Loading...
HomeMy WebLinkAboutFCI Constructors; 2004-04-13; 3907 Part 3 of 4SECTION 214 - PAVEMENT MARKERS Chip Seal/Ternporary Overlay Marker (Models Y2 and W1) 214-5 REFLECTIVE PAVEMENT MARKERS Pervo Traffic Center, 5038 B Ruffner Street San Diego, California, 921 11 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. TRPM TABLE 214-5.1(A) Telephone (858) 576-1412 Traffic Control Services Inc, 1326 Mission Road, TEMPORARY REFLECTIVE PA~MENT MARKERS Type Manufacturer or Distributor I Type Safe-Hit SH236MA Manufacturer or Distributor Traffic Control Services Inc, 1326 Mission Road, Escondido, California 92029. Carsonite "Super Duck" SDF-436 I Escondido, California 92029, Telephone (760) 480-1 177 Pervo Traffic Center, 5038 B Ruher Street I Telephone (760) 480-1 177 Rep0 "The Replaceable Post" San Diego, California, 921 11 Telephone (858) 576-1 41 2 Pervo Traffic Center, 5038 B Ruffner Street San Diego, California, 921 11 Telephone (858) 576-1412 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 prequaliied design and material requirements approved by the engineer and were manufactured in accordance with the approved quality control program. Add the following section: SECTION 215 - FENCING Add the following section: '4 7/31/02 Contract No. 3907 Page 247 of 414 Environmental fence shall be minimum 4' high, orange colored plastic construction fencing installed prior to performing any work. Environmental fence shall be constructed of non-toxic, non-conductive polyethylene capable of withstanding temperatures from -58F degrees to 194F degrees. Color shall be non-fading. Posts shall be 6'-6" long, shall be spaced no more than 10'-0 apart and buried portion shall be no less than 2-6" deep. Used materials may be installed providing the used materials are good, sound, and are suitable for the purpose intended, as determined by the Engineer. Materials may be commercial quality providing the dimensions and sizes of the materials are equal to, or greater than, the dimensions and sizes specified herein. Posts shall be either metal or wood at the Contractor's option. Galvanizing and painting of steel items will not be required. Treating wood with wood preservatives will not be required. Concrete footings for metal posts will not be required. The Contractor shall, in accordance with Section 2-5.3.3, 'Submittals", of these special provisions, submit the proposed materials to be used for environmental fencing. SECTION 217 - INSTRUMENTATION AND TELEMETRY RELATING TO RECYCLED WATER IMPROVEMENT ONLY 217-1 GENERAL Add the following: for work shown in Bid Schedule D. 21 7-1 .I General Requirements. This section provides the specification for the instrumentation and telemetry interface to be supplied. The Contractor shall retain a System Integrator for providing, installing, and testing of the instrumentation, telemetry, and communication system. Shop Drawings: Submit shop drawings (diagrams) for review in complete bound sets indexed by Specification number, with exterior tabs marked by subject. Submit manufacturer's catalog cuts for each item for which shop drawings are not required. Manufacturer's catalog cuts, specifications or data sheets shall be clearly marked to delineate the options or styles to be furnished. Show dimensions, physical configurations, methods of connecting instruments together, mounting details and wiring schematics. Drawings shall be complete with device tag numbers, wire numbers and terminal board numbers. Submit fabrication details, nameplate legends and control panel wiring and piping schematic drawings. Include materials lists and/or bills of material. 217-2 SUBMITTALS 1. Loop diagrams: Submit Instrument Loop Diagrams per ISA 35.4, to provide necessary detail for connection of analog instrument and control system components including those components specified in other sections of these Specifications. Provide with the Instrument Loop Diagrams all instrument model numbers, ranges, set points, sizes process fluids, section reference numbers, and all other information listed as desirable and optional items of information per ISA S5.4. 2. Interconnection diagrams: Submit point-to-point type interconnection diagrams conforming to ANSI Y14.15a. Include each conduit run, with wire fill noted for each run. Include electric panel and circuit numbers for all sources of 12OV AC power. Show conduit and wiring interconnections between each control panel, instrument, telemetry unit, motor control center, motor combination starter, valve actuator, and other field-mounted devices. Include all equipment and appurtenances provided in this contract regardless of the Division in which it is specified. @ 7/31/02 Contract No. 3907 Page 248 of 414 3. Elementary diagrams: Submit an elementary diagram (also known as a schematic diagram) for control, protection, and monitoring circuits. Elementary diagrams are not required for lighting, communications and those systems clearly defined as part of these special provisions. Show all interconnections between power sources, apparatus, and device elements of a particular system or equipment, and all interlocks with other systems in a manner which fully indicates circuit function and operation. Refer to the Drawing for functional and operational requirements. Specification Forms: Submit completed Specification Forms per ISA S20, including those instrumentation and control components directly related to process control, but specified in other Divisions of these Specifications. Include on each form the assigned tag numbers, manufacturer's part numbers, and device data. More than one tag numbered item may be included on a sheet. As-Built Drawings: Submit a revised set of shop drawings that incorporates all change orders and modifications made during performance of the work. In addition to updated loop diagrams, interconnect diagrams and elementary diagrams, submit equipment and device wiring diagrams and other drawings as necessary to depict the as-built condition of equipment. Include all installed field and panel conduit and piping/tubing runs and routing, tray systems, supports, mounting details, interconnection diagrams with cable, wire, tube and termination numbers. Coordinate all drawings with the conductor identification requirements in these special provisions. Submit a copy of CAD produced drawings, version 14, on magnetic media in AutoCAD. DWG format. Operation and Maintenance Manuals: Furnish Operation and Maintenance Manuals, including Instruction Manuals and Part Lists, for equipment provided. Obtain data from manufacturers, and format and bind as specified. Obtain distribution method instructions from the Owner or his representative. 1. Schedule: Deliver at least two (2) copies of manuals in 3-ring binders (8-% by 1 l-inch format) not later than the equipment shipment date. 2. Contents: Include in manuals not less than the following information, as applicable, for each instrument, equipment, subsystem and/or control loop: a. b. C. d. e. f. 9. h. General, introduction and overall description, purpose, functions, simplified theory of operations, etc. Specifications (including equipment specification data sheet as described above under Shop Drawings), sufficiently detailed for reordering exact duplicates of the original items. Installation instructions, procedures, sequence tolerances, and precautions. Operational procedures. Shutdown procedures. Maintenance, calibration, and repair instructions. Parts list and spare parts recommendations. Calibration curves, rating tables, and any other data showing the relationship of the variable inputs and the calibrated output of all measuring devices and controlled equipment. 3. Format: Use drawing and pictorials to illustrate the text to the extent necessary to insure a clear, concise presentation. If manuals have been written to cover a family of similar instruments or equipment, strike out inapplicable information in a neat fashion or emphasize applicable portion by heavily weighted arrows, circles or boxes; whichever provides the clearest and neatest presentation. Group manuals by system control panels, including field instrumentation connected or associated with the panel. Where identical instruments are used in more than one control loop or subsystem, include only one instruction manual, per panel grouping; however, an index by tag number for all instruments shall identify its location G 7/31/02 Contract No. 3907 Page 249 of 414 in that manual. Provide control loop and/or subsystem operational descriptions to identify the function of each instrument and its relation to the other instruments in the loop. 4. Binding: Bind each manual in a cover which indicates the panel or process area to which it applies, manufacturers name, local address and telephone number, and year of purchase. Punch and bind manuals in standard three ring binders and include system name and subcontractor s name on binding. Accessory and Maintenance Materials: Submit data for the following items: 1. Special tools and accessories: Special tools, instruments, and accessories for maintaining instruments and equipment requiring periodic repair and adjustments as specified elsewhere herein. Also, furnish special lifting and handling devices for equipment requiring such devices. 2. Maintenance materials and spare parts: Submit a list of manufacturer recommended spare parts for each item specified. Refer to other sections of these Specifications. Test Reports: Submit the following test reports as described herein: 1. Instrument Calibration Data Sheets. 217-3 PRODUCT DELIVERY, STORAGE AND HANDLING 217.3.1 General. Box, crate, or otherwise enclose and protect instruments and equipment during shipment, handling, and storage. Keep all equipment dry and covered from exposure to weather, moisture, corrosive liquids and gases or any element, which could degrade the equipment. Protect painted surfaces against impact, abrasion, discoloration, and other damage. Notify the Engineer in writing in the event that any equipment or material is damaged. Obtain prior favorable review by the Engineer before making repairs to damaged products. 2174 TELEMETRY POINTS 21 7-4.1 General. DIGITAL INPUTS Intrusion Vault Flood ANALOG INPUTS Valve #1 Position Valve #2 Position Upstream Pressure Downstream Pressure 217-5 PRODUCTS 21 7-5.1 Telemetry. Provide telemetry hardware as indicated below: Gravhill (1 ) - #7OLRCK-l6P, 16 Position Dual Module Rack (1 ) - #74-pwr-aclt VDC Power Supply, 60 watt (1 ) - #72-OPT-4000, Open LT Controller (Optomux) (1) - #73L-IV5, Analog Modules, Dual 0 to 5 VDC (2) - #70L-IAC, Digital Modules, Dual 12OVAC Input (2) - #7OL-OAC, Digital Modules, Dual 12OVAC Output (1 ) - #72-CNV-5, Communications Adapter RTU Enclosure: Hoffman D-L30H2412LPB with A-30P24 panel. 4- '(ts 7/31/02 Contract No. 3907 Page 250 of 414 .-. Radio Modems: enclosure. Loose ship 3400 Rackmount modem, Item MD880C for mounting at CMWD control center: Black Box Corporation #I3400 Standalone, Item #MD880A for mounting in RTU Carlsbad Municipal Water District 5950 El Camino Real Carlsbad, CA 92008 217-5.2 Conduits and Bushings. All conduits terminating at the enclosure shall enter cabinet precise and straight. Each conduit shall be terminated with a nut and an insulating bushing. All throughout job, bushings shall be high impact thermosetting phenolic, 150C, Oz Gedney type A, or equal. 217-5.3 Pressure Transmitters. Pressure transmitters shall be Endress + Hauser Model PMC 133- 1 Nl F2B6Q4S available from RPS Industries (526) 921-7200. 217-5.4 Valve Position Transmitters. Valve positions transmitter are Claval XI 17C, or equal. 21 7-6 QUALITY ASSURANCE 217-6.1 General. The Contractor shall furnish the services of a trained technician to perform a complete system calibration. This shall provide that those components having adjustable features are set for the specific conditions and applications, and that the components and system are within the specified limits of accuracy. Defective elements which cannot achieve proper calibration or accuracy, either individually or within the system or subsystem, shall be replaced. A complete record of the calibration checks and adjustments shall be made and delivered to the Engineer upon completion of the system calibration. Systems shall be exercised through operational tests in the presence of the Engineer in order to demonstrate achievement for the specified performance. Attention is directed to Section 315-4 "Telemetry - Installation and Inspection", for additional requirements relating to testing. The system supplier shall provide a minimum of two days training on the operation and maintenance of all items provided as part of this section. The training may be performed concurrently with system testing and start-up if approved by the Engineer. 217-7 ACCEPTANCE TEST 217-7.1 General. After startup has been completed, the control system will be given an acceptance test. The complete system must run continuously for 7 consecutive days. During this period, all system functions shall be exercised, and any system interruption and accompanying component, subsystem, or program failure shall be logged for cause of failure, as well as time of occurrence and duration of each failure. The Contractor shall provide a competently trained technician or programmer at the owner's site during all normal working days from the start of the acceptance test until final acceptance of the system. 217-7.2 Testing. The systems to be tested on-line shall include the pump control system, switches, interlocks, and telemetry 110. Failure of Contractor supplied (non RTU) part of the system during the 7 day program testing shall be considered as indicating that the system does not meet the requirements of the specifications and corrective action must be taken. Any failure will require a restart of a full seven day acceptance test. Only those components, subsystems, and systems covered in this specification and supplied under this Section of this contract shall be considered for this acceptance test. Problems and failures of other systems shall not be considered part of this test. - @ 7/31/02 Contract No. 3907 Page 251 of 414 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. Add the following: Clearing for the project has been completed under a separate previous contract and water pollution control measures have been installed and remain consisting of silt fence, drainage inlet protection (rock), drainage outlet protection (rock), erosion control (Type BFM), gravel bags, stabilized construction entrance (gravel), and stabilized construction roadway (gravel). The Contractor shall be responsible for any clearing work necessary to meet the requirements of Section 300-1 of the SSPWC and these supplemental provisions. 300-1.3 Removal and Disposal of Materials. Add the following: Also included in clearing and grubbing shall be removal and disposal of existing street poles and lights, metal guard rail, fences, concrete curb and gutter, concrete sidewalk, existing gate, existing headwalls, rip-rap, traffic signs, existing Rancho Santa Fe Road Bridge, and other existing features which interfere with the work, excluding removal of asphalt paving where shown on plans. Whether or not such items are shown on the plans they shall be removed as a part of clearing and grubbing. Please refer to Section 31 6-1 'Bridge Removal", of these special provisions, for additional information regarding the removal of the existing Rancho Santa Fe Road Bridge. Unless otherwise noted on plans, the Contractor shall remove, as part of clearing and grubbing, 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 that are within the road right-of-way only, and shall replace said pipelines and conduits with properly compacted soils. The Contractor shall be responsible for removing and disposing of existing water pollution control measures consisting of silt fence, drainage inlet protection (rock), drainage outlet protection (rock), erosion control (Type BFM), gravel bags, stabilized construction entrance (gravel), and stabilized construction roadway (gravel) that will not be incorporated into the approved water pollution control plan for this project. , Add the following section: 300-1.3.1 Remove and Dispose of Existing Pressure Reducing Station. The existing pressure reducing stations shall be removed of as shown on the plans. Portions of each reducing station shall be salvaged per the plans and in accordance with the SSPWC and these special provisions. The portions of each pressure reducing station that are not salvaged shall be disposed of in accordance with the plans, 7/31/02 Contract No. 3907 Page 252 of 414 the SSPWC and these special provisions. The existing underground structure shall be removed and the resulting void shall be backfilled in accordance with Section 300-4 of the SSPWC. Equipment removed from the existing pressure reducing station shall become the property of the Contractor and shall be disposed of in accordance with Section 300-1.3 of the SSPWC. 300-1.4 Payment. modify as follows: Payment for cleating and grubbing shall be made at the contract lump sum price for clearing and grubbing within the project limits and no other payments will be made. Unless othewise 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. Payment for removal, disposal and backfill of existing pressure reducing stations shall be made at the contract lump sum price for remove and dispose of existing pressure reducing station and no other payments will be made. Full compensation for all costs involved in removing and disposing of materials not associated with clearing and grubbing, including all costs of hauling, shall be considered as included in the price paid for the contract item of work involving the materials and no additional compensation will be allowed therefor. Add the following section. 300-1.5 Remove and Dispose of Asphalt Concrete Pavement. This work shall consist of removing existing asphalt concrete pavement as shown on the plans and in accordance with these special provisions. Only those areas shown on plans as remove asphalt concrete pavement will be paid for as remove asphalt concrete pavement. Any other existing surfacing needed to be removed shall be considered as included in item of work for which removal is required. The exact limits of asphalt concrete surfacing to be removed will be as shown on plans. The material remaining in place, afier removing surfacing and base to the required depth, shall be graded to a plane, watered, and compacted. The finished surface of the remaining material shall not extend above the grade established by the Engineer. Native material shall be placed as shoulder backing, compacted and graded to drain. Add the following section. 300-1.5.1 Saw Cut Surfacing. The limits of asphalt concrete to be removed shall be cut with a power- driven saw to a depth of not less than 2 inches before removing the surfacing. Surfacing and base shall be removed without damage to surfacing that is to remain in place. Damage to pavement which is to remain in place shall be repaired to a condition satisfactory to the Engineer, or the damaged pavement shall be removed and replaced with new asphalt concrete if ordered by the Engineer. Repairing or removing and replacing pavement damaged outside the limits of pavement to be removed shall be at the Contractor's expense and will not be measured nor paid for. Add the following section. 300-1.5.2 Disposal. Removed materials may be disposed of outside the highway right of way in accordance with the provisions in 300-1.3, "Removal and Disposal of Materials", or incorporated into the fill in accordance with the provisions in 300-4.3, "Other Fill Materials". Add the following section. 300-1.5.3 Measurement and Payment. The quanti of asphalt concrete removed shall be paid for by the cubic yard. The volume to be paid will calculated on the basis of the volume the removed asphalt concrete pavement occupies in place before disturbance. Limits of removal will be approved by the Engineer prior to the work being performed. . The contract price paid per cubic yard for Remove and Dispose of Asphalt Concrete Pavement shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in saw cutting and removing asphalt concrete pavement, as shown on the plans, as specified in the Standard Specifications and these special provisions, and as directed by the Engineer. Costs to place shoulder backing where shown on the plans shall be considered as included in @ 7/31/02 Contract No. 3907 Page 253 of 414 the contract price paid for Remove and Dispose of Asphalt Concrete Pavement, and no additional payment shall be made. Add the following section. 300-1.6 Remove and Dispose of PCC Curb and Gutter. This work shall consist of removing existing Portland cement concrete curb and gutter as shown on the plans and in accordance with these special provisions. Only those areas shown on plans as remove Portland cement concrete curb and gutter will be paid for as remove Portland cement concrete curb and gutter. Any other existing surfacing needed to be removed shall be considered as included in item of work for which removal is required. The exact limits of Portland cement concrete curb and gutter to be removed will be as shown on plans. The material remaining in place, after removing, shall be graded to a plane, watered, and Compacted. Add the following section. 300-1.6.1 Saw Cut Surfacing. The limits of Portland cement concrete curb and gutter to be removed shall be cut with a powerdriven saw to a depth of not less than 2 inches before removing the concrete. Portland cement concrete curb and gutter shall be removed without damage to concrete that is to remain in place. Damage to concrete which is to remain in place shall be repaired to a condition satisfactory to the Engineer, or the damaged concrete shall be removed and replaced with new concrete if ordered by the Engineer. Repairing or removing and replacing concrete damaged outside the limits of pavement to be removed shall be at the Contractor‘s expense and will not be measured nor paid for. Add the following section. 300-1.6.2 Disposal. Removed materials may be disposed of outside the highway right of way in accordance with the provisions in 300-1.3, “Removal and Disposal of Materials”, or incorporated into the fill in accordance with the provisions in 3004.3, “Other Fill Materials”. Add the following section. 300-1.6.3 Measurement and Payment. The quantity of Portland cement concrete curb and gutter removed shall be paid for by the linear foot. Limits of removal will be approved by the Engineer prior to the work being performed. The contract price paid per linear foot for Remove and Dispose of PCC Curb and Gutter shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in saw cutting, removing, and disposing PCC Curb and Gutter, as shown on the plans, as specified in the Standard Specifications and these special provisions, and as directed by the Engineer. 300-1.7 Remove and Dispose of PCC Sidewalk. This work shall consist of removing existing Portland cement concrete sidewalk as shown on the plans and in accordance with these special provisions. Only those areas shown on plans as remove Portland cement concrete sidewalk will be paid for as remove Portland cement concrete sidewalk. Any other existing surfacing needed to be removed shall be considered as included in item of work for which removal is required. The exact limits of Portland cement concrete sidewalk to be removed will be as shown on plans. The material remaining in place, after removing, shall be graded to a plane, watered, and compacted. Add the following section. 300-1.7.1 Saw Cut Surfacing. The limits of Portland cement concrete sidewalk to be removed shall be cut with a power-driven saw to a depth of not less than 2 inches before removing the concrete. Portland cement concrete sidewalk shall be removed without damage to concrete that is to remain in place. Damage to concrete which is to remain in place shall be repaired to a condition satisfactory to the Engineer, or the damaged concrete shall be removed and replaced with new concrete if ordered by the Engineer. Repairing or removing and replacing concrete damaged outside the limits of pavement to be removed shall be at the Contractor’s expense and will not be measured nor paid for. Add the following section. @ 7/31/02 Contract No. 3907 Page 254 of 414 300-1.7.2 Disposal. Removed materials may be disposed of outside the highway right of way in accordance with the provisions in 300-1.3, "Removal and Disposal of Materials", or incorporated into the fill in accordance with the provisions in 3004.3, "Other Fill Materials". Add the following section. 300-1.7.3 Measurement and Payment. The quantity of Portland cement sidewalk removed shall be paid for by the square foot. Limits of removal will be approved by the Engineer prior to the work being performed. The contract price paid per square foot for Remove and Dispose of PCC Sidewalk shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in saw cutting, removing, and disposing PCC Sidewalk, as shown on the plans, as specified in the Standard Specifications and these special provisions, and as directed by the Engineer. 300-2 U N CLASS IF1 ED EXCAVATION 300-2.1 General. Add the following: Unclassified excavation shall include removal and stockpile of suitable material, all blasting, cut and fill, shoulder backing where shown on the plans, fill processing, selective grading, salvaging clean excavated material and filling areas to the required grades and cross section. Unclassified excavation shall be utilized onsite to make all fills shown on the plans. Unclassified excavation shall also include scarification and moisture adjustment and compaction of the top 300 mm (1') of the subgrade in the roadway prism to 95 percent relative compaction, transporting of remaining excess material to a disposal site or spoil area, pumping and disposal of storm and ground water 300-2.2.1 General. Add the following: Alluvial and colluvial soils removal and recompaction shall consist of excavating, blending and recompacting loose soils in areas that are designated to receive fills, as approved by the Engineer. The existing loose soils shall be removed by the Contractor until a firm unyielding surface is exposed and determined to be acceptable by the Engineer. The excavated material shall be placed and compacted in accordance with section 3004 of the specifications except that section 300-4.9, Measurement and Payment, shall not apply. Excavation, blending and recompacting loose soils will be paid for in accordance with the third paragraph of Section 300-2.2.1 of the SSPWC. If the excavated material contains excess moisture, the Contractor shall blend the wet soil with soils having a lower moisture content and/or spread the excavated material in a manner that enables the material to dry to optimum moisture content. The cost of spreading and/or drying shall be paid for as "Extra Work," in accordance with Section 3-3 of the SSPWC, provided the excess moisture content is not the result of any action on the part of the Contractor, or inaction in protecting the work during the course of the Contract. 300-2.2.1 General. Add the following to the first paragraph: Such direction may include, but is not limited to, directing the Contractor to blend, adjust moisture content of, rework, or place unsuitable soils at specific locations or elevations on the site. Add the following section: 300-2.2.3 Compressible Soil. Compressible soils such as existing uncontrolled or unacceptable fill, alluvium, and colluvium does exist within portions of the Project site. Where required by the Engineer, the Contractor shall remove such compressible soils from areas to receive fill or from areas upon which surface improvements are to be placed. Removal and disposal of compressible soils will be paid in accordance with Section 300-2.2 of the SSPWC. Areas in which compressible soils are excavated shall be replaced with suitable backfill material and recompacted in accordance with Section 300-4, "Unclassified Fill," of the SSPWC. Placement and compaction of suitable backfill will be paid in accordance with the third paragraph of Section 300-2.2.1 of the SSPWC. 7/31/02 Contract No. 3907 Page 255 of 414 300-2.2.4 Instability of Cuts. Add the following: The Contractor shall remove additional material as directed by the Engineer to improve the stability of excavated cuts. The removal of such excavated material shall be paid for at the Contract Unit Price for unclassified excavation unless it is considered otherwise unsuitable by the Engineer, in which case it will be paid for in accordance with Subsection 300- 2.2.1. 300-2.5 Slopes. Add the following: The hinge points (the top and bottom) of slopes shall be located within 75 mm (0.25') of the locations shown on the plans, except where excavation is in rock no point shall vary more than 1' from the designated slope. In no cdse shall any portion of the slope encroach on the roadbed. 300-2.5 Slopes. Add the following: after the first sentence of the first paragraph: defined as any area steeper than three horizontal to one vertical. A slope shall be 300-2.6 Surplus Material. Delete this section and add the following: Unless otherwise shown on the plans or specified in these Special Provisions, surplus excavated material shall become the property of the Contractor and be disposed of at the Contractor's expense outside of the right of way. The Contractor shall be satisfied that there is sufficient material available for the completion of the embankments before disposing of any material outside the right of way. Any shortage of material, caused by premature disposal of any material by the Contractor, shall be replaced by the Contractor and no compensation will be allowed the Con- tractor for such replacement. 300-2.8 Measurement. Delete the second paragraph relating to materials removed from stockpiles and add the following: Unclassified Excavation shall be measured based on the volume it occupies in its original position before excavating. The measurement shall be from the original ground contours after clearing and grubbing to the design elevations shown on the plans or actual ground contours existing in borrow sites after excavation or those for removal and recompaction of alluvial and colluvial materials or those for materials excavated to improve the stability of cuts, whichever is lower in elevation. No excavated material which is re-excavated will be measured for payment. Materials excavated or otherwise removed as all or part of any other bid item shall not be measured as Unclassified Excavation. Rock over-excavation per details shown on plans shall be measured and paid for as Unclassified Excavation. 300-2.9 Payment. Delete this section and add the following: Payment for Unclassified Excavation will be made at the contract unit price paid for unclassified excavation. Only the quantity of unclassified excavation measured shall be paid for. No excavated material which is re-excavated will be paid for. For progress payments, the quantity of unclassified excavation shall be estimated by the Engineer. The Engineer's calculations shall be considered the definitive determinant for quantities for final payment. All topographic surveying and calculations necessary to quantify payment quantities for Unclassified Excavation shall be performed by the Engineer. Payment for Adjust Subgrade shall include full payment for the work described in the third paragraph of section 300-2.2.3, "Compressible Soil". Payment for Unclassified Excavation shall include costs of surveying, staking, blasting, blasting permit requirements, excavation, transport, placement, compaction, processing, slope rounding, selective grading, stockpiling, placing shoulder backing where shown on the plans, access road, temporary detour roads, earthen swales and drainage channels as shown on the drawings or required by the contract documents. Excavation required for waterline, recycled waterline, sewer and storm drain facilities, including excavation in rock, shall be considered as included in the price bid for the item to which excavation is incidental or appurtenant. Add the following section: 300-2.10 Grading Tolerance. Excavated areas other than slopes and subgrade below structures, a 7/31/02 Contract No. 3907 Page 256 of 414 within the roadway and sidewalk areas shall be finished-within 30 mm (0.1,) of the grades shown on the plans. Excavated areas designated as rock overexcavation shall be finished within 150mm (0.5 feet) of grades per details shown on the plans. Add the following section: 300-2.1 1 Adjust Subgrade. Following the establishment of road subgrade elevation the Engineer shall conduct tests to determine the R-value of the subgrade material. The Engineer shall determine the depth of the structural section, Crushed Aggregate Base and Asphalt Concrete, based upon that value. If directed by the Engineer, a subgrade adjustment shall be made. Payment for Adjust Subgrade shall be at the unit price bid including full payment for excavation below, or fill above, plan elevation, disposal or delivery of additional material. Add the following: 300-2.1 1 Blasting Operations. Add the following: 300-2.1 1 .I Blasting Plan. The Contractor shall abide by all requirements of the City blasting permit and shall submit a plan to the Engineer detailing how blasting will be implemented and No blasting operation, including drilling, shall start until the Engineer has reviewed and approved this blasting control plan in accordance with the provisions in Section 2-5.3, "Shop Drawings and Submittals," of the SSPWC. Approval of the Contractor's blasting control plan or blasting procedures shall not relieve the Contractor of any of his responsibility under the contract for assuring the complete safety of his operations or for the successful completion of the work in conformity with the requirements of the plans and specifications. In general, the Contractor's plan shall include, but not be limited to, measures that prevent soil instability, erosion, or dam instability. The blasting control shall provide for limiting the maximum peak particle velocity as follows: 0 The maximum particle velocity at the nearest point to pipelines shall be 6.0 inches per second at a minimum frequency of 10 hertz. In the event neither of these limitations is met, the Contractor shall, at his expense, perform excavations, repair pipeline as necessary, and backfill the excavations. This work shall be done at the Contractor's expense whether or not damage has been incurred. The maximum particle velocity at any other structure within the blast area, including Mahr Reservoir dam, shall be 0.5 inches per second at frequency of 10 hertz or less and shall progress linearly to a maximum of 2.0 inches per second at a frequency of 40 hertz or greater in accordance with the recommendations of the United States Bureau of Mines Publication RI 8507, Figure 11.14. Air blast overpressure shall not exceed 0.03psi at any structure within the blast area. Impact or impulsive noise from blasting operations shall not exceed 140 dB measure at the nearest structure. , The plan shall indicate the type and method of instrumentation proposed to determine the ground motion particle velocity and air noise. The plan shall indicate type and placement of appropriate construction area signs for public traffic if blasting area is visible to public traffic or if blasting safety may be jeopardized by publicly operated electronic devices. Add the following: 300-2.1 I .2 Blasting Records. The Contractor shall keep accurate records of each blast. Blasting records shall be available to the Engineer at all times and shall contain the following as a minimum: 1 ) Blast identification by numerical and chronological sequence. ' 2) Location (referenced by stationing), date and time of blast. 3) Type of material blasted. 4) Number of holes, burden and spacing. 5) Diameter and depth of holes. 6) Height or length of stemming. e 7/31/02 Contract No. 3907 Page 257 of 414 7) Types of explosives used. 8) Type of caps used and delay periods used. 9) Total amount of explosives used. IO) Maximum amount of explosives per delay period of 9 milliseconds or greater. 11) Powder factor (pounds of explosive per cubic yard of material blasted). 12) Method of firing and type of circuit. 13) Weather conditions (including wind direction). 14) Direction and distance to nearest structure of concern. 15) Type and method of instrumentation. 16) Location and placement of instruments. 17) Instrumentation records and calculations for determination of ground motion particle velocity or for 18) Measures taken to limit air noise, air pressure and fly rock. 19) Any unusual circumstances or occurrences during blast. 20) Name of Contractor. 21) Name and signature of responsible blaster. charge size based on scaled distance. Add the following: 300-2.11.3 Public Safety. Blasting guards in sufficient numbers to assure that people, property and improvements will not be endangered, shall be stationed around the blasting area during blasting operations. Blasting operations may be suspended by the Engineer, at no cost to the Agency for any of the following: 1) Safety precautions taken are inadequate. 2) Ground motion particle velocity or air noise exceed the limits specified. 3) Blasting control plans have not been approved. 4) Required records are not being kept. Suspension of blasting operations shall in no way relieve the Contractor of these responsibilities under the terms of this contract. Blasting operations shall not resume until modifications have been made to correct the conditions that resulted in the suspension. Blasting complaints shall be accurately recorded by the Contractor as to complainant, address, date, time, nature of the complaint, name of person receiving the complaint, the complaint investigation conducted, and the disposition of the complaint. Complaint records shall be available to the Engineer at all times. No blasting shall be done between the hours of 4:OO p.m. and 9:00 a.m., nor on weekends and holidays. Add the following: 300-2.11.4 Blast Monitoring. All blasting within 500 of Mahr Reservoir and within 300 of in-service pipelines, including secondary blasting, associated with the project shall be monitored with portable seismograph and airblast instrumentation. Instrumentation shall provide an immediate digital display of vibratory ground motion particle velocity results in three mutually perpendicular directions and a permanent printed or photographic record of the vibratory waveform. Airblast results shall also be immediately displayed in digital form and the waveform printed. Blast monitoring shall be performed by a qualified independent firm or individual not associated with, or employed by, prime contractor or subcontractors. Costs associated with independent blast monitoring shall be considered as included in contract unit price paid for roadway excavation and no additional compensation will be allowed. Add the following: 300-2.1 1.5 Blasting Permit. No blasting operations shall occur without a valid blasting permit. Blasting permits will be issued only to qualified blasters. A blaster will be considered qualified upon presentation to the Engineer of a valid blaster's license issued by the California Division of Industrial Safety and a valid explosive permit issued by the Sheriff of San Diego County. Application for a blasting permit shall be made at the City's Engineering Department. The Engineer may revoke a blasting permit issued, at no cost to the Agency, if the Contractor has, in the 7/31/02 Contract No. 3907 Page 258 of 414 opinion of the Engineer: 1. 2. 3. Conducted or been responsible for careless or reckless blasting operations. Failed to observe any standard safety orders or other applicable rules and regulations. Failed to adhere to any provision of the blasting policy or permit. There is no fee for this permit. Add the following: 300-2.1 1.6 Regulations. In addition to these Special Provisions, all applicable provisions of Title 8 Article 8 of the California Industrial Safety Construction Orders, the National Fire Protection Association Code for the Manufacture, Transportation, Storage and Use of Explosive Materials, and all requirements of any governing agency having jurisdiction shall apply. Add the following: 300-2.1 1.7 Notification. Before any blasting operations can proceed the following notifications shall be given: The Contractor shall give a one time written notice to all residences or businesses located within 600 feet of any potential blast location. Such notice will be given immediately upon approval of the blasting plan. The notice will state when the blasting operations will begin, how long they will continue, and the approximate frequency. The notice will also give the name and phone number of a responsible and responsive employee of the blaster who can answer any questions that the public may have. The written notice shall also state that all complaints of blasting caused damages shall be made in writing to the blaster and that said blaster will respond within 10 days of receipt of same. In addition to the notice described in (l), a notice by the blaster shall be given to all residences or businesses within 300 feet of the blast area prior to blasting. Notice shall state when blasting operations shall begin, how long they will continue and the approximate frequency. The blaster shall notify the City’s police and fire department of any scheduled blast at least 1 hour prior to blasting. 1. 2. 3. Add the following: 300-2.11.9 Preblast Survey. The Contractor shall make and document a pre-blast survey of properties and improvements located within 300 feet of excavation areas where blasting is required. Pre-blast surveys shall be made no more than 45 days in advance of the planned commencement or resumption of blasting operations. The pre-blast surveys shall, as a minimum, contain the following: 1) The names of the property owner and occupants, the address of the property, the date and time of the inspection. 2) The name of the person making the inspection. 3) A complete description of the structure(s) or other improvement(s). 4) A detailed interior inspection with each interior room (including attic and basement spaces) designated and described. 5) A detailed exterior inspection fully describing the existing conditions of all foundations, walls, roofs, doors and windows, and porches. 6) A detailed listing, inspection and documentation of existing conditions of garages, outbuildings, sidewalks and driveways. 7) A survey of any wells or other private water supplies including total depth and existing water surface levels. The documentation may consist of either a written report, or a video tape with voice narration. The video tape, if used, must included the date and time displayed on the image. Copies of the pre-blast inspection reports or video tape documentation shall be given to the Engineer at the time that the blasting plan is submitted. The Contractor shall conduct post-blast inspections upon receipt of a written complaint of property damage due to the blasting operations from any owner and / or resident. This inspection shall be completed within 10 days of receipt of the written complaint. The Contractor shall compile a written report of this inspection which shall include one of the following statements based on his professional opinion: e 7/31/02 Contract No. 3907 Page 259 of 414 1. The damage was not caused by the blasting operation. 2. The damage was caused by the blasting operation. A copy of this report shall be sent to the complainant and the Engineer within 10 working days of the inspection date. The Contractor, at his expense, shall commence and diligently prosecute any remedial work required due to blasting damage within 30 days of the post-blast inspection. If the complainant disputes the report, the Contractor shall immediately provide the complainant, in writing, with the Contractor's liability insurance carrier so that a claim may be tendered. Add the following: 300-2.1 1.9.1 Measurement and Pavment. Pavment for work described in this section, "Preblast Survev," 'including post-blast inspection, will 6 made at the lump sum price bid for preblast survey and shall include full compensation for furnishing all labor, materials, tools, equipment and incidentals, and for doing all work described in this section and as directed by the Engineer and no additional compensation shall be allowed therefor. 300-3 STRUCTURE EXCAVATION AND BACKFILL 300-3.1 General. Add the following: The Contractor shall excavate to the lines and levels required and/or shown on the Drawings. The Contractor shall provide all shoring, bracing, cribbing, pumping, and planking required. The Contractor shall excavate and maintain the bottom of all trenches in a condition that is level, firm, clean and free from all debris or foreign matter. Excavations shall be kept free from water at all times. The Contractor shall remove any unsuitable material encountered below grade as directed by the Engineer. 300-3.5.1 Requirements. Replace paragraph 3 with the following: Structure backfill shall be placed in accordance with 300-4.5 and shall be mechanically compacted to a minimum relative compaction of 90% except for the following. The area behind bridge abutments and bounded by wingwalls shall be compacted to a minimum relative compaction of 95%. Except for the outer 5 feet measured horizontally from the embankment side slopes, the full width of embankment within 150 feet of bridge abutments shall be compacted to a relative compaction of not less than 95 percent. The 150-foot limit of 95 percent compaction will be measured horizontally from the bridge abutment and either parallel or concentric with the roadway centerline. 300-3.6 Payment. Add the following: No payment will be made for any dewatering required for structure excavation. Dewatering costs shall be considered as included in the price bid for the construction or installation of the item to which such structure excavation is incidental or appurtenant. 300-4 UNCLASSIFIED FILL 300-4.1 General. Add the following: Unclassified Fill shall be designated per detail shown on plans as either select fill, upper fill or lower fill. On-site material processing is permissible. Obtaining all permits and adhering to State and Local regulations will be the responsibility of the Contractor. Hours of operation shall be per Section 6-7.2 of these special provisions. 300-4.4 Benching. Add the following: Slope bench shall conform to the detail shown on the plans. 300-4.5 Placing Materials for Fills. Add the following: 300-4.5.1 Select Fill. Material placed in areas designated as select fill per details shown on plans shall meet the following grading requirements: a v4 7/31/02 Contract No. 3907 Page 260 of 414 US. Standard Sieve Size 3” No. 4 No. 200 The Contractor shall perform grading such that the upper 900mm (3), from subgrade, of fill placed under the roadway pavement area is composed of properly compacted low expansive soils. The more highly expansive soils shall be placed in the deeper fill areas and properly compacted or exported from the site. Low expansive soils are defined as those soils that have an Expansion Index of 50 or less when tested in accordance with 1994 UBC Standard 18-2 as published by the International Conference of Building Officials. Should insufficient soils meeting the requirement of an expansion index of 50 or less be present within the limits of work, soils of the least expansion index that are available within the limits of work shall be incorporated in the upper 900 mm (39, from subgrade, of fill placed under the roadway. 300-4.5.2 Upper Fill. Material placed in areas designated as upper fill per details shown on plans shall contain no particles with dimensions greater than 12”. The Contractor shall break rock encountered in the excavation intended to be placed into areas designated as upper fill into particles of less than 12”. Particles with dimensions greater than 6“ shall be uniformly distributed over the area to be filled so that construction equipment can be operated in such a manner that the larger pieces will be broken into smaller particles and become incorporated with the other material in the layer. 300-4.5.3 Lower Fill. Material placed in areas designated as lower fill per details shown on plans shall contain no particles with dimensions greater than 36“. The Contractor shall break rock encountered in the excavation intended to be placed into areas designated as upper fill into particles of less than 36”. Rocks having any dimensions greater than 36“ shall not be incorporated into the fill. Particles with dimensions greater than 18” shall be uniformly distributed with sufficient room between them so that intervening voids can be adequately filled with fine material to form a dense compact mass. 300-4.6 Application of Water. Add the following: The Contractor shall place all fill soil at moisture content no less than one (1) percent below optimum moisture as determined by ASTM test D-1557-91. Percent Passing (by weight) 100 >40 40 In areas of rock fill, the Contractor will be responsible for furnishing and applying sufficient amounts of water in order to achieve maximum densification of each lift. 3004.7 Compaction. Add the following: The Contractor shall compact all fill soils placed within the top 1 m (3’) of roadway subgrade to a minimum of 95 percent relative compaction. On all areas to receive planting, the top 150 mm (6”) shall be compacted to 85% to allow for plant growth. Acceptability of placement and compaction of upper and lower fills will be determined by visual inspection by the Engineer when the presence of rocks makes use of other methods impracticable. The Contractor shall excavate test pits to the sizes and locations determined by the Engineer, in order to allow for visual verification that the lifts of material are adequately compacted and free of unacceptable voids. The Engineer shall be the sole judge as to the acceptability of the placement and compaction of such fills. Payment for labor, equipment, and materials necessary to excavate and backfill test pits shall be considered as included in the unit price bid for unclassified excavation and no additional compensation shall be allowed therefor. In addition to relative compaction requirements specified elsewhere, acceptability of placement and compaction of select fills will also be determined by visual inspection by the Engineer. As a result, the provisions of the preceding paragraph shall apply to select fills. 