND TESTING A. 0. C. D. E. F. G. H. I. The CONTRACTOR shall be responsible for all costs associated with inspection and testing of materials, products, or equipment at the place of manufacture. This shall include costs for travel, meals, lodging, and car rental for two OWNERdesignated inspectors for the days required to complete such inspections or observations exclusive of travel days, if the place of manufacture, fabrication and factory testing is more than fifty (50) miles outside the geographical limit of the City. The CONTRACTOR shall not be responsible for salary or salary-related costs of the inspectors. The CONTRACTOR shall provide the CONSTRUCTION MANAGER a minimum of 14 days advance notice of the start of any shop coating work and a minimum of 3 days advance notice for field work. Unless the CONSTRUCTION MANAGER has granted prior approval, all coating work shall be performed in the presence of the CONSTRUCTION MANAGER. Inspection Devices: The CONTRACTOR shall furnish inspection devices that are calibrated and in good working condition for the detection of holidays and measurement of coating film thicknesses. Inspection: The CONTRACTOR shall retain the services of trained technicians to test the coating system in the shop and field, and prepare reports, at no additional cost to the OWNER. As a minimum, the tests shall include holiday detection and coating film thickness. Tape application to straight pipe sections shall be monitored using instrumentation devices that continuously measure and record the tape width drawdown and the tape temperature. Each tape application station shall be equipped with the instrumentation devices. The tape tensions and temperatures shall be controlled using the data obtained from the instrumentation devices. Manufacturer Representative: The CONTRACTOR shall require the tape material manufacturer to furnish a qualified factory technical representative to visit the pipe coating shop for technical support at the beginning of the tape coating operation and as may be necessary to resolve shop or field problems. Holiday Detection: Prior to application of the first layer of mechanical protection tape, the inner layer tape shall be electrically tested for coating flaws with a holiday detector approved by the CONSTRUCTION MANAGER. Holidays detected shall be immediately repaired and retested before application of the first layer of mechanical protection tape. Immediately before the coated pipe is lowered into the trench, the CONTRACTOR shall provide a visual and holiday inspection of the coating on the underside of the JULY 2003 TAPE COATING FOR STEEL PIPE CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 09810-2 SECTION 09810 -TAPE COATING FOR STEEL PIPE 1.6 C. D. E. pipe. PRODUCT DELIVERY, STORAGE, AND HANDLING Materials shall be stored within the temperature ranges specified for application, using heated areas if necessary. Tape shall be stored at a minimum temperature of 70 degrees F. Pipe shall be square-stacked no more than 2 high on padded supports or racks. Lifting equipment shall be padded and wide fabric slings shall be used. To the extent possible, the coated pipe shall be handled from the cut-back ends. Tie down devices shall be padded where in contact with the pipe. PART 2 - PRODUCTS 2.1 COATING SYSTEMS A. Straight pipe sections shall be provided with a fourlayer polyethylene tape system as described below. 1. Primer layer. 2. Filler tape, extruded butyl rubber compound compatible with the primer and tape. Weld stripping tape, if required (25 mils). Inner layer, corrosion protection tape (20 mils). Middle layer, mechanical protection tape (30 mils). Outer layer, mechanical protection tape (30 mils) with ultraviolet light stabilizers. Total system thickness shall be at least 80 mils The coating materials shall be supplied by a single manufacturer, and shall have a successful application and service history on pipe fabricated in accordance with ANSVAWWA C200. 3. 4. 5. 6. 7. 8. B. Fittings, specials, and field joints shall be provided with a three layer polyethylene tape system as described below: 1. Primer layer 2. Filler tape, extruded butyl rubber compound compatible with the primer and tape. Inner layer, corrosion protection tape (50 mils). 3. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 TAPE COATING FOR STEEL PIPE PAGE 09810-3 SECTION 09810 -TAPE COATING FOR STEEL PIPE 4. 5. 6. Outer layer, mechanical and ultraviolet light protection tape (30 mils). Total system thickness shall be at least 80 mils. The coating materials shall be supplied by the same manufacturer as the materials for straight pipe. C. Storage of Materials: Materials shall be stored within the temperature ranges specified for application, using heated storage areas if necessary. Tape shall be stored at a minimum temperature of 70 degrees F. Mortar Coating: A 3/4-inch thick reinforced mortar coating shall be applied overthe tape coat system. The mortar coating shall meet the requirements ofANSI/AWWA C205. D. 2.2 MANUFACTURERS A. Products shall be of the following manufacture, type, and model (or equal): 1. Straight Pipe: Polyken Technologies Primer 1029 Weld stripping tape 933-25 black Inner layer tape 989-20 black Middle layer tape 955-30 gray Outer layer tape 956-30 white Filler tape 939 2. Fittings, Specials, and Field Joints: Polyken Technologies Primer 1029 Inner layer tape 930-50 black Outer layer tape 955-30 white Filler tape 939 PART 3 - EXECUTION 3.1 TAPE APPLICATION A. Tape coating materials shall be applied in accordance with this Section, the product application instructions of the tape manufacturer, and the field technical SUPOO~~ instructions from the manufacturer. 3.2 WELD SURFACE PREPARATION A. To provide for an effective, long-term bond between the tape coating system and the substrate, the following pipe weld surface preparation shall be provided. 1. Weld surfaces with a reinforcement greater than 1132-inch and all longitudinal and coil splice welds shall be ground to provide a smooth surface with a reinforcement not exceeding 1/32-inch. The resulting weld surface shall have a cross-section shape that is free of discontinuities, abrupt JULY 2003 CWRF PIPELINE TO "D' TANKS - REACHES 1 AND 3 TAPE COATING FOR STEEL PIPE PAGE 09810-4 SECTION 09810 -TAPE COATING FOR STEEL PIPE changes in curvature, with no ridges or valleys that may promote bridging or disbondment of the tape from the substrate. Weld Stripping Tape: Weld stripping tape, 6 inches wide, shall be used if any of the following conditions are present. The tape shall be applied with the center of the tape at the weld. a. 2. If the CONTRACTOR elects to use stripping tape in lieu of grinding or part of the grinding required above. In such a case, the weld reinforcement shall not exceed 3/32-inch, and the weld surface shall have a cross-section shape that is free of discontinuities, abrupt changes in curvature, with no ridges or valleys that may promote bridging or disbondment of the tape from the substrate. If the initial pipe sections taped have indications that the inner tape layer is not bonding completely to the pipe at the welds. If the tape bond to the welds or adjacent surfaces is less than the tape bond to the pipe surface away from the welds. b. C. 3. Welds that have been prepared with a reinforcement not exceeding 1132- inch, and a cross-section slope that is free of discontinuities, abrupt changes in curvature, with no ridges or valleys that may promote bridging or disbondment of the tape from the substrate require no additional preparation. The plastic tape coating shall be applied in accordance with AWWA C 214, C 209, and modified herein. The CONTRACTOR shall retain the services of a representative of the tape manufacturer to ensure that the application of tape to field joints and the coating repairs made in the field are done properly and in accordance with the manufacturers recommendations. The tape manufacturer shall submit certification that the CONTRACTOR has been properly trained to apply tape coatings in the field and that the procedures used by the CONTRACTOR in the field meet the tape manufacturers requirements. This certification shall be received by CMWD representatives within two weeks of the beginning of pipe laying operations. 4. 3.3 PIPE SURFACE PREPARATION A. Surfaces to be coated shall be detergent cleaned in accordance with SSPC-SP1 prior to abrasive blasting. All burrs, sharp edges, and weld splatter shall be removed prior to abrasive blasting. Immediately before application of the primer, abrasive blasting shall be performed using sand, metallurgical slag, or a combination of steel grit and shot to produce a surface in conformance with SSPC-SP6. Steel grit shall comprise at least 60 percent of the working mix of abrasive, if a centrifugal wheel abrasive blaster is used. The prepared surface shall have a surface profile not exceeding 2 mils. Abrasive blasting and primer application shall be done when the substrate surface is at least 5 degrees F above the dew point. Abrasive blasting, priming, and inner layer tape application shall be done during the same working day for each pipe section. 5. C. D. JULY 2003 TAPE COATING FOR STEEL PIPE CWRF PIPELINE TO "D"TANKS - REACHES 1 AND 3 PAGE 09810-5 3.4 3.5 SECTION 09810 -TAPE COATING FOR STEEL PIPE PIPE END PREPARATION A. Coating cut-backs at the pipe ends shall be 6 inches, with the CI ; parallel to the pipe ends. Exposed substrate surfaces shall be protected with a storage primer applied immediately after taping and before flash rusting of the surface. B. Spiral or longitudinal pipe welds within two feet of the pipe ends shall be ground flush prior to abrasive blast cleaning. Pipe ends that will be connected with sleeve-type couplings shall be epoxy coated for immersion service. The cut-backs shall be greater than 6 inches at couplings to provide clearance between the coupling and tape. The epoxy coating shall extend at least 6 inches beyond each side of the sleeve coupling on the outside surface of the pipe. C. APPLICATION OF TAPE A B. C. D. E. F. G. H. I. Pipe shell temperature shall be maintained within a range of 45 degrees F to 100 degrees F during application of the tape system. Inner layer tapes shall be maintained at a minimum temperature of 70 degrees F during application. Middle and outer layer tapes shall be maintained at a minimum temperature of 90 degrees F during application. Tape application tension shall be maintained at a value that produces a tape width reduction equal to 1.0 to 2.0 percent of the tape width during application, as recommended by the tape manufacturer. This width reduction shall be maintained simultaneously with the minimum tape temperature. At the point of tape application, all tape, including weld stripping tape, shall be pressed onto the pipe with a pressure roller that maintains a constant pressure. Enough pressure shall be used to fully bond the tape at all welds. Filler tape shall be used at lap joints, weld step-downs, and other discontinuities. The tape application equipment and materials shall result in a fully bonded tape coating system, without blisters, voids, wrinkles or any areas that have a lack of bond to the pipe. Succeeding layers of tape shall be applied so that the laps are staggered by at least two inches. Before tape application, the primer shall be dried sufficientlyso that the primer is in a tacky to dry condition. Primer shall be applied while it is in a temperature range of 50 degrees F to 80 degrees F, using airless spray equipment and a drum agitator. The primer application shall be of uniform thickness on all pipe surfaces. JULY 2003 TAPE COATING FOR STEEL PIPE CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 09810-6 SECTION 09810 -TAPE COATING FOR STEEL PIPE 3.6 REPAIR PATCHES A. Repair patches shall be applied by wrapping tape completely around the pipe, using the tape system for joints. 