300-4.8 Slopes. Add the following: Feathering of fill over the tops of slopes will not be permitted. The Contractor shall compact the faces of fill slopes with equipment approved by the Engineer at vertical intervals no greater than 600 mm (2’) or shall be over-built and cut back to finish grade. In addition, if not 7/31/02 Contract No. 3907 Page 261 of 414 over built and cut back, the face of the slope shall be track walked upon completion. 300-4.9 Measurement and Payment. Delete and substitute the following: Grading, shaping, compacting or consolidating, slope rounding, construction of transitions, excavating and backfilling test pits, processing, and all work included in unclassified fill, consisting of select fill, upper fill and lower fill, will be paid as a part of unclassified excavation, and no additional payment will be made therefor. 300-1 1 STONEWORK FOR EROSION CONTROL 300-11.1 General. Replace the first sentence with: Stone for rock slope protection shall be in conformance with Section 200-1.6 and the following provisions. Add the following section: 300-1 1.2.1 Preparation of Subgrade. Prior to placing rock slope protection fabric the Contractor shall clear the surfaces upon or against which rock slope protection fabric is to be placed of loose or extraneous material and sharp objects that may damage the fabric during installation. Equipment or vehicles shall not be operated or driven directly on the rock slope protection fabric. Rock slope protection fabric damaged during placement shall be replaced or repaired by the Contractor at his expense as directed by the Engineer. Add the following section: 300-11.2.2 Placement of Rock Slope Protection Fabric. The Contractor shall place rock slope protection fabric prior to placing rock slope protection. The Contractor shall grade surfaces to be covered by rock slope protection so as to provide full support for the fabric. Rock slope protection fabric shall conform to the provisions in Section 213-2, "Geotextiles," and shall be placed by the Contractor in accordance with the details shown on the plans and as specified herein. The Contractor shall handle rock slope protection fabric with care that it is not tom or stretched and place it in accordance with the manufacturer's recommendations, these specifications and as directed by the Engineer. The Contractor shall place and fit rock slope protection fabric loosely upon or against the surface to receive the fabric so that the fabric conforms to the surface without damage when the cover material is placed. Rock slope protection fabrics shall be joined, at the option of the Contractor, either with overlapped joints or stitched seams. When fabric is joined with overlapped joints, all adjacent borders of the fabric shall be overlapped not less than 610 mm (24"). The fabric shall be placed such that the fabric being placed shall overlap the adjacent section of fabric in the direction the cover material is being placed. When the fabric is joined by stitched seams, the fabric shall be stitched with yam of a contrasting color. The size and composition of the yam shall be as recommended by the fabric manufacturer. The number of stitches per 25 mm (1") of seam shall be 6 f 1. The strength of stitched seams shall be the same as specified for the fabric, except when stitched seams are oriented up and down a slope the strength shall be a minimum of 80 percent of that specified for the fabric. Fabric damaged beyond repair, as determined by the Engineer, shall be replaced by the Contractor and no additional payment will be made therefor. Repairing damaged fabric shall consist of placing new fabric over the damaged area. The minimum fabric overlap from the edge of the damaged area shall be 1 m (3') for overlap joints. If the new fabric joints at the damaged areas are joined by stitching, the stitched joints shall conform to the requirements specified herein. Damaged fabric that is suitable for repair, as determined by the Engineer, shall be repaired by the Contractor and no additional payment will be made therefor. 300-11.4 Measurement and Payment. Delete and substitute the following: The contract lump sum price paid for rock slope protection (500 Ib) shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in constructing the rock slope protection, complete in place, including excavation, preparation of subgrade and backfilling footing trenches, as shown on the plans, as specified in the specifications and these Special Provisions, and as directed by the Engineer. Payment for rock slope protection fabric and 35kg (Facing) Class filter layer will be included in the lump sum price paid for rock slope protection (500 Ib) and no additional payment will be made therefor. b 7131102 Contract No. 3907 Page 262 of 414 Add the following section: 300-12 RIP RAP ENERGY DISSIPATOR 300-12.1 General. Rip Rap Energy Dissipator and rip rap fill slope shall consist of rip rap stone, crushed rock, sand, geotextile fabric, and reinforced portland cement concrete sill, as shown on the plans. Portland cement concrete shall be of class 56O-C-3250. 300-12.2 Preparation of Subgrade. Prior to placing rock slope protection fabric the Contractor shall clear the surfaces upon or against which rock slope protection fabric is to be placed of loose or . extraneous material and sharp objects that may damage the fabric during installation. Equipment or vehicles shall not be operated or driven directly on the rock slope protection fabric. Rock slope protection fabric damaged during placement shall be replaced or repaired by the Contractor at its expense as directed by the Engineer. 300-12.3 Placement of Stone. A footing trench shall be excavated along the toe of the slope. The larger stones shall be placed in the footing trench. Stones shall be placed with their longitudinal axis normal to the embankment face, and arranged so that each stone above the foundation course has a 3- point bearing on the underlying stones. The foundation course is the course placed on the slope in contact with the ground surface. Bearing on smaller stones which may be used for chinking voids will not be acceptable. Placing of stones by dumping will not be permitted. Local surface irregularities of the slope protection shall not vary from the planned slope by more than 0.3m (1 foot) measured at right angles to the slope. 300-12.4 Placement of Geotextile Fabric. The Contractor shall place the geotextile fabric prior to placing rip rap. The Contractor shall grade surfaces to be covered by rip rap so as to provide full support for the fabric. The geotextile fabric shall conform to the provisions in Section 213-2, "Geotextiles," and shall be placed by the Contractor in accordance with the details shown on the plans and as specified herein. The Contractor shall handle the fabric with care that it is not tom or stretched and place it in accordance with the manufacturer's recommendations, these specifications and as directed by the Engineer. The Contractor shall place and fit the fabric loosely upon or against the surface to receive the fabric so that the fabric conforms to the surface without damage when the cover material is placed. The geotextile fabric shall be joined, at the option of the Contractor, either with overlapped joints or stitched seams. When fabric is joined with overlapped joints, all adjacent borders of the fabric shall be overlapped not less than 610 mm (24"). The fabric shall be placed such that the fabric being placed shall overlap the adjacent section of fabric in the direction the cover material is being placed. When the fabric is joined by stitched seams, the fabric shall be stitched with yam of a contrasting color. The size and composition of the yam shall be as recommended by the fabric manufacturer. The number of stitches per 25 mm (1") of seam shall be 6 f 1. The strength of stitched seams shall be the same as specified for the fabric, except when stitched seams are oriented up and down a slope the strength shall be a minimum of 80 percent of that specified for the fabric. Fabric damaged beyond repair, as determined by the Engineer, shall be replaced by the Contractor and no additional payment will be made therefor. Repairing damaged fabric shall consist of placing new fabric over the damaged area. The minimum fabric overlap from the edge of the damaged area shall be 1 m (3) for overlap joints. If the new fabric joints at the damaged areas are joined by stitching, the stitched joints shall conform to the requirements specified herein. Damaged fabric that is suitable for repair, as determined by the Engineer, shall be repaired by the Contractor and no additional payment will be made therefor. 300-12.5 Measurement and Payment. Rip Rap Energy Dissipator shall be measured and paid for as each and shall be paid as Rip Rap Energy Dissipator. The unit price paid for Rip Rap Energy Dissipator shall include full compensation for furnishing all labor, materials (including rip rap stone, crushed rock, sand, geotextile fabric, reinforcement, and portland cement concrete), tools, eduipment and incidentals, and for doing all the work, including all earthwork and construction of cut-off walls and sills, involved in installing, complete in place, Rip Rap Energy Dissipators, and rip rap fill slope, as shown on the plans, and as specified in these special provisions. @ 7/31/02 Contract No. 3907 Page 263 of 414 Add the following section: 300-1 3 WATER POLLUTION CONTROL Add the following section: 300-13.1 General. Water pollution control measures have been installed and remain within the limits of this project from a separate previous clearing contract. The presence of such water pollution control measures shall in no way relieve the Contractor from satisfying the requirements for Water Pollution Control outlined in these supplemental provisions. Should the Contractor incorporate existing water pollution control measures into the water pollution control plan, it shall be the Contractor's responsibility to repair or replace any existing control measures that are damaged or not to specification. The Contractor shall exercise every reasonable precaution to protect streams, lakes, reservoirs, bays, and coastal waters from pollution with fuels, oils, bitumens, calcium chloride and other harmful materials and shall conduct and schedule operations so as to avoid or minimize muddying and silting of streams, lakes, reservoirs, bays and coastal waters. Care shall be exercised to preserve roadside vegetation beyond the limits of construction. Water pollution control work is intended to provide prevention, control, and abatement of water pollution to streams, waterways, and other bodies of water, and shall consist of constructing those facilities which may be shown on the plans, specified herein or in the special provisions, or directed by the Engineer. In accordance with the requirements set forth in this Section 300-13, 'Water Pollution Control", of the special provisions, the contractor shall utilize straw, hydroseeding, mulching, or other suitable materials or techniques during construction activities to reduce the erosion potential for uncovered soils. The Contractor shall install temporary culverts, ditches, catchment basins, and settling pools where needed during construction to collect excess water and sediments carried from the construction site. Sediments collected shall be disposed of onsite, unless contamination of sediment with hazardous material occurs, which would require disposal at an appropriate disposal site for hazardous materials. In order to provide effective and continuous control of water pollution it may be necessary for the Contractor to perform the contract work in small or multiple units, on an out of phase schedule, and with modified construction procedures. The Contractor shall provide temporary water pollution control measures, including but not limited to, dikes, basins, ditches, and applying straw and seed, which become necessary as a result of the Contractor's operations. The Contractor shall coordinate water pollution control work with all other work done on the contract. Unless otherwise approved by the Engineer in writing, the Contractor shall not expose a total area of erosible earth material, which may cause water pollution, exceeding 750,000 ft (17.217 acres) for each separate location, operation, or spread of equipment before either temporary or permanent erosion control measures are accomplished. 2 Where erosion which will cause water pollution is probable due to the nature of the material or the season of the year, the Contractor's operations shall be so scheduled that permanent erosion control fea- tures will be installed concurrently with or immediately following grading operations. Nothing in the terms of the contract nor in the provisions shall relieve the Contractor of the responsibility for compliance with Sections 5650 and 12015 of the Fish and Game Code, or other applicable statutes relating to prevention or abatement of water pollution. Compliance with the requirements of this section shall in no way relieve the Contractor from the responsibility to comply with the other provisions of the contract, in particular the responsibility for damage and for preservation of property. When borrow material is obtained from other than commercially operated sources, erosion of the borrow site during and after completion of the work shall not result in water pollution. The material source shall be finished, where practicable, so that water will not collect or stand therein. 7/31/02 Contract No. 3907 Page 264 of 414 The requirements of this section shall apply to all work performed under the contract and to all non- commercially operated borrow or disposal sites used for the project. The Contractor shall also conform to the following provisions: 1. 2. 3. 4. 5. 6. 7. 8. 9. Where working areas encroach on live streams, barriers adequate to prevent the flow of muddy water into streams shall be constructed and maintained between working areas and streams, and during construction of the barriers, muddying of streams shall tie held to a minimum. Removal of material from beneath a flowing stream shall not be commenced until adequate means, such as a bypass channel, are provided to carry the stream free from mud or silt around, the removal operations. Should the Contractor's operations require transportation of materials across live streams, the operations shall be conducted without muddying the stream. Mechanized equipment shall not be operated in the stream channels of the live streams except as may be necessary to construct crossings or barriers and fills at channel changes. Water containing mud or silt from aggregate washing or other operations shall be treated by filtration, or retention in a settling pond, or ponds, adequate to prevent muddy water from entering live streams. Oily or greasy substances originating from the Contractor's operations shall not be allowed to enter or be placed where they will later enter a live stream. Portland cement or fresh portland cement concrete shall not be allowed to enter flowing water of streams. When operations are completed, the flow of streams shall be returned as nearly as possible to a meandering thread without creating possible future bank erosion, and settling pond sites shall be graded so they will drain and will blend in with the surrounding terrain. Material derived from roadway work shall not be deposited in a live stream channel where it could be washed away by high stream flows. Where there is possible migration of anadromous fish in streams affected by construction on the project, the Contractor shall conduct work operations so as to allow free passage of the migratory fish. IO. Contractor's hauling operations shall be accomplished in a manner that minimizes the spillage of soil onto roads within and outside of the project site. 11. All refuse generated during grading shall be contained and removed. 12. Refuse material such as oil, grease, and broken equipment generated during grading shall be properly contained and removed offsite to a disposal site. 13. All temporary exposed manufactured slopes necessary to accommodate the roadway shall be landscaped immediately with a hydroseed mix and jute matting. 14. The Contractor shall perform street sweeping to avoid silt being carried over to adjacent public thoroughfares. 15. The Contractor shall perform street sweeping on streets from which construction access is taken to remove dirt carried from the new alignment to the existing roadway to keep vehicles from pulverizing a 7/31/02 Contract No. 3907 Page 265 of 414 the dirt into fine particles. 16. The Contractor shall use water and/or dust palliatives on all disturbed areas. 17. During construction the Contractor shall use water trucks or sprinkler systems to keep all areas where vehicles move damp enough to prevent dust raised when leaving the site and the Contractor shall wet down areas in the late morning and after work is completed for the day. 18. The Contractor shall terminate soil excavation, clearing or grading when wind speeds exceed 25 mph for an hourly average. Add the following section: 300-13.2 Applicable Permits. This project shall conform to the requirements of Permit No. OOC-045 issued by the California Regional Water Quality Control Board. This permit, hereafter referred to as the "Permit," regulates storm water discharges associated with construction activities. Add the following section: 300-13.3 Liability. The Contractor shall be responsible for the costs and for any liability imposed by law as a result of the Contractor's failure to comply with the requirements set forth in this section "Water Pollution Control", including but not limited to, compliance with the applicable provisions of the Caltrans Storm Water Quality Handbooks, Permit and Federal, State and local regulations. For the purposes of this paragraph, costs and liabilities include, but are not limited to, fines, penalties and damages whether assessed against the State or the Contractor, including those levied under the Federal Clean Water Act and the State Porter Cologne Water Quality Act. Unless arrangements for disturbance of areas outside the project limits are made by the City and made part of the contract, it is expressly agreed that the City assumes no responsibility to the Contractor or property owner whatsoever with respect to any arrangements made between the Contractor and property owner to allow disturbance of areas outside the project limits. Add the following section: 300-13.4 Retention of Money. In addition to any remedy authorized by law, the City may retain money due the Contractor under the contract in an amount considered necessary by the City may be retained by the City until disposition has been made of the costs and liabilities. The retention of money due the Contractor shall be subject to the following: 1. 2. The City will give the Contractor 30 days notice of its intention to retain funds from any partial payment which may become due to the Contractor prior to acceptance of the contract. Retention of funds from any payment made after acceptance of the contract may be made without prior notice to the Contractor. No retention of additional amounts out of partial payments will be made if the amount to be retained does not exceed the amount being withheld from partial payments pursuant to Section 9-3.2, "Partial and Final Payments," of the Standard Specifications. Add the following section: 300-13.5 Access. The Contractor shall, at reasonable times, allow authorized agents of the California Regional Water Quality Control Board, State Water Resources Control Board, U. S. Environmental Protection Agency and local storm water management agency, upon the presentation of credentials and other documents as may be required by law, to: 1. Enter upon the construction site and the Contractor's facilities pertinent to the work; 2. Have access to and copy any records that must be kept as specified in the Permit; - 7/31/02 Contract No. 3907 Page 266 of 414 3. Inspect the construction site and related soil stabilization practices and sediment control measures; and 4. Sample or monitor for the purpose of ensuring compliance with the Permit. The Contractor shall notify the Engineer immediately upon request from regulatory agencies to enter, inspect, sample, monitor or otherwise access the project site or the Contractor's records. Add the following section: 300-13.6 Storm Water Pollution Prevention Plan. As part of the water pollution control work, a Storm Water Pollution Prevention Plan, hereafter referred to as the "SWPPP," is required for this contract. The SWPPP shall conform to the requirements of the Standard Specifications, the requirements in the Caltrans Storm Water Quality Handbooks, the requirements of the Permit, the requirements in the plans and these special provisions. In general, the Contractor shall implement Best Management Practices (BMP's) to control storm water runoff and provide dust control. These measures include but are not limited to: Gravel berms, filter fabric fences, lines of straw bales to prevent erosion Surfacing of roadways shall occur as soon as possible Periodic watering of areas to keep dust down Prompt revegetation of surrounding areas to prevent erosion - - - - No work having potential to cause water pollution, as determined by the Engineer, shall be performed until the SWPPP has been accepted by the Engineer. Within 20 calendar days after award of the contract, the Contractor shall submit 6 copies of the SWPPP to the Engineer, pursuant to Section 2-5.3.3. The City may withhold issuance of the Notice to Proceed pending acceptance of the Contractor's SWPPP. In order to allow construction activities to proceed, the Engineer may conditionally approve the SWPPP while minor revisions are being completed. The objectives of the SWPPP shall be to identify pollution sources that may adversely affect the quality of storm water discharges associated with the project and to identify, construct, implement and maintain water pollution control measures, hereafter referred to as control measures, to reduce to the extent feasible pollutants in storm water discharges from the construction site both during and after construction is completed under this contract. The SWPPP shall incorporate control measures in the following categories: 1. Soil stabilization practices; 2. Sediment control practices; 3. Sediment tracking control practices; 4. Wind erosion control practices; and 5. Non-storm water management and waste management and disposal control practices. Specific objectives and minimum requirements for each category of control measures are contained in the Handbook. The Contractor shall consider the objectives and minimum requirements presented in the Handbook for each of the above categories. When minimum requirements are listed for any category, the Contractor shall incorporate into the SWPPP and implement on the project, one or more of the listed minimum controls required in order to meet the pollution control objectives for the category. In addition, the Contractor shall consider other control measures presented in the Handbook and shall incorporate into the SWPPP and implement on the project the control measures necessary to meet the objectives of the SWPPP. The Contractor shall document the selection process in accordance with the procedure specified in the Handbook. The following contract items of work, as shown on the project plans, shall be incorporated into the SWPPP as permanent post-construction control measures: rip rap energy dissipaters, median 7131102 Contract No. 3907 Page 267 of 414 landscaping complete in place, slope landscaping complete in place and hydroseeded slopes. These control measures shall be utilized as construction period control measures. The following control measures which are not separate contract items of work shall be incorporated into the SWPPP as permanent postconstruction control measures as shown on the project plans: sandbag barrier, environmental fence, silt fence, gravel bags, and gravel bag weir. Attention is directed to "Order of Work" of these special provisions. The Contractor shall consider other control measures to supplement these permanent, post-construction control measures when necessary to meet the pollution control objectives of the SWPPP. The Contractor shall maintain and protect the permanent control measures throughout the duration of the project and shall restore these controls to the lines and grades shown on the plans prior to acceptance of the project. The SWPPP shall include, but not be limited to, the following items as described in the Handbook and Permit: 1. 2. 3. 4. 5. 6. 7. 8. 9. Source Identification; Erosion and Sediment Controls; Non-Storm Water Management; Waste Management and Disposal; Maintenance, Inspection and Repair; Training; List of Contractors and Subcontractors; Post-Construction Storm Water Management; PreDarer: 10. A wpy of the Notice of New Construction submitted by the City for this project; 11. Copy of the local permit; 12. BMP Consideration Checklist; 13. SWPPP Checklist; 14. Schedule of Values; and 15. Water Pollution Control Drawings. The Contractor shall amend the SWPPP, graphically and in narrative form, whenever the City determines a change in construction activities or operations that may affect the discharge of significant quantities of pollutants to surface waters, ground waters, municipal storm drain systems, or when deemed necessary by the Engineer. The SWPPP shall also be amended if it is in violation of any condition of the Permit, or has not effectively achieved the objective of reducing pollutants in storm water discharges. Amendments shall show additional control measures or revised operations, including those in areas not shown in the initially accepted SWPPP, which are required on the project to control water pollution effectively. Amendments to the SWPPP shall be submitted for review and acceptance by the Engineer in the same manner specified for the initially accepted SWPPP. Accepted amendments shall be dated and logged in the SWPPP. Upon acceptance of the amendment, the Contractor shall implement the additional control measures or revised operations. The Contractor shall keep a copy of the accepted SWPPP and accepted amendments at the project site. The SWPPP shall be made available upon request of a representative of the Regional Water Quality Control Board, State Water Resources Control Board, U.S. Environmental Protection Agency or local storm water management agency. Requests by the public shall be directed to the Engineer. By June 15 of each year, the Contractor shall submit an annual certification to the Engineer stating compliance with the requirements governing the Permit. If the project is in non-compliance at any time, the Contractor shall make a written report to the Engineer within 15 days of identification of non- Compliance. - Add the following section: 300-13.7 Water Pollution Control Schedule of Values. The Contractor shall submit with the SWPPP, for acceptance by the Engineer, a schedule of values detailing the cost breakdown of the contract lump sum item for Water Pollution Control. The schedule of values shall reflect the items of work, quantities e 7/31/02 Contract No. 3907 Page 268 of 414 and costs for control measures shown in the SWPPP and shown on the plans, except for critical temporary controls and permanent control measures which are shown on the project plans and for which there is a contract item of work. Adjustments in the items of work and quantities listed in the schedule of values shall be made when required to address accepted amendments to the SWPPP. The sum of the amounts for the units of work listed in the schedule of values shall be equal to the contract lump sum price for Water Pollution Control. If accepted in writing by the Engineer, the schedule of values will be used to determine progress payments for water pollution control during the progress of the work, and as the basis for calculating any adjustment in compensation for the contract item for Water Pollution Control due to changes in the work ordered by the Engineer. Add the following section: 300-13.8 SWPPP Implementation. Upon acceptance of the SWPPP, the Contractor shall be responsible throughout the duration of the project for installing, constructing, inspecting and maintaining the control measures included in the SWPPP and any amendments thereto and for removing and disposing of temporary control measures. Unless otherwise directed by the Engineer or specified in these special provisions, the Contractor's responsibility for SWPPP implementation shall continue throughout any temporary suspension of work ordered in accordance with Section 6-3, "Suspension of Work," of the Standard Specifications. Requirements for installation, construction, inspection, maintenance, removal and disposal of control measures are specified in the Handbook and these special provisions. Soil stabilization practices and sediment control measures, including minimum requirements, shall be provided throughout the winter season, defined as between October 1 and April 30. Implementation of soil stabilization practices and sediment control measures for soildisturbed areas of the project site shall be completed, except as provided for below, no later than 20 days prior to the beginning of the winter season or upon start of applicable construction activities for projects which begin either during or within 20 days of the winter season. Throughout the winter season, the active, soil-disturbed area of the project site shall be no more than 5 acres. The Engineer may approve, on a case-bycase basis, expansions of the active, soildiqturbed area limit. The Contractor shall demonstrate the ability and preparedness to fully deploy soil stabilization practices and sediment control measures to protect soildisturbed areas of the project site before the onset of precipitation. The Contractor shall maintain a quantity of soil stabilization and sediment control materials on site equal to 100% percent of that sufficient to protect unprotected, soildisturbed areas on the project site and shall maintain a detailed plan for the mobilization of sufficient labor and equipment to fully deploy control measures required to protect unprotected, soil-disturbed areas on the project site prior to the onset of precipitation. The Contractor shall include a current inventory of control measure materials and the detailed mobilization plan as part of the SWPPP. Throughout the winter season, soildisturbed areas of the project site shall be considered to be nonactive whenever soil disturbing activities are expected to be discontinued for a period of 20 or more days and the areas are fully protected. Areas that will become nonactive either during the winter season or within 20 days thereof shall be fully protected with soil stabilization practices and sediment control measures within 10 days of the discontinuance of soil disturbing activities or prior to the onset of precipitation, whichever is first to occur. Throughout the winter season, active soildisturbed areas of the project site shall be fully protected at the end of each day with soil stabilization practices and sediment control measures unless fair weather is predicted through the following work day. The weather forecast shall be monitored by the Contractor on a daily basis. The National Weather Service forecast shall be used, or an alternative weather forecast proposed by the Contractor may be used if accepted by the Engineer. If precipitation is predicted prior to @ 7/31/02 Contract No. 3907 Page 269 of 414 the end of the following work day, construction scheduling shall be modified, as required, and the Contractor shall deploy functioning control measures prior to the onset of the precipitation. The Contractor shall implement, year-round and throughout the duration of the project, control measures included in the SWPPP for sediment tracking, wind erosion, non-storm water management and waste management and disposal. The Engineer may order the suspension of construction operations, at no cost to the Agency, which create water pollution if the Contractor fails to conform to the requirements of this section as determined .by the Engineer. Add the following section: 300-1 3.9 Maintenance. To ensure the proper implementation and functioning of control measures, the Contractor shall regularly inspect and maintain the construction site for the control measures identified in the SWPPP. The Contractor shall identify corrective actions and time frames to address any damaged measures or reinitiate any measures that have been discontinued. The construction site inspection checklist provided in the Handbook shall be used to ensure that the necessary measures are being properly implemented, and to ensure that the control measures are functioning adequately. The Contractor shall submit one copy of each site inspection record to the Engineer, within three days of making the inspection. During the winter season, inspections of the construction site shall be conducted by the Contractor to identify deficient measures, as follows: 1. Prior to a forecast storm; 2. After any precipitation which causes runoff capable of carrying sediment from the construction site; 3. At 24 hour intervals during extended precipitation events; and 4. Routinely, at a minimum of once every 2 weeks. If the Contractor or the Engineer identifies a deficiency in the deployment or functioning of an identified control measure, the deficiency shall be corrected by the Contractor immediately, or by a later date and time if requested by the Contractor and accepted by the Engineer in writing, but not later than the onset of subsequent precipitation events. The correction of deficiencies shall be at no additional cost to the City. Add the following section: 300-13.10 Payment. The contract lump sum price paid for Water Pollution Control shall include full compensation for furnishing all labor, materials, tools, equipment and incidentals, and for doing all the work involved in developing, preparing, obtaining acceptance of, revising and amending the SWPPP, and for furnishing all labor, materials, tools, equipment and incidentals, and for doing all the work involved in installing, constructing, maintaining, removing and disposing of control measures, including those on the plans, and as specified in these special provisions, and as directed by the Engineer. Changes in control measures required by an'agency initiated amendment to the SWPPP that is not a result of the Contractor's change of construction activities or operations, or a result of a violation of any condition of the Permit, or a result of the accepted SWPPP not effectively achieving the objective of reducing pollutants in storm water discharges, will be considered extra work, in accordance with Section 3-3, "Extra Work," of the Standard Specifications and the following: If the control measure is listed in the accepted SWPPP schedule of values, an adjustment in compensation for the contract item for water pollution control will be made by applying the increase or decrease in quantities to the accepted schedule of values. No adjustment of compensation will be made to the unit price listed for any item in the schedule of values due to any increase or decrease in the quantities, regardless of the reason for the increase or decrease. If the control measure is not listed in the accepted SWPPP schedule of values, payment will be made according to Section 3-3, "Extra Work," of the Standard Specifications. Those control measures which are shown on the project plans and for which there is a bid item for the work will be measured and paid for as that item of work. . G 7/31/02 Contract No. 3907 Page 270 of 414 The Engineer will retain an amount equal to 25 percent of the estimated value of the contract work performed during estimate periods in which the Contractor fails to conform to the requirements of this section as determined by the Engineer. Retentions for failure to conform to the requirements of this section shall be in addition to the other retentions provided for in the contract. The amounts retained for failure of the Contractor to conform to the requirements of this section will be released for payment on the next monthly estimate for partial payment following the date that an accepted SWPPP has been implemented and maintained, and water pollution is adequately controlled, as determined by the Engineer. 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: instance reading “150mm (6 inches)” to “300 mm (12”)”. Change each 301-1.3 Relative Compaction. Delete the first paragraph and substitute the following: The Contractor shall compact the upper 300 mm (12”) of subgrade beneath areas to be paved, have base or subbase material placed on them, or curb, gutter, curb and gutter, alley pavement, driveway or sidewalk constructed over them to no less than 95 percent maximum dry density as determined by ASTM test D- 1557-91. 301-1.6 Adjustment of Manhole Frame and Cover Sets to Grade. Replace the first sentence of the first paragraph with: Utility manhole and vault frames and covers within an area to be paved of graded will be set to the finished grade by the owners with the following exceptions. Facilities belonging to WVD, CMWD shall be set to finish grade by the Contractor. SECTION 302 - ROADWAY SURFACING. 302-5 ASPHALT CONCRETE PAVEMENT 302-5.1 General. Add the following: The Contractor shall treat all vegetation within the limits of the paved area to receive asphalt concrete paving with a post emergent herbicide. Herbicide shall be applied at least 2 (two) working days prior to paving the area. Allowance for the two day period shall be shown in the schedule required per section 6-1. 302-5.2.5 Pavement Transitions. Add the following: The Contractor shall ramp the approaches and termini to all structures and vertical joints in the cold-milled area which are transverse to through traffic with temporary asphalt concrete pavement as specified in section 306-1 51. 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. Add the following: The Contractor shall place a tack coat between the successive interfaces of existing pavement and new pavement when, in the opinion of the Engineer, the Contractor has failed to maintain or prepare each existing or previously laid course of asphalt receiving the subsequent course of asphalt in a sufficiently clean state and the asphalt receiving the new pavement course is dirty enough to impair bonding between the next lift of asphalt. 7/31/02 Contract No. 3907 Page 271 of 414 302-5.5 Distribution and Spreading. Modify as follows: After second sentence of sixth paragraph, add: The Contractor shall provide a self-propelled paving machine for all paving and use an automatic screed control for surface course paving. The machine should have a full-width vibrating screed for the width of the paving pass. 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 operators during all paving. The Contractor shall provide an on-site backup paving machine during all paving operations. A backup asphalt windrow pickup machine (ASPWP) will be required at all times when a ASPWP is used. Additionally, a front end loader will be required during all ASPWP paving. The surface course shall be 50 mm (2”) thick. Leveling courses will be required in a variable thickness pavement section. 302-5.6.1 General. Mod@ as follows: Second paragraph, Part (Z), 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: breakdown rolling shall be followed by a pneumatic-tired roller. After last paragraph, add: Unless directed otherwise by the Engineer, the initial 302-5.9 Measurement and Payment. Add the following: Payment for asphalt concrete pavement, leveling, and surface course shall be at the unit price bid per ton. No additional payment shall be made for any tack coat. Add the following section: 302-5.10 Surface Finish for Asphalt Concrete Spiiiway. The Contractor shall provide a surface finish for asphalt concrete spillway to prevent the use of roller blades, skateboards, and other rolling devices. Surface finish shall be a rough rake finish approved by the Engineer. Add the following section: 302-1 1 PLACE ASPHALT CONCRETE: MISCELLANEOUS AREA AND DIKE Add the following section: 302-1 1.1 General. Surfacing of miscellaneous areas, such as median areas (exclusive of inside shoulders), island areas, sidewalks, spillways, interim ditches, gutters, gutter flares, ditches, overside drains, aprons at the ends of drainage structures, and other areas outside the traveled way which are designated on the plans as miscellaneous areas to be paved with asphalt concrete, and dikes, shall conform to these specifications. The combined aggregate grading for asphalt concrete placed on mis- cellaneous areas shall conform to that specified for the asphalt concrete placed on the traveled way, unless otherwise directed by the Engineer. The amount of asphalt binder used in the asphalt concrete placed in dikes, gutters, gutter flares, overside drains and aprons at the ends of drainage structures, unless otherwise directed by the Engineer, shall be increased one percent by mass of the aggregate over the amount of asphalt binder used in the asphalt concrete placed on the traveled way. The asphalt concrete placed in miscellaneous areas may be spread in one layer by self-propelled paving machine when possible. The material shall be compacted to the required lines, grades and cross section. Dikes shall be shaped and compacted with an extrusion machine or other equipment capable of shaping and compacting the material to the required cross section. Add the following section: 302-11.2 Measurement and Payment. The contract item to place asphalt concrete dike will be measured along the completed improvement. Quantities of asphalt concrete dike placed will be paid at the contract price per ton for asphalt concrete and also at the contract price per lineal foot for place asphalt concrete dike. Full compensation for any necessary excavation, backfill and preparation of the area shall be considered as included in the contract price paid per linear foot for place asphalt concrete dike, and no additional compensation will be allowed therefor. Quantities of asphalt concrete placed in miscellaneous areas designated in the special provisions or tabulated on the plans to be included in the contract item of place asphalt concrete (miscellaneous area), e 7/31/02 Contract No. 3907 Page 272 of 414 will be paid for at the contract price per ton for asphalt concrete and also at the contract price per square foot for of place asphalt concrete (miscellaneous area). Full compensation for any necessary excavation, backfill and preparation of the area shall be considered as included in the Contract price paid per square foot for place asphalt concrete (miscellaneous area) and no additional compensation will be allowed therefor. The above contract prices and payments shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in constructing asphalt concrete, complete in place, as shown on the plans and as specified in these special provisions, and as . directed by the Engineer. 302-12 POLICE RAMP 302-12.1 General. Police ramps shall be constructed as shown on plans and as specified in these supplemental provisions. 302-12.2 Earthwork. Fill for construction of police ramps shall be in accordance with Section 300-4 of the SSPWC, “Unclassified Fill.” 302-12.3 Subgrade Preparation and Placement of Base Materials. Preparation of subgrade shall be in accordance with Section 301 -1 , Subgrade Preparation, of the SSPWC and these supplemental provisions. Aggregate base shall be crushed aggregate base in accordance with Section 200-2.2, Crushed Aggregate Base, of the SSPWC and these supplemental provisions. Spreading and compacting of base shall be in accordance with Sections 301-2.2, Spreading, and 301-2.3, Compacting, of the SSPWC. 302-12.4 Roadway Surfacing. Asphalt concrete pavement materials shall be in accordance with Section 203-6, “Asphalt Concrete”, of the SSPWC and these supplemental provisions. Construction of a.c. pavement shall be in accordance with Section 302-5, Asphalt Concrete Pavement, of the SSPWC and these supplemental provisions. 302-12.5 Underground Conduit Construction. Corrugated steel pipe materials shall be in accordance with Section 207-1 1. “Corrugated Steel Pipe and Pipe Arches”, of the SSPWC and these supplemental provkions. Corrugated steel pipe shall be con#ructed in accordance with Section 306-1, Open Trench Operations, of the SSPWC and these supplemental provisions. 302-12.6 Measurement and Payment The contract unit price paid for police ramp shall be considered as full compensation for providing all materials, equipment, tools and labor for construction of police ramp including all earthwork, subgrade preparation, placement of base materials, and placement of corrugated steel pipe, as shown on plans and specified herein except for 8” Type B1 Median Curb and asphalt concrete pavement. Excluded items shall be paid at their respective contract unit prices. SECTION 303 - CONCRETE AND MASONRY CONSTRUCTION 303-1 CONCRETE STRUCTURES General. Add the following: No steps are to be placed in any drainage structure. Concrete for Concrete Retaining Wall shall be of class 560EC-3250 and reinforcing steel shall be of Grade 60 (ASTM A706). Earthwork conform to Section 300-3, “Structure Special Provisions. associated with the construction of Concrete Retaining Wall shall Excavation and Backfill,” of the Standard Specifications and these @ 7/31/02 Contract No. 3907 Page 273 of 414 Add the following subsection: 303-1.1 .I Concrete Barrier. This work shall consist of constructing concrete barriers at the locations and in accordance with the details shown on the Plans and as specified in these Special Provisions. Concrete barriers shall present a smooth, uniform appearance in their final position, conforming to the horizontal and vertical lines shown on the Plans or ordered by the Engineer, and shall be free of lumps, sags or other irregularities. The top and exposed faces of the barrier shall conform to the following requirements when tested with a ten-foot straightedge laid on the surfaces: Both the top and the faces shall not vary more than 0.02-foot from the edge of the straightedge. When concrete barriers are to be constructed on recently completed bridges, the height of the barriers shall be adjusted to compensate for the camber and dead load deflection of the superstructure. The amount of adjustment will be determined by the Engineer and will be ordered before the concrete is placed. Such barriers shall be placed after falsework, has been released and as long after superstructure construction as the progress of the work will permit, unless otherwise ordered by the Engineer. Materials. Concrete barriers (Caltrans Standard Plan A76A) shall be constructed of concrete conforming to the provisions in Section 201-1 of the SSPWC, “Portland Cement Concrete.” Reinforcing bars shall conform to the provisions in Section 201-2 of the SSPWC “Steel Reinforcement for Concrete.” Polystyrene shown on the Plans at connections to structures and at transitions to bridge columns shall conform to the provisions in Section 201 -3 of the SSPWC “Expansion Joint Filler and Joint Sealants.” The sheet metal, neoprene strip, and grease required at connections to structures shall conform to the following : Sheet metal shall be commercial quality galvanized sheet steel, smooth and free of kinks, bends or burrs. Joints in the sheet metal shall be butt joints sealed with plastic duct sealing tape. Construction Methods. Concrete barriers shall be constructed by the “cast-in-place with fixed forms” method. Concrete barriers constructed by casting-in-place with fixed forms shall conform to the provisions in Section 303 of the SSPWC Concrete And Masonry Construction,” and the details shown on the Plans. Pre-cast mortar blocks shall not be used to support the reinforcing steel on the traffic side of barriers. Finishing. The final surface finish of concrete barriers shall be Class 1 Surface Finish per Section 303- 1.9.3 of the SSPWC. Alternative final surface finish methods proposed by the Contractor shall be submitted in writing and shall not be used unless approved by the Engineer. Curing. Exposed surfaces of concrete barriers shall be cured with the non-pigmented curing compound (6) as provided in Section 201-4 of the SSPWC “Concrete Curing Materials.” At the Contractor‘s option, the formed surfaces of concrete barriers, which are on bridges or walls but which do not support sound walls, may be cured using the “Forms-ln-Place Method,” except the forms shall be retained in place for a minimum period of 12 hours after the concrete has been placed. When curing Type 50 series concrete barrier, curing compound shall be applied by a mechanical sprayer capable of applying the curing compound to at least one entire side and the top of the concrete barrier in one application at a uniform rate of coverage. The spray shall be adequately protected against wind. 303-1.4.2 Bridges. Replace the last sentence of the third paragraph with the following: All forms shall be removed except as otherwise provided herein. Forms for deck slabs of cast-in-place box girders, forms for the interior voids of precast members, and forms in hollow abutments or piers may remain in place when no permanent access is available into the cells or voids, when utility facilities are not to be installed in completed cells or voids, or when the only utilities to be installed in completed cells or voids are to be inserted into casings which are placed prior to the completion of the cell or void. When permanent access is available into the cells or voids, or when utility facilities other than those in preplaced casings are to be installed in cells or voids, forms used to support the deck of cast-in-place box girders or to form the void of a precast member shall be removed except that, when the dimensions of the structure or G 7/31/02 Contract No. 3907 Page 274 of 414 member permit, the forms may remain in place providing all of the following conditions are met: Any portions of the forms which obstruct access openings or conflict with utility facilities are removed. A longitudinal crawl space not les than 3-0" high and 2'4" wide is provided throughout the length of all such cells or voids. The forming system employed leaves no sharp projections into the cells or voids. Prior to the completion of forming for the deck of cast-in-place box girders or for the cells or voids of other . members when such forms are to remain in place, or after the removal of such forms or portions of forms, the inside of the cells or voids shall be cleared of all loose materials. 303-1.4.2.1 Wildlife Movement. Add the following: During construction of Rancho Santa Fe Road Bridge Left and Right the Contractor shall create an area approximately 10 (ten) feet wide and 10 (ten) feet high with dry substrate material, that has visual access from end to end to allow wildlife movement. The area shall be maintained throughout construction of both bridges and removed when the bridges are complete. 303-1.6.1 General. Add the following: Temporary bracing shall be provided, as necessary, to withstand all imposed loads during erection, construction, and removal of any falsework. The falsework drawings shall show provisions for such temporary bracing or methods to be used to conform to this requirement during each phase of erection and removal. Wind loads shall be included in the design of such bracing or methods. The Contractor will furnish calculations substantiating the amount of camber to be used in constructing the falsework. Welding of steel members, except for previously welded splices and except for when fillet welds are used where load demands are less than or equal to 175 N/mm for each 3 mm of fillet weld, shall conform to AWS D1.l or other recognized welding standard. The welding standard to be utilized shall be specified by the Contractor on the working drawings. Previously welded splices for falsework members are defined as splices made prior to the member being shipped to the project site. Splices made by field welding of steel beams at the project site shall undergo nondestructive testing (NDT). At the option of the Contractor, either ultrasonic testing (UT) or radiographic testing (RT) shall be used as the method of NDT for each field weld and any repair made to a previously welded splice in a steel beam. Testing shall be performed at locations selected by the Contractor. The length of a splice weld where NDT is to be performed shall be a cumulative weld length equal to 25 percent of the original splice weld length. The cover pass shall be ground smooth at the locations to be tested. The acceptance criteria shall conform to the requirements of AWS D1.1, Section 6, for cyclically loaded nontubular connections subject to tensile stress. If repairs are required in a portion of the weld, additional NDT shall be performed on the repaired sections. The NDT method chosen shall be used for an entire splice evaluation including any required repairs. For all field welded splices, the Contractor shall furnish to the Engineer a letter of certification which certifies that all welding and NDT, including visual inspection, are in conformance with the specifications and the welding standard shown on the approved working drawings. This letter of certification shall be signed by an engineer who is registered as a Civil Engineer in the State of California and shall be provided prior to placing any concrete for which the falsework is being erected to support. For previously welded splices, the Contractor shall determine and perform all necessary testing and inspection required to certify the ability of the falsework members to sustain the stresses required by the falsework design. This welding certification shall be in writing, shall be signed by an engineer who is .registered as a Civil Engineer in the State of California, and shall be provided prior to placing any concrete for which the falsework is being erected to support. The Contractor's engineer who signs the falsework drawings shall also certify in writing that the falsework is constructed in conformance with the approved drawings and the contract specifications prior to placing concrete. This certification shall include performing any testing necessary to verify the ability of the falsework members to sustain the stresses required by the falsework design. The engineer who signs . 7/31/02 Contract No. 3907 Page 275 of 414 the drawings may designate a representative to perform this certification. Where falsework contains openings for railroads, vehicular traffic, or pedestrians, the designated representative shall be qualified to perform this work, shall have at least three years of combined experience in falsework design or supervising falsework construction, and shall be registered as a Civil Engineer in the State of California. For other falsework, the designated representative shall be qualified to perform this work and shall have at least three years of combined experience in falsework design or supervising falsework construction. The Contractor shall certify the experience of the designated representative in writing and provide supporting documentation demonstrating the required experience if requested by the Engineer. 303-1.7.1 General. Add the following to the fourth paragraph: The minimum spacing center to center of . parallel bars shall be 21/2 times the diameter of the bar. 303-1.7.2 Splicing. Replace the second sentence of the first paragraph with: Where A 61 5 Grade 60 or A 706 reinforcing bars are required, the length of lapped splices shall be as follows: Reinforcing bars No. 8, or smaller, shall be lapped at least 45 diameters of the smaller bar joined, and reinforcing bars Nos. 9, 10 and 11 shall be lapped at least 60 diameters of the smaller bar joined, except when otherwise shown on the plans. Add the following: Unless otherwise shown on the plans or approved by the Engineer, splices in adjacent reinforcing bars at any particular section shall be staggered. The minimum distance between staggered lap splices or mechanical lap splices shall be the length required for a lapped splice in the bar. The minimum distance between staggered butt splices shall be two feet. Add the following subsection: 303-1.7.- Butt Welded Splices. All butt welded splices in reinforcing bars shall be full penetration butt welds conforming to the requirements in AWS D1.4 and the requirements of these specifications and these Special Provisions. Before any electrodes or fluxelectrode combinations are used, the Contractor, at his expense, shall furnish certified copies of test reports for all the pertinent tests specified in AWS A5.1, AWS A5.5, AWS A5.18 or AWS A5.20, whichever is applicable, made on electrodes or fluxelectrode combinations of the same class, brand and nearest specified size as the electrodes to be used. The tests may have been made for process qualification or quality control, and shall have been made within one year prior to manufacture of the electrodes and fluxes to be used. The report shall include the manufacturer's certifi- cation that the process and material requirements were the same for manufacturing the tested electrodes and the electrodes to be used. The forms and certificates shall be as directed by the Engineer. Electrodes for manual shielded metal arc welding of A 615 Grade 60 bars shall conform to the requirements of AWS A5.5 for E9018-M or El 001 8-M electrodes. Electrodes for manual shielded metal arc welding of A 706 bars shall conform to the requirements of AWS A5.5 for ESOXX, E8016-C3, E8018-C3, E9Ol8-M or E10018-M electrodes. Procedure qualification tests will not be required for direct butt splices made in accordance with AWS D1.4 figure 3.5 on A 706 bars when E8016-C3 or E8018-C3 electrodes are used to make the weld. Solid and composite electrodes for semiautomatic gas metal-arc and fluxcored arc welding of Grade 40 reinforcing bars shall conform to the requirements of AWS A5.18 for ER70S-2, ER70S-3, ER70S-6 or ER70S-7 electrodes; or AWS A520 for E70T-1, E70T-5, E70T-6 or E70T-8 electrodes. Electrodes for semiautomatic welding of A 615 Grade 60 and A 706 bars shall produce a weld metal deposit with properties conforming to the requirements of AWS Dl.l in paragraph 4.12 for E90S and E90T electrodes. Reinforcing bars shall be preheated for a distance of not less than 6 inches on each side of the joint prior to welding. For all welding of A 615 Grade 40 or Grade 60 bars, the requirements of Table 5.2, "Minimum Preheat and lnterpass Temperatures," of AWS D1.4 are superseded by the following: @ 7/31/02 Contract No. 3907 Page 276 of 414 The minimum preheat and interpass temperatures shall be 400" F. for Grade 40 bars and 600" F. for Grade 60 bars. Immediately after completing the welding, at least 6 inches of the bar on each side of the splice shall be covered by an insulated wrapping to control the rate of cooling. The insulated wrapping shall remain in place until the bar has cooled below 200" F. When welding different grades of steel, the electrode shall conform to Grade 40 steel requirements and the preheat shall conform to the Grade 60 steel requirements. In the event that any of the specified preheat, interpass and post weld cooling temperatures are not met, all weld and heat affected zone metal shall be removed and the splice rewelded. All welding shall be protected from air currents, drafts, and precipitation to prevent loss of heat or loss of arc shielding. The method of protecting the welding area from loss of heat or loss of arc shielding shall be subject to approval by the Engineer. Reinforcing bars shall not be direct butt spliced by thermite welding. Add the following subsection: 303-1.7.28 Welding Quality Control Welding quality control shall conform to the requirements in the AWS welding codes, the SSPWC and these Special Provisions. ~~ I D1.5 1995 D1.5 1996 Welding quality control shall apply when any work is welded in conformance with the provisions in 1) Section 205, "Piles," 2) Section 201-2, "Concrete Reinforcement," or 3) Section 303-1.7, "Placing Reinforcement," of the SSPWC. Welding quality control, as specified herein, shall not apply when welding is performed at a permanent fabrication facility that is certified under the AlSC Quality Certification Program, Category Ill, Major Steel Bridges. Wherever reference is made to the following AWS welding codes in the SSPWC, on the plans or in these Special Provisions, the year of adoption for these codes shall be as listed: I D1.4 -1 1992 I (metric only) All requirements of the AWS welding codes shall apply unless specified otherwise in the SSPWC, on the plans or in these Special Provisions. Wherever the abbreviation AWS is used, it shall -be equivalent to the abbreviations ANSVAWS or ANSI/AASHTO/AWS. The welding of all fracture critical members (FCMs) shall conform to the provisions specified in the Fracture Control Plan (FCP) and herein The Contractor shall designate in writing a welding Quality Control Manager (QCM). The QCM shall be responsible directly to the Contractor for the quality of welding, including materials and workmanship, performed by the Contractor and all subcontractors. The QCM shall not be employed or compensated by any subcontractor, or by other persons or entities -hired by subcontractors, who will provide other services or materials for the project. The QCM may be an employee of the Contractor. G 7/31/02 Contract No. 3907 Page 277 of 414 - -__ ._ No welding inspection personnel or nondestructive testing (NDT) firms to be used in the work shall be employed or compensated by any subcontractor, or by other persons or entities hired by subcontractors, who will provide other services or materials for the project. The QCM shall be the sole individual responsible to the Contractor for submitting and receiving all correspondence and required submittals and reports regarding welding to and from the Engineer. Prior to submitting the Quality Control Plan (QCP) required herein, a pre-welding meeting shall be held between the Engineer, Contractor and any welding subcontractors to be used in the work to discuss the requirements for the QCP. Prior to performing any welding, the Contractor shall submit to the Engineer, in accordance with the provisions of Section 2-5.3, "Shop Drawings and Submittals," of the SSPWC, 3 copies of a separate QCP for each item of work for which welding is to be performed. As a minimum, each QCP shall include the following: 1. The name of the welding firm and the NDT firm to be used; 2. A manual prepared by the NDT firm that shall include equipment, testing procedures, code of safe practices, the Written Practice of the NDT firm, and the names, qualifications and documentation of certifications for all personnel to be used; 3. The name of the QCM and the names, qualifications and documentation of certifications for all Quality Control (QC) Inspectors and Assistant Quality Control Inspectors to be used; 4. An organizational chart showing all QC personnel and their assigned QC responsibilities; 5. The methods and frequencies for performing all required quality control procedures, including QC inspection forms to be used, as required by the specifications including: 6. 7. 8. 9. (a) all visual inspections; (b) all NDT including radiographic geometry, penetrameter and shim selection, film quality, film processing, radiograph identification and marking system, and film interpretation and reports; and (c) calibration procedures and calibration frequency for all NDT equipment; A system for the identification and tracking of all welds, NDT and any required repairs, and a procedure for the reinspection of any repaired welds. The system shall have provisions for 1) permanently identifying each weld and the person who performed the weld and 2) placing all identification and tracking information on each radiograph; Standard procedures for performing noncritical repair welds. Noncritical repair welds are defined as welds to deposit additional weld beads or layers to compensate for insufficient weld size and to fill limited excavations that were performed to remove unacceptable edge or surface discontinuities, rollover or undercut. The depth of these excavations shall not exceed 65 percent of the specified weld size; The welding procedure specification (WPS), including documentation of all supporting Procedure Qualification Record (PQR) tests performed, and the name of the testing laboratory who performed the tests, to verify the acceptability of the WPS. The submitted WPS shall be within the allowable period of effectiveness; Documentation of all certifications for welders for each weld process and position that will be used. Certifications shall list the electrodes used, test position, base metal and thickness, tests performed, and the witnessing authority. All certifications shall be within the allowable period of effectiveness; and 10. One copy each of all AWS welding codes and the FCP which are applicable to the welding to be performed. These codes and the FCP shall become the permanent property of the Department. * 'd 7/31/02 Contract No. 3907 Page 278 of 414 The Engineer shall have 10 working days to review the QCP submittal after a complete plan has been received. No welding shall be performed until the QCP is approved in writing by the Engineer. Should the Engineer fail to complete the review within this time allowance and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in reviewing the QCP, the delay will be considered a right of way delay as specified in Section 6-6, "Delays and Extensions of Time," of the SSPWC. An amended QCP or addendum shall be submitted to, and approved in writing by the Engineer, for any proposed revisions to the approved QCP. An amended QCP or addendum will be required for any revisions to the QCP, including but not limited to a revised WPS, additional welders, changes in NDT firms or procedures, QC or NDT personnel, or updated systems for tracking and identifying welds. The Engineer shall have 3 working days to complete the review of the amended QCP or addendum. Work that is affected by any of the proposed revisions shall not be performed until the amended QCP or addendum has been approved. Should the Engineer fail to complete the review within this time allowance and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in reviewing the amended QCP or addendum, the delay will be considered a right of way delay as specified in Section 6-6, "Delays and Extensions of Time," of the SSPWC. After final approval of the QCP, amended QCP or addendum, the Contractor shall submit to the Engineer 7 copies each of these approved documents. A daily production log for welding shall be kept by the QCM for each day that welding is performed. The log shall clearly indicate the locations of all welding, and shall include the welders' names, amount of welding performed, any problems or deficiencies discovered, and any testing or repair work performed, at each location. The daily report from each Quality Control Inspector shall also be included in the log. It is expressly understood that the Engineer's approval of the Contractor's QCP shall not relieve the Contractor of any responsibility under the contract for the successful completion of the work in conformity with the requirements of the plans and specifications. The Engineer's approval shall not constitute a waiver of any of the requirements of the plans and specifications nor relieve the Contractor of any obligation thereunder, and defective work, materials and equipment may be rejected notwithstanding approval of the QCP. The following items shall be included in a Welding Report that is to be submitted to the Engineer within 7 days following the performance of any welding: 1. Reports of all visual weld inspections and NDT; 2. Radiographs and radiographic reports, and other required NDT reports; 3. Documentation that the Contractor has evaluated all radiographs and other nondestructive tests, corrected all rejectable deficiencies, and all repaired welds have been reexamined by the required NDT and found acceptable; and 4. Daily production log. All reports regarding NDT, including radiographs, shall be signed by both NDT technician and the person that performed the review, and then submitted directly to the QCM for review and signature prior to submittal to the Engineer. Corresponding names shall be clearly printed or typewritten next to all signatures. The Engineer shall review the Welding Report to determine if the Contractor is in conformance with the QCP. Except for steel piling, the Engineer shall be allowed 7 days to review the report and respond in writing after a complete Welding Report has been received. The review time for steel piling shall be as specified in "Piling" elsewhere in these Special Provisions. Prior to receiving notification from the Engineer of the Contractor's conformance with the QCP, the Contractor may encase in concrete or cover any welds for which a Welding Report has been submitted. However, should the Contractor elect to encase or cover those welds prior to receiving notification from the Engineer, it is expressly understood that the Contractor shall not be relieved of the responsibility for incorporating material in the work that conforms to the requirements of the plans and specifications. Any material not conforming to these requirements will be subject to rejection. Should the Contractor elect to wait to encase or cover any v3 7/31/02 Contract No. 3907 Page 279 of 414 welds pending notification by the Engineer, and should the Engineer fail to complete the review and provide notification within this time allowance, and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in notification, the delay will be considered a right of way delay as specified in Section 6-6, "Delays and Extensions of Time," of the SSPWC. Sections 6.1.1 through 6.1.3.3 of AWS D 1.1, Sections 7.1.1 and 7.1.2 of AWS D 1.4, and Sections 6.1 .I .1 through 6.1.3.3 of AWS D 1.5 are replaced with the following: Quality Control (QC) shall be the responsibility of the Contractor. As a minimum, the Contractor shall perform inspection and testing prior to welding, during welding and after welding as specified in this section and additionally as necessary to ensure that materials and workmanship conform to the requirements of the contract documents. The Quality Control (QC) Inspector shall be the duly designated person who performs inspection, testing, and quality matters for all welding. Quality Assurance (QA) is the prerogative of the Engineer. The QA Inspector is the duly designated person who acts for and on behalf of the Engineer. All QC Inspectors shall be responsible for quality control acceptance or rejection of materials and workmanship, and shall be currently certified as AWS Certified Welding Inspectors (CWI) in accordance with the provisions of AWS QCI, "Standard and Guide for Qualification of Welding Inspectors." The QC Inspector may be assisted by an Assistant QC Inspector provided that this individual is currently certified as an AWS Certified Associate Welding Inspector (CAWI) in accordance with the provisions of AWS QC1 , "Standard and Guide for Qualification of Welding Inspectors," or has equivalent qualifications. The QC Inspector shall monitor the Assistant QC Inspector's work, and shall be responsible for signing all reports. When the term "Inspector" is used without further qualification, it shall refer to the QC Inspector. Section 6.14.7, "Personnel Qualification," of AWS D 1 .I, Section 7.7.6, "Personnel Qualification," of AWS D 1.4 and Section 6.1.3.4, "Personnel Qualification," of AWS D 1.5 are amended to read: Personnel performing NDT shall be qualified in accordance with the current edition of the American Society for Nondestructive Testing (ASNT) Recommended Practice No. SNT-TC-1 A and the Written Practice of the NDT firm. Only individuals who are 1) qualified for NDT Level II, or 2) Level Ill technicians who have been directly certified by the ASNT and are authorized to perform the work of Level II technicians, shall perform NDT, review the results, and prepare the written reports. Section 6.5.4, "Scope of Examination," of AWS D 1.1 and Section 7.5.4 of AWS D 1.4 are amended to read: The QC Inspector shall inspect and approve the joint preparation, assembly practice, welding techniques, and performance of each welder, welding operator, and tack welder to make certain that the applicable requirements of this code and the approved WPS are met. Section 6.5.4 of AWS D 1.5 is amended to read: The QC Inspector shall inspect and approve the joint preparation, assembly practice, welding techniques, and performance of each welder, welding operator, and tack welder to make certain that the applicable requirements of this code and the approved WPS are met. The QC Inspector.shall examine the work to make certain that it meets the requirements of section 3 and 9.21. The size and contour of welds shall be measured using suitable gages. Visual inspection for cracks in welds and base metal, and for other discontinuities should be aided by strong light magnifiers, or such other devices as may be helpful. Acceptance criteria different from those specified in this code may be used when approved by the Engineer. The Engineer shall have the authority to verify the qualifications or certifications of any welder, Quality Control Inspector, or NDT personnel to specified levels by retests or other means. G 7/31/02 Contract No. 3907 Page 280 of 414 A sufficient number of QC Inspectors shall be provided to ensure continuous inspection when any welding is being performed. Continuous inspection, as a minimum, shall include (1) having QC Inspectors continually present on all shifts when any welding is being performed, or (2) having a QC Inspector within such close proximity of all welding operations that inspections by the QC Inspector of each operation, at each welding location, shall not lapse for a period exceeding 30 minutes. Inspection and approval of the joint preparation, assembly practice, welding techniques, and performance of each welder, welding operator, and tack welder shall be documented by the QC Inspector on a daily basis for each day that welding is performed. The QC Inspector shall provide reports to the QCM on a daily basis for each day that welding is performed. Except for noncritical weld repairs, base metal repairs, or any other type of repairs not submitted in the QCP, the Engineer shall be notified immediately in writing when any welding problems or deficiencies are discovered and also of the proposed repair procedures to correct them. The Engineer shall have 5 working days to review these procedures. No remedial work shall begin until the repair procedures are approved in writing by the Engineer. Should the Engineer fail to complete the review within this time allowance and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in reviewing the proposed repair procedures, the delay will be considered a right of way delay as specified in Section 6-6, "Delays and Extensions of Time," of the SSPWC. When joint details that are not prequalified by the applicable AWS codes are proposed for use in the work, all welders using these details shall perform a qualification test plate using the approved WPS variables and the joint detail to be used in production. The test plate shall be the maximum thickness to be used in production. The test plate shall be mechanically or radiographically tested as directed by the Engineer. Mechanical and radiographic testing and acceptance criteria shall be as specified in the applicable AWS codes. The period of effectiveness for a welder's or welding operator's qualification shall be a maximum of 3 years for the same weld process, welding position, and weld type. A valid qualification at the beginning of work on a contract will be acceptable for the entire period of the contract, as long as the welder's work remains satisfactory All qualification tests for welders, welding operators, and WPSs used in welding operations will be witnessed by the Engineer or an independent third party acceptable to the Engineer. Section 6.6.5, "Nonspecified Nondestructive Testing Other Than Visual," of AWS D 1 .I, Section 6.6.5 of AWS D 1.4 and Section 6.6.5 of AWS D 1.5 shall not apply. For any welding, the Engineer may direct the Contractor to perform NDT that is in addition to the visual inspection or NDT specified in the AWS welding codes, in the SSPWC or in these Special Provisions. Additional NDT required by the Engineer, will be paid for as extra work in accordance with Section 3-2, "Changes Initiated by the Agency," of the SSPWC. Should any welding deficiencies be discovered by this additional NDT, the cost of the testing will not be paid for as extra work, and shall be at the Contractor's expense. All required repair work to correct welding deficiencies, whether discovered by the required visual inspection or NDT, or by additional NDT directed by the Engineer, and any associated delays or expenses caused to the Contractor by performing these repairs, shall be at the Contractor's expense. At the completion of all welding, the QCM shall sign and furnish to the Engineer, a certificate of -compliance for each item of work for which welding was performed. The certificate shall state that all of the materials and workmanship incorporated in the work, and all required tests and inspections of this work, have been performed in accordance with the details shown on the plans and the provisions of the SSPWC and these Special Provisions. 7/31/02 Contract No. 3907 Page 281 of 414 Full compensation for conforming to all of the requirements of this section, Welding Quality Control, shall be considered as included in the contract prices paid for the various contract items of work involved and no additional compensation will be allowed therefor. Add the following subsection: 303-1.7.2C Ultimate Butt Splices. Ultimate butt splices shall be either welded or mechanical splices, shall be used at the locations shown on the plans, and shall conform to the provisions in Section 201-2, "Reinforcement for Concrete" and Section 303-1.7, "Placing Reinforcement" of the SSPWC and these special provisions. General Requirements: The Contractor shall designate in writing an ultimate butt splicing Quality Control Manager (QCM). The QCM shall be responsible directly to the Contractor for 1) the quality of all ultimate butt splicing including the inspection of materials and workmanship performed by the Contractor and all subcontractors; and 2) submitting, receiving, and approving all correspondence, required submittals, and reports regarding ultimate butt splicing to and from the Engineer. The QCM shall not be employed or compensated by any subcontractor, or by other persons or entities hired by subcontractors, who will provide other services or materials for the project. The QCM may be an employee of the Contractor. The length of any type of ultimate mechanical butt splice shall not exceed 10 times the bar diameter of the larger bar to be spliced. All ultimate prejob, production, and job control sample splices shall be 1) a minimum length of 5 feet for reinforcing bars No. 8 or smaller and 6 feet for reinforcing bars No. 9 or larger, with the splice located at mid-point, and 2) suitably identified prior to shipment with weatherproof markings that do not interfere with the Engineer's tamper-proof markings or seals. Any splice that shows signs of tampering will be rejected. A minimum of one control bar shall be removed from the same bar as, and adjacent to, all ultimate prejob, production, and job control sample splices. Control bars shall be 1) a minimum length of three feet for reinforcing bars No. 8 or smaller and 5 feet for reinforcing bars No. 9 or larger, and 2) suitably identified prior to shipment with weatherproof markings that do not interfere with the Engineer's tamper- proof markings or seals. The portion of adjacent bar remaining in the work shall also be identified with weatherproof markings that correspond to its adjacent control bar. Shorter length sample splice and control bars may be furnished if approved in writing by the Engineer. Each sample splice and its associated control bar shall be identified and marked as a set. Each set shall be identified as representing a prejob, production, or job control sample splice. The portion of hoop reinforcing bar, removed to obtain a sample splice and control bar, shall be replaced using a prequalified ultimate mechanical butt splice, or the hoop shall be replaced in kind. Plans must clearly show the location of the "No Splice Zones." Reinforcing bars, other than hoops, from which sample splices are removed, shall be repaired using ultimate mechanical butt splices conforming to the provisions in "Prejob Test Requirements for Ultimate Butt Splices" specified herein, or the bars shall be replaced in kind. These bars shall be repaired or replaced such that no splices are located in the "No Splice Zone" shown on the plans. The provisions for total slip shall not apply to any ultimate splices that are welded or that are used on hoops. The independent qualified testing laboratory used to perform the testing of all ultimate butt sample splices and control bars shall not be employed or compensated by any subcontractor, or by other persons or entities hired by subcontractors who will provide other services or materials for the project, and shall have the following: Proper facilities, including a tensile testing machine capable of breaking the largest size of A. reinforcing bar to be tested. a 7/31/02 Contract No. 3907 Page 282 of 414 B. A device for measuring the total slip of the reinforcing bars across the splice to the nearest 0.001 inch, that, when placed parallel to the longitudinal axis of the bar is able to simultaneously measure movement across the splice, at 2 locations, 180 degrees apart. C. Operators who have received formal training for performing the testing requirements of ASTM Designation: A 370/A 370M and California Test 670. D. A record of annual calibration of testing equipment performed by an independent third party that has 1) standards that are traceable to the National Institute of Standards and Technology, and 2) a formal reporting procedure, including published test forms. Ultimate Butt Splice Test Criteria Ultimate prejob, production, and job control sample splices shall be tensile tested in conformance with the requirements described in ASTM Designation: A 370/A 370M and California Test 670. Ultimate prejob and production sample splices shall rupture in the reinforcing bar either: 1 ) outside of the affected zone or 2) within the affected zone, provided that the sample has achieved at least 95 percent of the ultimate tensile strength of the control bar associated with the sample. In addition, necking of the bar shall be visibly evident at rupture regardless of whether the bar breaks inside or outside the affected zone. The affected zone is the portion of the reinforcing bar where any properties of the bar, including the physical, metallurgical, or material characteristics, have been altered by fabrication or installation of the splice. The ultimate tensile strength of each control bar shall be determined by tensile testing the bar to rupture and shall be determined for all control bars, regardless of where each sample splice ruptures. If 2 control bars are tested for one sample splice, the bar with the lower ultimate tensile strength shall be considered the control bar. Testing to determine the minimum tensile strength will not be required. Prejob Test Requirements for Ultimate Butt Splices Prior to use in the work, all ultimate butt splices shall conform to the following prejob test requirements: A. Eight prejob sample splices for each bar size of each splice type including ultimate mechanical butt splices, ultimate complete joint penetration butt welded splices, and ultimate resistance butt welded splices, that will be used in the work, shall be fabricated by the Contractor. For deformationdependent types of couplers, 8 sample prejob splices shall also be fabricated for each reinforcing bar size and deformation pattern that will be used in the work. B. The sample splices shall be fabricated using the same splice materials, position, operators, location, and equipment, and following the same procedures as will be used to make the splices in the work. In addition, for resistance butt welded splices, the sample splices shall have the weld flash removed and be epoxy-coated as specified elsewhere in these special provisions. C. At the option of the Contractor, operator qualification tests may be performed simultaneously with the preparation of prejob sample splices. D. If different diameters of hoops are shown on the plans, prejob sample splices, as described above, will only be required for the smallest hoop diameter. In addition, these splices shall be fabricated using the same radius as shown on the plans for these hoops. E. Unless otherwise directed in writing by the Engineer, 4 prejob sample splices and control bar sets shall be shipped to the Transportation Laboratory and the remaining 4 sets shall be tested by the Contractor's independent qualified testing laboratory. F. Each group of 4 sets from a prejob test shall be securely bundled together and identified by location and contract number with weatherproof markings prior to shipment. Bundles Qlr tQ 7/31 102 Contract No. 3907 Page 283 of 414 containing fewer than 4 sets will not be tested by the Transportation Laboratory, nor shall they be tested by the independent laboratory. G. All 8 sample splices from each prejob test shall conform to the provisions in "Ultimate Butt Splice Test Criteria" specified herein. H. Prior to performing any tensile tests on prejob test sample splices, one of the 4 samples shall be tested for, and shall conform to, the provisions for total slip. Should this sample not meet these requirements, one retest, in which the 3 remaining samples are tested for total slip, will be allowed. All 3 of these remaining samples tested shall conform to the aforementioned slip requirements. I. For each bundle of 4 sets, a Prejob Test Report shall be prepared by the independent testing laboratory performing the testing. The report shall 1) be signed by an engineer who represents the laboratory and is registered as a Civil Engineer in the State of California; 2) include, as a minimum, the following information for each set: contract number, bridge number, bar size, type of splice, length of mechanical splice, physical condition of test sample splice and control bar, any notable defects, limits of affected zone, total measured slip, location of visible necking area, ultimate strength of each splice, ultimate strength and 95 percent of this ultimate strength for each control bar, and a comparison between 95 percent of the ultimate strength of each control bar and the ultimate strength of its associated splice; and 3) be submitted to the QCM for review and approval, and then to the Engineer. J. Test results for each bundle of 4 sets will be reported in writing to the Contractor within 10 working days after receipt of the bundle by the testing laboratory. In the event that more than one bundle is received on the same day, 2 additional working days shall be allowed for providing test results for each additional bundle received. A test report will be made for each bundle received. K. Should the Engineer fail to provide the test results within this time allowance and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in providing the test results, the delay will be considered a right of way delay in conformance with the provisions in Section 6-6, "Delays and Extensions of Time," of the SSPWC. Production Test Requirements for Ultimate Butt Splices Production tests shall be performed for all ultimate butt splices used in the work. A production test shall consist of 4 sets of sample splices and control bars removed from each lot of completed splices, except when quality assurance tests are performed. A lot of ultimate butt splices is defined as 1) 150, or fraction thereof, of the same type of ultimate mechanical butt splices used for each bar size and each bar deformation pattern that is used in the work or 2) 150, or fraction thereof, of ultimate complete joint penetration butt welded splices, or ultimate resistance butt welded splices for each bar size used in the work. If different diameters of hoop reinforcement are shown on the plans, separate lots shall be used for each different hoop diameter. After all splices in a lot have been completed and the bars have been epoxy-coated, the QCM shall notify the Engineer in writing that all couplers in this lot conform to the specifications and are ready for testing. The sample splices will either be selected by the Engineer at the job site or a fabrication facility, provided the facility is located within an 80-km radius of the jobsite. At the option of the Contractor, sample splices for spiral reinforcement, may be either 1) removed from the completed lot, or 2) prepared in the same manner as specified herein for ultimate prejob sample splices and control bars. After notification has been received, the Engineer will randomly select the 4 sample splices to be removed from the lot and place tamper-proof markings or seals on them. The Contractor or QCM shall select the adjacent control bar for each sample splice bar, and the Engineer will place tamper-proof markings or seals on them. These ultimate production sample splices and control bars shall be removed 7/31/02 Contract No. 3907 Page 284 of 414 by the Contractor, and tested by an independent qualified testing laboratory, in the presence of either the Engineer or the Engineer's authorized representative. The Engineer or the Engineer's authorized representative will be at the independent qualified testing laboratory within a maximum of 5 working days after receiving written notification that the samples are at the laboratory and ready for testing. Should the Engineer or the Engineer's authorized representative fail to be at the laboratory within this time allowance, and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of this action, the delay will be considered a right of way delay in conformance with the provisions in Section 6-6, "Delays and Extensions of Time," of the SSPWC. A sample splice or control bar from any set will be rejected if any tamper-proof marking or seal is disturbed prior to testing. The 4 sets from each production test shall be securely bundled together and identified with a completed sample identification card prior to shipment to the independent laboratory. The card will be furnished by the Engineer. Bundles of samples containing fewer than 4 sets of splices shall not be tested. A Production Test Report for all testing performed on each lot shall be prepared by the independent testing laboratory performing the testing and submitted to the QCM for review and approval. The report shall be signed by an engineer who represents the laboratory and is registered as a Civil Engineer in the State of California. The report shall include, as a minimum, the following information for each set: contract number, bridge number, lot number and location, bar size, type of splice, length of mechanical splice, physical condition of test sample splice and control bar, any notable defects, limits of affected zone, total measured slip, location of visible necking area, ultimate strength of each splice, ultimate strength and 95 percent of this ultimate strength for each control bar, and a comparison between 95 percent of the ultimate strength of each control bar and the ultimate strength of its associated splice. The QCM must review, approve, and forward each Production Test Report to the Engineer for review before any splices represented by the report are encased in concrete. The Engineer shall have 3 working days to review each Production Test Report and respond in writing after a complete report has been received. Should the Contractor elect to encase any splices prior to receiving notification from the Engineer, it is expressly understood that the Contractor will not be relieved of the Contractor's responsibility for incorporating material in the work that conforms to the requirements of the plans and specifications. Any material not conforming to these requirements will be subject to rejection. Should the Contractor elect to wait to encase any splices pending notification by the Engineer, and should the Engineer fail to complete the review and provide notification within this time allowance, and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in notification, the delay will be considered a right of way delay in conformance with the provisions in Section 6-6, "Delays and Extensions of Time," of the SSPWC. Prior to performing any tensile tests on production test sample splices, one of the 4 samples shall be tested for, and shall conform to, the provisions for total slip. Should this sample not meet these requirements, one retest, in which the 3 remaining samples are tested for total slip, will be allowed. Should any of the 3 remaining samples not conform to these requirements, all splices in the lot represented by this production test will be rejected. If 3 or more sample splices from any production test conform to the provisions in "Ultimate Butt Splice Test Criteria" specified herein, all splices in the lot represented by this production test win be considered acceptable. Should only 2 sample splices from any production test conform to the provisions in "Ultimate Butt Splice Test Criteria" specified herein, one additional production test shall be performed on the same lot of 'splices. Should any of the 4 sample splices from this additional test fail to conform to these provisions, all splices in the lot represented by these production tests will be rejected. If only one sample splice from any production test conforms to the provisions in "Ultimate Butt Splice Test Criteria" specified herein, all splices in the lot represented by this production test will be rejected. 7/31/02 Contract No. 3907 Page 285 of 414 If a production test for any lot fails, the Contractor will be required to repair or replace all reinforcing bars from which sample splices were removed, complete in place, before the Engineer selects any additional splices from this lot for further testing. Whenever any lot of ultimate butt splices is rejected, additional ultimate butt splices shall not be used in the work until 1) the QCM performs a complete review of the Contractor's quality control process for these splices, 2) a written report is submitted to the Engineer describing the cause of failure for the splices in this lot and provisions for correcting these failures in future lots, and 3) the Engineer has provided the Contractor with written notification that the report is acceptable. The Engineer shall have 3 working days after receipt of the report to provide notification to the Contractor. Should the Engineer not provide notification within this time allowance, and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of this action, the delay will be considered a right of way delay in conformance with the provisions in Section 6-6, "Delays and Extensions of Time," of the SSPWC. Production tests will not be required on any repaired splice from a lot, regardless of the type of prequalified ultimate mechanical butt splice used to make the repair. Should an additional production test be required, the Engineer may select any repaired splice for use in the additional production test. Quality Assurance Test Requirements for Ultimate Butt Splices: For the first production test performed, and for at least one, randomly selected by the Engineer, of every 5 additional production tests, or portion thereof, performed thereafter, the Contractor shall concurrently prepare 4 additional ultimate job control sample splices along with associated control bars. These ultimate job control samples shall be prepared in the same manner as specified herein for ultimate prejob sample splices and control bars. Each time 4 additional ultimate job control sample splices are prepared, 2 of these job control sample splice and associated control bar sets and 2 of the production sample splice and associated control bar sets, together, shall conform to the requirements for ultimate production sample splices in "Production Test Requirements for Ultimate Butt Splices" specified herein. The 2 remaining job control sample splice and associated control bar sets, along with the 2 remaining production sample splice and associated control bar sets shall be shipped, unless otherwise directed in writing by the Engineer, to a second independent laboratory for quality assurance testing. The 4 sets shall be securely bundled together and identified by location and contract number with weatherproof markings prior to shipment. Bundles containing fewer than 4 sets will not be tested. Quality assurance testing will be performed in conformance with the requirements for ultimate production sample splices in "Production Test Requirements for Ultimate Butt Splices" specified herein. Test results for each bundle of 4 sets will be reported in writing to the Contractor within 3 working days after receipt of the bundle by the second independent laboratory. In the event that more than one bundle is received on the same day, 2 additional working days shall be allowed for providing test results for each additional bundle received. A test report will be made for each bundle received. Should the Contractor elect to encase any splices prior to receiving notification from the Engineer, it is expressly understood that the Contractor will not be relieved of the Contractor's responsibility for incorporating material in the work that conforms to the requirements of the plans and specifications. Any material not conforming to these requirements will be subject to rejection. Should the Contractor elect to wait to encase any splices pending notification by the Engineer, and should the Engineer fail to complete the review and provide notification within this time allowance, and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in notification, the delay will be considered a right of way delay in conformance with the provisions in Section 6-6, "Delays and Extensions of Time," of the SSPWC. The second independent laboratory shall conform to the requirements of these specifications and not be associated with the independent qualified testing laboratory. Payment for the second independent laboratory shall be made by the contractor. @ 7/31/02 Contract No. 3907 Page 286 of 414 Full compensation for conforming with all of the requirements of this section, Ultimate Butt Splice, shall be considered as included in the contract price paid for the various contract items of work involved and no additional compensation will be allowed therefor. 303-1.8.6 Joints. Add the following: Where shown on the plans, joints in structures shall be sealed with joint seals or joint seal assemblies in accordance with the details shown on the plans, the provisions in the specifications and these Special Provisions. Joint seal assemblies shall consist of metal or metal and elastomeric assemblies which are anchored or cast into a recess in the concrete over the joint. Joint seal assemblies shall be used when the Movement Rating (MR) ‘shown on the plans is more than 2 inches. 303-1.8.7 Application of Joint Sealants. Add the following subsection: (9 Joint Seal Assemblies. Sealed joints shall comply with the following requirements: 1. The seal shall be in planned position. 2. The seal shall satisfactorily resist the intrusion of foreign material and water. 