3.7 TAPE APPLICATION TO FITTINGS, SPECIALS, AND PIPE JOINTS A. 6. Filler tape shall be used to fill voids on fittings, specials, welds, and pipe joints. All bell and spigot joints, lap joints, and other locations where voids will otherwise exist shall be provided specially shaped, filler tape applied after priming. Field pipe joints shall be prepared as required by the paragraph entitled ”Pipe Surface Preparation,” except that shop blasted surfaces that have been coated with a storage primer or an epoxy coating may be power tool cleaned instead of abrasive blast cleaned. The power tool cleaning shall be done in accordance with SSPC- SP2. Pipe ends not effectively protected with a storage primer shall be abrasive blasted to SSPC-SP6. After primer has dried, apply tape to the joint and extend a minimum of 3 inches onto the plant applied tape coat. End splices shall be a minimum of 6 inches and shall be staggered. Maintain 55 percent overlap on all field joint tape to produce a minimum thickness of 100 mils. Apply tape with sufficient tension to conform with the surface irregularities. The finish tape wrap shall be smooth and wrinkle-free. Test the final applied joint tape coating in the presence of the CMWD representatives with an electrical holiday detector. Repair all holidays and physical damage to the final applied tape coating prior to application of the mortar coating. Apply mortar joint coating and reinforcement over tape coating using fabric diapers to retain the mortar. Apply the mortar coating immediately upon completion of tape wrapping, testing and inspections. Mortar at field joints shall overlap the shop- applied mortar overcoat a distance of not less than 5 inches. The thickness of the mortar shall be I-inch minimum at the joints. C. D. E. END OF SECTION JULY 2003 TAPE COATING FOR STEEL PIPE CWRF PIPELINE TO “D” TANKS - REACHES 1 AND 3 PAGE 09810-7 SECTION 10900 - MISCELLANEOUS SPECIALTIES PART I - GENERAL 1.1 1.2 1.3 THE REQUIREMENT A. General. The CONTRACTOR shall furnish all labor, equipment. materials, tools. supplies, fittings, and appurtenances required for the fabrication, support, installation, operation of all equipment, testing, and as specified herein, for a complete and workable installation in accordance with the requirements of the CONTRACT DOCUMENTS. The items specified under this Section shall be furnished by manufacturers having experience in the manufacture of similar products and having a record of successful installations. B. RELATED WORK SPECIFIED ELSEWHERE A. Painting and protective coating of metalwork and fabricated items shall be performed in accordance with the requirements of Section 09800 "Protective Coating". All metalwork specified herein shall be in accordance with the requirements of Section 05500 "Miscellaneous Metalwork". B. C. NOT USED SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. PART 2 - PRODUCTS 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED JULY 2003 MISCELLANEOUS SPECIALTIES CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 10900 - 1 SECTION 10900 - MISCELLANEOUS SPECIALTIES 2.9 PRESSURE GAGES A. B. . General. Pressure gages shall be provided where shown. Gaqe Construction. Gages shall be industrial quality type with Type 316 stainless steel movement and stainless steel or alloy case. Unless otherwise shown or specified, gages shall have a 3-112-inch dial, 1/4-inch threaded connection, a Type 316 stainless steel snubber adapter, and a shut-off valve. Gages shall be calibrated to read in applicable units, with an accuracy of 1 percent, to 150 percent of the working pressure of the pipe or vessel to which they are connected, or as shown. All gages shall be vibration and shock resistant and shall be silicone filled. Pressure gages shall be: 1. Ashcroft Duragage, Model 1279 2. Or approved equal. C. Diaphragm Seal. Gages attached to systems involving chemical solutions, corrosive fluids, or other liquids containing one percent or less of solids, shall be equipped with stainless steel diaphragm seals, or equivalent protective pressure sending devices, as follows: Supplier: 1. 2. Or approved equal. Ashcroft, Model 101 US. Gauge (Ametek) D. Snubber Suppliers: 1. Cajon Company, 2. Weksler Instruments Corporation. 3. Or approved equal. Installation: All gages and appurtenances shall be installed at the locations shown in the Contract Documents and in strict accordance with the manufacturet's printer instructions. Care shall be taken to minimize the effect of water hammer or vibrations on the gage. In extreme cases, the gages may have to be mounted independently, with flexible connectors. All dissimilar metals shall be insulated from each other. E. 2.10 NOTUSED 2.11 NOTUSED 2.12 BILCO LADDER-UP A. CONTRACTOR shall provide and install a Bilco Ladder-Up safety post in the locations identified within the CONTRACT DOCUMENTS. The device shall be manufactured of high strength steel with a telescoping section which locks automatically when fully extended. Upward and downward movement shall be controlled by a spring balancing mechanism. Ladder-up safety posts identified for JULY 2003 MISCELLANEOUS SPECIALTIES CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 10900 - 2 SECTION 10900 - MISCELLANEOUS SPECIALTIES use within underground vaults shall be hot dipped galvanized and provided with a special alloy spring. Ladder-up devices designated for use within hydraulic structures or other areas which experience wet-dry conditions shall be manufactured entirely of stainless steel. 2.13 SERVICE SADDLE A. CONTRACTOR shall install double band brass service saddle on PVC main to provide service connections. Outlets on PVC main shall be installed as per Carlsbad Municipal Water District standard drawing W8. Service Saddle shall be: 1. Ford 202BS 2. Jones J989 3. Romac 2028 4. or approved equal 2.14 DETECTOR TAPE A. All buried water lines shall require location tape installed over the centerline of the water line and twelve inches (12-inches) above the top of pipe. Tape shall be metalized foil core with two inch (2-inch) width. Tape shall be manufactured by: 1. Thor Enterprises 2. Or approved equal 2.15 NOTUSED 2.16 NOTUSED 2.17 NOTUSED 2.18 NOTUSED 2.19 NOTUSED END OF SECTION JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 MISCELLANEOUS SPECIALTIES PAGE 10900 - 3 SECTION 11209 -SUBMERSIBLE SUMP PUMPS PART I -GENERAL 1.1 WORK OF THIS SECTION A. The WORK of this Section includes providing submersible non-clog centrifugal sump pump with motors, controls, flanges, cables, lifting chains and accessories. 1.2 SUBMITTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. PART 2 - PRODUCTS 2.1 GENERAL A. Selection. Pumps shall be selected so that rated operation lies within 5% (based on capacity) of maximum efficiency. 2.2 ENVIRONMENTAL CONDITIONS A. Pumps and motors shall be recommended by the manufacturers for the service indicated and shall be submerged continuously and operated while submerged. 2.3 MATERIALS A. Pump materials shall comply with the following: ComDonent Material Pump and motor Cast iron, ASTM A48 Casing discharge Cast iron, ASTM A48 Impeller Cast iron, ASTM A48 Exposed nuts and bolts Stainless steel, ASTM A276 Type 304 shaft Stainless steel, ASTM A276 Type 303 All wetted parts of pump Epoxy coated according to Section 09800 2.4 EQUIPMENT A. Impellers. Impellers shall be statically and dynamically balanced and designed to be non-clog with ability to pass %inch solids and to pass stringy material. Bearings. Bearings shall be heavy-duty permanently oil lubricated ball bearings. Bearings for pumps 3-inch diameter discharge and larger shall be designed for an L-10 life of 20,000 hours heavy-duty service without additional lubrication. Pump and Motor Casing. Casing shall be constructed of corrosion resistant cast iron with bottom inlet and shall be designed to allow removal of all rotating parts from the motor end of the pumps. Mating surfaces where watertight sealing is required shall be machined and fitted with nitrile O-rings. Except as otherwise indicated, pump volute shall have vertical discharge. B. C. JULY 2003 SUBMERSIBLE SUMP PUMPS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 11 209-1 SECTION 11209 -SUBMERSIBLE SUMP PUMPS 2.5 D. Mechanical Seals. Pumps shall be provided with tandem carbon and ceramic faced inner and tungsten-carbide outer mechanical seals. Motor. Motor shall be designed to be non-overloading over the entire pump curve. Motor housing shall be of submersible construction with the windings operating in a sealed environment. Motors shall be either air-cooled or dielectric oil filled with built-in automatic reset overload protection. Cable. Pump motor and detector cables shall be suitable for submersible pump applications. Power for motor shall be carried by a heavy-duty, flexible, water resistant, plastic covered, portable cable, sealed at the motor bell and of sufficient length to connect to the junction box or the plug outlet where indicated. The cable entry shall prevent water from leaking into the motor due to capillary action even if cable is cut or damaged. Moisture Protection. Two moisture sensing probes shall be located between the mechanical seals to detect any influx of conductive fluid and signal outer seal failure. Lifting Chain. A IO-foot stainless steel (Type 304) lifting chain with bracket shall be provided for each pump. E. F. G. H. CONTROLS A. The CONTRACTOR shall provide a complete control system, located as shown on the drawings, housed in a NEMA 3R cabinet with hinged, gasketed door and mounting brackets or pedestal and all necessary components to provide the following functions: 1. 2. 3. 4. 5. 6. 7. 8. 