3. The seal shall provide bump free passage of traffic. Joints to be sealed shall be covered or otherwise protected at all times prior to installing joint seals to prevent debris and other foreign material from entering the joint. Hardboard and expanded polystyrene shall-conform to the provisions Section 201 -3.3 of the SSPWC. Joints in the sheet metal shall be butt joints sealed with plastic duct sealing tape. Metal parts of the joint seal assembly shall be pre-assembled before installation to verify the geometry of the completed seal. 303-1.8.1 0 Reinforced Elastomeric Bearing Pads Add the following subsection: Reinforced Elastomeric Bearing Pads Reinforced Elastic Bearing ads shall conform to the requirements of Section 51-1.12H(l) and Section 51- l.ZH(2) of CALTFWNS Standard Specifications Add the following subsection: 303-1.9.5 Finishing Bridge Decks: Bridge Deck finish shall conform to the requirements of Section 51-1.17 of the Caltrans Standard Specifications with the following addition. Deck Crack Treatment The Contractor shall use all means necessary to minimize the development of shrinkage cracks. The Contractor shall remove all equipment and materials from the deck and clean the surface as necessary for the Engineer to measure the surface crack intensity. Surface crack intensity will be determined by the Engineer after completion of concrete cure, prior to prestressing, and prior to the release of falsework. In any 50-m2 portion of deck within the limits of the new concrete deck, should the intensity of cracking be such that there are more than 5 m of cracks whose width at any location exceeds OS-mm, the deck shall be treated with methacrylate resin. The area of deck to be treated shall have a width that extends for the entire width of new deck inside the concrete barriers and a length that extends at least 1.5 rn beyond the furthest single continuous crack outside the 50-m2 portion, measured from where that crack exceeds 0.5-mm in width, as determined by the Engineer. - e 7/31/02 Contract No. 3907 .. Page 287 of 414 Deck crack treatment shall consist of test sealing, and furnishing and applying methacrylate resin in conformance with the requirements of these special provisions. If grinding operation is required, deck treatment shall take place after grinding. Prior to the start of deck treatment work, the Contractor shall submit for approval by the Engineer, a program for public safety associated with the use of methacrylate resin. The program shall identify materials, equipment, and methods to be used. The Contractor shall not perform deck treatment work, other than that specifically authorized in writing by the Engineer, until the program has been approved. If the measures being taken by the Contractor are inadequate to provide for public safety associated with use of methacrylate resin, the Engineer will direct the Contractor to revise the operations and the public safety program. Directions for revisions will be in writing and will specify the items in which the Contractor's program is inadequate. No further deck treatment shall be performed until public safety measures are adequate, and a revised program for public safety has been approved. The Engineer will notify the Contractor of the approval or rejection of any submitted or revised program for public safety associated with the use of methacrylate resin within 10 working days of receipt of the final submitted program. The City will not be liable to the Contractor for failure to approve all or any portion of an originally submitted or revised program for public safety associated with the use of methacrylate resin, nor for any delays to the work due to the Contractor's failure to submit an acceptable program for public safety associated with the use of methacrylate resin. If the Engineer does not review or approve the program submitted by the Contractor within the time specified and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in reviewing the program for public safety, the delay will be considered a right of way delay in conformance with the provisions in Section 8-1.09, "Right of Way Delays," of the Standard Specifications. The Contractor shall furnish an airborne emissions monitoring plan prepared by a certified industrial hygienist. Emissions will be monitored at a minimum of 4 points including the point of mixing, the point of application, and the point of nearest public contact, as determined by the Engineer. At the completion of work, a report by the certified industrial hygienist with results of the airborne emissions monitoring plan shall be furnished to the Engineer. 9. Use in urban areas, and delete Para 10, but retain the table. Materials: The material used for treating the deck shall be a low odor, high molecular weight methacrylate resin. Prior to adding initiator, the resin shall have a maximum volatile content of 30 percent when tested in conformance with the requirements in ASTM Designation: D 2369, and shall conform to the following: The material used for treating the deck shall be a high molecular weight methacrylate resin conforming to the following: 7 UL adaptor, 50 RPM at 25°C) minimum, at 25°C Flash Point Specific Gravity I mPa s, maximum, (Brookfield RVT with I I' I ASTM D 1475 0.90 ASTM D 3278 82 "C, minimum Vapor Pressure mm Hg, maximum, at 25°C Tack-free time ASTM D 323 1 .o California Test 400 minutes, maximum at 25°C Strength PCC Saturated Surface-Dry Bond MPa, minimum at 24 hours and 21kl "C I I * Test shall be performed prior to adding initiator. 551 551 California Test 3.5 q' 7/31/02 Contract No. 3907 Page 288 of 414 A Material Safety Data Sheet shall be furnished prior to use for each shipment of high molecular weight methacrylate resin. The promoter and initiator, if supplied separately from the resin, shall not be mixed directly with each other. Containers of promoters and initiators shall not be stored together in a manner that will allow leakage or spillage from one to contact the containers or material of the other. Testing: The Contractor shall allow 14 days for sampling and testing by the Engineer of the high molecular weight methacrylate resin prior to proposed use. The Contractor shall treat a test area within the project limits of approximately 50 m2 at a location approved by the Engineer. Conditions during the test treatment shall be similar to those expected on the deck. Equipment used in the test shall be similar to those used for the deck treating operations. If the test area is on the traveled way, traffic shall not be allowed on the treated test area until (1) the treated surface is tack free (non-oily), (2) the sand cover adheres sufficiently to resist brushing by hand, and (3) the coefficient of friction of the deck is at least 0.35 when tested in conformance with the requirements in California Test 342. Should the above requirements for traffic use not be met, the Contractor shall suspend treating of bridge decks until another test area is treated and complies with the requirements. Construction: Prior to deck treatment with methacrylate resin, the bridge deck surface shall be cleaned by abrasive blasting and all loose material shall be blown from visible cracks using high-pressure air. Concrete curing seals shall be cleaned from the deck surface to be treated, and the deck shall be dry when blast cleaning is performed. If the deck surface becomes contaminated at any time prior to placing the penetrating sealer, the deck surface shall be cleaned by abrasive blasting. Equipment shall be fitted with suitable traps, filters, drip pans, or other devices as necessary to prevent oil or other deleterious material from being deposited on the deck. Where abrasive blasting is being performed within 3 m of a lane occupied by public traffic, the residue including dust shall be removed immediately after contact between the abrasive and the surface being treated. The removal shall be by a vacuum attachment operating concurrently with the abrasive blasting operation. The relative humidity shall be less than 90 percent at time of treatment. A compatible promoterlinitiator system shall be capable of providing a resin gel time of not less than 40 minutes nor more than 1.5 hours at the temperature of application. Gel time shall be adjusted to compensate for the changes in temperature throughout treatment application. The quantity of resin mixed with promoter and initiator shall be limited to 20 L at a time for manual application. Machine application of the resin shall be performed by using a two-part resin system using a promoted resin for one part and an initiated resin for the other part. This two-part resin system shall be combined at equal volumes to the spray bars through separate positive displacement pumps. Combining of the 2 components shall be by either static in-line mixers or by external intersecting spray fans. The pump pressure at the spray bars shall not be great enough to cause appreciable atomization of the resin. Compressed air shall not be used to produce the spray. A shroud shall be used to enclose the spray bar apparatus. Hand held spray apparatus shall not be used. The Contractor shall allow methacrylate resin to be applied only to the specified area. Barrier rails, joints, and drainage facilities shall be adequately protected to prevent contamination by the treatment material. Contaminated items shall be repaired at the Contractor's expense. The prepared area shall be dry and the surface temperature shall be less than or equal to 38°C when the resin is applied. The rate of application of promoted/initiated resin shall be approximately 2.5 square meters per liter, f 0.1 square meter per liter. The deck surfaces to be treated shall be flooded with resin, allowing penetration into the concrete and filling of all cracks. The treatment shall be applied within 5 minutes after complete mixing. A significant - @ 7/31/02 Contract No. 3907 Page 289 of 414 increase in viscosity shall be cause for rejection. Excess material shall be redistributed by squeegees or brooms within 10 minutes after application. After the resin has been applied, at least 20 minutes shall elapse before applying sand. The sand shall be commercial quality dry blast sand. Ninety-five percent of the sand shall pass the 2.36-mm sieve, and 95 percent shall be retained on the 850-vm sieve. The sand shall be applied at a rate of one kilogram per square meter, f 0.1 kilogram per square meter. Excess sand shall be removed from the deck surface by vacuuming or sweeping prior to opening to traffic. Traffic shall not be allowed on the treated area until (1) the treated surface is tack free (non-oily), (2) the sand cover adheres sufficiently to resist brushing by hand, and (3) the coefficient of friction of the deck is at least 0.35 when tested in conformance with the requirements in California Test 342. 303-1.11 Payment. Add the following: Payment for concrete anchors, concrete pipe collar, pipe plug, brow ditches, utility crossing (protection encasement), minor and major drainage channels, storm drain cleanouts, junction structures, transition structures, curb inlets, curb outlets, curb ramps, catch basins, and headwalls, shall be made at the contract unit prices bid and shall include all labor, tools, equipment and materials (including reinforcement, earthwork, rip-rap and miscellaneous metal) required to furnish and install, complete in place the concrete structure, as shown in the plans, as specified in these Special Provisions. Cutoff walls constructed with brow ditches, cutoff walls constructed with concrete aprons, gutter depressions constructed with inlets and concrete aprons constructed with CSP inlets shall be considered as included in price paid for item for which previous is constructed with and no additional compensation will be allowed. The lump sum price paid for Concrete Retaining Wall shall include full compensation for furnishing all labor, materials, tools, and equipment and performing all work necessary to construct the concrete retaining wall and wood fence as shown on the plans and as specified herein including excavation, backfill, bar reinforcing steel, geocomposite drain, weep holes, and expansion joint filler. The Lump Sum Price paid for Complete Bridge in Place shall be full payment for all labor, tools, equipment, and materials, (including excavation, backfill, dewatering, disposing of surplus material, creating maintaining and removing an area of dry substrate for wildlife movement, pile construction, bar reinforcing steel, bearing pads, post tensioning, joint seal assemblies and joint armor, concrete approach slab, concrete barriers, conduits and casings placed in concrete barriers, deck drainage system, irrigation line placed in concrete barrier, parapet and tubular handrailing, miscellaneous iron and steel, utility blockouts, and removing forms), necessary to construct Rancho Santa Fe Rd. Left and Right Bridges as shown on the plans and specified in these Special Provisions. All other piping, conduit, support blocks, expansion and swivel joints shall not be included in the price paid for Complete Bridge in Place. 303-2 AIR-PLACED CONCRETE 303-2.1.1 General. Add the following: Modify Regional Standard Drawing D-75 as follows: replace stucco netting with 150mm x 150mm (6" x 6") by No. 10 welded wire mesh. Add the following: This work shall include the construction of apron median gunite ditch as shown on the plans, and as specified herein. 303-2.11 Measurement and Payment. Add the following: Payment for median gunite ditch will be made at the contract unit price and shall include all labor, tools, equipment and materials (including reinforcement and miscellaneous metal) required to furnish and install, complete in place median gunite ditch, as shown on the plans, as specified in these special provisions, and as directed by the Engineer. G 7/31/02 Contract No. 3907 Page 290 of 414 303-3 PRESTRESSED CONCRETE CONSTRUCTION 303-3.1 General. Replace the first sentence with: This work shall consist of prestressing precast or cast- in-place concrete by furnishing, placing, and tensioning of prestressing steel in accordance with details shown on the plans, and as specified in these specifications and the Special Provisions. 303-3.3 Prestressing Steel. Add the following to paragraph 8: Prestressing steel shall be packaged in containers or shipping forms for the protection of the steel against physical damage and corrosion during shipping and storage. A corrosion inhibitor which prevents rust or other results of corrosion shall be placed in the package or form, or shall be incorporated in a corrosion inhibitor carrier type packaging ma- terial, or when permitted by the Engineer, may be applied directly to the steel. The corrosion inhibitor shall have no deleterious effect on the steel or concrete or bond strength of steel to concrete. Packaging or forms damaged from any cause shall be immediately replaced or restored to original condition. The shipping package or form shall be clearly marked with a statement that the package contains high- strength prestressing steel, and the type of corrosion inhibitor used, including the date packaged. When acceptable prestressing steel for post-tensioning is installed in the ducts after completion of concrete curing, and if stressing and grouting are completed within 10 days after the installation of the prestressing steel, rust which may form during said 10 days will not be cause for rejection of the steel. Prestressing steel installed, tensioned and grouted in this manner, all within 10 days, will not require the use of a corrosion inhibitor in the duct following installation of the prestressing steel. Prestressing steel installed as above but not grouted within 10 days shall be subject to all the requirements in this section pertaining to corrosion protection and rejection because of rust. 303-3.5 Duct Enclosures. Add the following to paragraph 3: All compressed air used to blow out ducts shall be oil free. 303-3.6 Prestressing. Replace this section with the following: Prestressing steel shall be tensioned by means of hydraulic jacks so that the force in the prestressing steel shall not be less than the value shown on the plans. The maximum temporary tensile stress (jacking stress) in prestressing steel shall not exceed 75 percent of the specified minimum ultimate tensile strength of the prestressing steel. Pretensioned prestressing steel shall be anchored at stresses that will result in the ultimate retention of working forces at not less than those shown on the plans, but in no case shall the stress at anchorages after seating exceed 70 percent for normal relaxation strand, or 75 percent for low relaxation strand, of the specified minimum ultimate tensile strength of the prestressing steel. Working force and working stress will be considered as the force and stress remaining in the prestressing steel after all losses, including creep and shrinkage of concrete, elastic compression of concrete, creep of steel, losses in post-tensioned prestressing steel due to sequence of stressing, friction and take up of anchorages and all other losses peculiar to the method or system of prestressing have taken place or have been provided for. The loss in stress in post-tensioned prestressing steel due to creep and shrinkage of concrete, creep of steel and sequence of stressing shall be assumed to be 221 MPa (32,000 pounds per square inch} for normal relaxation wire or strand, 138 MPa (20,000 pounds per square inch} for low relaxation Are or strand and 152 MPa (22,000 pounds per square inch} for bars. If lightweight concrete is used, the loss shall be assumed to be 276 MPa (40,000 pounds per square inch} for normal relaxation wire or strand and 207 MPa (30,000 pounds per square inch} for low relaxation wire or strand. The loss in stress in pretensioned prestressing steel due to creep and shrinkage of concrete, creep of steel and elastic compression of concrete shall be assumed to be 310 MPa (45,000 pounds per square inch} for normal relaxation wire or strand and 242 MPa (35,000 pounds per square inch} for low relaxation wire or strand. If lightweight concrete is used, the loss shall be assumed to be 345 MPa - ?@ 7/31/02 Contract No. 3907 Page 291 of 414 (50,000 pounds per square inch} for normal relaxation strand or wire and 276 MPa (40,000 pounds per square inch) for low relaxation strand or wire. The following formula and friction coefficients shall be used in calculating friction losses in tendons: To = Txe (Ua + KI) Where: To = steel stress at jacking end Tx = steel stress at any point x e = base of Naperian logarithms U = friction curvature coefficient a = total angular change of prestressing steel profile in radians from jacking end to point x K = friction wobble coefficient (llmm) (l/ft} I = length of prestressing steel from jacking end to point x (mm) (ft} Type of Steel Wire or strand Plain bars Deformed bars Type of Duct K Galvanized- 0.0002 rigid Galvanized 6.6 x 10-7 (0.0002) Galvanized 9.9 x 10-7 (0.0003) U 0.15 0.1 5 0.30 - Each jack used to stress tendons shall be equipped with either: (1) two pressure gages or (2) one pressure gage and a load cell, at the option of the Contractor. The jack body shall be permanently marked with the ram area. Each pressure gage shall be fully functional and have an accurately reading dial at least 150 mm (6 inches} in diameter. The jack and each gage shall be calibrated as a unit with the cylinder extension in the approximate position that it will be at final jacking force. The load cell, if used, shall be calibrated and shall be provided with an indicator which may be used to determine the prestressing force in the tendon. The range of the load cell shall be such that the lower 10 percent of the manufacturer's rated capacity will not be used in determining the jacking stress. The jacking equipment calibration procedure shall be as follows: Each jack used to stress tendons, which are permanently anchored at 25 percent or more of the specified minimum ultimate tensile strength of the prestressing steel, shall be calibrated by the California Department of Transportation, Transportation Laboratory within one year prior to use and after each repair, unless otherwise directed. The Contractor shall be responsible for: 1. 2. 3. - 4. 5. Plotting the calibration results. Scheduling the calibration of the jacking equipment with the Transportation Laboratory; Verifying that the jack and supporting systems are complete, with proper components, and are in good operating condition; Mechanically calibrating the gages with a dead weight tester or other approved means prior to calibration of the jacking equipment by the Transportation Laboratory; Providing sufficient labor, equipment and material to install and support the jacking and calibration equipment and to remove the equipment after the calibration is complete; and e 7/31/02 Contract No. 3907 Page 292 of 414 Each jack used to stress tendons, which are permanently anchored at less than 25 percent of the specified minimum ultimate tensile strength of the prestressing steel, shall be calibrated by a private laboratory approved by the Transportation Laboratory within 6 months prior to use and after each repair, unless othewise directed. Prior to placing forms for closing slabs of box girder cells, the Contractor shall demonstrate to the satisfaction of the Engineer that either the prestressing steel is free and unbonded in the duct or, if prestressing steel has not yet been placed, that all ducts are unobstructed. Prior to post-tensioning any member, the Contractor shall demonstrate to the satisfaction of the Engineer that the prestressing steel is free and unbonded in the duct. Prestressing forces shall not be applied to cast-in-place concrete until at least 10 days after the last concrete has been placed in the member to be prestressed and until the concrete complies with one of the following requirements: 1. When the concrete is designated by compressive strength, the concrete compressive strength shall have reached the strength shown on the plans at the time of stressing. 2. When the concrete is designated by Class or cement content, either the concrete compressive strength shall have reached the strength shown on the plans at the time of stressing, or at least 28 days shall have elapsed since the last concrete to be prestressed has been placed, whichever occurs first. The tensioning process as applied to post-tensioned members shall be so conducted that tension being applied and the elongation of the prestressing steel may be measured at all times. Except as provided herein, tendons in continuous post-tensioned members shall be tensioned by jacking at each end of the tendon. Where one-end stressing is shown on the plans, tensioning of such tendons shall be done by jacking from one end or both ends of the tendon at the option of the Contractor. Prestressing tendons in simple span post-tensioned members may be tensioned by jacking from one end only. 303-3.10 Payment. Add the following: Prestressing concrete placed as shown on the plans and described in these Special Provisions shall be included in the lump sum price paid for Complete Bridge in Place. The prices paid for as above shall include full compensation for furnishing all labor, materials, tools, equipment and incidentals, and for doing all work involved in furnishing, placing, and tensioning the prestressing steel in cast-in-place concrete structures, complete in place, as shown on the plans, as specified in the specifications and these Special Provisions, and as directed by the Engineer. 303-4 MASONRY CONSTRUCTION Add the following section: 303-4.3 Articulated Block. Articulated Block shall be placed in accordance with the manufacturer‘s recommendations and the plans. Woven filter fabric shall be in accordance with Section 213 of the Standard Specifications. 303-4.3.1 Measurement and Payment. Articulated Concrete Block shall be measured by the square foot of material that is actually placed in accordance with the plans and with the approval of the Engineer. Payment for Articulated Block shall include all material, labor, equipment, and supervision required to install complete and in place the articulated concrete block as shown on the plans. Payment will include full compensation for earthwork, filter fabric, and cutting and splicing of block mats and no other payment will be allowed therefor. 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 @ 7/31/02 Contract No. 3907 Page 293 of 414 letters directly above the point that it is crossed by underground facilities with the marking specified in Table 303-5.5.2(A) Type of underground facilities Water Service Lateral Sewer Service Lateral Irrigation Water Lateral or Sleeve Marking W S RW 303-5.9 Measurement and Payment. add the following: Curb and gutter 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 tength of local depressions. Payment for Bus Turnout shall include all labor, equipment, and materiais to construct Bus Turnouts as shown on the plans including monolithic curb and gutter. Sidewalk adjacent the Bus Turnouts will be paid as PCC Sidewalk (4" Thick). Payment for Pedestrian Ramp Type C shall include all labor, equipment, and materials to construct Pedestrian Ramp Type C according to SDRSD G-29 and these Special Provisions including monolithic curb and gutter. 2" Type B1 Modified Curb, 4" Type B1 Modified Curb, 6" Type B1 Curb, 8" Type B1 Modified Curb and 8" Type B1 curb shall be measured and paid for as 8" Type B1 Modified Curb. 2" Type G Modified Curb, 4" Type G Modified Curb, and 6" Type G Modified Curb shall be measured and paid for as Type G Curb. 2" Type B2 Modified Curb, 4" Type 82 Modified Curb, and 8" Type 82 Modified Curb shall be measured and paid as 8" Type 82 Median Curb and Gutter. Add the following: Payment for PCC Driveways shall include full compensation for furnishing all labor, materials, tools and equipment, complete and in place, as shown on the plans, SDRSD G- 14A (6" Thick), City of Carlsbad Standard Drawing GS-20, and described in these Special Provisions, and as directed by the Engineer and no additional compensation will be allowed. Add the following: Payment for PCC Sidewalk shall include full compensation for furnishing all labor, materials, tools and equipment, complete and in place, as shown on the plans, SDRSD G-7, and described in these Special Provisions, and as directed by the Engineer and no additional compensation will be allowed. Add the following: Payment for PCC Bus Turnout shall include full compensation for furnishing all labor, materials, tools and equipment, complete and in place, as shown on the plans and described in these Special Provisions, and as directed by the Engineer and no additional compensation will be allowed. 303-6 STAMPED CONCRETE 303-6.3 Pattern. Add the following: Pattern shall match existing stamped concrete within raised median along Rancho Santa Fe Road, approximately 600' south of La Costa Avenue. For raised median north of Melrose Drive in the City of San Marcos, pattern shall be 'Flagstone'. 303-6.3.1 Method B (Intecrral Color). Add the following: Method B (Integral Color) method shall be used. Color shall be natural. For raised median north of Melrose Drive in the City of San Marcos, color shall be 'Terra Cotta'. Add the following section: 303-6.5 Payment. The contract unit price paid for stamped concrete (4" or 6" thick as indicated in Plans) shall include full compensation for furnishing all labor, materials, tools and equipment, 7/31/02 Contract No. 3907 Page 294 of 414 complete and in place, as shown on the plans and described in these Special Provisions, and as directed by the Engineer and no additional compensation will be allowed. Add the following: Construction of concrete thrust blocks for recycled water mains shall conform to Standard Drawing W15 of the Carlsbad Municipal Water District Rules and Regulations for construction of Public Recycled Water Mains, latest edition or to the Vallecitos Water District Standard Specification for Construction of Reclaimed Water Mains and Approved Materials List, latest edition, (depending upon the jurisdiction) and 303-12 CONCRETE THRUST BLOCKS . Sheet 59 of the Plans. Add the following: 303-12.1 Payment Payment for the installation of concrete thrust blocks as shown on the plans shall be considered as included in the various items of work for which the thrust blocks are required and no other payment will be made therefor. SECTION 304 - METAL FABRICATION AND CONSTRUCTION 304-2.1.4 Measurement and Payment. Add the following: Payment for Tubular Handrailing shall be considered as included in the lump sum price paid for Complete Bridge in Place and no other payment will be made therefor. Payment for Pedestrian Protective Railing, per SDRSD M-24 shall be considered as included in the lump sum price paid for Concrete Retaining Wall NO.^), and Concrete Retaining Wall (No. 2) and no other payment will be made therefor. The Lump Sum price paid for Construct Electrical Conduit Supports shall include full compensation for furnishing all labor, tools, equipment, materials, and supervision to provide PVC conduits, conduit supports, PVC coupling and caps, PVC expansion joints, shear plates, anchor bolts, and poly foam, and for performing the work to provide a complete conduit installation as shown on the plans. All work shall be inspected by SDG&E civil/structural representative. Additionally, all anchor bolts require “special inspection” by SDG&E civil/structural representative. No additional payment will be made for coordinating with SDG&E inspectors. 304-2.2 FLEXIBLE METAL GUARD RAIL 304-2.2.3 Measurement and Payment. Add the following: The contract unit price paid for Metal Beam Guard Rail shall include full compensation for furnishing all labor, materials, tools and equipment, and for performing the work to install Metal Beam Guard Rail per Caltrans Standard Plan A77A and no additional compensation will be allowed therefore. The contract unit price for Metal Beam Guard Rail Flare Type ‘3A shall include full compensation for furnishing all labor, materials, tools and equipment, and for performing the work to install Metal Beam Guard Rail Flare Type ‘3A per Caltrans Standard Plan A77D and no additional compensation will be allowed therefore. The contract unit price paid for Metal Beam Guard Rail Flare Type ‘SRT’ shall include full compensation for furnishing all labor, materials, tools and equipment, and for performing the work to install Metal Beam Guard Rail Flare Type ‘SRT’ per Caltrans Standard Plan A771 and no additional compensation will be allowed therefore. The contract unit price paid for Metal Beam Guard Rail Connection to Bridge Rail shall include full compensation for furnishing all labor, materials, tools and equipment, and for performing the work to install Metal Beam Guard Rail Connection to Bridge rail per Caltrans Standard Plan A77J and no additional compensation will be allowed therefore. SECTION 305 - PILE DRIVING AND TIMBER CONSTRUCTION @ 7131102 Contract No. 3907 Page 295 of 414 305-1 PILE DRIVING 305 - 1.3.2 Drilled Holes for Cast-in-Place Piles. Add the following: The Contractor shall submit a placing plan to the Engineer for approval prior to producing the test batch for cast-in-dnlled-hole concrete piling and at least 10 working days prior to constructing piling. The plan shall include complete description, details, and supporting calculations as listed below: A. Requirements for all cast-in-drilled hole concrete piling: 1. 2. 3. 4. 5. 6. 7. 8. Concrete mix design, certified test data, and trial batch reports. Drilling or coring methods and equipment. Proposed method for casing installation and removal when necessary. Plan view drawing of pile showing reinforcement and inspection pipes, if required. Methods for placing, positioning, and supporting bar reinforcement. Methods and equipment for accurately determining the depth of concrete and actual and theoretical volume placed, including effects on volume of concrete when any casings are withdrawn. Methods and equipment for verifying that the bottom of the drilled hole is clean prior to placing concrete. Methods and equipment for preventing upward movement of reinforcement, including the Contractor's means of detecting and measuring upward movement during concrete placement operations. B. Additional requirements when concrete is placed under slurry: 1. 2. 3. 4. 5. 6. Concrete batching, delivery, and placing systems including time schedules and capacities therefor. Time schedules shall include the time required for each concrete placing operation at each pile. Concrete placing rate calculations. When requested by the Engineer, calculations shall be based on the initial pump pressures or static head on the concrete and losses throughout the placing system, including anticipated head of slurry and concrete to be displaced. Suppliers test reports on the physical and chemical properties of the slurry and any proposed slurry chemical additives including Material Safety Data Sheet. Slurry testing equipment and procedures. Removal and disposal of excavation, slurry, and contaminated concrete, including methods and rates of removal. Slurry agitating, recirculating, and cleaning methods and equipment. In addition to compressive strength requirements, the consistency of the concrete to be deposited under slurry shall be verified before use by producing a batch to be tested. The test batch shall be produced and delivered to the project under conditions and in time periods similar to those expected during the placement of concrete in the piles. Concrete for the test batch shall be placed in an excavated hole or suitable container of adequate size to allow testing in conformance with California Test 533. Depositing of test batch concrete under slurry will not be required. For piles where the time required for each concrete placing operation, as submitted in the placing plan, will be 2 hours or less, the test batch shall demonstrate that the proposed concrete mix design achieves both the specified nominal penetration and a penetration of at least 2 inches after twice that time has elapsed. For piles where the time required for each concrete placing operation, as submitted in the placing plan, will be more than 2 hours, the test batch shall demonstrate that the proposed concrete mix design achieves both the specified nominal penetration and a penetration of at least 2 inches after that time plus 2 hours has elapsed. The time period shall begin at the start of placement. The concrete shall not be vibrated or agitated during the test period. Upon completion of testing, the concrete shall be disposed of in conformance with the provisions in Section 8-1, "Project Site Maintenance," of the SSPWC. 7/31/02 Contract No. 3907 Page 296 of 414 Concrete deposited under slurry shall not be vibrated until all temporary casing is removed and concrete contaminated with soil, slurry, or other materials is removed. Concrete deposited under slurry shall be vibrated in the upper 2 m of the pile. The concrete deposited under slurry shall be carefully placed in a compact, monolithic mass and by a method that will prevent washing of the concrete. Placing concrete shall be a continuous operation lasting not more than the time required for each concrete placing operation at each pile, as submitted in the placing plan, unless otherwise approved in writing by the Engineer. The concrete shall be placed with concrete pumps and delivery tube system of adequate, number and size to complete the placing of concrete in the time specified. The delivery tube system shall consist of one of the following: A. A tremie tube or tubes, each of which are at least 10 inches in diameter, fed by one or more concrete pumps. B. One or more concrete pump tubes, each fed by a single concrete pump. The delivery tube system shall consist of watertight tubes with sufficient rigidity to keep the ends always in the mass of concrete placed. If only one delivery tube is utilized to place the concrete, the tube shall be placed near the center of the drilled hole. Multiple tubes shall be uniformly spaced in the hole. Internal bracing for the steel reinforcing cage shall accommodate the delivery tube system. Tremies shall not be used for piles without space for a 10 in. tube. Spillage of concrete into the slurry during concrete placing operations shall not be allowed. Delivery tubes shall be capped with a water tight cap, or plugged above the slurry level with a good quality, tight fitting, moving plug that will expel the slurry from the tube as the tube is charged with concrete. The cap or plug shall be designed to be released as the tube is charged. The pump discharge or tremie tube shall extend to the bottom of the hole before charging the tube with concrete. After charging the delivery tube system with concrete, the flow of concrete through a tube shall be induced by slightly raising the discharge end. During concrete placement, the tip of the delivery tube shall be maintained to prevent reentry of the slurry into the tube. Until at least 10 ft. of concrete has been placed, the tip of the delivery tube shall be within 6 in. of the bottom of the drilled hole, and then the embedment of the tip shall be maintained at least 10 ft. below the top surface of the concrete. Rapid raising or lowering of the delivery tube shall not be permitted. If the seal is lost or the delivery tube becomes plugged and must be removed, the tube shall be withdrawn, the tube cleaned, the tip of the tube capped to prevent entrance of the slurry, and the operation restarted by pushing the capped tube 10 ft. into the concrete and then reinitiating the flow of concrete. When slurry is used, a fully operational standby concrete pump, adequate to complete the work in the time specified, shall be provided at the site during concrete placement. The slurry level shall be maintained within 12 in. of the top of the drilled hole. A log of concrete placement for each drilled hole shall be maintained by the Contractor when concrete is deposited under slurry. The log shall show the pile location, tip elevation, dates of excavation and concrete placement, total quantity of concrete deposited, length and tip elevation of any casing, and details of any hole stabilization method and materials used. The log shall include a 8.5" x 1 I" sized graph of the concrete placed versus depth of hole filled. The graph shall be plotted continuously throughout placing of concrete. The depth of drilled hole filled shall be plotted vertically with the pile tip oriented at the bottom and the quanti of concrete shall be plotted horizontally. Readings shall be made at least at each 5 ft. of pile depth, and the time of the reading shall be indicated, The graph shall be labeled with the pile location, tip elevation, cutoff elevation, and the dates of excavation and concrete placement. The log shall be delivered to the Engineer within one working day of completion of placing concrete in the pile. After placing reinforcement and prior to placing concrete in the drilled hole, if drill cuttings settle out of slurry, the bottom of the drilled hole shall be cleaned. The Contractor shall verify that the bottom of the drilled hole is clean. - 7/31/02 Contract No. 3907 Page 297 of 414 If temporary casing is used, concrete placed under slurry shall be maintained at a level at least 5 ft. above the bottom of the casing. The withdrawal of casings shall not cause contamination of the concrete with slurry. Material resulting from using slurry shall be disposed of in conformance with the provisions in Section 8- 1, "Project Site Maintenance," of the SSPWC. Acceptance Testing and Mitigation Vertical inspection pipes for acceptance testing shall be provided in all cast-indrilled-hole concrete piles that are 24 inches in diameter or larger, except when the holes are dry or when the holes are dewatered without the use of temporary casing to control the groundwater. Inspection pipes shall be Schedule 40 polyvinyl chloride pipe with a nominal inside diameter of 2 inches. Each inspection pipe shall be capped top and bottom and shall have watertight couplers to provide a clean, dry and unobstructed 2 in. diameter clear opening from 3'-3" above the pile cutoff down to the bottom of the reinforcing cage. If the Contractor drills the hole below the specified tip elevation, the reinforcement and the inspection pipes shall be extended to 3 inches clear of the bottom of the drilled hole. Inspection pipes shall be placed around the pile, inside the outermost spiral or hoop reinforcement, and 3 in. clear of the vertical reinforcement, at a uniform spacing not exceeding 2'4" measured along the circle passing through the centers of inspection pipes. A minimum of 2 inspection pipes per pile shall be used. When the vertical reinforcement is not bundled and each bar is not more than 1 in. in diameter, inspection pipes may be placed 2 in. clear of the vertical reinforcement. The inspection pipes shall be placed to provide the maximum diameter circle that passes through the centers of the inspection pipes while maintaining the clear spacing required herein. The pipes shall be installed in straight alignment, parallel to the main reinforcement, and securely fastened in place to prevent misalignment during installation of the reinforcement and placing of concrete in the hole. The Contractor shall log the location of the inspection pipe couplers with respect to the plane of pile cut off, and these logs shall be delivered to the Engineer upon completion of the placement of concrete in the drilled hole. After placing concrete and before requesting acceptance tests, each inspection pipe shall be tested by the Contractor in the presence of the Engineer by passing a 1.9 in. diameter rigid cylinder 24 in. long through the complete length of pipe. If the 1.9 in. diameter rigid cylinder fails to pass any of the inspection pipes, the Contractor shall attempt to pass a 1.25 in. diameter rigid cylinder 4'-6" long through the complete length of those pipes in the presence of the Engineer. If an inspection pipe fails to pass the 1.25 in. diameter cylinder, the Contractor shall immediately fill all inspection pipes in the pile with water. The Contractor shall replace each inspection pipe that does not pass the 1.25 in diameter cylinder with a 2 in. diameter hole cored through the concrete for the entire length of the pile. Cored holes shall be located as close as possible to the inspection pipes they are replacing, no more than 6 in. inside the reinforcement, and coring shall not damage the pile reinforcement. Cored holes shall be made with a double wall core barrel system utilizing a split tube type inner barrel. Coring with a solid type inner barrel will not be allowed. Coring methods and equipment shall provide intact cores for the entire length of the pile concrete. The coring operation shall be logged by an Engineering Geologist or Civil Engineer licensed in the State of California and experienced in core logging. Coring logs shall include complete descriptions of inclusions and voids encountered during coring, and shall be delivered to the Engineer upon completion. Concrete cores shall be preserved, identified with the exact location the core was recovered from within the pile, and made available for inspection by the Engineer. . Acceptance tests of the concrete will be made by the Engineer, without cost to the Contractor. Acceptance tests will evaluate the homogeneity of the placed concrete. Tests will include gamma- gamma logging. Tests may also include crosshole sonic logging and other means of inspection selected by the Engineer. The Contractor shall not conduct operations within 8.0 m of the gamma-gamma logging operations. The Contractor shall separate reinforcing steel as necessary to allow the Engineer access to 7/31/02 Contract No. 3907 Page 298 of 414 the inspection pipes to perform gammagamma logging or other acceptance testing. After requesting acceptance tests and providing access to the piling, the Contractor shall allow 3 weeks for the Engineer to conduct these tests and make determination of acceptance if the 1.9 in. diameter cylinder passed all inspection pipes, and 4 weeks if only the 1.25 in. diameter cylinder passed all inspection pipes. Should the Engineer fail to complete these tests within the time allowance, and if in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in inspection, the delay will be considered a right of way delay as specified in Section 6-6, "Delays and Extensions of Time," of the SSPWC. All inspection pipes and cored holes in a pile shall be dewatered and filled with grout after notification by the Engineer that the pile is acceptable. Placement and removal of water in the inspection pipes shall be at the Contractors expense. Grout shall conform to the provisions in Section 303-3.7, "Bonding and Grouting," of the SSPWC. The inspection pipes and holes shall be filled using grout tubes that extend to the bottom of the pipe or hole or into the grout already placed. If acceptance testing performed by the Engineer determines that a pile does not meet the requirements of the specifications, then that pile will be rejected and all depositing of concrete under slurry or concrete placed using temporary casing for the purpose of controlling groundwater shall be suspended until written changes to the methods of pile construction are approved in writing by the Engineer. The Contractor shall submit to the Engineer for approval a mitigation plan for repair, supplementation, or replacement for each rejected cast-indrilled-hole concrete pile, and this plan shall conform to the provisions in Section 2-5.3, "Shop Drawings and Submittals," of the SSPWC. Prior to submitting this mitigation pian, the Engineer will hold a repair feasibility meeting with the Contractor to discuss the feasibility of repairing rejected piling. The Engineer will consider the size of the defect, the location of the defect, and the design information and corrosion protection considerations for the pile. This information will be made available to the Contractor, if appropriate, for the development of the mitigation plan. If the Engineer determines that it is not feasible to repair the rejected pile, the Contractor shall not include repair as a means of mitigation and shall proceed with the submittal of a mitigation plan for replacement or supplementation of the rejected pile. If the Engineer determines that a rejected pile does not require mitigation due to structural, geotechnical, or corrosion concerns, the Contractor may elect to 1) repair the pile per the approved mitigation plan, or 2) not repair anomalies found during acceptance testing of that pile. For such unrepaired piles, the Contractor shall pay to the State, $400 per cubic meter for the portion of the pile affected by the anomalies. The volume, in cubic meters, of the portion of the pile affected by the anomalies, shall be calculated as the area of the cross-section of the pile affected by each anomaly, in square meters, as determined by the Engineer, multiplied by the distance, in meters, from the top of each anomaly to the specified tip of the pile. If the volume calculated for one anomaly overlaps the volume calculated for additional anomalies within the pile, the calculated volume for the overlap shall only be counted once. In no case shall the amount of the payment to the State for any such pile be less than $400. The Department may deduct the amount from any moneys due, or that may become due the Contractor under the contract. Pile mitigation plans shall include the following: A. The designation and location of the pile addressed by the mitigation plan. B. A review of the structural, geotechnical, and corrosion design requirements of the rejected pile. C. A step by step description of the mitigation work to be performed, including drawings if necessary. D. An assessment of how the proposed mitigation work will address the structural, geotechnical, and corrosion design requirements of the rejected pile. E. Methods for preservation or restoration of existing earthen materials. F. A list of affected facilities, if any, with methods and equipment for protection of these facilities during mitigation. G. The State assigned contract number, bridge number, full name of the structure as shown on the contract plans, District-County-Route-Kilometer Post , and the Contractor's (and Subcontractor's if applicable) name on each sheet. . 7/31/02 Contract No. 3907 Page 299 of 414 H. A list of materials, with quantity estimates, and personnel, with qualifications, to be used to perform the mitigation work. I. The seal and signature of an engineer who is licensed as a Civil Engineer by the State of California. For rejected piles to be repaired, the Contractor shall submit a pile mitigation plan that contains the following additional information: A. An assessment of the nature and size of the anomalies in the rejected pile. B. Provisions for access for additional pile testing if required by the Engineer. For rejected piles to be replaced or supplemented, the Contractor shall submit a pile mitigation plan that contains the following additional information: A. The proposed location and size of additional piling. B. Structural details and calculations for any modification to the structure to accommodate the replacement or supplemental piling. All provisions for cast-indrilled-hole concrete piling shall apply to replacement piling. The Contractor shall allow the Engineer 3 weeks to review the mitigation plan af&er a complete submittal has been received. Should the Engineer fail to review the complete pile mitigation submittal within the time specified, and if, in the opinion of the Engineer, the Contractor's controlling operation is delayed or interfered with by reason of the delay in reviewing the pile mitigation plan, an extension of time commensurate with the delay in completion of the work thus caused will be granted in conformance with the provisions in Section 6-6, "Delays and Extensions of Time," of the SSPWC. When repairs are performed, the Contractor shall submit a mitigation report to the Engineer within 10 days of completion of the repair. This report shall state exactly what repair work was performed and quantify the success of the repairs relative to the submitted mitigation plan. The mitigation report shall be stamped and signed by an engineer that is licensed as a Civil Engineer by the State of California. The mitigation report shall show the State assigned contract number, bridge number, full name of the structure as shown on the contract plans, District-County-Route-Kilometer Post, and the Contractor (and Subcontractor if applicable) name on each sheet. The Engineer will be the sole judge as to whether a mitigation proposal is acceptable, the mitigation efforts are successful, and to whether additional repairs, removal and replacement, or construction of a supplemental foundation is required. Add the following sub-section: 305-1.8.4 Payment for ClDH Piling. Payment for ClDH piling shall be made at the unit price bid per foot and shall include all costs for labor, materials, supervision, temporary measures, and remedial measures as required to provide piles that conform to the plans, specifications, and these special provisions and no additional payment shall be made therefor. 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 G 7/31/02 Contract No. 3907 Page 300 of 414 bridging shall be used by the Contractor unless othetwise approved by the Engineer. It is recognized that to accommodate excavation work, steel plate bridging may be necessary. All conditions for use of steel plate bridging set forth in the following requirements must be fulfilled as conditions of approval of the use of steel plate bridging. Consideration of steel plate bridging in the review process will take into account the following factors: 1. Traffic volume and composition. 2. Duration of use of the steel plate bridging. 3. Size of the proposed excavation. 4. Weather conditions. The following formula shall be used to score the permitted use of steel plate bridging: ps = [ ADT + EWL + DAYS + 10 X WEEKEND + 5 X NIGHTS + 20 X WEATHER + SPEED Ikmh) + SLOPE X 1001 X LANES IO00 a PS = [ ADT + EWL + DAYS + 10 X WEEKEND + 5 X NIGHTS + 20 X WEATHER + + SLOPE X 1001 X LANES 1000 5 where: WEEKEND = - NIGHTS - WEATHER = - SPEED - - SLOPE - - LANES - plate score. average daily traffic as defined in the CALTRANS Traffic Manual. equivalent wheel loads as defined in the CALTFWNS 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 q' 7/31 102 Contract No. 3907 Page 301 of 414 Contractor in accordance with all provisions of section 2-5.3 Shop Drawings and Submittals. The Contractor shall bacMill and resurface excavations in accordance with section 306-1 5. 0.3m (lo”) 0.6 m (23”) Add the following section: 306-1.1.7.3 Installation. When backfilling operations of an excavation in the traveled way, whether transverse or longitudinal cannot be properly completed within a work day, steel plate bridging with a non-skid surface and shoring may be required to preserve unobstructed traffic flow. In such cases, the following conditions shall apply: a) Steel plate bridging when the plate score exceeds 50 is not allowed except when, at the sole b) Steel plates used for bridging must extend a minimum of 610 mm (2’) beyond the edges of the c) Steel plate bridging shall be installed to operate with minimum noise. discretion of the Engineer, it is approved as specified hereinbefore. trench. 13 mm 19 mm (3/4n) 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. 0.8m (31”) Method 1 [For speeds more than 70 Km/hr (45 MPH)]: The pavement shall be cold planed to a depth equal to the thickness of the plate and to a width and length equal to the dimensions of the plate. The cold milling shall produce a flat surface that the plate shall rest on with no horizontal or vertical movement. Horizontal gaps between the unmilled pavement and the plate shall not exceed 25 mm (1”) and shall be filled with elastomeric sealant material which may, at the contractor‘s option, be mixed with no more that So%, by volume, of Type I aggregate conforming to the requirements of tables 203-5.2(B) and 203-5.3(A). 22 mm (’/8*) Method 2 [For speeds 70 Km/hr (45 MPH) or less]: Approach plate(s) and ending plate (if longitudinal placement) shall be attached to the roadway and shall be secured against displacement by using two adjustable cleats that are no less than 50 mm (2”) shorter than the width of the trench bolted to the underside of each plate and located within 150 mm (6”) of the beginning and end of the trench for plates at the beginning and end of the trench, a minimum of two 300 mm long by 19 mm diameter (12” x %”) steel bolts placed through the plate and driven into holes drilled 300 mm (12”) into the pavement section, or other devices approved by the Engineer. Subsequent plates shall be butted to each other. Fine graded asphalt concrete shall be compacted to form ramps, maximum slope 8.5% with a minimum 300 mm (12”) taper to cover all edges of the steel plates. When steel plates are removed, the dowel holes in the pavement section shall be completely filled with elastomeric sealant material. At the Contractor‘s option, the methods required for Method 1 may be used. If the Contractor so elects, all requirements of Method 1 shall be used. The Contractor shall maintain the steel plates, shoring, and asphalt concrete ramps and maintain and restore the street surface during and after their use. 1.0 m (41”) 1.6 m (63”) Add the following section: 306-1.1.7.4 Materials. 1 .I .7.4(A): The minimal thickness of steel plate bridging shall be as shown in Table 306- TABLE 306-1 .I .7.4(A) 25 mm (1”) 32 mm (1 X”) REQUIRED PLATE THICKNESS FOR A GNEN TRENCH WIDTH Maximum Trench Width (’I I Minimum Plate Thickness e 7131102 Contract No. 3907 Page 302 of 414 Steel plate bridging shall be steel plate designed to support the HS20-44 truck loading per CALTRANS Bridge Design Specifications Manual. The Contractor shall maintain a non-skid surface on the steel plate with no less than a coefficient of friction of 0.35 as determined by California Test Method 342. If a different test method is used, the Contractor may utilize standard test plates with known coefficients of friction available from the CALTRANS District I1 Materials Engineer to correlate skid resistance results to California Test Method 342. In addition to all other required construction signing, the Contractor shall install Rough Road (W33) sign with black lettering on an orange background in advance of steel plate bridging. Add the following section: 306-1 .1.7.5 Measurement and Payment. Steel plate bridge materials including, but not limited to: steel plates, anchoring devices, cold milling, elastomeric sealant material, asphalt ramping and padding, signage, placing, installation, removal, relocation, preparation and processing of shop drawings and submittals to support the use of steel plate bridging and all other materials, labor, supervision, overhead of any type or description will be paid for as an incidental to the work that the bridging is installed to facilitate. No separate payment for steel plate bridging will be made. No extension to contract time will be allowed for, or because of, the use of steel plate bridging. Add the following section: 306-1.1.8 Construction of Sewer Manholes. Sewer manholes in Bid Schedule E shall conform in all respects to Vallecitos Water District Standard Drawings. All new manholes in Bid Schedules E shall be provided with integrally locking PVC or polyurethane protective lining per Section 500-2 of the SSPWC. The contract unit price for various size sewer manholes shall include all labor, materials, equipment, and incidentals necessary to construct the various size manholes shown in Bid Schedule E. Add the following section: 306-1 .1.8.1 Double Ball Expansion Joints. Double ball seismic expansion joints shall be FLEX- TEND expansion joints manufactured by EBBAA Iron Sales Inc., or approved equal. Materials, fabrication and placement shall be per the manufacturer's recommendations. Payment for Double ball seismic expansion joints shall include all labor, tools, materials, equipment, incidentals, work and supervision required to place double ball expansion joints in accordance with the plans, Specifications, and these Special Provisions. Add the following section: 306-1.1.9 Remodeling Existing Sewer Manholes. The contract unit price for Remodel Existing Sewer Manhole shall include all labor, materials, equipment, and incidentals necessary to adjust invert elevations, bore and plug entrancedexits of pipe, and shall include all grout and reinforcement. 306-1.1.9 Adjust Existing Manholes to Grade. The contract unit price for Adjust Existing Sewer Manhole to Grade shall include all labor, materials, equipment, and incidentals necessary to adjust manhole elevations in accordance with the plans, specifications, and these special provisions and no additional payment will be made therefore. 306-1.2.1 Bedding. Add the following: All installation of, and bedding for, recycled water mains in Bid Schedule D shall conform in all respects to Part II, Carlsbad Municipal Water District Reclamation Rules and Regulations for Construction of .Reclaimed Water Mains, latest edition. All installation of, and bedding for Vallecitos Water District, recycled and potable water mains in Bid Schedule C and D, and gravity sewer main in Bid Schedule E, shall conform in all respects to the Vallecitos Water District Standard Specification for Construction of Water and Sewer facilities, latest edition. Qlr 7/31/02 Contract No. 3907 Page 303 of 414 306-1 2.4 Field Jointing of Reinforced Concrete Pipe. Add the following: The Contractor shall provide Gasket-type joints for reinforced concrete pipe (watertight joints) where indicated on plans. 306-1 2.6 Field Jointing of Iron Pipe Relating to Recycled Water Improvements Only. Delete the following items: (b) Cement Joint (c) Lead Joints 306-1.2.12 Field Inspection for Plastic Pipe and Fittings. Replace the first sentence of the third paragraph with the following: A Deflection test shall be performed no sooner then 30 days after completion of placement and densification of backfill and following installation of all utilities, but prior to the placing of the permanent paving. 306-1.2.13 Installation of Plastic Pipe and Fittings Relating to Water Improvements. Add the following: 306-1.2.13.1 PVC pressure pipe and fittings shall be installed per ASTM D2321, Uni Bell pamphlet Uni-BB, and the manufacturer's recommendations. Proper care shall be used to prevent damage in handling, moving, and placing the pipe. The Contractor shall unload the pipe by mechanical means such as a crane or backhoe, or by rope and skids, as recommended by the manufacturer. In using skids, pipes must be prevented from striking other pipe. Dropping pipe from truck will not be permitted. General Installations Procedures and Workmanship. All pipe shall be laid without break, upgrade from structure to structure, with the bell ends of the pipe upgrade. Pipe shall be laid to the line and grade given so as to form a close concentric joint with the adjoining pipe and prevent sudden offsets of the flow line. The interior of the pipe shall be cleaned of all dirt and superfluous materials of all description immediately prior to installing the pipe. The Contractor shall wipe the mating surfaces of the pipe to be joined clean of all dirt and foreign matter and apply an approved lubricant. The spigot end shall be inserted to the proper depth of the socket as indicated by the home mark. 306-1.2.13.2 Preventing Foreign Matter From Entering the Pipe. At all times when pipe laying is not in progress, the open end of the pipe shall be closed with a tight-fitting cap or plug to prevent the entrance of foreign matter into the pipe. These provisions shall apply during the noon hour as well as overnight. In no event shall the pipeline be used as a drain for removing water with has infiltrated into the trench. The Contractor shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the Owner. 306-1.4 Testing Pipelines. 306-1.4.1 General. Add the following: The Pressure testing for Carlsbad Municipal Water District recycled water mains in Bid Schedule D shall be in accordance with the Carlsbad Municipal Water District Reclamation Rules and Regulations for Construction of Reclaimed Water Mains, latest edition. The pressure testing for Bid Schedule C and D shall be in accordance with the Vallecitos Water District Standard Specification for Construction of Water and Sewer Facilities and Approved Materials List, latest editions. The leakage and infiltration tests for Bid Schedule E shall be in accordance with the Vallecitos Water District Standard Specification for Construction of Water and Sewer Facilities and Approved Materials List, latest editions. 7/31/02 Contract No. 3907 Page 304 of 414 306-1.5 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 52 Permanent Resurfacing. Add the following: Except as provided in section 306-1 51, "Temporary Resurfacing," the Contractor shall perform permanent trench resurfacing within 24 hours after the completion of backfill and densification of backfill and aggregate base materials. 306-1.6 Basis of Payment for Open Trench Installations. Add the following paragraph: Payment for the recycled water improvements for Bid Schedule D, shall be made per lineal foot and shall include all labor, materials and equipment to construct the pipe systems including fittings, thrust blocks, excavation, bedding, laying of pipe, backfill, compaction, removal and disposal of any excess material and appurtenant work excluding gate valves, air release valves, air-vacuum assemblies, blow-off assemblies, air release assemblies, butterfly valves, water and meter boxes, and cradles which will be listed as their own pay items. Add the following paragraph: Payment for the potable water mains for Bid Schedules C shall be per lineal foot and shall include all labor, materials, and equipment to construct the potable water mains including pipe, specials, anchor blocks, excavation, bedding, laying of pipe, welding, joint completion, backfill, compaction, removal and disposal of any excess material, and appurtenant work excluding connections, inline valves, gate valves, butterfly valves, blow-off assemblies, backflow preventors, combination air valve assemblies, automatic air and vacuum valves, water sample point assemblies, cradles, cathodic protection and joint bonding, water and meter boxes which will be paid at the unit price bid for said items. Add the following paragraph: Price paid per linear foot for sewer improvements in Bid Schedules E shall include full compensation for providing all labor, tools, materials, equipment and incidentals required to perform all testing of sewer improvements as specified elsewhere in these supplemental provisions. Concrete Encasement of Sewer Pipe shall be paid at the unit price bid for that item of work. Add the following: The contract unit price for cast-in-place concrete cradles for sewer lines shall include full compensation for providing all labor, tools, materials, equipment and incidentals required to create cradles for sewer lines in accordance with the plans, the standard specifications, and these supplemental provisions. Add the following paragraph: Price paid per linear foot for the various sizes of Steel Casing shall include full compensation for providing all labor, tools, materials, equipment, incidentals, and supervision required to install the casing at the proper horizontal and vertical alignment, and seal into the bridge structure in accordance with the plans, Specifications, and these Special Provisions. Add the following paragraph: Payment for providing excavation safety measures including sheeting, shoring and bracing, or equivalent method for the protection of life and limb in trenches and open excavation in conformance with applicable safety orders, shall be included in the prices bid for the items involved and no additional payment shall be made therefor. Add the following paragraph: include full compensation for Price paid per unit for restrained joints in Bid Schedules C and D shall providing all labor, tools, materials, equipment, incidentals, work and -* 7/31/02 Contract No. 3907 Page 305 of 414 supervision required to install restrained joints in accordance with the plans, Specifications, and these Special Provisions. 306-5 ABANDONMENT OF CONDUITS AND STRUCTURES Add the following: 306-5.1 General. Unless otherwise noted on plans or allowed by the Engineer, the Contractor shall remove all existing abandoned pipelines and conduits of any type, or use, and shall replace said pipelines and conduits with properly compacted soils. When allowed by the Engineer, the contractor may abandon pipelines in place and fill with sand slurry and cap ends. When sand slurry backfill is to be used the Contractor shall submit a plan to the Engineer identifying the proposed mix of the sluny to be used, the method of placing slurry, and the method for assuring the pipeline or conduit is free of voids following placement of sluny. Payment for removal and disposal of abandoned utilities not identified on the plans shall be included in the lump-sum bid for Clearing and Grubbing, and no additional payment will be made. Payment, (in Bid Schedules C and D), for abandoning existing potable and recycled water lines in place, as shown on the plans, shall include all labor, tools, materials, equipment, incidentals, work and supervision required to abandon potable and recycled water lines in accordance with the plans, Specifications, and these Special Provisions. 306-5.2 Abandonment of Existing Recycled and Potable Main Piping Systems. When a portion of an existing recycled or potable water main is to be abandoned, the portion remaining open shall be securely sealed in accordance with the applicable Water District requirements. The District shall be consulted on proper abandonment procedures and construction. No additional payment will be made to the Contractor for his failure to verify district requirements. 306-10 PVC PRESSURE PIPE RELATING TO RECYCLED AND POTABLE WATER IMPROVEMENTS 306-10.1 General. This section pertains to the installation of all appurtenances for a complete and operable underground pressurized recycled water system. Installation of all bends, tees, adapters and flange gaskets for Vallecitos Water District water improvements shall conform in all respects to the Vallecitos Water District Standard Specification for Construction of Reclaimed Water Maifis, latest edition. 306-1 0.2 Pipe and Valves for Recycled Water. Installation of all PVC pressure potable water and recycled water pipe for Bid Schedule C and D and valves for Vallecitos Water District water improvements shall conform in all respects to the Vallecitos Water District Standard Specification for Construction of Water and Sewer Facilities and Approved Materials List, latest edition. 306-1 0.2.1 Mechanical Thrust Restraint. No mechanical thrust restraint devices which transfer forces from fittings to the PVC pipe wall shall be permitted. 306-10.3 Measurement and Payment of PVC Pressure Recycled and Potable Water Pipe. Measurement for payment for construction of PVC Pressure recycled and potable water pipe of the sizes, types, and classes shown on the Plans, will be based upon the number of linear feet of such pipe actually placed as determined by measurement along the centerline of such pipe, all in accordance with the requirements of the Contract Documents. m ES 7/31/02 Contract No. 3907 Page 306 of 414 Payment for construction of PVC pressure recycled and potable water pipe will be made at the unit price per linear foot named in the Bid Schedule, which price shall constitute full compensation for furnishing and placing such pipe including excavation, backfill, bedding, compaction, compaction testing, pipe, pipe identification, fittings, thrust blocks, disposal of excess excavated material removal of nuisance water from excavation, traffic control, testing, flushing and disinfection and any appurtenant work as shown in the Plans or called for in the Specifications, complete for the unit price. Pavement removal and replacement is not to be included in this work. All potable water mains shall be thoroughly flushed prior to disinfection. 306-1 0.4 Pressure Reducing Station. The installation of the pressure reducing station and its components shall conform in all respects to the to Vallecitos Water District Standard Specification for Construction of Water and Sewer Facilities and Approved Materials List, latest edition and .Construction Plan details. Refer to Section 315 "Electrical and Telemetry for Pressure Reducing Station", of these special provisions, for installation of electrical and telemetry. 306-10.4.1 Measurement and Payment. Payment for construction of the water pressure reducing station at the location shown on the plans and as described in the details will be made at the lump sum price named in the Bid Schedule C, which shall constitute full compensation for the complete work including excavation, backfill, bedding, compaction, compaction testing, sheeting, piping, manual valves, automatic valves, gauges, fittings, pipe enclosures, structural concrete vault, reinforcing steel, vault hatch, thrust blocks, disposal of excess excavated material, removal of nuisance water from excavation, electrical controls and telemetry, and any appurtenant work shown on the plans, called for in the Specifications, or required for a complete and operable pressure reducing station, complete for the lump sum price. 306-1 0.5 Connections to Existing Piping. Connections to existing recycled water piping shall conform in all respects to the Vallecitos Water District Standard Specification for Construction of Reclaimed Water Mains and Approved Materials List, latest edition. 306-1 0.5.1 Payment for Connections to Existing Piping. Payment for construction of recycled water connections will be made at the bid price for each connection point named in the Bid Schedule, which shall constitute full compensation for furnishing and placing such pipe including excavation, backfill, bedding, compaction, fittings, couplings, removal of existing piping, abandonment of existing piping and valves, removal of existing thrust block, properly plugging abandoned piping, thrust blocks, locator tape, disposal of excess excavated material, testing, flushing and disinfection and any appurtenant work as shown on the Plans or called for in the Specifications, complete in place for the unit price. 306-10.6 Testing of Recycled Water Mains. prior to hydrostatic testing. All recycled water mains shall be thoroughly flushed 306-1 1 APPURTENANCES FOR PRESSURE PIPE RELATING TO RECYCLED WATER IMPROVEMENTS ONLY 306-11.1 General. This section pertains to the installation of all appurtenances for a complete and operable underground pressurized recycled water system. 306-11.2 Valves for Recycled Water. Installation of all valves for recycled water mains in Bid Schedule D shall conform in all respects to Part II, Materials, Section C, of the Carlsbad Municipal Water District Reclamation Rules and Regulations for Construction of Reclaimed Water Mains, latest edition. Installation of all valves for Vallecitos Water District recycled water mains in Bid Schedule D shall conform in all respects to the Vallecitos Water District Standard Specification for Construction of Water and Sewer Facilities and Approved Materials List, latest edition. G 7/31/02 Contract No. 3907 Page 307 of 414 306-1 1.3 Appurtenances. The installation of all air release and vacuum relief valves, manual air release valves, blow-offs and other appurtenances for Carlsbad Municipal Water District recycled water mains in Bid Schedule D shall conform in all respects to Part II, Installation, Sections A and B, of the Carlsbad Municipal Water District Reclamation Rules and Regulations for Construction of Reclaimed Water Mains, latest edition. The installation of all air release and vacuum relief valves, manual air release valves, blow-offs and other appurtenances for Vallecitos Water District in Bid Schedule D shall conform in all respects to Vallecitos Water District Standard Specification for Construction of Water and Sewer Facilities and Approved Materials List, latest edition. 306-11.3.1 Thrust Blocks. Concrete thrust blocks shall be placed as shown on the Plans and shall consist of Class B Portland cement concrete containing not less than five sacks of portland cement per cubic yard and shall conform to Section 303, Concrete and Masonry Construction. Concrete blocks shall be placed between the undisturbed ground and the fittings to be anchored. Quantity of concrete and the bearing area of the pipe and undisturbed soil shall be as shown on the Plans, unless otherwise determined by the Owner's Representative. The concrete shall be placed, unless specifically shown otherwise on the Plans, so that the pipe joints and fittings will be accessible to repairs. Payment for Thrust Blocks shall be considered to be included in the unit price bid for the item of work for which the thrust block is required. 306-11.4 Recycled Water Metering Station. The installation of the recycled water metering station and its components shall conform in all respects to the Carlsbad Municipal Water District Requirements and Approved Materials List, latest edition, these special provisions and the SSPWC. All material used in construction of the Recycled Water Metering Station shall be submitted in accordance with Section 2 - Scope and Control of Work per the SSPWC. 306-1 1.4.1 Precast Concrete Utility Vault for Recycled Water Metering Station. Design of precast utility vault shall be in accordance with ASTM C857, C858, AASHTO Loading Class HS 204 and per manufacturer's recommendations. Utility vaults for recycled water metering station shall be constructed by an approved manufacturer. Cement shall be in accordance with ASTM C150, Type II, low alkali. Sealing gaskets for utility vault shall be preformed continuous rope form plastic material, protected by removable two-piece wrapper, and shall conform to Federal Specification SS-S-210. Hatch frames and covers for utility vault shall be made of aluminum, shall conform to OSHA requirements and shall be manufactured by The Bilco Company or approved equal. Ladder rungs for utility vault shall be made 'of galvanized steel with stainless steel anchor bolts, shall conform to OSHA requirements, shall provide ladder-up safety devise, and shall be manufactured by an approved manufacturer. Utility vault shall be installed in accordance with ASTM C891. 306-1 1.4.2 Earthwork for Recycled Water Metering Station Pipelines and Vault. Earthwork for Recycled Water Metering Station Pipelines and Vault shall be in accordance with Section 300 - Earthwork, Section 306 - Underground Conduit Construction of the SSPWC and Sections 300 and 306 of these Special Provisions, except as noted in the following: Bedding material shall have a Sand Equivalent greater than 30 (SE > 30). The bedding shall be as shown on the trench section on the drawings. The Contractor shall place a 12-inch layer of %-inch maximum aggregate base, compacted to 95% relative compaction, under recycled water metering station vault. . 306-1 1.4.3 Water System Piping and Accessories for Recycled Water Metering Station. Water System Piping and Accessories for Recycled Water Metering Station shall be in accordance with Section 207 - Pipes, Section 208 - Pipe Joint Types and Materials, Section 306 - Underground Conduit e 7/31/02 Contract No. 3907 Page 308 of 414 Construction of the SSPWC and Sections 207,208 and 306 of these Special Provisions, except as noted in the following: 306-1 I .4.3.1 General A. Pipe and valve sizes are nominal inside diameter unless otherwise noted. B. All materials delivered to the job site shall be new, free from defects, and marked to identify the material, class, and other appropriate data such as thickness for piping. C. Acceptance of materials shall be subject to strength and quality testing in addition to inspection of the completed product. Acceptance of installed piping systems shall be based on inspection and leakage and bacteriological tests as specified hereinafter. D. Buried nuts and bolts for flanges and couplings shall be Type 304 stainless steel unless otherwise specifically specified herein. E. Fusion Epoxy Coating: Materials and application shall be in accordance with AWWA C213, expect application shall be by the fluid bed method only unless the greatest dimension of the article to be coated exceeds 10 feet, in which case electrostatic spray method may be used. 306-1 1.4.3.2 Piping Materials A. Pipe Designation: Piping materials for miscellaneous small piping are designated on the Drawings. New recycled water transmission mains shall be the welded steel pipe system. All piping and materials to conform to Carlsbad Municipal Water District Water System Supplemental Standard Specifications. Pipe Systems: Each designation identifies not only the pipe itself, but the entire system as well as including the associated fittings, appurtenances, and installation and test procedures. B. C. Copper Pipe: 1. Pipe: Copper (Cu), ASTM B99, Type K. 2. Joints: Soldered using ASTM B32, alloy Sn96 or Sb5 solder, or flared. 3. Fittings: a. Soldered: Wrought copper, ASTM B73 for materials and ANSI B16.22 for dimensions; or cast bronze, ASTM B62 for materials and ANSI B16.18 for dimensions. Flared: AWWA C800 and ANSI B16.26. b. D. Polyvinyl Chloride Pipe: 1. Pipe: Polyvinyl chloride pressure pipe, cast iron pipe outside dimensions. Pipe shall be UL listed or Factory Mutual Approved. a. b. 4-inch through 12-inch: AWA C900. 14-inch through 36-inch: AWA C905. 2. Dimension ratio: per construction plans. (Pressure Class 150 or 200, per construction 3. Joints: plans.) a. b. Unrestrained joints: Bell and spigot, gasketed; or twin gasket coupling. Restrained joints: Bell and spigot (push-on) gasketed, or mechanical joints; both using ductile iron ciamp-on restraining devices. 1) Restraining devices: Ductile iron with ductile iron or cor-ten rods and bolts. Pressure rating of at least 150 psi. Series 1500 by EBBA Iron; equivalent by Uni-Flange; or equal for bell and spigot joints. Series 500 by EBBA Iron; equivalent by Uni-Flange; or equal for mechanical joints. 4. Gaskets: Isoprene. Submit two sample gaskets of each gasket type with an explanation of the markings. 7/31/02 Contract No. 3907 Page 309 of 414 5. Fittings: Fusion epoxy lined and coated push-on cast iron or mechanical joint, AWWA C110, with hubs cast and/or ground as required for pipe furnished and fusion epoxy coating. 306-1 1.4.3.3 Pipe Couplings A. B. General: For typical pipe joints refer to pipe material specifications. Other joint devices shall be furnished where called for as specified below. Flexible Couplings and Flange Coupling Adaptors: 1. Sleeve: Cast iron or fabricated steel. 2. Followers: Cast iron, ductile iron, or steel. 3. Sleeve bolts: ASTM A325, Type 3; malleable iron; or equivalent. 4. Coating: Fusion epoxy line and coat sleeve and followers. 5. Pressure rating: 250 psi. 6. Buried flexible coupling sleeve: Long barrel 7. Manufacturers: a. Flexible couplings: 1) Connecting pipe with identical outside diameters: Smith-Blair 41 1 or 431, Dresser Style 38 or 53, or equal. 2) Connecting pipe with slightly different outside diameters: Smith-Blair 41 3 or R 441, Dresser Style 162, or equal. 1) Connecting new pipe or new pipe to existing non-ferrous pipe: Smith-Blair 912 or 913, Dresser Style 127 or 128, or equal. 2) Connecting new pipe to existing ferrous pipe: Insulating flange coupling adaptor with insulating boot: Smith-Blair 932 or 933, or equal. b. Flange coupling adaptors: 8. 9. Gaskets: Oil and grease resistant; Smith-Blair Grade 60; or equal. Joint restraint: Provide joint harnesses (tie rod lug or attachment plate assemblies) across flexible couplings and flange coupling adaptors where indicated on the Drawings. For flanged coupling adaptors, anchor studs may be substituted for the harnesses on pipe up to 12-inch. Design restraint in accordance with AWWA M-1 1 for 250 psi if sizes of the rods are not indicated on the Drawings. 10. Protection for buried connectors and adaptors: Double wrap with polyethylene encasement, AWWA C105 and tape the edges of the encasement with PVC tape. 306-1 1.4.3.4 Valves and Accessories A. General Requirements for Valves: 1. All valves of each type shall be the product of one manufacturer. 2. All valves shall be furnished with control assembly, operators, handwheels, levers, or other suitable type wrench including handles as specified herein or as shown on the Drawings. Mastic; Protect0 Wrap CA1180 Mastic; or equal, except where othewise indicated. 3. All threaded stem valves shall open by turning the valve stem counter-clockwise. 4. The exterior of all valves and valve operators shall be painted with two coats of Tape Coat B. Valves and Accessories: 1. Butterfly valves: a. b. c. Rating: 150 psi water. Leaktight in both directions. Type: Flanged body, or as shown on the Drawings, AWA (2504, geared operator, resilient seated, 90 degree seating. Connections: Flange, as shown on the Drawings. @ 7/31/02 Contract No. 3907 Page 310 of 414 - ... d. Materials: Cast iron body; cast iron or ductile iron disc with Ni-Chrome or Type 316 stainless steel edge: Type 304 stainless steel shaft; disc to be secured to shaft with Type 304 stainless steel taper pins. Operator: Traveling-nut type, 2-inch standard AWWA nut, designed for buried service, watertight to IO psi with extension stem as detailed on CMWD Standard Drawing W13. Provide three valve operator tee handles to the Owner. Valve seat: Buna-N seat shall be applied to the valve body. Bearings: Self-lubricating and corrosion resistant. Finish: Internal, asphalt varnish in accordance with AWWA C504; external, factory applied coal tar epoxy, 16 mils minimum thickness. e. f. g. h. Manufacturers: Pratt, Mueller, or equal. 2. Gate Valves: a. Rating: 150 psi water b. c. d. Stem seal: O-ring e. Finish: Fusion epoxy Manufacturers: AVK, M&H 4067, or equal. Type: Resilient seated, non-rising stem, AWWA C509, as modified herein Connection: As shown on the Drawings 3. Plug Valves: a. b. d. C. e. f. 9- h. 1. - Rating: ANSI Class 150 Service Pressure: 150 CWP to 500 CWP Body: Shall be made of ASTM A216 WCC cast carbon steel. Plug: Shall be made of ASTM A48 Class 45B/50B grey iron. A break-in friction reducing coating of molybdenum disulfide shall be applied to the plug bearing areas after fitting of the plug to the body. Connection: As shown on the Drawings Stem: O-ring gland with threadless and blowout proof stem design. The stem packing shall be of a pre-loaded, pressure energized design that is replaceable with the valve in-line (but not under pressure). Disassembly and removal of the plug to replace the stem packing is not acceptable. Finish: Fusion epoxy. Flow Parameters: Shall allow a minimum flow rate of 29 cfs during operating pressures of 80 psi to 100 psi with no damage to valve. Manufacturers: Nordstrom Valves, Inc., or equal. 4. Air release valves: Combination air release valves, 2" APCO Model 145C, or ValMatic 202,4 APCO Model 149C, or equal. a. b. Materials: Cast iron body, Buna-N seat, and stainless steel float. Operating pressure: Under 150 psi. 5. Valve boxes and lids: Shall be Brooks 41T Series or J. & R. 4T, normally closed valves shall be Brooks Series 3RT, per the Carlsbad Municipal Water District Water Standard Specifications. 6. Modulating Electric Motor Valve Actuators: a. Motor operated valve control shall include motorized actuator with motor, solidstate modulating controller, electro-mechanical starter, operator unit gearing, limit switch gearing, limit switches, torque switches, declutch lever and auxiliary handwheel as a self-contained unit in a NEMA 4 enclosure. Valve opening/closing time shall be 90 seconds. Valve actuator shall be rated for at least 100 starts per hour. The motor shall be reversible, squirrel cage induction rated for 11 5 volts, single phase 60 Hz with Class "F" insulating system. The motor shall be totally enclosed and nonventilated with all leads terminating within the limit switch compartment. - b. Q 7/31/02 Contract No. 3907 Page 311 of 414 C. d. e. f. 9. h. i. The motor shall be of sufficient size to open or close the valve at 200% of maximum required toque. The motor shall operate at *lo% of rated voltage and shall be sufficient for one complete cycle without exceeding its temperature rating. The drive unit shall be a multiple reduction unit with power gearing consisting of spur, helical and worm gearing. The spudhelical gears shall be made of treated steel. The worm shaft shall be of hardened alloy steel with the threads ground after heat treating. The worm gear shall be of alloy bronze accurately cut with a hobbing machine. All power gearing shall be grease lubricated and accurately machine cut. Ball or roller bearings shall be used throughout. Non-metallic or cast gearing shall not be allowed. Limit switches and gearing shall be an integral part of the valve control. The limit switch gearing shall be of the intermittent type, totally enclosed in its own gear case, grease lubricated to prevent dirt and foreign matter from entering the gear train and shall be made of stainless steel. Limit switches shall be of the adjustable type capable of being adjusted to trip at any point between fully opened valve and fully closed valve positions. Each valve control shall be provided with minimum limit switches as shown on the Drawings. Geared limit switches must be geared to the driving mechanism and in step at all times whether in motor or manual operation. Operator shall include a "hand," "remote" selector switch and "open," "close" pushbuttons and indicating lights indicating status as well as a mechanical attachment to indicate valve position. The actuator shall contain an integral modulating controller capable of receiving a 4-20 mA input (command) signal corresponding to a valve position. The modulating controller shall include an integral control power transformer. The actuator shall automatically adjust the position of the valve when the error in the comparison to feedback is greater than the preset or field adjusted deadband of the modulating controller. The modulating controller shall compare the command signal with a position feedback potentiometer and position the actuator to the appropriate position. The modulating controller shall have the following features: 1) Input signal: 4-20 mA that shall cause a movement of actuator for an adjustable range throughout the fully open to fully closed position. For example, the range should be adjusted from 20% to 80% of full open. 2) Zero and span adjustment. 3) At a loss of signal, the actuator shall maintain last position except where designated otherwise in the plans and specifications. 4) Two-wire position transmitter calibrated 4-20 mA 0-100% travel. 5) Auxiliary contacts for remote monitoring of "open," "close," and "ready" indication. Ready indication shall be indicated when the valve selector is in the "remote" position. A permanently attached handwheel shall be provided for manual operation. The handwheel shall not rotate during electric operation but must be responsive to manual operation at all times except when being electrically operated. The motor shall not rotate during hand operation, nor shall a fused motor prevent manual operation. When in manual operation position, the unit will remain in this position until motor is energized at which time the valve operation will automatically return to electric operation and shall remain in motor position until handwheel operation is desired. This movement from motor operation to handwheel operation shall be accomplished by a positive declutching lever that will disengage the motor and motor gearing mechanically but not electrically. Hand operation must be reasonably fast. It shall be impossible to place the unit in manual operation when the motor is running. Manufacturer: Rotork; Limitorque; Auma; EIM; or equal. e 7/31/02 Contract No. 3907 Page 312 of 414 306-1 1.4.3.5 Service Connections A. General: All corporation stops, service clamps or saddles, and service connection accessories shall be the product of one (1) manufacture. B. Service Clamps: 1. 2. Type: Bronze, double strap, retained O-ring gasket, rolled strap threads, and tapping boss with full length threads. Manufacturer: Ford or Jones Company, or equal per the Carlsbad Municipal Water District Water Standard Specifications. C. Corporation Stops: 1. Rating: 100 psi water 2. 3. Type: Per the Carlsbad Municipal Water District Water Standard Specifications. Manufacturer: Ford or Jones Company, or equal per the Carlsbad Municipal Water District Water Standard Specifications. D. Curbstops: Rating: 100 psi water Type: Per the Carlsbad Municipal Water District Water Standard Specifications. Manufacturer: Ford or Jones Company, or equal per the Carlsbad Municipal Water District Water Standard Specifications. E. Meter Boxes 1. 2. Type: Per the Carlsbad Municipal Water District Water Standard Specifications. Manufacturer: Per the Carlsbad Municipal Water District Water Standard Specifications. 306-1 1.4.3.6 Appurtenances Provide all necessary assembly bolts, washers and nuts, thrust blocks, supports, gaskets, flanges, and all other appurtenant items shown on the Drawings, specified or required for the proper installation and operation of the piping, and devices included in or on the piping, equipment, and piping accessories. 306-1 1.4.3.7 Piping Installation A. General Buried Piping Installation: 1. 2. 3. Trenching, bedding, and backfill for buried piping shall be as shown on the Drawings and as specified in these Special Provisions. Where no grade elevations are shown on the Drawings, buried piping shall have at least 4 feet of cover. Provide each pipe with a firm, uniform bearing for its full length in the trench except at field joints. Do not lay pipe in water or when trench conditions or weather are unsuitable for such work. Protect buried piping against thrust by use of restrained pipe joints, or thrust blocks if shown on the Drawings. Securely brace all exposed free pipe ends. 4. B. Installation Specifics: 1. Copper Pipe: a. b. c. Bends shall be made in a manner that does not crimp or flatten pipe. Dielectric unions shall be installed at connections with ferrous piping. Pipe shall have joints squarely cut clean, properly fluxed and heated before solder is placed in the joint. Joints must be driven up tight before solder is added. Compression and flared joints shall be made up in accordance with the manufacturer's instructions. 2. Polyvinyl Chloride Pipe: Installation shall conform to AWWA M23, Chapters 6 and 7, as modified he rein . a 7/31/02 Contract No. 3907 Page 313 of 414 306-1 1.4.3.8 Testing of Recycled Water Metering Station. All piping associated with the Recycled Water Metering Station shall be thoroughly flushed prior to hydrostatic testing in accordance with the City of Carlsbad Municipal Water District requirements. 306-1 1.4.4 Modified Bituminous Sheet Membrane Waterproofing for Recycled Water Metering Station. In addition to the requirements of Section 2 - Scope and Control of Work of the SSPWC, the Contractor shall submit the following: A. Product Data: Submit manufacturer's product date, installation instructions, use limitations and recommendations. Include certification of data indicating Volatile Organic Compound (VOC) content of all components of waterproofing system. Also submit material manufacturer's certification of installer's qualifications. B. Samples: Submit representative samples of the following for approval: 1. Sheet Membrane. 2. Protection board. 3. Prefabricated drainage composite. 306-1 1.4.4.1 General A. Sheet Membrane Waterproofing Systems shall be manufactured and marketed by a firm with a minimum of 10 years experience in the production and sales of modified bituminous self- adhesive Sheet Membrane Waterproofing. Contractor shall submit evidence of ability to meet all requirements specified, and include a list of projects of similar design and complexity completed within the past 5 years. B. Installer shall be a firm meeting the following criteria: 1. 2. C. Materials: Contractor shall provide materials, which are the products of one manufacturer for all work under this Section. D. Pre-Installation Conference: A pre-installation conference with the Contractor, installer, system manufacturer, construction manager and Design Engineer shall be held prior to commencement of field operations. Review project requirements to establish procedures to maintain optimum working conditions and coordinate this work with related and adjacent work. Include review of special details and flashing. E. Manufacturer's Representative: Contractor shall make arrangements necessary to have a trained employee of the manufacturer on site periodically during membrane waterproofing work to review installation procedures and certify that all work was done correctly prior to backfill placement. F. Delivery, Storage, and Handling: Contractor shall deliver, handle, and store materials and products in labeled packages and per the manufacturer's recommendations. G. The Contractor shall provide a 5-year warranty against water intrusion issued by the membrane manufacturer upon completion of the work. A firm exclusively engaged in waterproofing membrane installation and having at least 3 years of experience in work of the type and scope required by this Section. A firm certified in writing by the material manufacturer as being qualified and experienced in the work required by this Section. 7/31/02 Contract No. 3907 Page 314 of 414 306-1 1.4.4.2 Modified Bituminous Sheet Membrane Waterproofing Materials Color Thickness, ASTM D 3767, Method A Low Temperature Flexibility, ASTM D 1970 Tensile Strength, Membrane, A. Modified Bituminous Sheet Membrane Waterproofing System: 1. The Contractor shall provide all required materials for a complete Sheet Membrane Waterproofing system made by a single manufacturer. All products described in this Section are made by W. R. Grace and Company and are for use with the bituthene modified bituminous Sheet Membrane Waterproofing system. Equivalent systems by other manufacturers may be submitted for evaluation if they include all of the products required made by a single manufacturer, including a product suitable for blind side waterproofing. Liquidapplied membranes and bentonite products are not considered equivalents. Use materials suitable for installation in soil contaminated with hydrocarbons. 2. 3. 4. Acceptable Manufacturers and Systems: a. Bituthene 3000 and Bituthene Pre-Pour (for blind side waterproofing) by W. R. Grace and Company; or equal. Gray-black 60 mils (I .5 mm) Unaffected at -32°C (-25°F) 2240 kNlm2 (325 psi minimum) B. System Components: I. Modified Bituminous Membrane: A self-adhesive 60-mil-thick cold-applied composite sheet consisting of 56 mils of rubberized asphalt and 4 mils of cross-laminated, high- density polyethylene film. Provide rubberized asphalt membrane covered with release paper, which is removed during installation. No special adhesive or heat shall be required to form laps. Bituthene 3000 by W. R. Grace and Company; or equal. a. Physical Properties: ASTM D412, Die C Modified Elongation, Ultimate Failure or Rubberized Asphalt, 300% ASTM D412 Modified Crack Cycling, 100 Cycles, ASTM C836 Lap Adhesion at Minimum Application Temp ASTM 700 Nlm (4.0 Iblin. width) . Tensile Strength, Film, ASTM D 882 Modified 34,500 kN/m2 (5000 psi minimum) Unaffected at -32°C (-25°F) D1876 Modified Peel Strength, ASTM D 903 Puncture Resistance, Membrane, ASTM E 154 Resistance to Hydrostatic Head, ASTM D 5385 Exposure to Fungi, 16 weeks, GSA PBS 071 15 Permeance, ASTM E 96, Water Method Water Ahanrntinn 77 hours ASTM D 570 1576 N/m (9.0 Iblin. width) 222 N (50 Ib. minimum) 60m (200 R. minimum) No effect 2.9 nglm2-spa (0.05 perms maximum) O.lo/n maximum 2. Modified Bituminous Pre-pour Membrane: A four-layer composite Sheet Membrane consisting of 0.76 mm (0.030 in) of high density polyethylene film, 0.64 mm (0.025 in) of specially formulated synthetic adhesive, 0.03 mm (0.001 in) of protective coating and a surface treatment. Bituthene Pre-Pour HD by W. R. Grace and Company; or equal. a. Physical properties: e 7/31/02 Contract No. 3907 Page 315 of 414 Thickness Peel Adhesion to Concrete Lap Adhesion Resistance to Hydrostatic 1.07 mm nominal (0.042 in.) 880 N/m minimum (5.0 Ib/in.) 528 N/m minimum (3.0 Ib/in.) 70 m (231 ft) ASTM D 3767 Method A ASTM D 903 Modified1 ASTM D 1876 Modified2 ASTM D 5385 Modified3 1Concrete is cast against the protective coating surface of the membrane and allowed to properly dry (7days minimum). Peel adhesion of membrane to concrete is measured at a rate of 24nch (50 mm) per minute at room temperature. 2The test is conducted 15 minutes after the lap is formed and run at a rate of (2-inch (50 mm) per minute at -4°C (25°F). 3Hydrostatic head tests are performed by casting concrete against the membrane with a lap. Before the concrete sets, a 0.125-inch (3 mm) spacer is inserted perpendicular to the membrane to create a gap. The cured block is placed in a chamber where water is introduced to the membrane surface up to a head of 231 feet (70 m). Head Low Temperature Flexibility Puncture Resistance Tensile Strength, Film 3. Modified Bituminous Pre-Pour HD Membrane: A four-layer composite Sheet Membrane consisting of 0.76 mm (0.030 in) of highdensity polyethylene film, 0.64 mm (0.025 in) of specially formulated synthetic adhesive, 0.03 mm (0.001 in) of protective coating and a detackifying surface treatment. a. Physical Properties: Unaffected at 23°C (-1 0°F) 445 N minimum (100 Ibs) 27,600 kPa minimum (4000 psi) ASTM D 1970 ASTM E 154 ASTM D 412 Property Value Color Black with white protective coating Thickness 1.42 mm nominal (0.056 in.) Peel Adhesion to 880 N/m minimum (5.0 Ib/in.) Concret e Lap Adhesion 528 N/m minimum (3.0 Ibhn.) Resistance to Hydrostatic 70 m (231 ft) Low Temperature Unaffected at 23°C (-10°F) Head Flexibilit Test Method ASTM D 3767 Method A ASTM D 903 Modifiedl ASTM D 1876 Modified2 ASTM D 5385 Modified3 ASTM D 1970 1 Concrete is cast against the protective coating surface of the membrane and allowed to properly dry (7days (2-inch) per minute at mom temperature. 2 The test is conducted 15 minutes after the lap is formed and run at a rate of 2-inch (50 mm) per minute at 4°C (25°F). 3 Hydrostatic head tests are performed by casting concrete against the membrane with a lap. Before the concrete sek, a 0.125inch (3 mm) spacer is inserted perpendicular to the membrane to create a gap. The cured block is placed in a chamber where water is introduced to the membrane surface up to a head of 231 feet (70 m). minimum). Peel adhesion of membrane to concrete is measured at a rate of 50 mm Y Puncture Resistance Tensile Strength, Film 4. Hydrocarbon Resistant Drainage Composite: Composed of a 1/4-inch-thick (6 mm) dimpled drainage core, a nonwoven filter fabric and a high modulus backing film, all manufactured from polyethylene terephthalate. Hydroduct HR by W. R. Grace and Company; or equal. 5. Protection Board: 990 N minimum (200 Ibs) 27,600 kPa minimum (4000 psi) ASTM D 412 - ASTM E 154 7/31/02 Contract No. 3907 Page 316 of 414 6. 7. 8. 9. a. Asphaltic Hardboard, 1/4-inch-thick, premolded, semi-rigid protection board consisting of a bitumen and mineral core between two reinforcing liners. Use on horizontal surfaces. W. R. Grace and Company; or equal. Expanded Polystyrene Protection Board 1 -inch-thick and having a nominal density of 1 Ib. per cubic foot. Use on vertical surfaces. W. R. Grace and Company; or equal. b. Liquid Membrane: A two-component, elastomeric, cold-applied, trowel-grade material designed for use with the specified membrane waterproofing system. Bituthene Liquid Membrane by W. R. Grace and Company; or equal. Mastic: A rubberized asphalt-based mastic designed for specific uses only as recommended by the maker of the specified membrane waterproofing system. Bituthene Mastic by W. R. Grace and Company; or equal. Edge Guard Tape: A specially formulated tape designed for applications where resistance to hydrocarbon contaminated soil is required. Two inches (51 mm) wide and constructed of a 2-mil (0.025 mm) polyesther film with a l-mil pressure sensitive solvent-resistant acrylic adhesive on one face. Bituthene Edgeguard Tape by W. R. Grace and Company; or equal. Miscellaneous Materials: a. b. C. d. e. f. Use products manufactured by the maker of the Sheet Membrane Waterproofing System and recommended by the maker for the applications listed below. Products listed are by W. R. Grace and Company and are intended for use with the Bituthene Sheet Membrane Waterproofing System. Equivalent products by makers of other systems may be submitted with those complete systems for evaluation. Surface conditioners. Primers: 1) Primer: Bituthene P3000. 