9. IO. Magnetic starter with overload protection Circuit breaker Hand-off-automatic switch for end pump Pilot light High water alarm with contact and bell or horn Alarm reset switch Alarm for moisture in seal chamber. Alarm for over temperature in pump motor. Mercury level control switches with sealed cables and stainless steel Wall bracket Electric alternator JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 SUBMERSIBLE SUMP PUMPS PAGE 1 1209-2 SECTION 11209 - SUBMERSIBLE SUMP PUMPS , 11. Low water level cutoff 2.6 TOOLS AND SPARE PARTS Tools. The WORK includes special tools necessary for maintenance and repair; tools shall be stored in tool boxes, and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box. Spare Parts. The following spare parts shall be provided for each pump: 1. 2. 2 sets all bearings A. B. 2 sets all gaskets and O-rings 2.7 PUMP REQUIREMENTS A. Sump pump shall comply with the following requirements: Max. Sphere Rated Max. Discharge Passage Cap a c i ty , Design Max. Voltage & Horse- Pipe Size, Size, wUt-B€P-- PlxY!eI hlctles lsxbes 20 20 1550 1 15/1 .33 1%” %” 2.8 MANUFACTURERS A. Products shall be manufactured by one of the following (or equal): 1. Hydromatic SW33M1 2. Approved equal PART 3 - EXECUTION 3.1 INSTALLATION A. General. manufacturer‘s written installation instructions. Alignment: Equipment shall be properly aligned and operate free from defects including binding, scraping, vibration, end-shaft runout, or other defects. Drive shafts shall be measured just prior to assembly to ensure correct alignment without forcing. Equipment shall be bolted in position and neat in appearance. Lubricants. The installation includes oil and grease for initial operation. Products and equipment shall be installed in accordance with the B. C. END OF SECTION \ JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 SUBMERSIBLE SUMP PUMPS PAGE 11 209-3 SECTION 15020 -VALVES AND APPURTENANCES PART 1 - GENERAL 1 .I THE REQUIREMENT A. The CONTRACTOR shall provide all tools, supplies, materials, equipment and all labor necessary for furnishing, coating, installing, adjusting, and testing of all valves and appurtenant WORK, complete and operable, all in accordance with the requirements of the CONTRACT DOCUMENTS. Where buried valves .are indicated, the CONTRACTOR shall furnish and install valve wells to grade. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Pipe, fittings, and supports appurtenant to the WORK referred to herein shall be as specified in the applicable Sections of Divisions 2 and 15. Painting and protective coating of valves of any components thereof shall be in accordance with the requirements of Section 09800, "Protective Coatings," except where otherwise specified in this Section. Particular valves and operators may require a combination of units, sensors, limit switches, and controls specified in other sections of the CONTRACT DOCUMENTS. It shall be the responsibility of the CONTRACTOR to properly assemble and install these various items so that all systems are compatible and operating properly. The relationship between interrelated items shall be clearly noted on shop drawing submittals. B. C. I .3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of the CONTRACT DOCUMENTS, all work specified herein shall conform to or exceed the applicable requirements of the referenced Standards; provided, that wherever the provisions of said publication are in conflict with the requirements specified herein, the more stringent requirement shall apply. All products and their installation shall be in accordance with the standards of the American Society for Testing and Materials (ASTM), as referenced herein, the American Water Works Association (AWWA), as referenced herein, and with manufacturer's published recommendations and specifications. B. I .4 CONTRACTOR SUBMllTALS A. Shop drawings of all valves and operators including electrical data and associated wiring and control diagrams, where applicable, shall be furnished in accordance with the requirements of Section 2-5.3.3 of the latest edition of the SSPWC. JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 VALVES AND APPURTENANCES PAGE 15020 - 1 SECTION 15020 -VALVES AND APPURTENANCES 1.5 QUALITY ASSURANCE A. Unless otherwise specified, each valve body shall be tested under test pressure equal to twice its design water working pressure. PART 2 - PRODUCTS 2.1 VALVES, GENERAL A. General. The CONTRACTOR shall furnish all valves, valve-operating units, stem extensions and other accessories as indicated in the CONTRACT DOCUMENTS. All valves and gates shall be new and of current manufacture. Valve Flanqes. The flanges of valves may be raised or plain faced with full-face gaskets. Flanges of valves for water working pressures of 150 psi or less shall be faced and drilled to the 125-lb American Standard template unless otherwise shown or specified. Flanges of valves for water working pressures greater than 150 psi shall be faced and drilled to the 250-lb American Standard template unless othelwise shown or specified. Valve Wells. All buried valves shall be provided with valve wells to allow access to the operator. Wells shall be constructed of &inch diameter C900 PVC water pipe. Valve well covers shall be marked "RECYCLED WATER", and shall be: a) South Bay Foundry No. SBF 1208, b) or approved equivalent. Galvanized sheet metal shall be provided as required to seal the valve well to prevent entry of dirt or other materials. Where the valve nut is deeper than 5 feet below finish grade, a valve stem extension shall be provided in accordance with CMWD W-23. Bronze ComDonents. Unless otherwise specified, all interior bronze parts of valves except gate valve stems, shall conform to the requirements of the "Specification for Composition Bronze or Ounce Metal Casting," ASTM 862. B. C. D. E. Manual Ooerators. Unless otherwise indicated within the CONTRACT DOCUMENTS, valves with manual operators (excepting corp cocks and miscellaneous small valves) shall conform to the following requirements: 1. Operators shall clearly indicate valve position and shall close valve when rotated in a clockwise manner. Operators shall be fully enclosed and designed to produce the required torque with a maximum pull of 80 lbs on handwheels or levers and to withstand a maximum input of 300 ft-lbs at extreme actuator positions without damage. Actuators shall be sized based on the pressure class of the valve and a full open velocity of 16 feet per second for butteffly valves and 36 feet per second for other valves. Exposed nuts, bolts and washers for above grade installations shall be zinc plated, for below grade and submerged installations they shall be 316 stainless steel. 2. JULY 2003 VALVESANDAPPURTENANCES CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 15020 - 2 SECTION 15020 -VALVES AND APPURTENANCES 3. Quarter tum valves 2-inches and smaller installed between floor level and five feet above shall be supplied with lever wrench operators. Quarter turn valves 3-inches and larger and all multi-tum valves installed between floor level and five feet above shall be provided with a cast iron hand wheel. Worm gear or travelling nut operators shall be supplied for quarter tum operators in this configuration. All buried valves shall be provided with a 2-inch square operating nut, extension stems, and valve well, as required below. Buried or submerged quarter turn valves shall be supplied with worm gear or travelling nut operators properly sealed to operate continuously under 35 feet of external water pressure. Valves located more than 5 feet above the finished floor or operating platform shall be equipped with chainwheels, sprockets, and galvanized steel chain extending to three feet above the operating floor. Worm gear or travelling nut operators shall be supplied for quarter turn operators in this configuration. Operator shaft and the gear quadrant shall be supported on permanently lubricated bearings. 4. 5. 6. F. NOT USED. G. Epow Coatinq. Except where othenvise provided, ferrous surfaces, exclusive of stainless steel surfaces, in the water passages of all valves 4-inch and larger, as well as the exterior surfaces of all buried or submerged valves, shall be epoxy coated as specified below. Coating shall be applied to castings prior to assembly to insure that all exposed areas, including bolt holes, will be covered. 1. Material: Except as otherwise provided herein, the material used shall be 100 percent powder epoxy and shall be: a. 3-M Company "Scotchcoat," b. C. Or approved equal. Where, in the ENGINEERS opinion, because of the nature of the item being coated, it would be impossible to use the powder epoxy method without causing damage to the item (Le.: most Butteffly valves) the use of a liquid epoxy will be permitted. Liquid epoxy shall be: a. 3-M Company No. 302 b. C. Tnemec Series 20 Pota-Pox d. Or approved equal Thickness of Coating: The minimum dry coating thickness shall be 8 mils, except that the thickness of coating in the grooves for valves or fittings designed to receive a rubber gasket shall be approximately 5 mils, minimum. Michigan Chrome and Chemical Company "Micron 650 or 651 2. SOC-CO Plastic Coating Co. Keysite 740 3. JULY 2003 VALVES AND APPURTENANCES CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 15020 - 3 SECTION 15020 -VALVES AND APPURTENANCES H. I. J. K L. 2.2 AIR A. 0. C. Buried Valves. In addition to the coating specified above, buried valves shall be coated with a non-oxide grease and tightly wrapped in an &mil thick polyethylene sheet with all joints and edges lapped and sealed with duct tape. Manufacturer's Experience. Valves, gates, and operators described in this section shall be furnished by a manufacturer who has a record of a minimum of 5 years of successful experience in the operation and manufacture of such equipment in similar installations and applications. NOT USED NOT USED Approved Materials List. All valves and appurtenances specified under this Section shall also conform to the Carlsbad Municipal Water District's Approved Materials List. VACUUM AND AIR RELEASE VALVES General. Valves shall be of the size shown and shall have screwed or flanged ends to match piping. Bodies shall be of high-strength cast iron, conforming to ASTM A126 class B. Floats shall be heavy stainless steel, suitable to withstand 1000 psi external pressure. Seats shall be Buna-N. Other internal components shall be constructed of stainless steel, bronze, delrin, or cast iron as appropriate. Inlet and outlet ports for large orifice valves shall be baffled to prevent the action of high volume airtlows from interfering with valve operations. Interior and exterior carbon steel surfaces shall be epoxy coated per part 2.1 of this section. Valves shall be designed for a minimum of 200 psi water working pressure, unless otherwise shown. Automatic Air Release Valves. Automatic air release valves shall be supplied where shown to vent small quantities of air under full line pressure that may become entrained in the system and collect at high points of pipelines, pressure vessels, pump cans, etc. Valves shall be provided by: 1. APCO 2. Val-Matic Corp. 3. or approved equal. Air and Vacuum Valves. Air and vacuum valves shall have a larger orifice than air release valves and shall be supplied where shown to vent large quantities of air from a pipeline or pressure vessel during filling, and to allow the reentty of air to prevent vacuum conditions from developing within the pipeline or pressure vessel. Air and vacuum valves need not vent air while under full line pressure. Valves shall be provided by: 1. APCO 2. Val-Matic Corp. 3. or approved equal. JULY 2003 VALVES AND APPURTENANCES CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 15020 - 4 SECTION 15020 -VALVES AND APPURTENANCES 2.3 2.4 2.5 2.6 2.7 D. Combination Air Valves. Combination air valves shall be supplied where shown. They shall have both large and small orifices in a single body. The large orifice shall serve to vent large quantities of air during filling operations and shall automatically open to relieve vacuum conditions. The small orifice shall vent small quantities of air under full line pressure that may become entrained in the system and collect at high points. Valves shall be provided by: 1. 2. 3. NOT USED NOT USED NOT USED NOT USED BUlTERFL' APCO Val-Matic Corp. Or approved equal. Vb IES A. General. The CONTRACTOR shall furnish and install flanged, tight-closing, rubber seated butterfly valves of the size shown within the CONTRACT DOCUMENTS. Valves shall be bubble-tight at rated pressures (Class 150 or 250 as indicated on the drawings) with flow in either direction, and shall be satisfactory for applications involving throttling service and/or frequent operation and for applications involving valve operation after long periods of inactivity. All valves and valve operators shall be suitable for buried service and shall conform to the requirements of AWWA Standard C504, latest revision, as modified or supplemented by the following provisions: 1. 2. All valves shall be short body. Valves shall be designed for manual operation and shall be opened by rotating the operator hand wheel in a counterclockwise direction. Taper pins, bolts, nuts and washers in contact with the water in the valve shall be fabricated from stainless steel conforming to the requirements of ASTM Standard A276, type 304 or ASTM A-564, type 630 condition H1100. Flow direction shall be indicated on the valve body. Unless otherwise specified, all valves shall have an AWWA C504 "B designation, suitable for a maximum velocity of 16 feet per second in the upstream pipe section. 3. 4. B. Additional CONTRACTOR Submittals. The CONTRACTOR shall furnish with the equipment submittal a written certification from the valve manufacturer stating that operator torque has been computed and operators have been sized in accordance with the method described in Appendix A of ANSVAWWA C 504, latest edition. JULY 2003 VALVESANDAPPURTENANCES CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 15020 - 5 SECTION 15020 -VALVES AND APPURTENANCES Also, the CONTRACTOR shall provide an Affidavit of Compliance, in accordance with Section 1.7 of AWWA C504, to the ENGINEER prior to incorporating the valve into the WORK. EDOW Coatinq. Butterfly valves and operators shall be epoxy coated as specified in part 2.1 of this specification, except coating shall have 12 mil thickness. C. D. NOT USED E. - Seats. Rubber for valve seats shall conform to the applicable provisions of AWWA Standard C504. latest revision. Valve seats for butterfly valves between 3 and 12 inches shall be vulcanized and bonded to the valve body, or shall be mechanically attached to the valve disc utilizing a 316 stainless steel retaining ring and self locking screw fasteners. Valves between 12 and 24 inches shall be provided with vulcanized and bonded body seats only. Vulcanized and bonded body seats shall withstand a minimum 75 Ibs. pull under test procedure ASTM D-429, Method B. For valves 24 inches and larger, valve seats shall be field adjustable around the 360 degree circumference and shall be replaceable without dismantling the operator, disc or shaft, or removing the valve from the pipeline. Retaining rings, clamps, screws and bolts used to attach the rubber seat to the valve body shall be fabricated from 316 stainless steel. For valves 24 inches and larger the valve manufacturer shall certify that the rubber seat is field replaceable as specified above. Spool-type rubber liners covering the entire inner surface of the valve body and extending over any portion of the flange faces will not be acceptable. Valves employing the use of a snap ring to retain the rubber seat will not be acceptable. - Discs. Valve discs shall have no external ribs transverse to the flow of water through the valve. The disc shall not have any hollow chambers that can entrap water. Discs shall be fabricated from cast iron with Ni-Chrome or 316 stainless steel edges for 3-inch to 20-inch butterfly valves. Discs for butterfly valves greater than 20 inches shall be fabricated of cast iron ASTM A-48 with stainless steel seating edge or ductile iron ASTM A-536 with stainless steel seating edge. Valve discs shall rotate 90 degrees from the full open position to the fully closed position. For butterfly valves 30 inches and larger, the disc shall employ a “flow through” design to minimize headloss. Valve Shafts. Valve shafts shall be fabricated of Type 304 or Type 316 stainless steel or ASTM A-564 type 630 condition H-1100. Shaft diameters shall meet minimum requirements in accordance with AWWA C504 for their class as shown on the drawings and as specified herein. Valve Body. Flanges shall be flat-faced and flange drilling shall be in accordance with ANSI 816.1, Class 125 or 250 as indicated. Valve bodies shall be constructed of cast iron, ASTM A126 Class B. On valves 30 inches or larger, the valve port diameter shall not reduce more than 1-1/2 inches of nominal diameter. The use of a stop lug cast integrally with or mechanically secured to the body for limiting disc travel will not be acceptable. F. G. H. JULY 2003 VALVES AND APPURTENANCES CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PAGE 15020 - 6 SECTION 15020 -VALVES AND APPURTENANCES I. Thrust bearinas shall be provided per the governing standard. Thrust bearings that are exposed to water and consist of a metal bearing surface in rubbing contact with an opposing metal bearing surface will not be acceptable. J. NOT USED K. Butterflv valve testing. Hydrostatic and leakage tests shall be conducted in strict accordance with AWWA C504. L. Spare Parts. None required. M. Manufacturers. Butterfly valves shall be as manufactured by American Darling, Mueller. M & H, or approved equivalents. 2.8 NOTUSED 2.9 NOTUSED 2.10 NOTUSED 2.11 NOTUSED 2.12 GATE VALVES A. General. Gate valves for water service shall conform to the AWWA Standard for "Resilient-Seated Gate Valves for Water and Sewerage Systems" (AWWA C509, latest edition). Valves shall be of the resilient seated type with non-rising stem, closing in a clockwise direction. Sealing mechanism shall provide zero leakage at the water working pressure against line flow from either direction. The rubber covered gate shall not be wedged into a pocket nor slide across the seating surface to obtain a tight closure. Synthetic thrust washers shall be provided to minimize operating torque. Valves shall be flanged or have ends to match pipe and shall have solid bronze internal working parts. All gate valves shall be wax taped. Stems. Gate valve stems shall be of bronze containing not more than 5 percent of zinc nor more than 2 percent of aluminum, and shall have a minimum tensile strength of 60,000 psi, a yield strength of 35,000 psi, and an elongation of at least ten percent in 2 inches, as determined by a test coupon poured from the same ladle from which the valve stems to be furnished are poured. Seats. Resilient valve seats shall consist of styrene butadiene (SBR) rubber permanently bonded to a high-strength iron wedge gate. The gate shall be totally encapsulated. The bonding process shall meet the requirements of ASTM D429. Mechanically attached seats or seats attached to the valve body shall not be accepted. Operators. Buried valves shall be provided with a 2-inch square operating nut, extension stems, and valve well, as required in Part 2.1. Unless otherwise shown B. C. D. JULY 2003 VALVES AND APPURTENANCES CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 15020 - 7 SECTION 15020 -VALVES AND APPURTENANCES on the drawings, valves in vaults or above grade shall be supplied with a cast iron handwheel. Pressure Ratins and Testinq. Valves shall be rated for a working water pressure of 250 psi and shall be seat tested at this pressure with no leakage. Shell test of 400 psi shall be applied to body with valve in the open position with no leakage through the metal, flanged joints, or stem seals. Epow Coatinq. Valve and operator shall be epoxy coated as specified in part 2.1 of this section, except coating shall have 12 mil thickness. Soare Parts. Each valve shall be supplied with a spare set of upper and lower o- rings and weather seal. Manufacturer. Resilient seat gate valves shall be manufactured by: 1. 2. M&H 3. American AVK. 4. Or approved equal. Gate Valve Boxes. Buried gate valve boxes shall be Brooks 3RT. All gate valve box covers shall be marked "Recycled Water and painted with 2 coats of Frazee Aero Plate II, Purple. Installation of valve boxes shall be as per Carlsbdad Municipal Water District, Standard Drawings, W13. E. F. G. H. American Flow Control Series 500 I. 2.13 NOTUSED 2.14 NOTUSED 2.15 BACKWATER CHECK VALVE A. General. The CONTRACTOR shall furnish and install the backwater check valve as shown in the CONTRACT DOCUMENTS, and as recommended by the manufacturer. The valve shall provide positive shut off preventing reverse flow. The valve shall be of PVC construction with stainless steel hardware and rubber seal. Valve ends shall match the diameter of the connecting pipe. Manufacturer. Backwater check valves shall be manufactured by: 1. 2. or approved equal. B. Daniel L. Jerman Co., 1-800-554-3733 2.16 PILOT OPERATED CONTROL VALVES, GLOBE OR ANGLE PAlTERN A. General. The CONTRACTOR hereunder shall furnish and install flanged, tight- closing, pilot operated control valves of the size and type shown within the CONTRACT DOCUMENTS. Valves shall be hydraulically operated, diaphragm actuated, globe or angle pattem valves. Valves shall be bubble-tight at rated pressures and shall be satisfactory for applications involving throttling service JULY 2003 VALVES AND APPURTENANCES CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 15020 - 8 SECTION 15020 -VALVES AND APPURTENANCES andlor frequent operation and for applications involving valve operation after long periods of inactivity. Valves shall be rated for 150 psi unless otherwise shown and shall be supplied with class 125 flanges, unless otherwise specified or shown. Where pressure and/or flow set points are shown or specified, such set points shall be factory adjusted prior to shipping and plainly marked on the valve. 