2) Water Based Primer: Bituthene Water-Based Primer 3) Primer for Uncured Concrete: Bituthene Green Concrete Primer 4) VOC Compliant Primer: Bituthene Low VOC Primer Deck Prep: Bituthene Deck Prep Protection Board Adhesive: Bituthene Protective Board Adhesive Two-sided tape for use with protection boards and drainage composites: Bituthene Two-sided Tape 10. Miscellaneous Pre-Pour Materials: a. b. Pre-Pour Tape: A reinforced two-sided pressure sensitive adhesive tape, 2-1/2- inch (64 mm) wide, interwound with silicone-coated release liner. Pre-Pour Penetration Seal: A two-sided reinforced seal tape 2-1/2-inch (64 mm) wide with an aggressive pressure-sensitive adhesive on one side and two layers of adhesive that forms a continuous bond with concrete cast against it on the other side. 306-1 1.4.4.3 Application of Modified Bituminous Sheet Membrane Waterproofing 306-11.4.4.3.1 Preparation of Substrates A. Review Sheet Membrane Waterproofing System manufacturer's requirements for preparation of substrates. Apply membrane only to surfaces that are structurally sound and free of voids, @ 7/31/02 Contract No. 3907 Page 317 of 414 spalled areas, loose aggregate and sharp protrusions. Remove contaminants such as grease, oil and wax from exposed surfaces. Remove dust, dirt, loose stone and debris. Use repair materials and methods, which are acceptable to manufacturer of Sheet Membrane Waterproofing. Cure concrete with clear resin-based curing compounds free of oil, wax and pigment. Remove all traces of curing compound prior to installing membrane. B. Cast-in-Place Concrete Substrates: 1. Do not proceed with installation until concrete has properly cured and dried, minimum 7 days for normal structural concrete and minimum 14 days for lightweight structural concrete. 2. Fill form tie rod holes with concrete and finish flush with surrounding surface. 3: Repair bug holes over 1/2-inch in width or length and finish flush with surrounding surface. 4. Remove scaling to sound, unaffected concrete and repair exposed area. 5. Grind irregular construction joints and offsets to suitable flush surface. C. Related Materials: Treat joints and install flashings as recommended by waterproofing manufacturer. 306-1 1.4.4.3.2 Application of Membrane Waterproofing Environmental Conditions A. Apply Sheet Membrane waterproofing system only in dry weather when air and surface temperatures are above -4°C (25°F). B. Apply Bituthene 3000 only in dry weather when air and surface temperatures are above 5°C (40°F). Use Bituthene Low Temperature Membrane between -4°C (25°F) and 5°C (40°F). C. Apply Bituthene Low Temperature Membrane up to 16°C (60°F). D. Apply Surface Conditioner and other accessory products in dry weather above -4°C (25°F). E. Conditions Suitable for Primers Application: 1. 2. 3. 4. Apply solvent primers in dry weather above -4°C (25°F). Apply green concrete primer in dry weather above 5°C (40°F). Apply Bituthene water-based primer in dry weather above 10°C (50°F). Do not apply products to frozen concrete. 306-1 1.4.4.3.3 Application of Membrane Waterproofing Conditioning A. 8. Dilute surface conditioner according to label instructions. Spray diluted Surface Conditioner uniformly to substrate at a rate of 12-15 sq. mR (500-600 sq. ft. per gallon). Use appropriate sprayer and nozzle. Allow surface conditioner to dry completely and thoroughly prior to membrane application. The surface conditioner is considered dry when the substrate returns to its original color (minimum one hour). To test for dryness, rub small conditioned area by hand. Wet conditioner will ball up under the fingertips. Let dry until conditioner cannot be rubbed off. If conditioned areas are not covered that day, recondition the area if there is significant dust or dirt contamination. 306-1 1.4.4.3.4 Application of Membrane Waterproofing Priming -* b 7/31/02 Contract No. 3907 Page 318 of 414 A. B. C. D. Apply one of the primers manufactured by the Sheet Membrane Waterproofing System maker and selected by the system manufacturer as being the best choice based on job conditions. Apply Bituthene primers by lamb’s wool roller at a coverage rate of 6-8 sq. m/L (250 to 350 sq. ft. per gallon). Allow primer to dry one hour or until tack-free. Apply Bituthene water based primer by spray or roller at a coverage rate of 12-15 sq. mR (500 to 600 sq. ft. per gallon). Allow primer to dry one hour or until concrete returns to original color. Dry time may be longer in cold temperatures. Reprime areas if contaminated by dust. If the work area is dusty, apply membrane as soon as the primer is dry. Surfaces treated with Deck Prep do not require conditioning or priming. Metal does not require priming but must be clean, dry, and free of loose paint, rust or other contaminants. 306-1 1.4.4.3.5 Application of Membrane Waterproofing Corner Details A. Use the comer treatment recommended by the System manufacturer based on the location of the corner. Comply with recommendations of system manufacturer‘s field representative. B. At Wall to Footing Inside Comers: 1. Apply membrane to within l-inch (25 mm) of base of wall. Treat the inside comer by installing a 3/4-inch (1 9 mm) fillet of Liquid Membrane, extend Liquid Membrane at least 2-1/2-inch (64 mm) onto footing, and 2-1/2-inch (64 mm) onto wall membrane. Treat the inside comer by installing a 3/4-inch (19 mm) fillet of Liquid Membrane. Apply 12-inch (305 mm) wide strip of membrane centered over fillet. Apply wall membrane over inside comer and extend 6-inch (150 mm) onto footing. Apply l-inch (25 mm) wide troweling of mastic or Liquid Membrane over all terminations and seams within 12-inch (300 mm) or comer. 2. C. At footings where the elevation of the floor slab is 6-inch (1 52 mm) or more above the footing, treat the inside comer either by the above methods or terminate the membrane at the base of the wall. Seal the termination with Mastic or Liquid Membrane. D. Outside comers, apply 12-inch (305 mm) membrane strip centered on corner. Cover the treated comer with a full sheet of membrane to ensure 2-ply coverage. Or, lap Sheet Membrane from two adjacent surfaces at least 12 inches at an outside comer so there is 2- ply coverage at comer and extending 6 inches on each side of comer. Apply Edge Guard Tape over all membrane joint laps. E. Joints: Properly seal all joints with waterstop, joint filler and sealant as required. Sheet Membrane is not intended to function as the primary joint seal. Prestrip all slab and wall cracks over 1/16-inch (1.5 mm) wide and all construction and control joints with 12-inch (300 mm) wide membrane. 306-1 1.4.4.3.6 Application of Membrane Waterproofing on Horizontal Surfaces A. Apply membrane from the low point to the high point so that laps shed water. B. Overlap all seams at least 2-112-inch (64 mm). Stagger all end laps. Roll the entire membrane firmly and completely as soon as possible. Use a linoleum roller or standard . water-filled garden roller less than 30-inch (760 mm) wide, weighing a minimum of 34 kg (75 Ibs.) when filled. To assure obtaining uniform overall contact between the membrane and the primed substrate use a roller that is wrapped with two layers of indoor-outdoor carpet or one layer of 1/2-inch (1 3 mm) thick plastic foam. Apply Edge Guard Tape over all Sheet Membrane joint laps. C. Seal all T-joints and membrane terminations with Liquid Membrane at the end of the day. @ 7/31/02 Contract No. 3907 Page 319 of 414 D. Patch tears and inadequately lapped seams with sheet membrane material. Slit fishmouths, repair with a patch extending &inch (152 mm) in all directions from the slit and seal edges of the patch with Liquid Membrane. Do not apply mastic where it will be covered with membrane. E. Flood test all horizontal applications with a minimum 2-inch (51 mm) head of water for 24 hours. Mark any leaks and repair when the membrane is dry. For well-sloped decks, segment the flood test to avoid deep water near drains. Start floor test one day after completing the application of Sheet Membrane Waterproofing System. F, 306-1 1.4.4.3.7 Application of Membrane Waterproofing on Protrusions and Penetrations A. Protrusion of Items Cast In Concrete: 1. Apply Sheet Membrane to within I-inch (25 mm) of the base of the protrusion. Apply Liquid Membrane 90 mils thick (3/32-inch or 2.3 mm) around protrusion. Liquid Membrane should extend over the membrane a minimum of 2-1/2-inch (64 mm) and at least 6 inches out onto the protruding item. Apply a layer of Sheet Membrane or edge seal tape lapping the Liquid Membrane at least 6 inches on each side. Seal all edges of Sheet Membrane with Liquid Membrane. 2. B. Penetrations: 1. 2. Apply membrane to the wall or slab surface and extend at least 6 inches inside the hole in the wall or slab. Insert a sealant backer rod and install a two-part polyurethane sealant to fill the annular space between the penetrating item and the Sheet Membrane that has been extended inside the hole in the wall or slab. Apply the sealant filler to a thickness equal to 2/3 of the widest part of the annular space. Apply two layers of Sheet Membrane fitted around the hole or opening in the wall or slab and extending out onto the Sheet Membrane applied to the face of the wall or slab. Extend the first layer of Sheet Membrane 6 inches out onto the penetrating item and 6 inches onto the membrane on the face of the wall or slab. Extend the second layer of Sheet Membrane 6 inches beyond the edges of the first layer. Seal the edges of all layers of Sheet Membrane with Liquid Membrane. 3. 306-1 1.4.4.3.8 Application of Membrane Waterproofing on Vertical Surfaces A. Apply membrane in lengths up to 8 feet (2.4 m). Overlap all seams at least 2 112-inch (64 mm). On higher walls apply membrane in two or more sections with the upper overlapping the lower by at least 2-1/2-inch (64 mm). Roll all membrane with a hand roller. B. Seal all laps within 12-inch (305 mm) of all comers with a troweling of Liquid Membrane. Apply a troweled bead of Liquid Membrane to all vertical and horizontal joints and terminations at the end of each workday. C. Patch tears and inadequately lapped seams with Sheet Membrane. Slit fishmouths and repair with a Sheet Membrane patch extending 6 inch (1 52 mm) in all directions from thedit and seal edges of the patch with Liquid Membrane. Inspect the membrane thoroughly and make any required repairs before covering. 306-1 1.4.4.3.9 Protection of Membrane Waterproofing A. On vertical applications use Hydrocarbon-Resistant Drainage Composite. Adhere drainage composite to membrane with two-sided tape. Adhere polystyrene Protection Board to the 7/31/02 Contract No. 3907 Page 320 of 414 earthfill side of the drainage composite with Bituthene Protection Board Adhesive or two- sided tape. B. On horizontal surfaces apply Hydrocarbon-Resistant Drainage Composite and Asphaltic Hardboard to the backfill side of the Sheet Membrane. Adhere as necessary to membrane with Bitustik Tape. Cover all Sheet Membrane exposed abovegrade with 16 02. copper or neoprene flashing. Install two layers of 1/4-inch-thick Asphalt Hardboard protection board over the drainage composite the same day as the membrane is applied or immediately after 24-hour flood testing. 306-11.4.4.3.10 Installation of Pre-Pour HD Membrane A. Substrate Preparation: Substrates must be relatively smooth and sound with no gaps or voids greater than 0.5 inch (12 mm). Earth substrates should be compacted to produce an even, sound substrate. Loose aggregate, sharp protrusions and standing water should be removed. Concrete substrates (i.e., mud slabs) should be smooth and monolithic. Surfaces must be free of large voids, spalled areas, loose aggregate and sharp protrusions. Broom finishes for concrete are NOT acceptable. Apply Pre-Pour HD membrane as soon as the substrate can accept foot traffic: the concrete surface does not need to be cured for 7 days since the membrane does not have to adhere to the substrate. Remove any standing water prior to applying the membrane. 1. 2. 3. B. Membrane Installation: 1. 2. Apply membrane in fair weather at temperatures of -4°C (25°F) or above. Apply the membrane with the HDPE side facing the properly prepared substrate and the treated white coating surface facing the concrete to be poured. The membrane may be installed at any convenient length. Apply succeeding sheets by overlapping previous sheets 3-inch (75 mm) along the self-adhesive edge of the membrane. Remove the silicone-coated release liner covering the membrane and roll the side lap to assure a tight seal. End laps are made by overlapping the end of the previously installed sheet a minimum of 3-inch (75 mm) and applying Pre-Pour Tape centered over the end lap. Roll the end lap to assure a tight seal. C. “Through Slab or Wall” Penetrations: 1. 3. A ”through slab or wall” penetration is any penetration through both the waterproofing system and the concrete slab to be poured. Examples of ”through slab” penetrations include pipes and conduits. Use the following three-step process to seal around “through slab” penetrations. a. Cut membrane tight to the penetration. If the membrane is not within 0.25-inch (6 mm) of the penetration, then install Pre-Pour Tape to cover the gap. b. Wrap the penetration with Pre-Pour Tape. Position the tape 0.5-inch (12 mm) above the membrane. c. Apply Liquid Membrane around the penetration to provide a tight seal between the tape and the membrane. 2. D. “In Slab” Penetrations: 7/31/02 Contract No. 3907 Page 321 of 414 1. An ‘in slab” penetration is a penetration through the waterproofing system that is encapsulated in the concrete slab to be poured. Use the following two-step process to seal around ‘in slab” penetrations. a. Cut membrane tight to the penetration. If the membrane is not within 0.25-inch (6 mm) of the penetration, then install Pre-Pour Tape to cover the gap. b. Apply Liquid Membrane around the penetration to provide a tight seal between the tape and the membrane. E. Tie-Ins: 1. Modified Bituminous Pre-Pour HD Sheet Membrane Tie-in to Sheet Membrane Wall Waterproofing: a. Install Pre-Pour HD membrane over the mud slab and extend it up the vertical surface of the slab formwork. Terminate the membrane 12-inch (300 mm) above the elevation of the top of the structural floor slab or wall footing when it is poured. Once the slab or footing is poured and cured for 7 days, remove the forms and trim the excess membrane. Install the Sheet Membrane Waterproofing System on the wall according to standard application procedures. Overlap the Sheet Membrane at least 12-inch (300 mm) onto the Pre-Pour HD Membrane. Seal the membrane edge joints and terminations with Liquid Membrane. Inspect the membrane before placement of reinforcement steel, formwork and concrete. Repair damaged areas by applying Pre-Pour Tape over the damaged area and roll firmly. Remove the release liner. Cast concrete within 10 days of application of the membrane and within 2 days of removing the release liner. b. c. d. 2. Pre-Pour Membrane Repair: a. b. c. 306-1 1.4.4.4 Water Repellent Sealer for Recycled Water Metering Station Water repellent sealer shall be delivered, stored and applied per the manufacturer‘s recommendations. Sealer shall be applied by a licensed Waterproofing Specialty Contractor exclusively engaged in applying waterproofing materials, sealers and sealants. Material to be used for Water Repellent Sealer shall conform to the following: A. Material: 1. 2. 3. 4. 5. 6. Waterbased penetrating clear water repellent sealer for lightweight concrete block and architectural concrete. Not less than 20% solids content. Meet requirements of Air Quality Management District having jurisdiction. Meet ASTM C67-78 and ASTM C14-75 submersion tests with a repellency rating of 96%. Apply at the rate recommended by the manufacturer for the density, porosity and texture of concrete and/or concrete block used. Manufacturer: Hydrozo No. 190; or equal. 7/31/02 Contract No. 3907 Page 322 of 414 306-1 1.4.4.5 Protective Coatings for Recycled Water Metering Station Protective Coatings for Recycled water Metering Station shall conform to manufacturer's recommendations, these Special Provisions, the SSPWC, and the Steel Structures Painting Manual Volume 2 published by the Steel Structures Painting Council. The Contractor shall conform to Section 2 - Scope and Control of Work of the SSPWC and the following: The Contractor shall provide the following information on each paint product: Abrasion resistance, ASTM D4060, 1 kg load at 1000 cycles, CS-17 wheel. Impact resistance, ASTM D2794, direct and reverse. Moisture vapor transmission, ASTM F1249. 1. 2. 3. 4. Adhesion, ASTM D4541. The Contractor shall provide Manufacturer's Certification that products furnished meet applicable Air Quality Management District regulations as to allowable volatile organic compound (VOC) content for the place of application and use intended. The Contractor shall a full range of the manufacturer's standard and let down finish colors for review and selection by the Engineer. After final colors have been selected, submit two 8 112- x ll-inch samples on cardboard of each color indexed as to manufacturer and color designation. Color chips 3/4-inch x 1-1/2- inch may be used for pipe color codes. The Contractor shall four pipe and equipment color code charts, 11 x 14 inches in size, with typed labels and using color chips. Upon favorable review, frame charts and mount under glass, suitable for hanging in work areas. Where there is a question of paint or coating adhesion to surfaces, demonstrate to the Engineer's satisfaction that the coating adhesion to the area in question is equal to or greater than that which the paint manufacturer literature states may be achieved by his product. An "Elcometer Adhesion Tester" is to be used by the Contractor to accomplish this demonstration. The Contractor shall furnish one-gallon (minimum) container of each type and color of finish product used. All containers shall be labeled. Each product shall have a minimum of 11 months of shelf life at project completion. 306-1 1.4.4.5.1 Materials for Protective Coatings for Recycled Water Metering Station A. Paints used in each system to be the product of one manufacturer. B. Shop applied prime coats shall be compatible with the systems included in these specifications. C. Substituted coating systems shall be of the same generic type as those specified. D. Coating systems shall not contain lead. E. Abrasives shall not be classified a hazardous material under California Title 22. 7/31/02 Contract No. 3907 Page 323 of 414 The following paint systems shall be used: General Ferrous Exposed to Atmosphere 1st Coat - bare metal High Solids Epoxy Finish Coat(@ High Solids Epoxy Final coat for exterior surfaces DFT = 2 mils additional Total DFT = 12 mils Aliphatic Polyurethane Buried Valves One full brush coat DFT = 20 - 30 mils Add the following to: (A) Amerlock 400 (T) Series 135 (A) Amerlock 400 (T) Series 135 (A) Amercoat 450HS (T) Series 74 (PW) 16011 60 H Mastic (TC) TC Masti 306-1 1.4.5 Measurement and Payment. Payment for construction of the recycled water metering station at the location shown on the plans and as described in the details will be made at the lump sum price named in the Bid Schedule D, which shall constitute full compensation for the complete work including excavation, backfill, bedding, compaction, compaction testing, sheeting, piping, manual valves, automatic valves, gauges, fittings, pipe enclosures, structural concrete vault, reinforcing steel, vault hatch, thrust blocks, disposal of excess excavated material, removal of nuisance water from excavation, electrical controls and telemetry, operation and maintenance manuals, trained system calibration technician, and any appurtenant work shown on the plans, called for in the Specifications, or required for a complete and operable recycled water metering station, complete for the lump sum price. Add the following section: 306-12 DUCTILE IRON PRESSURE PIPE Ductile iron pipe and fittings shall be assembled in accordance with the applicable sections of AWWA C600, "Installation of Gray and Ductile Cast-Iron Water Mains and Appurtenances" and as specified herein. Transportation shall be by competent haulers and accomplished in a manner that will avoid damage to the pipe, its lining, or coating. The Contractor shall unload by mechanical means, such as a crane or backhoe, or by rope and skids, as recommended by the manufacturer. In using skids, pipes must be prevented from striking other pipe. No dropping of pipe from trucks will be allowed. Excavation and backfill, including the pipe bedding, shall conform to Section II of the Vallecitos Water District Standard Specifications for Construction of Water and.Sewer Facilities, latest edition Prior to laying the pipe, the bottom of the trench shall be graded and prepared to provide uniform bearing throughout the entire length of each joint of pipe. Bell holes of ample dimension shall be dug in the bottom of the trench at the location of each joint to facilitate the joining. The trench shall have a flat or semi-circular bottom conforming to the grade to which the pipe is to be laid. The pipe shall be accurately placed in the trench to the lines and grades on the Plans. Fittings shall be supported independently of the pipe. - Cutting and machining of the pipe shall be accomplished in accordance with the pipe manufacturer's standard procedures for this operation and in accordance with AWWA C600. Pipe shall not be cut with a cold chisel, standard iron pipe cutter, nor any other method that may fracture the pipe or will produce ragged, uneven edges. G 7/31/02 Contract No. 3907 Page 324 of 414 Pipe shall be carefully handled to prevent damage to the lining and coating. Cable, rope, or other devices used for lowering fittings into the trench shall be attached around the exterior of the fitting for handling. Under no circumstances shall the cable, rope, or other device be attached through the fitting's interior for handling. No joint shall be backfilled until it has been observed by the Owner's Representative. Sufficient trench space shall be left open in the vicinity of each joint to permit visual observation around the entire periphery of the joint. .At all times when pipe laying is not in progress, the open end of the pipe shall be closed with a tight-fitting cap or plug to prevent the entrance of foreign matter into the pipe. These provisions shall apply during the noon hour as well as overnight. In no event shall the pipeline be used as a drain for removing water which has infiltrated into the trench. The Contractor shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the Owner's Representative. Damaged pipe or fittings shall be removed upon discovery and without delay from the Project Site. All pipelines shall be tested in conformance to Section 11-21 and 11-22 of the Vallecitos Water District Standard Specifications for Construction of Water and Sewer Facilities, latest edition A. General B. Allowable Leakage No pipe installation will be accepted if the leakage is greater than that determined by the following formula: ,S D @+ L = 1 33,200 in which L = the allowable leakage, in gallons per hour S = length of pipe tested, in feet D = nominal diameter of the pipe, in inches P = average observed test pressure of the pipe being tested, as is shown on the Plans or specified in Section 01410, Testing and Inspection, in pounds per square inch gauge, based on the elevation of the lowest point in the line or section under test and corrected to the elevation of the test gauge. The test pressure shall be 50 psi in excess of the designated working pressure specified for the class of pipe unless the test pressure is shown on the Plans or specified elsewhere in the Specifications. 306-12.1 Installation of Restrained Joints for Ductile Iron Pipe Installation of restrained joints for 12"-20" ductile iron pipe shall be per the following instructions: Components required for each joint: 2 right-hand locking segments (painted red, marked RH) 2 left-hand locking segments (painted black, marked LH) 2 rubber restrainers .1 TYTON Gasket, or approved equal TYTON JOINT lubricant or approved equal Instructions: 1. Lay pipe or fitting such that both of the bell slots are accessible (in the horizontal position if possible). Q 7/31/02 Contract No. 3907 Page 325 of 414 2. 3. 4. 5. 6. 7. 8. 9. Clean the socket and insert a TYTON Gasket, or approved equal. Clean the pipe spigot end back to the assembly stripes. Lubricate the exposed surface of the gasket and the pipe spigot end back to the weld bead. Make a conventional push-on joint assembly, fully homing the pipe until the first assembly stripe is in the bell socket. Keep the joint in straight alignment during assembly. Insert lower locking segment into a bell slot and slide the segment around the pipe. Insert upper locking segment into the same bell slot and rotate around the pipe. Hold the upper segment in place and wedge the rubber retainer into the slot between the two locking segments. Repeat steps 6-8 for other slot. Make sure that all 4 locking segments and 2 rubber retainers are securely in place. 10. Extend the joint to remove the slack in the locking segment cavity. Joint extension is necessary to attain the marked laying length on the pipe and to minimize growth or extension of the line as it is pressurized. 11. Set joint deflection as required. Installation of restrained joints for 24-36" ductile iron pipe shall be per the previous instructions except as follows: Components required for each joint: 4 right-hand locking segments (painted red, marked RH) 4 left-hand locking segments (painted black, marked LH) 4 rubber retainers 1 TYTON Gasket or approved equal TYTO JOINT lubricant or approved equal Step 9 shall read as follows: 9. Repeat steps 6-8 for other slots. Make sure that all 8 locking segments and 4 rubber retainers are securely in place. 306-12.2 Payment Payment for Ductile Iron Pipe will be made at the unit price bid for each size. Payment shall include all excavation, backfill, trench safety, and traffic control procedures, as specified in the specifications and these Special Provisions. Add the following section: 306-13 STEEL PIPE 306-13.1 Welded Steel Pipe for Potable and Recycled Water Mains. The fabrication and installation of all welded steel pipe for potable water mains in Bid Schedule C shall conform in all respects to the Vallecitos Water District Standard Specifications and Drawings for the Construction of Water and Sewer Facilities, latest edition. The fabrication and installation of all welded steel pipe for recycled water mains in Bid Schedule D shall conform in all respects to the Carlsbad Municipal Water District Standard Specifications and Drawings, latest edition. Polyethylene encasement will not be applied or installed on buried steel pipe but will be used to wrap buried valves and flanged connections. @ 7/31/02 Contract No. 3907 Page 326 of 414 .. 306-13.1.1 General. At all times when the work of installing pipe is not in progress, including worker break times, the ends of the pipe shall be closed with a vermin-proof and child-proof cap or plug. Do not permit trench water to enter the pipe. Do not place tools, clothing, or other materials in the pipe. The Contractor shall maintain the interior of the pipe in a sanitary condition free from foreign materials. 306-13.4.2 Dewatering. The Contractor shall provide, and maintain at all times during construction, ample means and devices to promptly remove and dispose of all water from any source entering trench excavations or other parts of the work in accordance with !hese specifications. Any damage caused by flooding of the trench shall be the Contractor's responsibility. Dewatering shall be performed by methods that will maintain a dry excavation, preservation of the final lines and grades and protection of all utilities. If flooding of the trench does occur, the Contractor shall immediately dewater and restore the trench. Damaged or altered pipeline appurtenances shall be repaired or replaced as directed by the Engineer. 306-13.1.3 Pipe Installation. When the work requires and the size of the pipe allows entry of personnel into the pipe, the Contractor shall comply with all Federal and State regulations for confined space entry. Work inside pipelines shall not be undertaken until all the tests and safety provisions of the Code of Federal Regulations 1910.146, and the General Industry Safety Orders of the California Code of Regulations, Title 8, Section 5159 for confined space entry have been performed and the area is verified as safe to enter. Generally, the aforementioned safety provisions apply to pipe 600mrn (24") and larger. Note that for pipe less than 600mm (24") diameter, more stringent safety procedures apply. The Contractor shall furnish and install all pipe, specials, fittings, closure pieces, valves, supports, bolts, nuts, gaskets, jointing materials, and all other appurtenances as shown on the Approved Plans and as required to provide a complete and workable installation. Pipe installations shall be as shown on the Approved Plans and Shop Drawings in accordance with the following: A. No pipe shall be installed where the linings or coatings show cracks that may be harmful as determined by the District Engineer. Such damaged linings and coatings shall be repaired or new, undamaged pipe sections shall be provided. 6. Pipe damaged prior to Substantial Completion shall be repaired or replaced by the Contractor. C. The Contractor shall inspect each pipe and fitting to ensure that there are no damaged portions of the pipe. The Contractor shall remove or smooth out any burrs, gouges, weld splatter, or other small defects prior to laying the pipe. D. Before placement of pipe in the trench, each pipe or fitting shall be thoroughly cleaned of any foreign substance which may have collected thereon and shall be kept clean at all times thereafter. For this purpose, the openings of all pipes and fittings in the trench shall be closed during any interruption to the work as noted above. E. Pipe shall be laid directly on the bedding material. No blocking will be permitted, and the bedding shall be such that it forms a continuous, solid bearing for the full length of the pipe. Excavations shall be made as needed to facilitate removal of handling devices after the pipe is laid. Bell holes shall be formed at the ends of the pipe to prevent point loading at the bells or couplings and to permit visual inspection 'of the joint. Excavation shall be made as needed outside the normal trench section at field joints to permit -adequate access to the joints for field connection operations and for application of coatings on field joints. F. Installation Tolerances: Each section of pipe shall be laid in the order and position shown on the approved layout schedule to the proper lines and grades in accordance with the following: 1. Each section of pipe having a nominal diameter less than 1200mm (48") shall be laid not to vary more than 50mm (2") horizontally or 25mm (1") vertically from the alignment and elevations shown on the - @ 7/31/02 Contract No. 3907 Page 327 of 414 Approved Plans. 2. Each section of pipe having nominal diameter 1200mm (48") and larger shall be laid not to vary more than five percent (5%) of the pipe diameter horizontally or two and one half percent (2.5%) of the pipe diameter vertically. 3. In addition to the horizontal and vertical tolerances above, lay the pipe so that no high or low points occur along the pipeline other than those shown on the approved layout schedule. G. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the District Engineer may change the alignment and/or the grades. Such change shall be made by the deflection of joints, by the use of bevel adapters, or by the use of additional fittings. However, in no case shall the deflection in the joint exceed seventy five percent (75%) of the maximum deflection recommended by the pipe manufacturer. No joint shall be deflected any amount that will be detrimental to the strength and water tightness of the finished joint. In all cases the joint opening, before finishing with the protective mortar inside the pipe, shall be the controlling factor. H. Pipes shall be laid uphill on grades exceeding 10 percent. Pipe that is laid on a downhill grade shall be blocked and held in place until the following pipe section has been installed to provide sufficient support to prevent movement. I. Temporary internal pipe bracing shall be left in place in pipe sizes larger than 600mm (24") until pipe zone compaction has been completed. Bracing in pipe smaller than 600mm (24") may be removed immediately after the pipe has been laid into the trench. The Contractor shall employ a laboratory to monitor pipe deflection by measuring pipe inside diameter before bracing is removed and 24 hours after struts are removed. Pipe deflection shall not exceed 3 percent in 24 hours after the bracing has been removed. After the backfill has been placed, the struts shall be removed. J. Cold Weather Protection: No pipe shall be installed upon a foundation onto which frost has penetrated or at any time that there is a danger of the formation of ice or penetration of frost at the bottom of the excavation. No pipe shall be laid unless it can be established that the trench will be backfilled prior to formation of ice and frost. K. Pipe and Special Protection: The openings of all pipe and specials where the pipe and specials have been mortar-lined in the shop shall be protected with suitable bulkheads to maintain a moist atmosphere and to prevent unauthorized access by persons, animals, water, or any undesirable substance. The bulkheads shall be designed to prevent drying out of the interior of the pipe. The Contractor shall introduce water into the pipe to keep the mortar moist where moisture has been lost due to damaged bulkheads. 306-13.1.4 Rubber-Ring Joints. Shall only be used as shown on plans. For pipe sizes smaller than 24- inches, the bell end shall be buttered with cement mortar in a manner and quantity that will completely fill the recess between the respective linings of the two joined sections of pipe. The spigot end shall then be entered into the bell end of the adjacent pipe section the distance shown on the Shop Drawings. Immediately after joining, the pipe interior shall be swabbed to remove all excess mortar by drawing a swab or squeegee through the pipe. The pipe interior shall be inspected by a closed circuit television camera, to assure quality of internal mortar. For pipe sizes 24-inches and larger, the joint recess shall be pointed from the inside with cement mortar after the backfill has been placed and compacted and the pipe permitted to take any normal settlement. The mortar shall be mixed of one part cement to one and one-half parts of sand and pointing accomplished in two or more lifts and finished off flush by troweling. Pipe shall be inspected visually by work persons within the pipe, to assure internal mortar quality. Each pipe joint shall be bonded to provide electrical continuity along the entire pipeline. The bond shall be made by the proper welding of pipe joints together as indicated on the Plans. e 7/31/02 Contract No. 3907 Page 328 of 414 The outside joint recess shall be grouted with cement mortar after a diaper has first been placed around the joint and tightened securely to prevent leakage while the mortar is being poured. The diaper shall be made of moisture resisting paper or heavy duty sail cloth of sufficiently close weave to prevent cement loss from the mortar. The diapers shall be hemmed on each edge and shall contain a metal strap within each hem sufficiently longer than the circumference of the pipe to allow a secure attachment of the diaper to the pipe. The diaper width will depend upon pipe size and design and shall be the width recommended by the manufacturer. Following installation of the diapers, the joints shall be poured and rodded from one side only until the mortar comes up to the top of the diaper on the opposite side. Approximately one hour subsequent to the pouring of the joint, the joint shall be rechecked and, if any settlement, leakage or shrinkage has taken place, the joint shall be refilled with mortar. Outside joints may be grouted before or after the placement of bedding and backfill materials if those materials are to be mechanically compacted. If bedding and backfill materials are to be hydraulically densified, grout shall be poured and allowed to set before applying water. In any case, joints shall be grouted before backfill is placed over the top of the pipe. 306-1 3.1.5 Butt-Strap Closure Joints. Butt-Strap Closure Joints: Butt-strap closure joints shall be completed in the trench after the pipe has been laid to the alignment and grade shown on the Plans. They should be field welded by fullcircumferential fillet welds or one of the edges may be shop welded and the other field welded. Welding shall be done in the same manner as specified for welded joints. The interior of the joints shall be filled with stiff plastic mortar and finished off smoothly with the inside of the pipe. Clean the inside steel surfaces by wire brushing or power brushing. Wire mesh, 2" x 4" x No. 13 gauge, clean, and free from rust, shall be applied to the interior of the joints so that the wires on the 2- inch spacing run circumferentially around the pipe. The wires on the 4-inch spacing shall be crimped in such a manner that the mesh will be held 3/8-inch from the metal joint surface. The mesh shall be lapped a minimum of 8-inches and shall be securely wired in position. Pack the cement mortar into the recess of the joint and steel trowel finish to match the adjoining pipes. The joint exterior shall be coated with mortar to a minimum thickness of 1%-inches. Immediately prior to applying mortar to the interior or exterior of the joints, a cement wash shall be applied to the metal to be coated. 306-13.1.6 Field Welded Joints A. Welded joints shall be completed after the pipe is in final position. Welded joints shall be a lap- welded slip joint as shown on the Plans. The minimum overlap of the assembled bell and 9 pigot section of lap joint shall be shown on the plans. Any recess between the bell and spigot shall be caulked with a rod to facilitate the welding. Pipe of 30-inches in diameter or more may be welded from the inside. Joints shall be welded on the inside and outside where indicated on the Plans as "Double Welded Joints." Field Welding shall be in accordance with AWWA C206 and AWS D1.l, except as modified herein. Welders assigned to the Work shall be qualified under the AWS standard qualification procedure, within the past three (3) years. B. Joints to be welded shall be cleaned, preferably prior to placing the pipe in the trench, of all loose scale, heavy rust, paint, cement, and grease. At least a IR-inch recess shall be provided between adjacent mortar-covered surfaces to place the weld. In all hand welding, the metal shall be deposited in successive layers and the minimum number of passes shall be 2. Preheat the joints to be welded where required in accordance with Table 1 of AWA C206. C. All joints shall be visually inspected and, excepting closing sections, shall undergo dye testing and hydrostatic testing, closing section shall be subjected to a dye test, or by soap solution method of testing, in accordance with AWA C-206. E. Welded joints shall be completed in the trench per AWA C206. F. Both the bell and spigot ends shall be cleaned of foreign matter prior to welding. G. Welding electrodes shall be as recommended by the pipe manufacturer. Typically, electrodes shall be ' D. After the joints have been welded, the interior joint shall be grouted with cement mortar. 7/31/02 Contract No. 3907 Page 329 of 414 E6010 for root passes and E7018 for additional passes. Do not deposit more than 3.2mm (1/8") of throat thickness per pass. H. Weld material shall be deposited in successive layers. Complete and clean each pass around the entire circumference of the pipe before commencing the next pass. I. The minimum number of passes in the completed weld shall be as follows: Steel Cylinder Thickness Field Weld Minimum mm (inches) Number of Passes 6.35 or less Greater than 6.35 (0.2500 or X") (0.2500 or X") 2 3 J. To minimize longitudinal stresses due to temperature variations, it is necessary to leave unwelded one joint per each 120m (400') of pipeline. This joint shall be left unwelded until all the joints on both sides of it are welded, and it shall be welded at the coolest time of the working day. The District Engineer shall decide if and when this procedure is warranted. K. Tack-welding the joint may be permitted to hold the pipe in place. If the joint is to be circumferentially welded, sufficient time shall elapse to allow for an initial set of interior joint lining prior to proceeding with joint welding. Rapid-setting mortar may be used in accordance with this Section. In some cases, the District Engineer may require hand holes. L. Field welders shall be certiied in accordance with ASME Section 9 (pipe welders) or AWS D1 .I (plate welders). Welders shall present a copy of their certification to the District Engineer prior to performing any field welding. M. Prior to butt-strap welding, the pipe and pipe joint shall be properly positioned in the trench using line- up damps so that, in the finished joint, the abutting pipe sections shall not be misaligned by more than 1 59mm (1 /I 6"). N. The pipe ends shall be cut straight on joints where butt straps are used for realignment, adjustment, or deflection, and fillet welds shall be made as indicated. 0. Inspection of Field Welded Joints: 1. 2. The District shall arrange for the welds to be inspected. Inspection of welds shall take place as soon as possible following the completion of the welds. The Contractor shall coordinate and supply ventilation, lighting, and other equipment deemed necessary for inspection. The Contractor shall be responsible for providing safe entry into and out of the trench, safety of inspection personnel, traffic control and other safety precautions deemed necessary for the inspections. 306-13.1.7 Preventing Foreign Matter From Entering The Pipe. At all times when pipe laying is not in progress, the open end of the pipe shall be closed with a tight-fitting cap or plug to prevent the entrance of foreign matter into the pipe. These provisions shall apply during the noon hour as well as overnight. In no event shall the pipeline be used as a drain for removing water which has infiltrated into the trench. The Contractor shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the Owner's Representative. 306-13.1.8 Interior Joint Finish - Pipe Less THAN 600mm (24"). Complete interior mortar joints for pipe sizes less than 600mm (24") by drawing through a tight-fitting swab or squeegee. Coat the face of the cement mortar lining at the bell with a sufficient amount of stiff cement mortar to fill the gap. Immediately after joining the pipes, draw the swab through the pipe to remove all excess mortar and expel it from the open pipe end. Do not move the pipe after the swab has been pulled past the joint. See requirements under "Field Welded Joints" for these joints requiring welding. a 7/31/02 Contract No. 3907 Page 330 of 414 306-13.1.9 Interior Joint Finish - Pipe 600mm (24") And Larger. A. Complete interior mortar joints for pipe sizes 600mm (24") and larger by the trowel method. Prior to applying interior mortar at the joints all bacMill in the area shall be completed. After cleaning the interior joint, pack cement mortar into each joint. Finish the surface with a steel trowel to a smooth finish and equal thickness to match the adjoining pipe mortar. B. Where more than a 1OOmm (4") joint strip of mortar is required, place galvanized welded wire mesh reinforcement in 50mm x 1OOmm (2" x 4") pattern of No. 13 gauge over the exposed steel. Install the mesh so that the wires on the 50mm (2") spacing direction run circumferentially around the pipe. Crimp the wires on the 1OOmm (4") spacing to support the mesh 9.5mm (3/8") from the metal surface. Steel- trowel finish the interior mortar to match adjoining mortar-lined pipe sections. 306-13.1.10 Exterior Joint Finish A. The outside annular space between pipe sections shall be completely filled with grout formed by the use of polyethylene foam-lined fabric bands. The grout space shall be flushed with water prior to filling so that the surfaces of the joint to be in contact with the grout will be thoroughly moistened when the grout is poured. The joint shall be filled with grout by pouring from one side only. Grout shall be rodded with a wire or other flexible rod or vibrated so that the grout completely fills the joint recess by moving down one side of the pipe, around the bottom of the pipe and up the opposite side. Pouring and rodding the grout shall be continued to allow completion of the filling of the entire joint recess in one operation. Care shall be taken to leave no unfilled space. Grouting of the outside joint spaces shall be kept as close behind the laying of the pipe as possible except that in no case shall grouting be closer than three joints of the pipe being laid. B. The grout bands or heavy-duty diapers shall be polyethylene foam-lined fabric with steel strapping of sufficient strength to hold the fresh mortar, resist nodding of the mortar, and allow excess water to escape. The foam plastic shall be 100 percent closed cell, chemically inert, insoluble in water and resistant to acids, alkalis and solvents. Foam Plastic shall be Dow Chemical Company, Ethafoam 222, or equal. The fabric backing shall be cut and sewn into 224mm (9") wide strips with slots for the steel strapping on the outer edges. The polyethylene foam shall be cut into strips 150mm (fY) wide and slit to a thickness of 6.35mm (1/4") that will expose a hollow or opencell surface on one side. The foam liner shall be attached to the fabric backing with the open or hollow cells facing towards the pipe. The foam strip shall cover the full interior circumference of the grout band with sufficient length to permit a 200mm (8") overlap of the foam at or near the top of the pipe joint. Splices to provide continuity of the material will be permitted. The polyethylene foam material shall be protected from direct sunlight. The polyethylene foam-lined grout band shall be centered over the joint space with approximately equal widths extending over each pipe end and securely attached to the pipe with the steel straps. After filling the exterior joint space with grout, the flaps shall be closed and overlapped in a manner that fully encloses the grout with polyethylene foam. C. Following grouting, the joint shall then be wrapped with two layers of polyethylene encasement in accordance with Section 15000. 306-1 3.1 .I 1 Butt Strap Joints. Butt strap closure joints shall be installed where shown on the Approved Plans in accordance with AWA C206. A. Butt straps shall be field welded to the outside plain end of the pipe along both edges with a full circumferential weld. A minimum of two weld passes shall be used. B. The interior of the joints shall be filled with a rapid-set mortar and finished off smoothly to match the pipe interior diameter. C. Clean the butt strap with a wire brush and apply a cement and water wash coat prior to applying - , @ 7/31/02 Contract No. 3907 Page 331 of 414 cement mortar. D. Galvanized wire mesh, 50mm x 1OOmm (2" x 4") x No. 13 gauge shall be installed to the exterior of the joint prior to applying the mortar coating. E. Coat the exterior of the closure assemblies with mortar to cover all steel with a minimum of 32mm (1- F. Seal weld the steep plug to the hand hole after the interior of the joint has been inspected and approved by the District Engineer. G. Following grouting, the joint shall then be wrapped with two layers of polyethylene encasement in accordance with Section 15000. 1 /4). 306-13.1.12 Flanged Connections. Flanged connections shall be installed where indicated on the Approved Plans. A. Bolt holes shall straddle the horizontal and vertical centerlines. B. The bolts, nuts and flange faces shall be thoroughly cleaned by wire brush prior to assembly. C. Bolts and nuts shall be lubricated with a District-approved anti-seize compound. D. Nuts shall be tightened in an alternating "stat" pattern to the manufacturer's recommended torque. E. Slip-on type flanges intended for field fit-up and welding shall be welded inside and outside in accordance with AWA C207. F. Coat the exterior of exposed flanges, bolts and nuts in accordance with Section 09910. 306-13.1.13 Flanged Coupling Adapters. Flanged coupling adapters shall be installed in accordance with the manufacturer's recommendations. Bolts shall be tightened with a toque wrench in the presence of the District Engineer to the toque recommended by the manufacturer. 306-13.1.14 Joint BondingKathodic Protection Insulation. Bonding of joints to provide continuity, flange insulation kits, internal epoxy linings, and other cathodic protection items and materials shall be installed where shown on the Approved Plans. 306-13.1.1 5 Wax Tape. Wax tape shall be installed as shown on the Approved Plans. 306-13.1.16 Concrete. Where required, concrete thrust and anchor blocks shall be installed in accordance with CMWD Rules and Regulations for the Construction of Reclaimed Water Mains, October 1993. 306-13.1.1 7 Waminghdentification Tape. Waming/ldentification Tape shall be installed in accordance with these special provisions and the Standard Drawings. 306-13.1.18 Hydrostatic Testing. Field hydrostatic testing shall be performed in accordance with CMWD Rules and Regulations for the Construction of Reclaimed Water Mains, October 1993. 306-13.1.19 Field Painting And Coating. A. Exterior surfaces of all pipe and appurtenances not otherwise mortar-coated shall be field painted with a material from the CMWD approved material list. B. Areas in contact with potable water such plain ends of pipe, grooved and shouldered ends of pipe and exposed inside surfaces of threaded outlets and blind flanges shall be coated with a material from the CMWD approved material list. @ 7/31/02 Contract No. 3907 Page 332 of 414 306-13.2 Plastic Tape Coating with Mortar Overcoat for Potable Water Mains. Plastic tape coating shall be applied in accordance with AWA C 209, C 214, and as modified herein. Prior to shipment of pipe, a certificate of compliance shall be provided stating that tape materials and work for all pipe delivered complies with the requirements of these Specifications and AWWA C 209 and C 214. This certificate shall be submitted by the pipe manufacturer and endorsed by the tape manufacturer. The pipe manufacturer shall retain the services of a representative of the tape manufacturer to ensure proper installation of all tape materials in the pipe manufacturer's shop. 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 manufacturer's 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 manufacture's requirements. This certification shall be received by the Engineer within two weeks of the beginning of pipe laying operations. 