1, Main Valve: Main valve body and cover shall be of cast iron construction conforming to ASTM A48. Trim materials on the main valve shall be of 303 stainless steel. Valves shall be oriented to fail in the closed position. Valves shall contain a resilient, synthetic rubber disc, having a rectangular cross-section, contained on three and one-half sides by a disc retainer and forming a tight seal against a single removable seat insert. The diaphragm assembly containing a Dura Kleen valve stem shall be the only moving par! and shall be fully guided by bearings in the valve cover and lower body or valve seat. The diaphragm shall consist of nylon fabric bonded with synthetic rubber and shall not be used as a seating surface. Packing glands and/or stuffing boxes are not permitted and there shall be no pistons operating the valve. All necessary repairs shall be possible without removing the valve from the line. Pilot Controls: Pilot controls, consisting of copper tubing, pressure control valves, solenoid valves, filter screens, flow restricters, isolation valves, etc., shall be provided as necessary to accomplish the specific functions required. Pilot valves shall be cast bronze with 303 stainless steel trim. All pilot systems shall have a "Y" strainer with filter screens of monel construction and a ball valve for strainer flushing. All pilot systems shall be furnished with shutoff cocks to isolate the pilot system. Other components shall be of brass, bronze, or stainless steel construction. Epoxy Coating: The main valve shall be epoxy coated as specified in part 2.1 of this Section. 2. 3. B. Pressure ReducinalReaulatinq Valve. The pressure reducing/regulating valves shall modulate to maintain a constant downstream pressure regardless of varying inlet pressure. The downstream pressure set point shall be adjustable in the range of 30 to 300 psi initially set to 108 psi. 1. Initial set point: 2-inch valve - 92 psi 4-inch valve - 87 psi Manufacturer: Cla Val Company, Model 92-01 KCBCF 2. Pressure Relief Valve. The pressure relief valve shall modulate to relieve high upstream pressure. The upstream pressure set point shall be adjustable in the range to 30 to 300 psi, initially set to 97 psi. 1. C. Manufacturer: Cla Val Company, Model 92-01 KCBCF JULY 2003 VALVES AND APPURTENANCES CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 15020 - 9 SECTION 15020 -VALVES AND APPURTENANCES 2.17 NOTUSED 2.18 NOTUSED 2.19 NOTUSED 2.20 NOTUSED 2.21 NOTUSED 2.22 UNDESIGNATED SMALL VALVES A. All valves not designated within the CONTRACT DOCUMENTS as to type shall be subject to approval of the ENGINEER. All valves shall be new, of top quality, and of materials and construction generally acceptable for public works construction. PART 3 - EXECUTION 3.1 3.2 3.3 VALVE INSTALLATION A. Flange Ends 1. 2. Flanged valve bolt holes shall straddle vertical centerline of pipe. Clean-flanged faces, insert gasket and bolts, and tighten nuts progressively and uniformly. B. Valve Orientation Install operating stem vertical when valve is installed in horizontal runs of pipe having centerline elevations 4 feet 6 inches or less above finished floor, unless otherwise shown. TESTS AND INSPECTION A B. Valve may be either tested while testing pipelines, or as a separate step. Test valves open and close smoothly with operating pressure on one side and atmospheric pressure on the other, in both directions for two-way valve and applications. Count and record number of turns to open and close valve; account for any discrepancies with manufacturer's data. C. EPOXY APPLICATION JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 VALVES AND APPURTENANCES PAGE 15020 - 10 SECTION 15020 -VALVES AND APPURTENANCES A. Surface Preparation. The surface shall be blast-cleaned in accordance with The grit size used shall be as SSPC-SP5 (White Metal Blast Cleaning). recommended by the epoxy manufacturer. Application. Application of the epoxy coating shall be in accordance with the manufacturer's printed instructions, provided that, if liquid epoxy is permitted, it shall be applied in not less than 3 spray coats to give the required total thickness. Field Repairs. If small local repairs of the epoxy coating are necessary, they shall be made using a liquid epoxy recommended by the manufacturer of the epoxy with which the item was initially coated. The surface shall first be hand-tool cleaned in accordance with SSPC-SP-2 (hand tool cl'eaning). The repair epoxy material shall be applied in accordance with the manufacturer's instructions. B. C. 3.4 TESTING OF EPOXY COATING A. The epoxy coating thickness shall be checked with a non- destructive magnetic type thickness gage. Coating integrity shall be tested with a sponge-testing unit operating at approximately 60-volts. All pinholes shall be marked, repaired and retested. No pinholes or other irregularities will be permitted in the final coating. If small local repairs are necessary, they shall be made using a liquid epoxy recommended by the manufacturer of the epoxy with which the item was initially coated. The surface shall first be hand-tool cleaned in accordance with SSPC-SP- 2 (Hand Tool Cleaning). The repair epoxy material shall be applied in accordance with the manufacturer's instructions. END OF SECTION JULY 2003 VALVES AND APPURTENANCES CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 15020 - 11 SECTION 15120 - PIPING SPECIALTIES 1.1 1.2 1.3 PART 1 -GENERAL PART 2 - PRODUCTS 2.1 2.2 2.3 2.4 2.5 THE REQUIREMENT A. The CONTRACTOR shall furnish and install piping specialties as shown and specified, complete, including small steel pipe, solvent-welded PVC pipe mechanical and sleeve couplings, gaskets bolts, piping insulating, and such other specialties as required for a complete and operable piping system in accordance with the requirements of the CONTRACT DOCUMENTS. 6. The CONTRACTOR shall inspect and evaluate the existing flexible expansion joints at the Poinsettia bridge crossing over Interstate 5. If the pressure class rating of the existing flexible expansion joints is less than specified in part 2.10 of this Section, or if the existing flexible expansion joints are in poor condition, the CONTRACTOR shall remove and replace the existing flexible expansion joints with new 14-inch Ductile Iron Flanged Double Ball Expansion Joints in accordance with the CONTRACT DOCUMENTS. RELATED WORK SPECIFIED ELSEWHERE A. NOTUSED. 6. Section 02200, "Earthwork". C. Section 09800, "Protective Coatings". SUBMllTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. SMALL STEEL PIPE A. Unless otherwise shown, galvanized steel pipe and black steel pipe in sizes 6 inches in diameter and smaller shall conform to the requirements of ASTM A 120 "Specifications for Black and Hot-Dip Zinc-Coated (Galvanized) Welded and Seamless Steel Pipe for Ordinary Uses," and shall be standard weight. Galvanized steel pipe shall not be cement mortar lined unless otherwise shown. Fittings for galvanized steel pipe shall be of galvanized malleable iron. NOT USED NOT USED NOT USED MECHANICAL-TYPE COUPLINGS (GROOVED END) JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PIPING SPECIALTIES PAGE 15120 - 1 SECTION 15120 - PIPING SPECIALTIES A. Mechanical-type couplings shall be designed for a water working pressure not less than the design pressure of the pipe on which they are to be installed. Buried or submerged couplings shall be provided with Type 316 stainless steel bolts and nuts. When pipe ends are banded couplings for steel pipe shall be: 1. Gustin-Bacon 2. 3. Or approved equal. When pipe ends are grooved, couplings shall be equipped with Grade H rubber gaskets and shall be manufactured by: 1. Gustin Bacon 2. Victaulic Style 77 3. Approved equal Couplings for ductile iron pipe shall be equipped with Grade M gaskets and shall be manufactured by: 1. Gustin-Bacon 2. Victaulic Style 31 3. Or approved equal B. Victaulic Style 44, groove type C. D. 2.6 SLEEVE-TYPE COUPLINGS A. Couplings shall be of steel with steel bolts, without pipe stop, and shall be of sizes to fit the pipe and fittings shown. The middle ring shall not be less than %-inch in thickness and shall be either 5 or 7 inches long for standard steel couplings, and 16 inches long for long-sleeve couplings. Bolts for exposed couplings shall be hot- dip galvanized. Bolts and nuts for buried or submerged couplings shall be of type 316 stainless steel. Buried sleeve-type couplings shall be epoxy-coated at the factory as specified in Section 09800 Protective Coatings. Sleeve-type couplings shall be provided where shown, and shall be: 1. Smith-Blair, Style 41 1 2. Dresser, Style 38 3. Or approved equal. B. 2.7 GASKETS AND BOLTS A. Except as otherwise provided, gaskets for flanged joints shall be 1II6-inch thick laminated asbestos fiber or lI8-inch thick rubber fabric, full face. Except where otherwise shown or Specified, all bolts, anchor bolts, and nuts installed above grade or in a dry vault or pit shall be steel, galvanized after fabrication in accordance with ASTM standards. Threads on galvanized bolts and B. JULY 2003 PIPING SPECIALTIES CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 15120 - 2 SECTION 15120 -PIPING SPECIALTIES 2.8 2.9 2.10 2.1 1 nuts shall be formed with suitable taps and dies such that they retain their normal clearance after hot-dip galvanizing. Unless otherwise shown or specified, all bolts, anchor bolts and nuts which are buried, submerged, or below top of the wall inside any hydraulic structure shall be of type 316 stainless steel. Except as otherwise provided herein, steel for bolts, anchor bolts and cap screws shall be in accordance with the requirements of ASTM A307, “Specifications for Carbon Steel Externally and Internally Threaded Standard Fasteners,” Grade B or threaded parts of ASTM A 36 and shall meet the following additional requirements: 1. 2. C. The nut material shall be free-cutting steel, and; The nuts shall be capable of developing the full strength of the bolts. Threads shall be Course Thread Series conforming to the requirements of the American Standard for Screw Threads. All bolts and cap screws shall have hexagon heads and nuts shall be Heavy Hexagon Series. NOT USED NOT USED FLEXIBLE EXPANSION JOINTS A. Flexible expansion joints shall be provided if necessary, where shown on the drawings, and shall be manufactured of ductile iron conforming to the requirements of AWWA C153. All flexible expansion joints shall be capable of deflecting and expanding simultaneously, and shall be capable of not less than 15O deflection and 4-inches expansion. Expansion capability shall be designed as an integral part of the ductile iron castings. Flexible expansion joints shall be rated for a working pressure of 250 psi. All pressure containing parts shall be lined with minimum 15- mils of fusion bonded epoxy conforming to the applicable requirements of AWWA C213, and shall be holiday tested with a 1500 volt spark test conforming to AWWA C213. PIPE TO WALL PENETRATION CLOSURE A. Description. Where shown, pipe to all penetration closures shall be: 1) “Link-Seal” as manufactured by Thunderline Corporation - Wayne Michigan, 48184. or 2) approved equal. Seals shall be modular mechanical type, consisting of interlocking synthetic rubber links shaped to continuously till the annular space between the pipe and wall opening. Links shall be loosely assembled with bolts to form a continuous rubber belt around the pipe with a pressure plate under each bolt head and nut. After the seal assembly is positioned in the sleeve, tightening of the bolts shall cause the rubber sealing elements to expand and provide an absolutely watertight seal between the pipe and wall opening. The seal shall be constructed so as to provide electrical insulation between the pipe and wall, thus reducing the possibility of cathodic reaction between them. Wall Openinq. CONTRACTOR shall determine the required inside diameter of each individual wall opening or sleeve before ordering, fabricating or installing. B. JULY 2003 PIPING SPECIALTIES CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PAGE 15120 - 3 SECTION 15120 - PIPING SPECIALTIES The inside diameter of each wall opening shall be sized as recommended by the manufacturer to fit the pipe and Link-Seal to assure a watertight joint. Sizing (correct Link-Seal model and number of links per seal) may be obtained through manufacturer's catalog. If pipe O.D. is non-standard due to coating, insulation. etc., consult manufacturer factory for engineering assistance and recommendation before proceeding with wall opening detail. Installation. CONTRACTOR shall familiarize his installing personnel with Link-Seal instruction bulletin (packed with each carton) that illustrates the proper procedure for installing and tightening the seal to provide a watertight pipe penetration. C. PART 3 - EXECUTION 3.1 GENERAL A. Except as modified herein, the installation of pipe and materials provided under this Section shall conform to the requirements of Section 02601, "Buried Piping Installation". 3.2 INSTALLATION A. Small Steel Pioe. Buried galvanized or black steel pipe shall be coated as specified in Section 09800, Protective Coatings, or provided with an extruded high density polyethylene coating with minimum thickness of 35 mils. PVC Pioe. PVC pipe joints shall be solvent-welded in accordance with the manufacturer's instructions. Expansion joints or pipe bends shall be provided to absorb pipe expansion over a temperature range of 100 degrees F. Couolinas. manufacturer's printed recommendations. B. C. Pipe couplings shall be installed in strict accordance with the D. *.&O!S fer F!z>n.C.ey. J5!.7!!5. yl/!?ereyer b$& ?aq.ss &.,$+!?., :*e p&& &+a!{. consist of 1/8-inch thick cloth-inserted rubber sheet which shall cover the entire inside surface of the blind flange and shall be cemented to the surface of the blind flange. 3.3 NOTUSED END OF SECTION JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PIPING SPECIALTIES PAGE 15120 - 4 SECTION 15130 - GAGES PART 1 -GENERAL 1.1 THE REQUIREMENT .- _- A. The CONTRACTOR shall fumish and install pressure gages as specified, complete, including all fittings, connections, snubbers, diaphragm seals, gaskets, supports, and accessories in the locations shown or specified, all in accordance with the requirements of the CONTRACT DOCUMENTS. 1.2 SUBMITTALS A. For the gages that it proposes to provide, the CONTRACTOR shall submit complete manufacturer's product specifications and performance details according to the requirements of Section 2-5.3.3 of the latest edition of the SSPWC. PART 2 - PRODUCTS 2.1 PRESSURE GAGES A. B. Pressure gages shall be provided where shown. Gages shall be oil-filled industrial quality type with stainless steel movement and stainless steel or alloy case. Unless otherwise shown, pressure gages shall have a 3-1/2-inch dial, l/4-inch threaded connection, and a stainless steel gage cock and pressure snubber. Gages shall be calibrated to read in psi units, with an accuracy of +/- 1 percent, to 150 percent of the working pressure of the pipe or vessel to which they are connected. The pressure range shall be 0 to 250 psi unless otherwise shown. Gages attached to systems involving chemical solutions, sludge, sewage or other liquids containing solids, shall be equipped with diaphragm seals or equivalent protective pressure sensing devices. Gages shall be as manufactured by: 1. Ashcroft 2. or approved equal. C. 2.2 DIFFERENTIAL PRESSURE GAGES A. Provide a differential pressure gage where shown or required. Gages shall be suitable for use with water. Gages shall have a 4-inch dial in a forged brass case. A silicone rubber diaphragm shall separate the high and low-pressure cells. The gage shall have a helical magnetic linkage between the diaphragm leaf spring and the gage pointer. The gage shall be protected from damage by over-pressure conditions of up to 500 psi. The gages shall be calibrated in 0-35 feet of differential water pressure and shall have an accuracy of +/- 3% of full scale. A zero adjustment screw shall be front accessible without disassembly. B. C. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 GAGES PAGE 15130- 1 SECTION 15130 -GAGES D. The gages shall have 1/4-inch NPT pressure taps. Gages shall be provided with bleed fittings at the top of each pressure cell to facilitate the purging of trapped air. CONTRACTOR shall provide a non-corrosive mounting bracket suitable for pipe or wall mounting. E. F. Gages shall be: 1. Series 4000 Capsuhelic as manufactured by Dwyer Instruments, Michigan City, Indiana 2. Or approved equal. 2.3 PRESSURE SNUBBER A. Unless otherwise shown, pressure snubbers shall be supplied with all pressure gages. Snubbers shall have 303 stainless steel bodies with 316 stainless steel filter disc. The disc porosity shall be suitable to dampen pressure surges for use with clean water, with openings in the range of 0.0013 inches to 0.0025 inches. Pressure snubbers shall be as manufactured by: 1. 2. Or approved equal. Ashcroft, a division of Dresser Industries, of Stratford. Connecticut 2.4 DIAPHRAGM SEAL A. Unless otherwise shown or specified, diaphragm seals shall be provided for each pressure gage supplied, except for those used with potable water. The materials of construction and intermediate fluid of all diaphragm seals shall be suitable for the intended process chemical. Unless othelwise specified or chemically incompatible, the bottom seal housing and clamping bolts shall be 316 stainless steel; the diaphragm shall be Teflon coated stainless steel, or for low pressure applications, Won; and the fill fluid shall be glycerine. Unless otherwise shown or specified, diaphragm seals shall have a 112-inch FNPT process connection and a 1/4-inch FNPT gage connection. The bottom housing shall be provided with a flushing connection. The seals shall be attached to the gages in a shop by a reputable firm with 5 years experience in this type of installation and with suitable vacuum equipment to assure the complete evacuation of air prior to filling of intermediate fluid. Filling of the gageldiaphragm unit in the field shall not be allowed. The pressure gage/diaphragm seal unit shall not be disassembled after the unit has been filled with suitable fluid. Should the unit become disassembled for any reason, the CONTRACTOR shall return the unit to the vendor for proper evacuation and re-filling. 6. C. D. E. JULY 2003 CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 GAGES PAGE 15130 - 2 SECTION 15130 -GAGES F. The pressure gage/diaphragm seal units shall be shipped to the job site clearly labeled with the process fluid the units are intended for. Diaphragm seals shall be as manufactured by: 1. 2. Or approved equal. G. Ashcroft, a division of Dresser Industries, of Stratford, Connecticut PART 3 - EXECUTION 3.1 INSTALLATION A. All gages and appurtenances shall be installed at the locations indicated in the CONTRACT DOCUMENTS and in strict accordance with the manufacturer‘s printed instructions. Gages shall be protected from excessive vibrations and shall be supplied with adequate support. END OF SECTION JULY 2003 CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 GAGES PAGE 15130 - 3 SECTION 15140 - PIPE HANGERS AND SUPPORTS PART I - DESCRIPTION 1.1 GENERAL A. w. CONTRACTOR shall provide all labor, material, equipment and incidentals required as shown, specified and required to design, furnish and install the system of support, guidance and anchorage for all piping, valves and specials. B. Coordination 1. Review installation procedures under other Sections and coordinate the WORK that must be installed with or attached to the hangers and supports. CONTRACTOR shall coordinate the location and placement of concrete inserts, and drilling of structural members required. 2. 1.2 QUALITY ASSURANCE A. Source Qualitv Control. Obtain each type of pipe hanger or support from no more than one manufacturer. Reference Standards. Comply with applicable provisions and recommendations of the following except as otherwise shown or specified. 1. The Manufacturers Standardization Society of the Valve and Fittings B. Industry: a. b. MSS SP-69, Pipe Hangers and Supports - Selection and MSS SP-58, Pipe Hangers and Supports - Materials and Design. Application. 2. 3. 4. Underwriters’ Laboratories, Inc., Standard UL-203 - Pipe Hanger Federal Specifications. FS WW-H-171. Hangers and Supports, Pipe. ASTM A 575, Merchant Quality Hot-Rolled Carbon Steel Bars. Equipment. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. Shop Drawinas. Submit for approval the following: 1. B. Detailed drawings showing all hangers and supports for each piping system specified. Shop Drawings shall show location, installation, material, loads or forces and deflection of all hangers and supports. JULY 2003 PIPE HANGERS AND SUPPORTS CWRF PIPELINE TO “D TANKS - REACHES 1 AND 3 PAGE 15140 - 1 SECTION 15140 - PIPE HANGERS AND SUPPORTS 2. Manufacturers' catalogs, literature, and engineering data on all hangers and supports. Load ratings, materials and installation shall be consistent with the recommendations of the MSS SP-58 and MSS SP-69. 1.4 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Delivew of Materials. All materials shall be inspected for size, quality, and quantity against approved shop drawings. Storage of Materials. All materials shall be packaged, labeled, and stored in a covered dry location until time of installation. B. PART 2 - PRODUCTS 2.1 GENERAL REQUIREMENTS A. Desicln Criteria. Fabrication of the pipe hangers and supports shall conform to the following criteria: 1. Accurate weight balance calculations shall be made to determine the required supporting force at each hanger location and the pipe weight load at each equipment concentration. Pipe hangers shall be capable of supporting the pipe in all conditions of operation. They shall allow free expansion and contraction of the piping, and prevent excessive stress resulting from transferred weight being induced into the pipe or connected equipment. Hangers shall be designed and installed so that they cannot become disengaged by movement of the supported pipe. 2. 