306-13.2.1 Straight Run Pipe Application. (a) Cold-applied plastic tape applied in the plant on straight run pipe shall be a four-layer system consisting of: (1) primer; (2) corrosion prevention tape (inner layer); (3) mechanical protective tape (first outer layer); and (4) mechanical protective tape (second outer layer). (b) The coating operation on each pipe section shall be performed with the pipe supported at the ends continuously throughout the application of the primer, plastic tape and mortar overcoat. Intermediate handling of the pipe involving rollers or blocks to support the pipe shall not be permitted. (c) Remove the exterior weld bead along the entire exterior surface of the pipe. The exterior weld bead shall be flush with the exterior surface of the pipe with a tolerance of plus 1/64 inch. Removal of the weld bead is to be conducted in such a manner that no gouging or nicking of the plate surface will occur. This operation is to result in a smooth exterior surface with no ridges or valleys which may result in bridging or disbonding of the tape from the surface of the pipe. 1) Bare pipe shall be clean of all foreign matter such as mud, mill scale, dirt, organic matter, weld slag and splatter, wax, coal tar, asphalt, oil, grease, or any contaminants. Wash pipe with hot water and allow the surface to dry. 2) Prior to blast cleaning, inspect surfaces and, if required, preclean in accordance with the requirements of SSPC SP-1, Solvent Cleaning, to remove oil, grease, and all foreign deposits. 1) Prior to primer and coating application, blast pipe surface using a commercially available shot grit mixture to achieve a prepared surface equal to that which is specified in SSPC SP-6, Commercial Blast Cleaning. 2) For plant mortar-lined pipe, perform blast cleaning of pipe exterior surfaces after the initial curing of the spun mortar lining. Perform the exterior blast cleaning in such a manner as not to damage the mortar lining in the pipe. Completely remove corrosion and foreign substances from the exterior of the pipe in the blast cleaning operation, and apply primer immediately after completion of blast cleaning. 3) The shot grit mixture shall not exceed 40 to 60percent grit. The shot grit mixture is to be determined prior to start of blast cleaning operations and this mixture ratio is not to be modified throughout the duration of the blast cleaning operations without the written approval of the Engineer. 4) Achieve from abrasive blasting an anchor pattern profile a minimum of 1 .O mil, but not exceeding 2.0 mils. Use NACE No. 3 Surface Profile Standard per NACE TM-01-75 as a visual comparison to define the acceptable anchor pattern profile during blast cleaning operations. (d) Surface preparation shall conform to AWA C 214 and the following: (e) Blast cleaning shall conform to AWA C 214 and the following: 7/31/02 Contract No. 3907 Page 333 of 414 5) Inspect the blast cleaned exterior of each pipe section for adequate surface preparation prior to application of the primer. Surface comparitor tapes are to be used by the pipe manufacturer in three (3) random areas along any given 40-foot length of pipe. The results of the surface comparitor tapes are to be included in the quality control records. 6) Coat each pipe section with primer and tape within the same day of being blast cleaned. Do not allow blasted and/or blasted and primed pipe to sit overnight. All blasted and primed pipe must be coated by the end of the day. No coating will be permitted on pipe sections showing evidence of rust. ~ . II (9 Primer application shall conform to AWA C 214 and the following: 1) Apply the primer in a uniform thin film at the coverage rate and thickness recommended by the manufacturer. Apply the inner layer of tape only after the primer is dried as specified by the tape manufacturer. 2) Apply primer only to those sections of pipe that can be taped within the same workday. Pipe coated with primer which was not taped within the same workday may be rejected at the discretion of the Engineer. The primer shall be removed from rejected pipe sections and the surface shall be re-primed. 3) Protect primercoated pipe sections from moisture, dirt, sand, and other potentially contaminating materials. Suspend primer application operations or provide full protection for the pipe during high wind periods. Pipe sections not adequately protected shall be rejected by the Engineer. If rejection occurs due to contamination of the primer, completely remove the primer from the exterior of the pipe section and reapplication of the primer will be required. 4) Store, mix and apply primer in strict compliance with the manufacturer's recommendations. (9) Inner layer tape application. Apply the inner layer of tape directly onto the primed surface using mechanical dispensing equipment recommended and approved by the tape manufacturer. Rollers shall be used to apply pressure on the tape as it comes in contact with the pipe. Tape shall be applied with uniform tension such that the surface is tight, smooth and wrinkle-free. The tape overlapped shall be a nominal 1 -inch with a 3/4-inch minimum overlap. The application of tension shall be such that the width of tape will be reduced between 1-112 to 2 percent of tape width prior to the pull. Provide instrumentation to measure and record tape tension throughout the tape application operation. Documentation of tape tension data shall be suitable to the Engineer. Apply inner layer tape at a minimum roll temperature of 70°F. Continuously monitor and record the temperature of the tape within 12 inches of the point of contact with the pipe surface. Document the temperature of the tape during application suitable to the Engineer. Pipe sections where the tape application tension and temperature is not maintained within manufacturer's recommendations shall be rejected and the tape removed from the entire pipe section and re-a pplied. Provide continuous electronic holiday testing of the inner tape layer at 6000 volts. The holiday test equipment shall be permanently mounted to the tape application station such that the tape is tested immediately after the tape is applied. The test equipment shall be equipped with an indicator light and audio buzzer suitable to the Engineer to alert the workmen of the presence of holidays in the coating system. Holidays shall be marked as found and repaired after the inner tape layer is completely applied to the pipe section but before the mechanical protection tape layers are applied. Splice each new roll with an overlap of at least 6 inches over the end of the previous roll. Provide cutbacks 10 inches from and parallel to the end of the pipe. Perform cutbacks using a cutting device that is guided from the end of the pipe to ensure a uniform, straight cutback. - 7/31/02 Contract No. 3907 Page 334 of 414 (h) Mechanical outer layer tape application. 1) The first mechanical outer layer of tape shall be applied using the same mechanical equipment used in the application of the inner layer tape. Longitudinal tape splices shall be a least 6 inches away from a longitudinal tape splice on the inner tape layer. Apply two mechanical outer layers of tape. The inner layer tape shall be electrically tested, inspected, and approved prior to the application of the first mechanical outer layer. Visually inspect the first mechanical outer layer prior to the application of the second mechanical outer tape layer. Both mechanical outer tape layers shall be smooth, tight, and wrinkle-free. 2) Apply the outer layer mechanical protection tapes in a similar manner to the inner protective tape except that the minimum tape roll application temperature shall be 90°F. Monitor tension and temperature during the application of the mechanical outer layer tapes. The use of rollers to apply pressure on the outer tape layers is not required during application. Holiday testing of the mechanical outer layer tapes in not required. (i) Storage primer application shall conform to AWWA C 214 as modified herein: 1) Clean the pipe surface free from foreign matter such as sand, grease, oil, grit, rust particles, and dirt prior to storage primer application. 2) Store, mix and apply storage primer in strict accordance with the primer manufacturer's recommendations. 3) Apply storage primer to the exposed steel pipe at tape cutbacks to prevent oxidation of the cleaned metal surface. Spray apply a minimum of 1.5 mils and maximum of 2.5 mils of storage primer to exposed steel per the manufacturer's recommendations. Do not place storage phmer on the edge of the steel plate. . (j) Mortar Overcoat. 1) Apply cement-mortar overcoating in accordance with AWAC205 immediately after the application and testing of the tape coating layers. Allow 3-1/2-inch cutback beyond the edge of the tape coating 2) Allow the mortar to cure properly before the pipe section is removed from the coating fixture and placed on rollers or timbers. 306-13.2.2 Fittings Coated at the Plant. Coat fittings which cannot be machine coated in accordance with AWWA C 209 using materials as specified herein. Weld bead preparation, surface preparation, blast cleaning, primer and tape application shall be as specified for straight run pipe. Apply an inner layer tape of Polyken No. 932-50 or approved equal, with a l-inch nominal, 3/4-inch minimum, tape overlap on all plant coated fittings. Apply an outer layer of cold-applied plastic tape as specified herein with a 55 percent overlap on all plant coated fittings. Provide a minimum thickness of 1 10 mils for the total tape coat system for plant coated fittings. Test all completed tape coated fittings in the presence of the Engineer with an electrical holiday detector prior to application of cement-mortar coating. Applied voltage shall be in the range of 1 1,000 to 15,000 volts. Repair any holidays found. Follow the procedure described herein for field tape coating repairs on fittings and for coating field joints. Apply cement-mortar coating in accordance with AWWA C 205 immediately after completion of tape coating, holiday testing indicating no holidays and inspections. e 7/31/02 Contract No. 3907 Page 335 of 414 306-13.2.3 Coating of Field Joints. Field coldapplied plastic tape coating shall be in accordance with 'AWWA C 209, as modified herein. Protect the plastic tape coating from heat and weld splatter damage at welded joints by wrapping an 18-inch-wide strip of heat resistance material completely around the coated pipe sections covering the exposed tape on each side of the joint prior to welding. Do not use the coated portion of the pipe for grounding. For exterior welded lap joints, remove the storage primer and wire brush areas to be welded immediately prior to welding. No field tape coating will be permitted until the welding has been completed and the pipe section has cooled sufficiently so as to not damage the integrity of the tape coating system. Do not permit trapped air under the tape in the joint. After joint welding, remove flash rusting by mechanical means, such as a wire brush. Wire brush the weld, storage primed steel and all exposed steel. Remove all buns and weld slag to achieve a smooth surface. Clean the pipe surface free of dirt, mud, mill scale, wax, tar, grease, or any foreign matter. Remove visible oil or grease using an approved solvent that will not leave any residue on the pipe surfaces. The pipe surface shall be free of any moisture and all foreign matter prior to the application of primer. Pack irregular surfaces in the joint with elastomeric joint filler. Apply primer immediately after surface is cleaned by brush or roller (4 mil wet, 1 mil dry). Overlap primer onto plant applied tape coating. After primer has dried, apply tape to the joint and extend a minimum of 3 inches onto the plant applied tape coating. 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 finished tape wrap shall be smooth and wrinkle-free. Test the final applied joint tape coating in the presence of the Engineer 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 shopapplied mortar overcoat a distance of not less than 5 inches. The thickness of the mortar shall be l-inch minimum. 306-13.2.4 Inspection of Tape Coating. (a) Inspection: The Engineer shall have access to witness the application of coatings on all pipe sections at his or her discretion. 1) Provide the Engineer with reasonable facilities and space at the pipe fabrication mill for the inspection and testing of the pipe coating. Assist the Engineer in obtaining any information required to determine the characteristics of the material to be used. Furnish to the Engineer at least two electrical pipe coating flaw detectors at the plant and one electrical pipe coating flaw detector per pipe installation heading in the field to aid in the inspection of the tape coating. 2) Provide free access to the Engineer to plants of the manufacturer furnishing the materials and to mill or the worksite. Holiday detection for tape coating. (b) e 7/31/02 Contract No. 3907 Page 336 of 414 1) Prior to the application of the mechanical outer layer tapes, electtically test the inner layer tape for any flaws in the coating with a suitable holiday detector as approved by the Engineer. The detector shall impress a voltage conforming to NACE Standard RP-0188. The voltage to be used to electrically test the tape shall be fully documented. 2) Clearly mark all holidays electrically or otherwise detected and immediately repair. Do not start wrapping the first mechanical outer layer tape until all detected holidays have been repaired. Perform repairs per tape manufacturer's recommendations. After the repair, retest the affected areas with the holiday detector prior to the application of the outer layer wrap. This process will be done until the coating has successfully passed the test. 306-13.2.5 Protecting Coated Pipe. (a) The mortar overcoat provides mechanical protection for the underlying tape coating; however, normal precautions are required to protect the mortar from damage and additional care must be taken to protect the exposed tape at the ends of each pipe section. At the fabrication plant, handle the coated pipe sections only after application of the cement-mortar coating using minimum 12-inch-wide belt slings with spreader bars or padded forklifts. Apply a storage wrap to the exposed tape ends to protect against ultraviolet exposure. Remove the storage wrap prior to completing the field joint. Tape exposed to ultraviolet light for more than 90 days without protection is subject to being rejected by the Engineer. 306-13.3 Testing and Disinfecting of Potable Water Mains. All testing and disinfecting of potable water mains in Bid Schedule C shall conform in all respects to the Vallecitos Water District Standard Specifications and Drawings for the Construction of Water and Sewer Facilities, latest edition. 306-13.4 Testing of Recycled Water Mains. All testing of recycled water mains in Bid Schedule D shall conform in all respects to the Vallecitos Water District Standard Specifications and Drawings for the Construction of Water and Sewer Facilities, latest edition, or the CMWD Rules and Regulations for the Construction of Reclaimed Water Mains, October 1993, in accordance with the jurisdiction as identified on the plans. 306-13.5 Payment Payment for Steel Pipe will be made at the unit price bid for each size. Payment shall include all materials, equipment, labor, hydrostatic testing, excavation, backfill, trench safety, and traffic control procedures, as specified in the specifications and these Special Provisions. Add the following section: 306-14 APPURTENANCES FOR POTABLE WATER MAINS 306-14.1 General. This section pertains to the installation of all appurtenances for a complete and operable underground pressurized potable water system for potable water mains in Bid Schedule C. 306-14.2 Valves for Potable Water Mains. Installation of all valves for potable water mains in Bid Schedule C shall conform in all respects to the Vallecitos Water District Standard Specifications and Drawings for the Construction of Water and Sewer Facilities, latest edition. 306-1 4.3 Appurtenances. Payment for relocation of existing appurtenances, including but not limited to fire hydrants and water valves, shall include all materials, equipment, tools and labor including excavation, backfill, trench safety, and traffic control procedures, and for performing all the work as specified in the specifications and these Special Provisions, and no additional payment will be made. Copper Piping shall adhere to Vallecitos Water District Standard Specifications. Payment for copper piping shall include all materials, equipment, tools and labor including excavation, backfill, trench safety, and traffic control procedures, and for performing all the work as specified in the specifications and these Special Provisions, and no additional payment will be made. Add the following section: (b) Q 7/31/02 Contract No. 3907 Page 337 of 414 306-1 5 INSTALLATION OF CORROSION PROTECTION FACILITIES ON BURIED METALLIC PIPELINES 306-15.1 Execution. All work shall be performed by qualified, experienced personnel working under continuous, competent supervision. Work not specifically described herein shall conform to NACE RPOl69 or NACE RP0286 306-1 5.2 Magnesium Anodes. A. B. C. D. E. F. G. Inspection: All lead wires shall be inspected to ensure that the lead wire is securely connected to the anode core and that the lead wire insulation has sustained no damage. Anode lead wire-to-anode connection failures shall require replacement of the complete anode and lead wire assembly. Pre-Packaged Anode Inspection: Each unit shall be inspected to ensure that the backfill material completely surrounds the anode and that the cloth bag containing the anode and bacMill material is intact. If the prepackaged anodes are supplied in a waterproof container or covering, that container or covering shall be removed before installation. Excavation Type and Depth: Anodes are to be installed in augured holes 12 feet deep as shown in the drawings. Location and Spacing: Approximate anode locations are shown in the drawings. Anode positions can and should be adjusted in the field to avoid interference with existing structures or undesirable soil conditions. Offset anodes as far as possible from pipe but all anodes must be in the WD easement. Space between anodes at a multiple anode bed shall be 15 feet if possible. Shorter spacings must be approved by the Corrosion Engineer. Alternate anode positions, greater than 10 feet from the stationing shown in the drawings must be approved by the corrosion Engineer. Anodes can be installed on either side of the pipe except as indicated in the drawings. Do not install anodes under paving if landscaped areas meeting spacing and easement criteria are available. Anodes can be installed on either side of the pipe except as indicated in the Drawings. Do not install anodes under paving if landscaped areas meeting the location criteria are available. 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. Soaking Requirements, Pre-Packaged Anodes: All prepackaged anodes shall be completely submerged in water for 30 minutes before being placed in the hole. Once in the hole, 15 . gallons of water shall be poured on top of the anode such that it is completely covered with water. Allow the anodes to soak for a minimum of 30 minutes before any soil backfill is added. Backfill with native, rock-free (1/2-inch maximum rock size) soil such that the soil backfill is 3 to 5 inches over the top of the anode. Add an additional 5 to 10 gallons of water to the hole to completely saturate the soil around the anode. Allow the anode and soil to soak for 15 minutes (minimum) before completing the backfill operation. Anode Upper Backfill: After the anode has soaked in the hole, the hole is backfilled with native spoil (not sand) with all stones over l-inch diameter removed. BacMill in 18-inch lifts and carefully tamp to compact the soil. No voids shall exist around the anode bags and the anode lead wire shall not be damaged. 306-1 5.3 At-Grade Test Stations. A. Location: At-grade corrosion monitoring test boxes shall be placed behind the curb out of traffic lanes. Location options depend on the curthidewalk configuration as indicated in the drawings. Alternate test station positions are shown in the drawings. Final locations must be approved by the Inspector or Corrosion Engineer. Avoid vehicle traffic locations. B. Native Soil: The bottom of the box shall be native soil not gravel, rock, or sand. 7/31/02 Contract No. 3907 Page 338 of 414 C. D. E. F. G. H. I. 306-1 5.4 A. 8. C. D. Test Lead Attachment: Test leads shall be attached to the pipe using the alumino-thermic weld process as shown in the drawings and as described herein. A single 18-inch slack wire coil shall be placed at each weld. Test Box Connections: Test leads shall be left Unconnected in the test box or connected to the anode shunt(s) (where applicable) with one or more brass split-bolt as shown in the drawings. All anode leads shall be left unconnected in the test box until activation by the Corrosion Engineer. Anode Connection: The Contractor shall leave all anode lead Wires unconnected in the test box. However, the Contractor shall additional split-bolts to the free end(s) of the shunt(s) that are suitably sized to connect the anode lead wires as shown in the drawings. Hardware: All brass tags and all hardware necessary for all wire connections at each test station shall be placed in the test box. Wire Installation: All buried lead wires (test or anode) shall be installed without damage or splices. All wire leads shall terminate at an anode, the pipe or in a test box. Provide slack wire in the test box such that all wires extend above the top of the box (grade) by 18 inches. Anode Connection: Contractor shall connect the shunt to the pipe lead with a split bolt connector as shown. The anode lead shall be left unconnected for testing and completion by the Corrosion Engineer. The Contractor shall connect a second split bolt to the other end of the shunt for connecting the anode lead to the shunt; however, the anode wire shall be left out of the connection until the system is activated by the Corrosion Engineer. All hardware necessary for all wire connections at each test station shall be placed in the rectifier box. Concrete Pad: A 26 inches square by 4 inches deep, reinforced (No. 4 rebar) concrete pad is required around each at-grade test station that is not located in a paved area. The pad shall be flush with grade except in grass areas where it shall be slightly raised. Wire and Cable. Test Lead Trenching and Backfilling: Horizontal test lead and anode lead runs shall be placed in a trench with a minimum depth of 24 inches. The bottom of the finished trench shall be sand or stone-free earth. Test lead shall be centered in the bottom of the trench and covered and tamped in a 6-inch layer of stone-free earth. Trench spoil can be used for the remainder of the backfill unless directed othetwise in these specifications. Soil compaction shall be as specified elsewhere in these specifications. Do not stretch or kink the conductor. Care shall be taken when installing Wire and backfilling trench so insulation is not broken, cut, or bruised. Do not place roots, wood scraps, organic matter or refuse in the backfill. Warning Tape: Warning tape shall be placed in all wire trenches at the depth indicated in the drawings. Damaged Wire: If any wire insulation is damaged during installation, it shall be rejected and replaced completely at the Contractor's expense. All rejected wire shall be removed from the job site at the close of each workday. Splicing: No wire splices are allowed unless specifically approved by the Engineer. 306-1 5.5 Insulating Flange Kits. A. Flange Kit Preparation: Insulating kits shall be installed as shown on drawings and as recommended by the manufacturer. Moisture, soil, or other foreign matter must be carefully prevented from contacting any portion of the mating surfaces prior to installing insulator gaskets. If moisture, soil, or other foreign matter contacts any portion of these surfaces, the entire joint shall be disassembled, cleaned with a suitable solvent, and dried prior to reassembly. @ 7/31/02 Contract No. 3907 Page 339 of 414 8. Component Compatibility: The Contractor shall be responsible that insulating flange kits fit up properly. Specifically, the Contractor is responsible to verify that the bolts or studs are the correct material and size and that there are the correct number of bolts (studs), nuts, sleeves, insulating washers and steel washers. The Contractor shall also verify that the gasket sealing surfaces match up properly on both flanges and that there is enough clearance for the sleeves between the bolts or studs and the flange hole. Misaligned or noncompatible flange kits shall be replaced by the Contractor at the Contractor's expense. C. Alignment: Alignment pins shall be used to properly align the flange and gasket. D. Bolt Tightening: The manufacturer's recommended bolt-tightening sequence shall be followed. Bolt insulating sleeves shall be centered within the insulation washers so that the insulating sleeve is not compressed and damaged. E. Testing: All insulating flanges must be tested as specified herein. All buried insulating flanges must be tested before backfilling and before the wax tape primer and wrap are applied. Insulating flanges over 16-inches in diameter shall also be tested after assembly in the pipe spool before the spool is installed in the ditch. These flanges must be retested after full assembly in the ditch. F. Wax Tape\Testing Sequence: All small and large insulating flanges shall be tested before the wax tape is applied. Wax tape shall be applied to large flanges above grade before the spool is installed in the ditch. Re-testing of large flanges (in the ditch) can be done after wax tape is applied. The Contractor shall make repairs to wax tape that has been damaged either during the pipe spool installation or during testing. - 306-15.6 Wax Tape Coating. All buried pipe fittings which require wax tape wrap as defined in this specification shall be wrapped with petrolatum wax tape per AWA C217 and this specification paragraph. This includes valves and fittings on DIP which are to be polyethylene encased over the wax tape. A. Surface Preparation: All surfaces to be wrapped, including bolt and nut surfaces, must be clean and free of all moisture, dirt, mud, dust, heavy mill scale, wax, paint, oil, grease or any foreign substance. Clean using a power or hand wire brush and by wiping with a clean cloth. If oil or grease is present clean using a suitable, safe solvent that does not leave a residue. The surface shall be dry prior to the application of the coating. B. Primer: Apply primer by brush, hand, glove or roller. A thin coating of primer shall be applied to all surfaces and worked into all crevices. The primer shall be applied generously around threaded bolts and nut, coupling tie rods, flanges, followers, and other irregular surfaces and shall completely cover all exposed surfaces and fill all voids. The primer should overlap the pipe coating by a minimum of 3 inches. C. Wax Tape: The petrolatum wax-tape shall be applied immediately after primer application. Short lengths of tape shall be cut and carefully molded around each individual bolt, nut, and stud-ends. Coupling tie rods and odd surfaces must be individually wrapped with wax tape to ensure complete coverage with tape directly against all surfaces. After all bolts and irregular surfaces are covered with short sections of tape, the tape shall be circumferentially wrapped over the flange, valve or coupling with sufficient tension and pressure to provide continuous adhesion without stretching the tape. The tape shall be formed by hand into all voids and spaces. There shall be no gaps or air spaces under the tape. The barrel of couplings shall be wrapped under the tie rods. The tape shall be applied with at least a 55% overlap. The wax tape system shall have a minimum thickness of 50 mils over smooth surfaces and 100 mils over sharp projections such as bolts and nuts. D. Outer Covering: The clear plastic outer covering shall be applied by hand such that the material conforms and adheres to the wax tape surface. Coupling tie rods shall be individually wrapped. Wrap with 50% overlap. a 7/31/02 Contract No. 3907 Page 340 of 414 306-15.7 Continuity Bonding. A. Ductile Iron Joints: All buried ductile iron joints shall be bonded with two copper wires as shown in the drawings. Alternate bonding methods must be approved by the Corrosion Engineer. B. Steel Pipe Joints: Steel pipe joints that are not welded must be bonded with two No. 4 AWG HMWPE wires (18-inch max length). All wire welds shall be by the alumino-thermic weld process. C. Mechanical Joints: All buried DIP or steel pipe mechanical joints (Le., flanges, valves, couplings, expansion joints, etc.), which are not specifically identified as an insulating joint, shall be bonded with bond wires as indicated in the drawings. D. Bond Wires and Wax Tape: Attach, test and inspect bond wires before wax tape wrap is applied. 306-15.8 Wire to Pipe Connections. A. Welds: All connections of copper wires to the cathodelstructure shall be made by the alumino-thermic weld method as shown in the drawings. Use weld charges that are specifically designated for the material to which the wires are welded. B. Preparation of Wire and Cable: Use a cutter to prevent deforming cable ends. Do not deform cable. Clean oily or greasy cable with a rapid-drying solvent, which leaves no residue. Remove only enough insulation from the cable to allow the alumino-thermic weld connection to be made. C. Preparation of Metal: Remove all coating, dirt, grime, and grease from the metal structure at weld locations by wire brushing and/or use of suitable safe solvents. Clean the structure to a bright, shiny surface free of all serious pits and flaws by using a file. The area of the structure where the attachment is to be made must be absolutely dry. D. Wire Position: The wire is to be held at a 30degree angle to the surface when welding. Only one wire shall be attached with each weld. E. Testing of All Completed Welds: As soon as the weld has cooled, the weld shall be tested by the Contractor as described below. F. Re-welding Failed Welds: Before attempting a weld where a previous weld has failed, it is necessary to completely remove all weld metal and remnants of the previous weld by grinding or by filing. G. Coating of All Completed Welds: Assure that the area to be coated is thoroughly wire brushed, clean, and completely dry. Apply the elastomeric weld cap primer and then the weld cap to the weld. Apply a bituminous mastic coating over the weld cap at sites where wax tape is not applied. Apply bituminous coating in accordance with the manufacturer's recommendations. This coating shall overlap the structure coating a minimum of three inches. Allow sufficient time to dry. Wax tape can be applied over the weld cap in lieu of the bituminous coating. Add the following section: 306-1 6 TESTING AND INSPECTION OF CORROSION PROTECTION FACILITIES ON -BURIED METALLIC PIPELINES 306-16.1 Test Leads and Bond Wires. A. Responsibility: The Contractor shall be responsible for testing all test leads and bond wire welds. 7/31/02 Contract No. 3907 Page 341 of 414 B. Test Method: All completed wire connection welds shall be tested for strength by striking the weld with a sharp blow with a two-pound hammer while pulling firmly on the wire. Welds failing this test shall be re-welded and re-tested. Wire welds shall be spot tested by the Engineer. After backfilling pipe, all test lead pairs shall be tested using a standard ohmmeter for broken welds. The resistance shall not exceed 150% of the total wire resistance as determined from published wire data. C. Acceptance: Welds not loosened or broken by the hammer test can be backfilled. The resistance between each pair of test leads shall not exceed 150% of the total wire resistance as determined from published wire data. Ultimate bond wire acceptance shall be determined by the continuity test results. 306-16.2 Test Lead Trenching and Backfill. A. Responsibility: The depth, trench bottom padding, backfill material and the placement of warning tape shall be inspected by the Engineer or the Inspector at his or her discretion. B. Method: The depth, trench bottom padding, and backfill material shall be visually inspected prior to backfilling. Visual verification of warning tape. C. Acceptance: Conformance with these specifications 306-16.3 Continuity Testing. A. B. C. D. E. Responsibility: Full metallic continuity is the responsibility of the Contractor. Continuity tests shall be conducted by the Corrosion Engineer. The Contractor is also responsible for providing test access at all test stations and at both ends of all pipe sections requiring testing. Pipe Requiring Continuity Testing: All reaches or sections of DIP or steel pipe that contain one or more bonded, mechanical or non-welded joint must be tested for continuity. For continuity testing purposes, a pipe reach is defined as the pipe span between test stations. Notification and Scheduling for Testing: The Contractor shall notify the Engineer or the Corrosion Engineer at least five days before the completed pipe installation is ready for testing and schedule testing at a mutually convenient time. It is advised that continuity testing be done as soon as possible and before road paving or landscaping tasks are started. Test Method: Pipeline continuity shall be tested using the Direct Resistance Method. Alternate methods must be approved by the DISTRICT. The Direct Resistance Method consists of measuring the linear resistance of individual pipe sections between two adjoining test stations (2-wire minimum) such that all sections requiring testing are tested. The resistance of the pipe section is measured by applying a known DC current through the section and measuring the IR drop. Current can be applied through the pipe using any DC source such as a battery. The IR drop shall be measured for a minimum of five different current values. Instruments used shall be sufficiently sensitive to measure a resistance equal to plus or minus 5% of the calculated resistance of the pipe section. Acceptance: The continuity of the pipeline shall be considered acceptable if the actual resistance measured as described above is equal to or less than 130% of the calculated pipe section resistance. The calculated resistance shall include the cylinder resistance and the bond wire resistance. If the actual resistance is greater than 130% of the calculated value the Contractor shall, at his own expense, locate the open or high resistance joints, make all necessary corrections, and retest until this criterion is met. e 7/31/02 Contract No. 3907 Page 342 of 414 306-1 6.4 Anodes and Cathodic Protection Performance. A. Responsibility: The Contractor is responsible for providing the proper rated potential anode, sufficient anode lead wire length, low resistance connections, the proper anode hole depth and for anode backfilling per these specifications. The Contractor shall be responsible for ensuring that the anode pre-packaged backfill sack is undamaged and that the wire leads are soundly attached and not damaged. The Corrosion Engineer shall test each installed anode for wire connection integrity and for open-circuit potential. B. Notification for Testing: The Contractor shall notify the Engineer and the Corrosion Engineer at least five days in advance of plans to install the anodes and five days in advance of system performance testing. At his or her discretion, the anode installation shall be witnessed by the Engineer. C. Cathodic Protection Performance Test Method: The performance of the cathodic protection system will be tested by the Corrosion Engineer. The testing shall include: measurement of all opencircuit anode potentials; pipe-to-soil potentials at each test station and other locations as needed to fully evaluate anode performance before the anodes are connected: initial anode currents after connecting anode leads to the pipe leads; and the pipe-to-soil potential at each previously tested site with all anodes connected. Pre- and post cathodic protection potentials at midpoints between anode beds are required to verify that the pipeline is fully protected. Adequate protection shall be as defined in NACE RP0169. D. Test Report: All system checkout test results, data and observations shall be submitted tom the Engineer in a "System Activation" letter report. The report shall include the Corrosion Engineer's conclusions regarding the performance of the cathodic protection system. Any deficiencies found during testing shall be reported to the Engineer immediately. The Contractor shall perform repairs due to system installation or material deficiencies. These repairs and system re-testing shall be provided at no additional cost to the DISTRICT. E. Acceptance: The system will be accepted if all anodes, insulators, test stations, and supporting facilities are installed and working properly. 306-16.5 Insular Testing. A. Responsibility: Insulators shall be tested and certified by the Corrosion Engineer. Testing shall be done in the presence of the Contractor. B. Test Method: The assembled flange shall be tested with an insulator testing device (i.e., Gas Electronics Model 601 Insulation Checker) specifically designed for this purpose. The testing shall be done by a qualified Corrosion Engineer or a corrosion technician working under the direct supervision of a corrosion engineer. C. Notification for Inspection: The Contractor shall notii the Corrosion Engineer at least five days in advance of the testing of insulator installations. D. Acceptance of the installation shall be considered complete when the testing device indicates that no shorts or partial shorts are present on the fully assembled and installed insulating joint. There must be no deflection of the insulating tester meter. If shorts are detected the Contractor shall assist the qualified Corrosion Engineer in finding partial shorts or shorted bolts. All disassembly and re-assembly necessary to gain the acceptance of the qualified Corrosion Engineer shall be done at the Contractor's expense. E. Test Sequence: Insulating flanges 16-inches or larger must be tested above grade after assembly in a pipe spool but before the application of wax tape. These flanges must be re- tested and all other insulating joints must be tested after full assembly in the ditch before backfilling. See wax tape application\testing sequencing. @ 7/31/02 Contract No. 3907 Page 343 of 414 306-16.6 Wax Tape Coating. A. Responsibility: All wax tape coating applications shall be inspected by the Inspector. 8. Notification for Inspection: The Contractor shall notify the Inspector at least three days in advance of completion of wax tape applications. C. Test Method: Each tape wrapped component shall be visually inspected. The Inspector shall verify that all irregular components are individually wrapped and that the tape if fully molded to the surface without gaps or voids. Backfilling shall not be done until this inspection is complete and the tape wrap application is approved by the Inspector. D. Acceptance: Conformance with this specification section. 306-1 6.7 Compliance With Specifications. A. Deficiencies: Any deficiencies or omissions in materials or workmanship found by these tests shall be rectified by the Contractor at his expense. Deficiencies shall include but are not limited to: unconnected or broken anode or test leads; incorrect anode type; improper or un- clean wire trench backfill; lack of 18 inches slack wire on each test lead in each test box; shorted or partially shorted insulators; inadequate insulator coating; failure to notify the Engineer in sufficient time to test buried insulators; high metallic pipeline resistance; and improperly mounted or located test boxes. 306-1 6.8 Measurement and Payment. Add the following: The lump-sum price set forth for Cathodic Protection shall include full compensation for furnishing all labor, materials, tools, and equipment and performing all work necessary to install, test and inspect sacrificial anode cathodic protection and corrosion monitoring facilities on the Vallecitos Water District (WD) domestic water and reclaimed water lines and Carlsbad Municipal Water District (CMWD) reclaimed water lines, as shown on the plans and as specified in the contract documents SECTION 307 - STREET LIGHTING AND TRAFFIC SIGNALS 307-3 STREET LIGHTING CONSTRUCTION Modify as follows: Section 209, "Signals, Lighting and Electrical Systems" herein, shall replace Section 307-3, "Electrical Components", of the SSPWC in all matters pertaining to the specifications for measurement, payment, warranty, and methods of construction for all elements of street lighting and traffic signals. 307-4 TRAFFIC SIGNAL CONSTRUCTION Modify as follows: Section 209, "Signals, Lighting and Electrical Systems" herein, shall replace Section 3074, "Electrical Components", of the SSPWC in all matters pertaining to the specifications for measurement, payment, warranty, and methods of construction for all elements of street lighting and traffic signals. Add the following Section: 307-9 GENERAL ELECTRICAL PRODUCTS AND EXECUTION 307-9.2 - Products 307-9.2.1 General m 7/31/02 Contract No. 3907 Page 344 of 414 A. All equipment and materials shall be new, shall be listed by UL, and shall bear the UL label where UL requirements apply. All equipment and materials shall be the products of experienced and reputable manufacturers in the industry. Similar items in the project shall be products of the same manufacturer. All equipment and materials shall be of industrial grade and standard of construction; shall be of sturdy design and manufacture; and shall be capable of reliable, trouble- free service. 307-9.2.2 Underground Ducts A. General: Where an underground distribution system is required, it shall be comprised of multiple runs of single bore metallic and nonmetallic ducts, concrete encased, with steel reinforcing bars, with underground manholes and pullboxes. When nonmetallic ducts are required, they shall be rigid Schedule 40 PVC for concrete encasement. 6. Concrete Envelope: The concrete envelope shall have compression strength of 3000 psi. 307-9.2.3 Raceways A. General: Raceway shall be manufactured in accordance with UL and ANSI standards and shall bear UL label as applicable. 6. Galvanized Rigid Steel (GRS) Conduit: 1. Rigid steel conduits and fittings shall be full weight, mild steel, hot-dip galvanized and zinc bichromate coated inside and outside after galvanizing. 2. Rigid steel conduit shall be manufactured in accordance with UL Standard No. 6 and ANSI C80.1. 3. Rigid steel conduit shall be manufactured by Triangle PWC, Republic Steel, or equal. C. Rigid Nonmetallic Conduit: Rigid nonmetallic conduit shall be Schedule 40 PVC. 1. Nonmetallic conduits and fittings shall be UL listed, sunlight-resistant, and rated for use with 90 degrees C conductors. 2. Nonmetallic conduits and fittings shall be manufactured by Carlon, Condux, or equal. D. Flexible Metallic Conduit: Flexible metallic conduit shall be fabricated from galvanized interlocked steel strip. Liquid-tight flexible metallic conduit shall have an extruded PVC covering over the flexible steel conduit. For conduit sizes 314 inch through 1-114 inches, flexible conduits shall have continuous built-in copper ground conductor. Flexible conduit shall be American Brass, Anaconda, Electroflex, or equal. E. PVC-Coated Raceway: PVC-coated raceway system shall conform to Federal Specification WW-C-581E, ANSI C80.1, and to UL specifications. 1. 2. 3. 4. 5. 307-9.2.4 The zinc surfaces of the conduits and fittings shall remain intact and undisturbed on both the inside and the outside of the conduit through the preparation and application processing. A PVC coating shall be bonded to the galvanized outer surface of the conduit. The bond between the PVC coating and the conduit surface shall be greater than the tensile strength of the plastic. The thickness of the PVC coating shall be a minimum of 40 mils. A PVC jacketed coupling shall be furnished with each length of conduit. A PVC sleeve equal to the OD of the conduit shall extend 1-1/2 inches from each end of coupling. PVC-coated conduits shall be as manufactured by Robroy, Occidental (OCCAL), or equal. Wire And Cable 7/31/02 Contract No. 3907 Page 345 of 414 A. B. C. D. E. General: All conductors, including ground conductors, shall be copper. Insulation shall bear UL label and the manufacturer's trademark, type, voltage and temperature rating, and conductor size. Wire and cable shall be products of American, Rome Cable, Okonite, Houston, or equal. Control Cables: All control cables shall be rated for 600 V and shall meet the following requirements: 1. 2. 3. 4. Control wires shall consist of No. 14 gage stranded copper conductors and shall be XHHW rated for 90 degrees C at dry locations and 75 degrees C at wet locations. Control wires at panels and cabinets shall be machine tool grade type W, UL approved, rated for 90 degrees C at dry locations. Multiconductor control cable shall be rated at 600 V and shall consist of No. 14 gauge stranded copper conductors, individually insulated with a minimum of 20 mils of polyethylene, 10 mils full color coded PVC jacket over each insulated conductor, a polyester tape over assembly, and an overall PVC jacket. Multiconductor cable shall be identified by either ICEA color coding or ink imprinting. Multiconductor cables may be used in conduits or cable trays as required by the Drawings. Multipull taped control conductor assemblies may be used in conduits as approved by the CONSTRUCTION MANAGER. Multiconductor tray cable shall be rated 600 V, listed by UL as Type TC cable per Article 340 of the NEC. The individual conductors shall be UL listed as Type XHHW, with a sunlight- resistant overall jacket. The cables shall pass UL and IEEE-383 ribbon bumer flame tests. Instrumentation Cables: Shielded instrumentation cables shall be rated at 300 V and shall comply with the following requirements: 1. 2. 3. Individual shielded cable shall consist of twisted 2 or 3 No. 14 gauge, stranded, color coded, tinned-coated copper in accordance with ASTM B 33 - Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes and B 8 - Specification for Concentric-Lay- Stranded Copper Conductors, Hard, Medium-Hard, and Soft. Color coding shall be black- clear, or black-red-clear. Insulation thickness shall be 32 mils of polyethylene, insulated with 2.3 mils 100% aluminum foil/polyester shield and No. 18 stranded tinned copper drain wire, all under a 32 mil PVC jacket. The shield shall be continuous and shall be grounded only at the receiving end, or as indicated. Multi-individual shielded pair or triad instrumentation cable shall consist of individual shielded and twisted pair copper conductors with an ethylene-propylene insulation, and No. 18 AWG tinned stranded copper drain wire, an overall aluminum mylar shield and an overall chloro- sulfonated polyethylene compound jacket. The cables shall be suitable for cable tray installation and shall be flame retardant. Building Wire and Cable: Building wires and cables shall be rated at 600 V and shall meet the following requirements: 1. Building wire shall be single conductor copper cable listed by UL as Type THHNlTHWN rated 75 degrees C in wet locations and 90 degrees C in dry locations. 2. Building wire No. 8 AWG and larger shall be stranded; size No. 10 AWG and smaller shall be solid or stranded. 3. No wire smaller than No. 12 AWG shall be used unless specifically indicated. Cable Terminations: Cable terminations shall be in accordance with the following: 1. Compression connectors shall be Bumdy "Hi Lug", Thomas & Betts "Shure Stake", or equal. Threaded connectors shall be split bolt type of high strength copper alloy. 2. Spring connectors (wire nuts) shall be 3M "Scotch Lok," "Ideal Wing Nuts", or equal. @ 7/31/02 Contract No. 3907 Page 346 of 414 3. Preinsulated fork tongue lugs shall be "Thomas & Betts" RC Series, Bumdy, or equal. 4. General purpose insulating tape shall be Scotch No. 33, Plymouth "Slip-knot", or equal. High temperature tape shall be polyvinyl by Plymouth, 3M, or equal. 5. Epoxy resin splicing kits shall be 3M Scotchcoat 82 Series, Burndy Hy Seal, or equal. 307-9.2.5 Pull And Junction Boxes A. Surface Mounted Boxes: Outlet, switch, pull and junction boxes where surface mounted in exposed locations shall be cast ferrous boxes with mounting lugs, zinc or cadmium plating, and enamel finish. B. Corrosive Locations: Control station, pull and junction boxes, including covers, for installation in corrosive locations shall meet the NEMA 4X requirements and shall be stainless steel or fiber glass-reinforced polyester and shall be furnished with mounting lugs. 307-9.2.6 Conduit Fittings A. General: Fittings shall comply with the same requirements as the raceway with which they will be used. Fittings having a volume less than 100 cubic inches for use with rigid steel conduit, shall be cast or malleable nonferrous metal. Such fittings larger than one inch shall be "mogul size." Fittings shall be of the gland ring compression type. Covers of fittings, unless in "dry" locations, shall be closed with gaskets. Surface-mounted cast fittings, housing wiring devices in outdoor and damp locations, shall have mounting lugs. Provide PVC coated fittings when used with PVC coated conduit. B. Insulated Bushings: Insulated bushings shall be molded plastic or malleable iron with insulating ing, similar to 0-Z Type A and B, equivalent types by Thomas & Betts, Steel District, Appleton, O-UGedney, or equal. C. Insulated Grounding Bushings: Insulated grounding bushings shall be malleable iron with insulating ring and with ground lug, such as 0-Z Type BL, equivalent types by T & 8, Steel District, O-UGedney, or equal. D. Erickson Couplings: Erickson couplings shall be used at all points of union between ends of rigid steel conduits which cannot be coupled. Running threads and threadless couplings shall not be used. Couplings shall be 3-piece type such as Appleton Type EC, equivalent types such as manufactured by T & B, Steel District, 0-UGedney, or equal. E. Liquid-Tight Fittings: Liquid-tight fittings shall be similar to Appleton Type ST, equivalent types such as manufactured by Crouse-Hinds, T & B, O-UGedney, or equal. Fittings shall be PVC coated in outdoor, damp, and corrosive locations. F. Hubs: Hubs for threaded attachment of steel conduit to sheet metal enclosures, where required, shall be similar to Appleton Type HUB, equivalent types such as manufactured by T & B, Myers Scnrtite, or equal. Hubs shall be PVC coated or stainless steel when used in outdoor, damp, or corrosive locations. G. Transition Fittings: Transition fittings to mate steel to PVC conduit, and PVC access fitting, shall be as furnished or recommended by the manufacturer of the PVC conduit. H. Sealed Fittings: Sealing fittings are required in conduit runs entering corrosive areas and . elsewhere as shown. Sealing fittings shall be Appleton Type EYS, 0-2 Type FSK, or equal. Sealing compound shall not be poured in place until electrical installation has been otherwise accepted. Expansion Fittings: Expansion fittings shall be installed wherever a raceway crosses a structural expansion joint. Such fittings shall be expansion and deflection type and shall accommodate lateral and transverse movement. Fittings shall be O-UGedney Type "DX," Crouse Hinds "XD," or equal. These fittings are required in metallic and nonmetallic raceway installations. When the 1. 