3. B. The hangers and supports shall meet with the following requirements: 1. Standard and fabricated hangers and supports shall be furnished complete with necessary inserts, bolts, nuts, rods, washers, and other accessories. Run piping in groups and parallel to building walls where practicable. Provide minimum clearance of 1-inch between pipe and other work. Install hangers or supports at all locations where piping changes direction. All hangers and supports shall be capable of adjustment after placement of piping. Each type of hanger or support shall be the product of one manufacturer. Types of hangers or supports shall be kept to a minimum. All suspended or supported ductile iron pipe shall have a hanger or support adjacent to each hub. 2. 3. 4. 5. 6. JULY 2003 PIPE HANGERS AND SUPPORTS CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PAGE 15140 - 2 SECTION 15140 -PIPE HANGERS AND SUPPORTS 7. Vertical piping shall be supported at each floor by stays or braces designed to prevent rattling and vibration. Hanger rods shall be straight and vertical. Chain, wire, strap or perforated bar hangers shall not be used. Hangers shall not be suspended from piping. Prevent contact between dissimilar metals by use of copper plated, rubber or vinyl coated, or stainless steel hangers or supports. Thin walled stainless steel piping shall be isolated from carbon steel by use of plastic coated hangers or supports. Hangers and supports shall provide for expansion throughout the full operating temperature range. Provide lateral support, anchors and guides for all pipelines in which expansion joints are installed. Anchors and guides shall be in accordance with the recommendations of the manufacturer of the expansion joints. 8. 9. IO. 11. 12. 2.2 HANGERS AND SUPPORTS A. Hangers and supports shall be in accordance with MSS SP-58. Special hangers and supports shall be in accordance with details shown on the Drawings. Product and Manufacturer. Provide hangers 'and supports as manufactured by one of the following: 1. IT Grinnell Company 2. Elcen Metal Products Company. 3. Approved equal. Fabricated Concrete and Steel Hangers and Supports: 1. B. C. Fabricated concrete and steel hangers and supports shall be as detailed on the Drawings. Materials and design shall conform to the standards of MSS SP-58 and as required for the specific piping system. Hanger rod steel shall conform to ASTM A 575, with square head nut on top and running thread on the bottom end. 1. D. Minimum size single hanger rods shall be in accordance with the schedule below unless otherwise shown or specified. Double rods used for pipe 8- inches and greater may be 1/4-inch less in diameter than indicated. JULY 2003 PIPE HANGERS AND SUPPORTS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 15140- 3 SECTION 15140 - PIPE HANGERS AND SUPPORTS 2.3 2.4 Pipe Size onches) Less than 2 2-112 through 3 4 through 6 8 through 12 14 through 20 Larger than 20 Rod Diameter (inches) 318 1 12 314 718 1 1-114 E. Concrete Inserts. 1. 2. Concrete inserts shall be MSS SP-58 malleable Type 18. Where shown or required concrete inserts shall be of the continuous type capable of supporting 2,000 pounds per foot of insert. Section shall be 1- 518 inches wide and 1-518 inches deep. The continuous inserts shall be as manufactured by one of the following: a. Unistrut Corporation b. Elcen Metal Products c. Approved equal. F. Steel Beam Clamos. Steel beam clamps shall be of malleable iron and conform to MSS SP-58. G. NOT USED Brackets. Brackets for wall mounting shall be MSS SP-58 Type 32 or 34 PAINTING A. Except where otherwise specified, shop painting and coatings shall conform to manufacturers best standard finish. Field painting shall be as specified in Section 09800, Protective Coatings. PART 3 - EXECUTION 3.1 GENERAL A. Locate hangers, supports, and accessories to support piping, valves, at all concentrated loads, and where shown. Locate hangers, supports, and accessories within maximum span lengths specified to support continuous pipeline runs. B. JULY 2003 CWRF PIPELINE TO "D" TANKS - REACHES 1 AND 3 PIPE HANGERS AND SUPPORTS PAGE 15140 - 4 SECTION 15140 - PIPE HANGERS AND SUPPORTS C. Locate hangers and supports to prevent vibration or swaying and to provide for expansion and contraction. Install items to be embedded before concrete placement. D. E. Fasten embedded items securely to prevent movement during concrete placement. Adjust hangers and supports and place grout for concrete supports to bring pipelines to specified elevations. All ferrous pipes shall be supported by galvanized steel pipe attachment. All copper piping shall be supported by plastic-coated or copper-plated steel pipe attachments. All plastic piping shall be supported by plastic-coated steel pipe attachments. G. H. I. J. 3.2 INSTALLATION A. Supports and Hangers for Horizontal Pipes: 1. Space supports and hangers for all piping no farther apart than indicated below unless otherwise shown. a. Copper Tube: I. 2-inch and smaller: 6 feet. II. b. Steel Pipe: 2-1/2-inch and larger: 8 feet. I. 1-inch and smaller: 6 feet. ii. 1-1/2-inch and larger: 10 feet. C. Stainless Steel Pipe: I. 2-inch and smaller: 8 feet. d. Plastic Pipe: I. Maximum support spacing for plastic pipe at ambient temperature shall be one-half the above values specified for steel pipe. e. Ductile Iron Pipe: I. Flanged: 8 feet. ii. Bell and Spigot: Two supports per length. JULY 2003 PIPE HANGERS AND SUPPORTS CWRF PIPELINE TO "D TANKS - REACHES 1 AND 3 PAGE 15140 - 5 SECTION 15140 - PIPE HANGERS AND SUPPORTS 2. Additional supports shall be placed immediately adjacent to any change in piping direction, and on both sides of valves and couplings. Accurately locate inserts for hanger rods in forms before concrete is placed. Use expansion anchors only to support rods, hangers and brackets for piping 2-inch and smaller and only if the expansion anchors are designed to carry 100 percent of the full load, hanger, and/or bracket and pipe load. 3. 4. B. Supports for Vertical Pipinq 1. Provide riser clamp placed under hub. fitting or coupling with approved solid bearing on steel sleeve at each floor level. Where riser clamps are used with plastic piping, they shall be modified so as not to exert any compressive forces on the pipe. 2. 3.3 ACCEPTANCE AND SERVICE A. Acceptance. All pipe systems shall be brought up to operating pressures and temperatures. Systems shall be cycled to duplicate operating conditions. All malfunctions shall be corrected. CONTRACTOR shall fumish all labor materials to readjust and correct faults with hangers and supports for the piping systems. END OF SECTION JULY 2003 PIPE HANGERS AND SUPPORTS CWRF PIPELINE TO “D TANKS - REACHES I AND 3 PAGE 15140 - 6 SECTION 16641 - SACRIFICIAL ANODE CATHODIC PROTECTION 1.1 GENERAL. 1.1 SCOPE A. Furnish all labor, materials, tools and incidentals to install the sacrificial anode cathodic protection system for the 24-inch CML&Tape coated steel, CWRF recycled water pipeline to "D Tanks, reaches 1 and 3. 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. OWNER. The OWNER, as referred to in these specifications. is the City of Carlsbad ENGINEER. The ENGINEER is the OWNER'S representative who is assigned to be the direct contact between the OWNER and the CONTRACTOR. 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 International Certified Cathodic Protection Specialist. E. C. D. 1.3 SPECIFICATIONS AND STANDARDS A. American Society for Testing and Materials (ASTM): C94-86 Ready-Mixed Concrete D-2220 D-1248 83 B8 Concentric-Lay Stranded Copper Conductors Polyvinyl chloride Insulation for Wire and Cable Polyethylene Plastics Molding and Extrusion Materials Soft or Annealed Copper Wire E. Federal Specifications (FS) Military Specification (Mil. Spec): MIL-C-184808 Underwriter's Laboratories, Inc. (UL) Publications: 83-80 Thermoplastic-Insulated Wires 486-76 Wire Connectors and Soldering Lugs for Use with Copper Coating Compound, Bituminous, Solvent, Coal Tar Base C. Conductors D. National Association of Corrosion Engineers (NACE): RP0169-96 Recommended Practice, Control of External Corrosion on Underground or Submerged Metallic Piping Systems National Association of Corrosion Engineers (NACE): RP0286-99 E. Electrical Isolation of Cathodically Protected Pipelines JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO "D TANKS- REACHES 1 AND 3 PAGE 16641-1 SECTION 16641 - SACRIFICIAL ANODE CATHODIC PROTECTION 1.4 2.0 2.1 2.2 SUBMllTALS A. B. CATALOG CUTS (5 COPIES) Submittals shall be in accordance with Section 2-5.3.3 of the latest edition of the SSPWC. I. 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 IO. Wax tape coating system C. 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. MATERIALS GENERAL A. 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. HIGH POTENTIAL MAGNESIUM ANODES A. CAPACITY. 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. CHEMICAL COMPOSITION (HIGH POTENTIAL MAGNESIUM). B. 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 (rnax) 0.03 percent (max) 0.002 percent (max) 0.05 percent each (max) balance JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO "D" TANKS- REACHES 1 AND 3 PAGE 16641-2 SECTION 16641 - SACRIFICIAL ANODE CATHODIC PROTECTION 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. INGOT SIZE AND WEIGHT. Anodes shall be 48-pound prepackaged, high potential ingots with a trapezoidal cross section. Ingot length shall be 32 inches long. The total packaged weight shall be 105 Ibs. 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 112 inch. D. E. F. ANODE PRE-PACKAGED 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 lid shall be 9-112 inches in diameter and cast with the legend "City of Carlsbad Corrosion Test Station". IDENTIFICATION TAGS. All test leads shall be identified with an Avery label (model 5361 ), self-adhesive covered with polyolefin clear heat shrink tubing (3mfp301). The label shall include: name of facility - size - pipe material: type of insulation; station number. 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. B. C 2.4 WIRE AND CABLE A. 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 88. HMWPE insulation shall conform to ASTM D1248 type 1, class c, grade 5. THWN insulation shall conform to ASTM D-2220. B. TEST LEADS. No. 8 AWG HMWPE. C. ANODE LEAD WIRE. Anode lead wires shall be No. 12 AWG THWN. JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO "D TANKS- REACHES 1 AND 3 PAGE 16641-3 SECTION 16641 - SACRIFICIAL ANODE CATHODIC PROTECTION D. MECHANICAL JOINT BOND WIRE. No. 2 AWG HMWPE. E. F. WIRE CONNECTORS. All wire and copper connectors shall conform to UL 486-76. WIRE SPLICING. NO wire splicing is permitted. 2.5 EXOTHERMIC WELD KIT A. Wire-to-metal connections shall be made by the exothermic "cadweld" welding process. Weld alloy shall be for steel pipe. It is the CONTRACTORS responsibility to determine the manufacturer's recommended weld charge size for metallic surfaces. WELD CAPS. Royston Roybond Primer 747 and Royston Handy Cap 2 or equal. WELD COATING. Cold-applied fast-drying mastic consisting of bituminous resin and solvents per Mil. Spec. Mil-C-184808 such as Koppers bitumastic 50 or505. Tnemec40-h- 413, tape-coat TC mastic or 3M Scotch Clad 244. The minimum coating thickness shall be 25 mils (0.025 inch). B. C. 2.6 INSULATING FLANGE KITS A. Gaskets: ANSI 8-16.21, Type E. NEMA G10 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. lnsulatinq Sleeves: 1/32-inch thick tube, full length, GI0 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. lnsulatino Washers: 118-inch thick, full length, G10 glass per NEMA LI-1 for operation between 20-deg. F and 150-deg. F. Steel Washers: 1/8-inch cadmium plated steel placed between the nut and insulating washer. Coatinq: All buried insulating flanges shall be wax taped coated perAWWA C217 and these specifications. See section for "External Coating for Buried Surfaces" below. B. C. D. E. 2.7 EXTERNAL COATING FOR BURIED SURFACES A. All buried insulating flange kits, and buried pipe sections and fitting surfaces that are not dielectrically coated (epoxy coated for specials and tape coated for pipeline sections) shall be wrapped with a three-layer petrolatum wax tape coating system per AWWA C217 and these specifications. Primer: All surfaces shall be prime coated with a blend of petrolatum, plasticizer, inert fillers, and corrosion inhibitors having a paste-like consistency. 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. Plastic Outer Wrap: The primed and wax taped surface shall be covered with a plastic E. c. D. JULY 2003 CWRF PIPELINE TO "D" TANKS- REACHES 1 AND 3 SACRIFICIAL ANODE CATHOTIC PROTECTION PAGE 16641-4 SECTION 16641 - SACRIFICIAL ANODE CATHODIC PROTECTION 2.8 3.0 3.1 3.2 outer wrap consisting of three layers of 50-guage (1 0-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". CATHODIC PROTECTION INSTALLATION GENERAL A. STANDARD. Cathodic protection installation shall conform to NACE RPO169-96 "Recommended Practice, Control of External Corrosion on Underground or Submerged Metallic Piping Systems. 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. TEST RESULTS. The CONTRACTOR shall submit a CORROSION ENGINEER'S report including all test data, conclusions, repairs, and cathodic protection system performance. NOTIFICATION FOR TESTING. The CONTRACTOR shall notify the ENGlNEERat least five days in advance of the anodes and test station installations. The ENGINEER or the OWNERS representative shall, at their discretion, witness the installation of anodes and cathodic protection facilities. Testing shall be as described in this specification section. B. C. D. MAGNESIUM ANODES A. INSPECTION. 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-PACKAGED ANODE INSPECTION. Each anode shall be inspected to ensure that the backfill material completelysurrounds 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. Additionally, anodes shall be installed such that no foreign metallic pipeline lies between the anode and the CWRF Pipeline. Anode positions can be adjusted slightly to avoid interference with existing structures. Alternate anode positions must be approved by the ENGINEER. HANDLING. Care shall be taken to ensure that the anode is never lifted, supported, transported, or handled by the lead wire. All anodes shall be lowered into the hole using a sling or a rope. E. C. D. JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO "D" TANKS- REACHES 1 AND 3 PAGE 16641-5 SECTION 16641 -SACRIFICIAL ANODE CATHODIC PROTECTION E. ANODE HOLE SIZE AND DEPTH. Anodes shall be placed verticallyat the bottom of a 12 feet deep augured hole, 12 inches in diameter (minimum). F. SOAKING REQUIREMENTS, PRE-PACKAGED 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. G. 3.3 AT-GRADE TEST STATIONS A. LOCATION. At-grade corrosion monitoring test boxes shall be located at the edge of the road or 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 l&inch length of slack wire shall be coiled at each weld at the pipe and inside each test box. CONCRETE PAD. A 24-inch square by 4-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. D. 3.4 WIRE AND CABLE A. TEST LEAD TRENCH. Horizontal test or anode lead runs shall be placed in a 36-inch trench. WIRE HANDLING. 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 CONTRACTORs expense. All rejected wire shall be removed from the job site at the close of each workday. PLASTIC WARNING TAPE. Plastic warning tape shall be installed in all wire trenches and 12 inches below finished grade. SPLICING. Wire splices are not permitted. B. C. D. 3.5 WIRE-TO-PIPE CONNECTION A. B. All connections of copper wires to the pipe shall be made by the exothermic weld method. WELD CHARGE SIZE. It is the CONTRACTORS responsibility to ensure that the manufacturer's recommended weld charge size is used. JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO "D TANKS- REACHES 1 AND 3 PAGE 16641 -6 SECTION 16641 - SACRIFICIAL ANODE CATHODIC PROTECTION 3.6 3.7 C. 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 the structure 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. TESTING OF ALL COMPLETED WELDS. After the weld has cooled, the weld shall be tested by striking the weld with a 2-lb hammerwhile pulling firmlyon the wire. All unsound welds shall be cleaned, re-welded, and re-tested. All weld slag shall be removed. COATING 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. D. E. F. G. H. BOND WIRES A. MECHANICAL JOINT BOND WIRES. Two (2) No. 2 HMWPE bond wires are required across all non-insulating, in-line mechanical joints such as; valves, couplings, flanges, and adapters. A third No. 6 HMWPE bond wire is required from the valve body 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. INSULATING FLANGE KITS A. B. C. D. General: Insulating flange kits shall be pre-assembled and installed as recommended by the manufacturer, and per NACE RPO 286-99. 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. Installation: Align and install insulating joints according to the manufacturel's recommendations to avoid damaging insulating materials. The manufacturer's bolt tightening sequence and torque specifications shall be followed. Paint Piqments: internally or externally on the bolts, washers, or flanges. Insoection: All buried insulating flanges shall be inspected, tested, and approved by the ENGINEER as described in Part4 of this specification, prior to the application of wax tape coating and backfilling. No electrically conductive pigments or paints shall be used either JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO "D TANKS- REACHES 1 AND 3 PAGE 16641-7 SECTION 16641 - SACRIFICIAL ANODE CATHODIC PROTECTION 3.8 4.0 4.1 EXTERNAL COATING A. All buried insulating flanges shall be covered with a 3-layer wax tape coating system per AWWA C217 and these specifications. All non-dielectrically coated valves, flanges, couplings, adapters and pipe sections that are not coated with a bonded dielectric coating shall be wax tape coated per AWWA C217 and these specifications. 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 coverall exposed areas. The primer should overlap the pipe coating by a minimum of 3-inches. Petrolatum Saturated TaDe: 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 1-inch minimum overlap. Outer Coverinq: A plastic outer cover shall be applied over the petrolatum-saturated tape. The plastic shall be a minimum of 50-guage (10-mils) and shall have two layers applied. B. C. D. TESTING AND INSPECTION. A. 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. TEST LEADS. A. B. It is the CONTRACTORS responsibility to test all test leads. 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. ACCEPTANCE. The resistance between each pair of test leads shall not exceed 150% of the total wire resistance as determined from published wire data. C. JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO “D TANKS- REACHES 1 AND 3 PAGE 16641-8 SECTION 16641 - SACRIFICIAL ANODE CATHODIC PROTECTION 4.2 ~ 4.3 4.4 4.5 ANODE LEAD WIRE A. The CONTRACTOR is responsible for inspecting anode lead wires. Lead wires shall be spot inspected by the ENGINEER. TEST METHOD. A visual inspection and by running his hand along the full length of the lead while installing. ACCEPTANCE. All leads shall be free of cuts nicks or abrasions in the wire insulation. Damaged leads shall be rejected. B. C. TEST LEAD TRENCHING A. The ENGINEER, at his or her discretion, shall inspect wire trenches and backfill material and methods. TEST METHOD. The depth, trench bottom, padding, and backfill material shall be visually inspected prior to backfilling. B. C. ACCEPTANCE. Conformance with specifications. PIPELINE CONTINUITY THROUGH IN-LINE VALVES A. The CONTRACTORS 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 bythe CORROSION ENGINEER in the presence of the ENGINEER. TEST METHOD. Resistance shall be measured by the linear resistance method. Adirect 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. ACCEPTANCE. 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 theoretical resistance and measured pipe resistance for each section tested. B. C. INSULATING FLANGE KITS A. ResDonsibility: Insulating flanges shall be inspected and tested by the CONTRACTORS 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. Test Method: The assembled flange shall be tested using a Gas Electronics Model 601 Insulation Checker specifically design for testing insulating flanges or equal. The testing B. JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO "D TANKS- REACHES 1 AND 3 PAGE 16641-9 ~ ~~ - SECTION 16641 -SACRIFICIAL ANODE CATHODIC PROTECTION shall be done by a qualified CORROSION ENGINEER accepted by the ENGINEER and shall be done in accordance with NACE RPO 286-99. Acceptance: The installation of the insulating flange kit shall be considered complete when the testing device indicates no short.?, 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. C. 4.6 CATHODIC PROTECTION PERFORMANCE A. The cathodic protection system shall be activated and tested by the CONTRACTORS CORROSION ENGINEER in the presence of the ENGINEER. 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. 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. B. C. D. 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** JULY 2003 SACRIFICIAL ANODE CATHOTIC PROTECTION CWRF PIPELINE TO “D” TANKS- REACHES 1 AND 3 PAGE 16641-10