7/31/02 Contract No. 3907 Page 347 of 414 installation is in a nonmetallic run, a %foot length of rigid conduit shall be used to connect the nonmetallic conduit to the fitting. 307-9.2.7 Wiring Devices A. General: All wiring devices shall be a product of a single manufacturer and shall conform to applicable NEMA Standards for UO series. Devices shall be as manufactured by Hubbell, Sierra, Pass & Seymour, or equal. General purpose duplex receptacles and toggle switch handles shall be brown everywhere except in finished rooms, where they shall be ivory. Special purpose receptacles shall have a body color as shown. Receptacles and switches shall conform to Federal Specifications W-C-596E and W-S-896E, respectively. 1. Switches: a. Switches at outdoor locations shall be Crouse-Hinds DS 128, Mackworth Rees Style 3845, Joy Flexitite, or equal. b. Switches at damp locations shall be Mackworth Rees Style 3496, Joy Flexitite, or equal. c. Switches at dry locations shall be Crouse-Hinds DS 32G, Pyle National SCT-IOk, or equal. d. Toggle switches shall conform to the following table, or equal: Hubbell No. Bryant No. Hubbell No. Bryant No. Single Pole 1221 (brown) 4901 (brown) 1221 I (ivory) 4901 I (ivory) Three Way 1223 4903 12231 49031 Momentary 1556 4821 15561 4821 I Four Way 1224 12241. 307-9.2.8 Electrical Identification A. Nameplates: Nameplates shall be fabricated from white-letter, black-face laminated plastic engraving stock, Formica type ES-1, or equal. Each shall be fastened securely, using fasteners of brass, cadmium plated steel, or stainless steel, screwed into inserts or tapped holes, as required. Engraved characters shall be block style of adequate size to be read easily at a distance of 6 feet with no characters smaller than ?/&inch high. B. Conductor and Equipment Identification: Conductor and equipment identification devices shall be either imprinted plastic-coated cloth marking devices such as manufactured by Brady, Thomas & Betts, or equal, or shall be heat-shrink plastic tubing, imprinted split-sleeve markers cemented in place, or equal. C. Identification Tape: Identification tape for protection of buried electrical installation shall be a 6- inch wide yellow polyethylene tape imprinted "CAUTION - ELECTRIC UTILITIES BELOW." 307-9.2.9 Pressure Transmitter A. Pressure transmitters shall be Bristol Babcock 3508-1 OC-231-110-111-1, no substitution. 307-9.3 - Execution 307-9.3.1 Grounding A. Shield Grounding: 1. Shielded power cable shall have its shield grounded at each termination in a manner recommended by the cable manufacturer. a 7/31/02 Contract No. 3907 Page 348 of 414 2. Shielded instrumentation cable shall be grounded at one end only; this shall be at the Main Control Panel or otherwise at the "receiving" end of the signal carried by the cable, unless shop drawings indicate that the shield shall be grounded at both ends. 3. Termination of each shield drain wire shall be on its own terminal screw. All of these terminal screws in one rack shall be jumpered with No. 16 solid tinned bare copper wire; connection to ground shall be accomplished with a No. 12 green insulated conductor to the main ground bus. 307-9.3.2 Raceways A. General: Raceways shall be installed as indicated, however, conduit routings shown are diagrammatic. Raceway systems shall be electrically and mechanically complete before conductors are installed. Bends and offsets shall be smooth and symmetrical, and shall be accomplished with tools designed for the purpose intended. Factory elbows shall be used for all 3/4-inch conduit. Bends in larger sizes of metallic conduit shall be accomplished by field bending or by the use of factory elbows. All installations shall be in accordance with the latest edition of the NEC. B. Installation: Raceways shall be installed in accordance with the following schedule: 1. Low Voltage Raceway (control, power, and signal): a. Rigid Schedule 40 PVC shall be used for concrete encased duct in earth unless noted otherwise. b. PVC-coated galvanized rigid steel raceways shall be used on exposed locations in corrosive areas, outdoor, vaults, and damp locations. c. Rigid Schedule 40 PVC shall be used for conduits embedded in concrete slab on grade and above grade unless otherwise noted. a. Conduits shall be rigidly supported with clamps, hangers, and Unistrut channels. b. Intervals between supports shall be in accordance with the National Electric Code. C. Conduit Terminations: Empty conduit terminations not in manholes or pullboxes shall be plugged. Exposed raceway shall be installed perpendicular or parallel to buildings except where otherwise indicated. Conduit shall be terminated with flush couplings at exposed concrete surfaces. Conduit stubbed up for floor-standing equipment shall be placed in accordance with approved shop drawings. Metallic raceways installed below-grade or in outdoor locations and in concrete shall be made up with a conductive waterproof compound applied to threaded joints. Compound shall be Zinc Clads Primer Coatings No. B69A45, HTL-4 by Crouse-Hinds, Kopr Shield by Thomas & Betts, or equal. 2. Exposed Raceways: D. Conduit Installations: 1. Conduit may be cast integral with horizontal and vertical concrete slabs, providing one-inch clearance is maintained between conduit surface and concrete surface. If said clearance cannot be maintained, the conduit shall be installed exposed below elevated slabs; provided, that in the case of slabs on grade, conduit shall be installed below the slab. Maximum size of conduit that can be cast in slab shall be 1-112 inches. 2. Nonmetallic conduit may be cast integral with horizontal slabs with placement criteria stated above. Non-metallic conduit may be run beneath structures or slabs on grade, without concrete encasement. In these instances conduit shall be placed at least 12 inches below the bottom of the structure or slab. Nonmetallic conduit may be buried 24 inches minimum below grade, with a 3-inch concrete cover, in open areas or where otherwise not protected by concrete slab or structures. Top of concrete cover shall be colored red. Nonmetallic conduit @ 7/31/02 Contract No. 3907 Page 349 of 414 shall be permitted only as required by the Specifications and in concealed locations as described above. 3. Where a run of concealed PVC conduit becomes exposed, a transition to rigid steel conduit is required. Such transition shall be accomplished by means of a factory elbow or a minimum %foot length of rigid steel conduit, either terminating at the exposed concrete surface with a flush coupling. Piercing of concrete walls by nonmetallic runs shall be accomplished by means of a short steel nipple terminating with flush couplings. 4. Flexible conduit shall be used at dry locations for the connection of equipment such as motors, transformers, instruments, valves, or pressure switches subject to vibration or movement during normal operation or servicing. Flexible conduit may be used in lengths required for the connection of recessed lighting fixtures; otherwise the maximum length of flexible conduit shall be 18 inches. 5. In other than dry locations, connections shall be made using flexible liquid-tight conduit. Equipment subject to vibration or movement which is normally provided with wiring leads, such as solenoid valves, shall be installed with a cast junction box for the make-up of connections. Flexible conduits shall be as manufactured by American Brass, Cablec, Electroflex, or equal. 6. Conduit penetrations on walls and concrete structures shall be performed in accordance with the following: a. Seal all raceways entering structures at the first box or outlet with oakum or suitable plastic expandable compound to prevent the entrance into the structure of gases, liquids, or rodents. b. Dry pack with nonshrink grout around raceways that penetrate concrete walls, floors, or ceilings aboveground, or use one of the methods indicated for underground penetrations. c. Where an underground conduit enters a structure through a concrete roof or a membrane waterproofed wall or floor, provide an acceptable, malleable iron, watertight, entrance sealing device. When there is no raceway concrete encasement, provide such device having a gland type sealing assembly at each end with pressure bushings which may be tightened at any time. When there is raceway concrete encasement indicated, provide such a device with a gland type sealing assembly on the accessible side. Securely anchor all such devices into the masonry construction with one or more integral flanges. Secure membrane waterproofing to such devices in a permanently watertight manner. d. Where an underground raceway without concrete encasement enters a structure through a nonwaterproofed wall or floor, install a sleeve made of Schedule 40 galvanized pipe. Fill the space between the conduit and sleeve with a suitable plastic expandable compound, or oakum and lead joint, on each side of the wall or floor in such a manner as to prevent entrance of moisture. A watertight entrance sealing device may be used in lieu of the sleeve. 307-9.3.3 Wires And Cables A. General: Conductors shall not be pulled into raceway until: 1. Raceway system has been inspected and accepted by the CONSTRUCTION MANAGER. 2. Plastering and concrete have been completed in affected areas. 3. Raceway system has been freed of moisture and debris. 1. Conductors of No. 1 size and smaller shall be hand pulled. Larger conductors may be installed using power winches. Pulling tensions on the cables shall be within the limits B. Wire and Cables: e 7/31/02 Contract No. 3907 Page 350 of 414 recommended by the cable manufacturer. Wire pulling lubricant, where needed, shall be UL approved. 2. Wire in panels, cabinets, and gutters shall be neatly grouped using nylon tie straps, and shall be fanned out to terminals. 1. The CONTRACTOR shall provide, install, and terminate the conductors required for power and controls to electrical equipment and to interconnect incoming control and instrumentation equipment except where indicated elsewhere. There shall be no cable splices in underground pullboxes. 2. Two- and threeanductor shielded cables installed in conduit runs which exceed 2000 feet may be spliced in pullboxes. These cable runs shall have only one splice per conductor. 3. Control conductors shall be spliced or terminated only at the locations indicated and only on terminal strips or terminal lugs of vendor furnished equipment. For the purposes of Division 16, "control conductors" are defined as conductors operating at 120 V or less in circuits that indicate equipment status or that control the electric energy delivered to a power consuming device. 4. Solid conductors shall be terminated at equipment terminal screws with proper care that conductor is tightly wound around screw and does not protrude beyond screw head. Stranded conductors shall be terminated directly on equipment box lugs making sure that all conductor strands are confined within lug. Use forked-tongue lugs where equipment box lugs have not been provided. 5. Control devices, such as solenoid operated valves, that are normally supplied with conductor pigtails, shall be terminated as described for control conductors. D. Continuity Test: All control and instrumentation cables shall be tested for continuity, polarity, undesirable ground, and origination. Such tests shall be performed prior to placing all cables in service. C. Splices and Terminations: 307-9.3.4 Pull And Junction Boxes A. Sizing: Pull and junction boxes shall be sized in accordance with the requirements of the NEC. B. Outlet Boxes: Outlet boxes shall be used as junction boxes wherever possible. Where separate pullboxes are required, they shall have screw covers. C. Requirements: Pullboxes shall be installed when conduit run contains more than three 90- degree bends and runs exceed 200 feet. 307-9.3.5 Cable And Equipment Identification A. General: The completed electrical installation shall be provided with adequate identification to facilitate proper control of circuits and equipment and to reduce maintenance effort. B. Cable: Assign each control and instrumentation wire and cable a unique identification number. Said numbers shall be assigned to all conductors having common terminals and shall be shown on all shop drawings. Identification numbers shall appear within 3 inches of conductor terminals. "Control" shall be defined as any conductor used for alarm, annunciator, or signal purpose& 1. Multiconductor cable shall be assigned a number which shall be attached to the cable at intermediate pull boxes and at stub-up locations beneath free-standing equipment. It is expected that the cable number shall form a part of the individual wire number. All individual control conductors and instrumentation cable shall be identified at pull points as described above. The instrumentation cable numbers shall incorporate the loop numbers indicated on the Drawings. 2. General purpose dc control cables shall be blue. a 7/31/02 Contract No. 3907 Page 351 of 414 3. All spare cables shall be terminated on terminal screws and shall be identified with a unique number as well as with destination. 4. Terminal strips shall be identified by imprinted, varnished, marker strips attached under the terminal strip. C. Equipment: Equipment and devices shall be identified as follows: 1. Nameplates shall be provided for all switches. 2. Control devices within enclosures shall be identihed similar to the paragraph above. 3. Install identification tape directly above buried unprotected raceway; install tape 8 inches below grade and parallel with raceway to be protected. Identification tape is required for all buried raceway not under buildings or equipment pads except identification lape is not required for protection of street lighting raceway. SECTION 308 - LANDSCAPE AND IRRIGATION INSTALLATION 308-2 EARTHWORK AND TOPSOIL PLACEMENT 308-2.3.2 Fertilization and Conditioning Procedures. Add the following: The Contractor shall provide a cultivated surface for all areas to be planted by discing, ripping or scarifying the finish grade, or over- excavating and importing material. After cultivation the Contractor shall clear the planting areas of stones to the depth of cultivation and shall rake the planting areas to a smooth friable and plantable surface. The Contractor shall cultivate all planting areas, except slopes steeper than 3-1/2:1 (horizontal to vertical), to a depth of 300 mm (12"). The planting areas that are slopes steeper than 3-1/21, shall be cultivated to a depth of 150 mm (6"). After cultivation, the soil amendments shown in table 308-2.3.2(A) shall be thoroughly blended 150 mm (6") deep in all planting areas. Except for planting pits the cultivation depths are designated as the root area. Backfill for planting pits shall conform to the requirements of section 308-4.5. After surface preparation and application of the soil amendments shown in Table 308-2.3.2(A) the Contractor shall obtain a minimum of one test for each soil property listed in Tables 308-2.3.2(B) and 308-2.3.2(C) from each median planter, at least one test per 150 m (500') from each parkway and for each hectare (2.5 acres) of hydroseeded area and shall submit the results of said tests to the Engineer. The Contractor shall then adjust the soil properties to the acceptable ranges of soil properties shown in Tables 308-2.3.2(B) and 308-2.3.2(C) using such materials and methods as may be necessary. Organic soil amendment materials shall not be included in the samples used to determine compliance to the soil particle gradation requirements of Table 308-2.3.2(C). If adjustments are necessary the soil shall be tested by the Contractor after such adjustments for each soil property listed in Table 308-2.3.2(8) and 30&2.3.2(C) to determine that the adjustments to the soil made by the Contractor result in soil properties within the acceptable range. The Contractor shall adjust the soil properties and show acceptable ranges prior to any planting or application of hydroseed slurry. Prior to the start of any planting or application of hydroseed slurry the surface and root area shall be evenly and thoroughly moistened to no less than 75 percent of field capacity. The Contractor shall certify, in writing, that the ground surface has been prepared in accordance with this section and shall request inspection by the Engineer prior to any planting or seeding. The Contractor shall obtain the Engineer's approval before any planting or hydroseeding. @ 7/31/02 Contract No. 3907 Page 352 of 414 Soil Amendment Agricultural Gypsum Iron Sulfate Calcium Carbonate Lime Organic Soil Amendment Metric Application Rate Approx. U.S. Application Rate 500 g per square meter 50 g per square meter 500 g per square meter 0.041 15 cubic meters per square 5 cubic yards per 1,000 square feet meter (average depth 41 mm) 100 Ibs. per 1,000 square feet 10 Ibs. per 1,000 square feet 100 Ibs. per 1,000 square feet (average depth 1 5/e") TABLE 308-2.3.2(C) SOIL PARTICLE GRADATION Soil Property Acceptable Range Test Method PH 6.5 to 7.3 Saturation Paste pH Dissolved Salts < 4.0 dS m-' Saturation Paste Soluble (E%) Salts Liquid Limit N/A to 30 ASTM D 423 Plasticity Index NP to 10 ASTM D424 Repeatability Range of Test fO.l pH f 7% +2 52 For areas to receive planting of all types, excluding only hydroseeding, the Contractor shall amend the prepared soil by blending 200 g of 7-7-7 fertilizer per square meter (40 Ibs. per 1,000 square feet) into the top 150 mm (6") of soil after the completion of adjustment of soil properties and acceptance of the planting area by the Engineer. The Contractor shall apply post-plant 12-4-6 fertilizer at the rate of 20 pounds per 1,000 square feet, 30 days after planting and every 30 days through the end of the maintenance period. Sieve Size 19 mm (3/4") 9.5 mm ('/e") 4.75 mm (No. 4) 1.89 mm (No. 10) 475 km (No. 40) 75 pm (No. 200) 308-2.4 Finish Grading. Add following: The Contractor shall prepare the finish grade in hydroseed slope areas with a moderately rough texture to provide a suitable surface for adherence of the hydroseed mix. Rounding the edges of new cuts and fills shall occur to blend new slopes into existing terrain. Step grading techniques where feasible shall be used in the construction of the three cut slopes proposed south of Rancho Santa Fe Bridge Left and Right to simulate existing terrain and to accommodate hydroseeding and planting efforts. Following demolition of the old bridge over San Marcos Creek, this area will be restored to support southern willow scrub habitat under a separate contract. Following temporary impacts necessary to construct the new bridge, pre-construction contours shall be restored. Percent Passing 100 95 - 100 60 - 85 40 - 75 35 - 70 30 - 70 308-4 PLANTING 3084.1 General. Add the following: The Contractor shall perform actual planting within three months after grading, when weather and soil conditions are suitable and in accordance with locally accepted horticultural practice and as approved by the Engineer. No planting shall be done in any area until it has been satisfactorily prepared in accordance with these specifications. Soil moisture level prior to planting shall be no less than 75 percent of field capacity. The Contractor shall obtain the Engineer's approval of planting pits before planting operations begin. For pit planted vegetation when the soil moisture level is G 7131102 Contract No. 3907 Page 353 of 414 found to be insufficient for planting, the Contractor shall fill the planting pits with water and allow them to drain before starting planting operations. No more plants shall be distributed in the planting area on any day than can be planted and watered on that day. The Contractor shall plant and water all plants as herein specified immediately after removal from their containers. Containers shall not be cut prior to placing the plants in the planting area. It shall be the responsibility of the Contractor to provide continuous horticultural services and temporary and/or permanent irrigation to all planted and hydroseeded areas so that the planted and hydroseeded vegetation is 100 percent healthy and thriving prior to, and throughout the, landscape maintenance period. All fill slopes necessary to accommodate construction of the roadway shall receive straw matting as described in Section 308-4.1 0 "Erosion Control Matting Installation" of these special provisions. In fill slopes straw matting shall be placed over hydroseed. Temporary irrigation shall then be applied over straw matting. All exposed rock cut slopes necessary to accommodate construction of the roadway shall receive Erosion Control (Type BFM) as described in Section 308-4.11 "Erosion Control (Type BFM)" of these special provisions. In rock cut slopes hydroseed shall be placed over temporary irrigation. Erosion Control (Type BFM) shall then be applied over hydroseed. 308-4.2 Protection and Storage. Add the following: The Contractor shall submit a sheltered and secure location for on-site plant storage area for the Engineer's approval prior to the delivery of any plant materials. Any plant determined by the Engineer to be wilted, broken, or otherwise damaged shall be rejected at any time during the project, whether in the ground or not. All plants shall be handled by their containers. Any plant that has been handled by its trunk or stem shall be rejected. All rejected plants shall be removed from the site immediately. 308-4.3 Layout and Plant Location. Modify as follows: Planting areas shall be staked by the Contractor and the Contractor shall obtain the Engineer's approval of the planting layout before planting operations begin. 308-4.5 Tree and Shrub Planting. Add the following: The Contractor shall amend the backfill for planting holes to a thoroughly blended mixture of clean loamy soil meeting the requirements of Tables 308-2.3.2(B) and 308-2.3.2(C) and then blend the amendments listed in Table 30845(A) into the backfill for planting holes. TABLE 308-4.5(A) BACKFILL AND AMENDMENTS FOR TREE AND SHRUB PLANTING I size container I size container 1. Pruning shall be limited to the minimum necessary to remove injured twigs and branches, and to compensate for loss of roots during transplanting, but never to exceed one-tenth the branching structure. Pruning may be done only with the approval of, and in the presence of, the Engineer. Cuts over 19 mm (5%") shall be painted with an approved tree wound paint. 7/31/02 Contract No. 3907 Page 354 of 414 Add the following section: 3084.5.1 Root Barriers. Root barriers shall conform to section 212-1.8, Root Barriers. The Contractor shall install root barriers continuously at the edges of all median planter areas. The top of the root barrier shall be 25 mm (1") !elow the finish grade of the planted area. The bottom of the root barrier shall be installed 520 mm (20 12") below the finish grade of the planted area. Install as indicated on the plans, eliminating any breaks in the barrier by providing at least 150 mm (6") of overlap at splices or damaged areas. Splices and repair patches shall be stitched to the root barrier material by a running stitch of no less than 6 2 1 stitches per 25 mm (1"). 3084.6 Plant Staking and Guying. add the following: The Contractor shall install all boxed trees per the details shown on the Dlans. 308-4.8.2(b) Method B. Add the following: The Contractor shall prepare hydroseeding slurry on the job site. Slurry additives shall arrive at the site in bags sealed and properly identified by the manufacturer. All specified additives and water shall be added on the job site at the rates specified and shall be thoroughly mixed at the job site. The Contractor shall add seed to the sluny after the fiber mulch has been thoroughly incorporated. The Contractor shall spray all areas with a uniform, visible coat using the green color of the mulch as a guide. The Contractor shall apply the slurry in a sweeping motion, in an arched stream so as to fall like rain allowing the mulch fibers to build on each other until a good coat is achieved and the material is spread, evenly, at the required rate per area. The Contractor shall use care not to drag spray hoses over container planted material and shall attempt to spray from the edges of the planting areas wherever possible. Any slurry mixture which has not been applied to the planting areas within four (4) hours after mixing is to be rejected and removed from the project at the Contractor's expense. Any slurry spilled into areas outside the limits of work shall be cleaned up at the Contractor's expense to the satisfaction of the Engineer. The Contractor shall assure that the site is properly prepared. The Contractor shall repair all tire ruts created by the equipment. Areas needing grading repair prior to hydroseeding shall be blended and floated to match surrounding grades. Areas having less than 80% plant coverage within thirty (30) days after the initial application shall be reseeded every twenty (20) days until 80% of the ground surface is evenly covered by hydroseeded or subsequently reseeded growth. Add the following section: . 3084.8.3.1 Weed Eradication. The Contractor shall water all irrigated areas to be hydroseeded for three (3) weeks prior to hydroseeding to allow for germination of the weed seeds. The Contractor shall spray all weeds with a post emergent herbicide immediately after the completion of the three week irrigation period. After two (2) weeks, the Contractor shall again eradicate the weeds and complete the preparation of the soil prior to the application of the hydroseed mixes. Add the following: In compliance with the Executive Order on Invasive Species, E.O. 13112, and subsequent guidance from the FHWA, the landscaping and erosion control included in the project will not use species listed as noxious weeds. In areas of particular sensitivity, such as San Mams Creek, extra precautions shall be taken if invasive species are found in or adjacent to the construction areas. These will include, but not be limited to, the inspection and cleaning of construction equipment and eradication strategies to be deployed should an invasion occur. Add the following section, 308-4.10 Erosion Control Matting Installation Add the following section, .3084.10.1 General. All temporary exposed fill slopes necessary to accommodate construction of the roadway shall be landscaped immediately with a hydroseed mix and straw matting. Before installation of erosion control matting the Contractor shall complete all soil preparation, fine grading, and hydroseeding of the areas to receive erosion control matting. Temporary irrigation shall be placed after hydroseeding and placement of erosion control matting. Materials for straw matting shall conform to Section 212-4.2 "Straw Matting," of these special provisions. @ 7/31/02 Contract No. 3907 Page 355 of 414 Add the following section: 308-4.10.2 Coordination with Hydroseeding. Erosion control matting shall be installed by the Contractor immediately after the first application of hydroseed materials. In all cases the Contractor shall place the erosion control matting within three days after the first hydroseed material application. Should any seed in the hydroseed materials begin to germinate within the threeday period after application or before the installation of the erosion control matting, the installation of the erosion control matting shall be considered as late and the Contractor shall disc the hydroseed materials into the top 100m (4“) of the underlying soil, condition the soil for hydroseeding, apply hydroseeding materials at the rates and of the type specified and then install the erosion control matting. No additional payment will be made for second or subsequent hydroseed applications resulting from late installation of erosion control matting. Add the following section: 308-4.10.3 Installation. The Contractor shall install erosion control matting using the following techniaues: 1. 2. 3. 4. 5. 6. 7. Bein at the top of the slope by placing the erosion control matting into a 150 mm (6’) wide by 150 mm (6‘) deep trench with the end of the matting laid flat in the bottom of the trench Anchor the end of the erosion control matting with erosion control mat staples spaced no more than 300 mm (12) on centers placed at the intersection of the bottom and the downhill vertical face of the trench. Roll the erosion control matting down the slope. Staple the erosion control matting on an alternating grid consisting of three across and two across lines of staples in horizontal lines spaced 900mm (3’) on centers. Erosion control mat so stapled shall be spaced such that no less than 1 3/4 staples per square meter (1% staples per square yard) are provided to anchor the erosion control matting. Start the adjacent erosion control mat as in Item 1. of this section, overlapping the previously placed mat by no less than 50 mm (2”). Staple placement may be such as to use the staples used to secure the adjacent mat to secure both mats along their edges. Add the following section, 308-4.1 1 Erosion Control (Type BFM) 308-4.11.1 General. Erosion control (Type BFM) shall meet the material requirements in Section 212- 4.1 “(Type BFM) Materials” of these special provisions and shall conform to the provisions in Section 308-4.9 of the Standard Specifications and these special provisions. 3084.11.2 Installation. Erosion control (Type BFM) work shall consist of applying erosion control materials to embankment and excavation slopes and other areas disturbed by construction activities to create a bonded fiber matrix cover. Erosion control (Type BFM) shall be applied during the period starting November 16 and ending April 14 or, if the slope on which the erosion control is to be placed is finished during the winter season is specified in “Storm Water Pollution Prevention” of these special provisions, the erosion control shall be applied immediately; or, if the slope on which the erosion control is to be placed is finished outside both specified periods and the contract work will be completed before September 1, the erosion control shall be applied as a last item of work. Prior to applying erosion control (Type BFM) materials, vegetative growth, temporary erosion control materials and other debris shall be removed from areas to receive erosion control (Type BFM). Do not apply erosion control (Type BFM) materials if rain is expected within 24 hours. Do not apply to saturated soils. Wet surfaces, caused by sub-surface seeps and drainages shall be remedied prior to application. The Contractor shall prepare erosion control (Type BFM) slurry on the job site. Slurry additives shall arrive at the site in bags sealed and properly identified by the manufacturer. All specified additives and @ 7/31/02 Contract No. 3907 Page 356 of 414 water shall be added on the job site at the rates specified and shall be thoroughly mixed at the job site. The Contractor shall spray all areas with a uniform, visible coat. The Contractor shall apply the sluny in a sweeping motion, in an arched stream so as to fall like rain allowing the mulch fibers to build on each other until a good coat is achieved and the material is spread, evenly, at the required rate per area. The Contractor shall use care not to drag spray hoses over material already placed and shall attempt to spray from the edges of the receiveing areas wherever possible. Any slurry mixture which has not been applied to the receiving areas within four (4) hours after mixing is to be rejected and removed from the project at the Contractor’s expense. Any slurry spilled into areas outside the limits of work shall be cleaned up at the Contractor‘s expense to the satisfaction of the Engineer. The Contractor shall assure that the site is properly prepared. Material Bonded fiber matrix shall be mixed into a liquid slurry and shall pass a free liquid quality test. The binder shall not dissolve or dispense upon watering. The matrix shall have no holes greater than 1/16” in size. The matrix shall leave no gaps between the product and the soil. The matrix shall have a minimum holding capacity of 1.2 Gal/Lb. The matrix shall have no germinating inhibiting factors and shall not form a water impermeable crust. The matrix shall be comprised of materials which are 100 percent biodegradable. Pounds Per Acre Erosion control (Type BFM) materials shall be applied in three applications to ensure adequate coverage. BFM (Fiber & Stabilizing Emulsion) 3800 The ratio of total water to stabilizing emulsion in the mixture shall be as recommended by the manufacturer. The ratio of stabilizing emulsion to total fiber in the mixture shall be as recommended by the manufacturer. The proportions of erosion control materials may be changed by the Engineer to meet field conditions. Erosion control materials shall be applied from alternate directions to achieve 100 percent soil cover and avoid “shadowing”. Erosion control materials shall be applied to produce a cover of not less than %” over the entire area. 308-5 IRRIGATION SYSTEM INSTALLATION 308-5.1 General. Add the following: The Contractor shall apply irrigation water as often and in sufficient amounts, as conditions may require, to germinate and establish the seed and keep the container plants healthy and growing. The Contractor shall lay out lines, valves, and other underground utilities and receive the approval of the Engineer before digging trenches. The Contractor shall be responsible for damages caused by its operations. Connections shall be made at approximately the locations shown on the drawings. The Contractor shall be responsible for unapproved changes. Permission to shut off any existing in-use water lines must be obtained 48 hours in advance, as to the date, time and exact length of time of each shut-off. The Contractor shall demonstrate that the entire .irrigation system is under full automatic operation for a period of seven days prior to any planting. 308-5.2 Irrigation Pipeline Installation. Add the following: The Contractor shall install all pressure main line piping from the irrigation system so as to maintain 3.1 m (10’) minimum horizontal separation from all potable water piping. Where recycled and potable water pressure mainline piping cross, the recycled water piping shall be installed below the potable water piping, sleeved in a pressure rating of 200 PSI SDR 21 ”Alertline” PVC sleeve which extends a minimum of 3.1 m (IO’) on either side of the 7/31/02 Contract No. 3907 .. Page 357 of 414 potable water piping and be located to provide a minimum vertical clearance of 300 mm (12") between the recvcled and potable water lines. Conventional (white) PVC pipe Schedule 30 may be used for sleeving'material if it is taped along its entire length with 75 mm (3") wide purple warning tape which reads "Caution Recycled Water". For trenching through areas where topsoil has been spread, the Contractor shall deposit topsoil on one side of trench and subsoil on opposite side. Subsoil shall be free of all rocks 13 mm (%Ir) in diameter or larger, debris, and litter, prior to use as backfill. The Contractor shall repair any leaks and replace all defective pipe or fittings until lines meet test requirements. The Contractor shall not cover any lines until they have been inspected and approved by the Engineer for tightness, quality of workmanship, and materials. The Contractor shall not be backfill trenches until all required tests and observations are performed. Observations include sprinkler heads, all fittings, lateral and mainline pipe, valves, and direct burial wire. 308-5.2.3 Plastic Pipeline. Add the following: The Contractor shall store all pipe and fittings under cover until used, and all pipe and fittings shall be transported in a vehicle with a bed long enough to allow the length of pipe to lay flat so as not to be subjected to undue bending or concentrated external load at any point. Pipe ends and fittings shall be wiped with MEK, or equal, before welding solvent is applied. Welded joints shall be given a minimum of 15 minutes to set before moving or handling. All field cuts shall be beveled to remove buns and excess before fitting and gluing together. The Contractor shall center load pipe with small amount of backfill to prevent arching and slipping under pressure. Joints shall be exposed for inspection during testing. Plastic-to-plastic joints shall be solvent-welded, using only solvent recommended by pipe manufacturer. Add the following section: 308-5.2.6 Installation of Brass Pipe. The Contractor shall cut brass piping by power hacksaw, circular cutting machine using an abrasive wheel, or hand hacksaw. No piping shall be cut with metallic wheel cutter of any description. The Contractor shall ream and remove rough edges or burrs on all pipe so that smooth and unobstructed flow is obtained, place Teflon tape, Teflon dope, or approved equal on male threads only, and tighten to prevent any leakage. The Contractor shall tighten screwed joints with tongs or wrenches. Caulking is not permitted. Add the following section: 308-5.3.1 Valves. The Contractor shall install each control valve in a separate valve box with a minimum of 300 mm (1 2") separation between valves and 150 mm (6") from any fixed object or structure. Add the following section 308-5.3.2 Valve Boxes. The Contractor shall install no more than one valve per box. All boxes are to be marked as to the type of valve. Remote control valve boxes shall also indicate control station number. Add the following section: 308-5.3.3 Backfiow Preventer. The Contractor shall install backflow preventer assembly in accordance with manufacturer's specifications and as directed on drawings. Exact location and positioning shall be verified on the site by the Engineer. 308-5.4.4 Sprinkler Head Adjustment. Add the following: The Contractor shall flush and adjust all irrigation heads and valves for optimum performance and to prevent overspray onto walks, roadways buildings, walls, and other structures. 308-5.5 Automatic Control System Installation. Add the following: The Contractor shall install all portions of the electrical installation with materials and methods conforming to the requirements of the 1996 National Electrical Code. The Contractor shall provide no less than one control wire and one common ground wire to service each valve in system. 308-5.6.3 Sprinkler Coverage Test. Add the following: This test shall be accomplished before any 7/31/02 Contract No. 3907 Page 358 of 414 ground cover is planted. 308-6 MAINTENANCE AND PLANT ESTABLISHMENT Add the following: For hydroseeded areas, median planting, parkway planting, and mitigation area, The Contractor shall maintain said areas for period of no less than 120 days or until final acceptance of the project, whichever is the greater. Mowing is not required for hydroseeded areas. The Contractor shall provide complete landscape maintenance of all planted areas. The work shall include, but not be limited to, watering, litter control, weed control, stake repair, cultivating, supplementary fertilization, repair of irrigation systems, and control of diseases and pests. All median planting areas shall be treated with a Parks Department approved granular preemergent herbicide, according to the manufacturer's specifications. The Contractor shall submit a written plan to control weeds, disease, and pest infestations in the planting areas. The submittal shall conform to the requirements for shop drawings as specified in section 2-5.3 et seq. of the specifications. The Engineer shall approve all methods and materials for such control. Upon approval, the Contractor shall implement the control measures, exercising extreme caution in using pesticides and taking all steps to ensure the safety of the public. Only licensed personnel will be permitted to perform toxic spraying work. During the plant establishment period, the Contractor shall furnish sufficient workers and equipment on a daily basis to perform the work required by this section. Any day when the Contractor fails to adequately carry out specified maintenance work, as determined necessary by the Engineer, will not be credited as one of the plant establishment days. All planting areas which are damaged by construction shall be repaired by the Contractor within twenty (20) days following completion of construction in such. The Contractor shall repair such damaged areas. The repair shall consist of bringing the damaged area back to final grade, preparing the soil, replanting the area with the same vegetation as originally specified, and maintaining the area to achieve acceptable plant establishment. The Contractor shall provide temporary irrigation for other hydroseeded areas identified as erosion control hydroseed on the grading plans for a minimum of 120 days to ensure adequate plant establishment. Towards the end of the maintenance period, the Contractor shall gradually reduce the amount of irrigation to allow plant adaptation to nonirrigated conditions. Upon the approval of the Engineer, the temporary irrigation system shall be shut off at the end of the maintenance period. The hydroseeded areas must have their growth of 80% established and the coverage must be evenly successful over the entire hydroseeded area and adequate to prevent erosion no less than 30 days before the end of the maintenance period. Should the coverage not be achieved the maintenance period shall be extended until the required coverage is achieved plus an additional 30 day period. The Contractor shall call for a final inspection 30 days before the end of the maintenance period and at the end of the maintenance period. Failure to pass inspection will result in an extension of the maintenance period. The Contractor shall continue to provide maintenance for such time necessary to obtain conformance to the specifications. The Contractor shall furnish the Engineer with a statement from the vendor that the order for the seed required for this contract has been received and accepted by the vendor. The statement shall be furnished not less than 60 days prior to applying seeds. The statement from the vendor shall also include the names and quantity of seed ordered and the anticipated date of delivery. Full compensation for conforming to above requirements will be considered as included in the prices paid for the various contract items of work and no additional compensation will be allowed therefor. 308-7 GUARANTEE , Add following: The Contractor shall guarantee all box trees installed under the contract to live and grow for one year from the day of final acceptance of the contract work. The Contractor shall guarantee all other plant material, including ground covers to live and grow for a period of 30 days from the last day of the maintenance period or final acceptance of the contract work, whichever is the later. The Contractor shall replace, at its expense, all plant material found to be dead, missing, or in poor condition during the em 7/31/02 Contract No. 3907 Page 359 of 414 maintenance period within 5 days of discovery of such plant material. The Engineer shall be the sole judge as to the condition of the plant material. Plant material found to be dead or in poor condition within the guarantee period shall be replaced by the Contractor, at its expense, within 15 days of written notification. Replacements shall be made to the same specifications required for the original plantings. The Contractor shall submit written vegetation, planting and irrigation guarantee in approved form that all work showing defects in materials or workmanship will be repaired or replaced at no cost to the Engineer for a period of one year from the date of acceptance by the Engineer. The Guarantee form shall be retyped on the Contractor's letterhead and contain the following verbiage: "Guarantee For Vegetation, Planting and Irrigation System For Rancho Santa Fe Road North. Phase 2 We hereby guarantee that the vegetation, planting and irrigation system we have furnished and installed for Rancho Santa Fe Road North, Phase 2 is free from defects in materials and workmanship, and the work has been completed in accordance with the drawings and specifications. We agree to repair or replace any defect in vegetation, material or workmanship, including that due to ordinary wear and tear, which may develop during the periods specified in section 308-7 of the Standard Specifications and the Special Provisions of said project from date of completion of the Work or termination of any maintenance period, whichever is the later, and also to repair or replace any damage resulting from the repairing or replacing of such defects at no additional cost to the Agency. This guarantee does not extend to unusual abuse or neglect that may occur subsequent to the date of completion of the Work or termination of any maintenance period, whichever is the later. We shall make such repairs or replacements within a reasonable time, as determined by the Engineer, after receipt of written notice. In the event of failure to make such repairs or replacements within a reasonable time after receipt of written notice from the Engineer, we authorize the Engineer to proceed to have said repairs or replacements made at our expense, and we will pay the costs and charges therefor upon demand. Project: Rancho Santa Fe Road North. Phase 2 Location: (Legal Description of Project Propem) Name of Contractor: Address: (Of Contractor) Telephone: (Of Contractor) By: (Typed or printed names of signing Ottjcer(s) of the Contractor authorized to bind the Contractor in legal matters) Title: (Of said ofker(s)) Signature (s) Date of Execution:' Add the following section: 308-7.1 Record Drawings. In addition to the requirements of section 2-5.4, herein, the Contractor shall prepare record drawings that show all changes in the work constituting departures from the original contract drawings, including those involving both constant-pressure and intermittent-pressure lines and appurtenances. The Contractor shall accurately record, on a daily basis, on one set of blue line prints of the irrigation drawings, all changes in work constituting departures from the original contract drawings, including changes in both pressure and nonpressure line. The Contractor shall post information on record drawings no later than the next working day after the work is installed. The Contractor shall record changes and dimensions in a legible and professional manner. When the drawings are approved by the Engineer the Contractor shall transfer all information to a set of reproducible photo mylar drawings. Items required to be shown shall be dimensioned by the Contractor from two permanent points of reference (buildings, monuments, sidewalks, curbs, pavement). The accuracy of location of all items to be shown on the drawings shall be 150 mm (6") in both the vertical and horizontal planes. All text and numerals placed on drawings shall be 0.30 mm ('/B") in size. Facilities and items to be located in their horizontal and vertical positions and shown on the record drawings include all: @ 7/31/02 Contract No. 3907 Page 360 of 414 Point(s) of connection, for water and electrical services Routing of irrigation pressure mainlines Backflow preventors Ball, gate and check valves Irrigation control valves. Quick coupler valves Routing of service wires Routing of control wires Electrical service equipment Electrical junction boxes Irrigation controllers Sleeves for future connections Other equipment of a similar nature (as directed by the Engineer). The Contractor shall keep the blue print drawings available for the Engineer's inspection at any time. The Contractor shall make all changes to reproducible drawings in waterproof black ink (no ball point pen). Changes in dimensions shall be recorded in a legible and professional manner. Record construction drawings shall be maintained at the job site during construction. The Contractor shall provide one set of mylar "record" drawings to the Engineer after submitting blue-line prints of the proposed "record" drawings for, and obtaining their approval by, the Engineer. Add the following section: 308-7.2 Controller Chart. The Contractor shall prepare record drawings which shall be submitted to the Engineer for approval by the Engineer before charts are prepared. The Contractor shall provide one controller chart of the maximum size the controller door will allow, for each controller supplied, showing the area covered by that automatic controller. The chart shall be a reduction of the actual record system drawing with a legend to explain all symbols. If the controller sequence is not legible when the drawing is reduced, The Contractor shall enlarge it to a size that will be readable when reduced. The Contractor shall photocopy the chart, with a pastel transparent color used to show area of coverage for each station. When completed and approved, the Contractor shall hermetically seal the chart between two pieces of plastic, each piece being a minimum 20 mils thick. The Contractor shall complete the charts and obtain the Engineers approval prior to final inspection of the irrigation system. Add the following section: 308-7.3 Operation and Maintenance Manuals. The Contractor shall prepare and deliver to the Engineer, within 10 calendar days prior to completion of construction, all required and necessary descriptive material in complete detail and sufficient quantity, properly prepared in four individual bound copies. The descriptive material shall describe the material installed in sufficient detail to permit qualified operating personnel to understand, operate, and maintain all equipment. The Contractor shall include spare parts list and related manufacturer information for each equipment item installed. Each manual shall include the following: a) b) Duration of Guarantee period. c) d) e) Index sheet stating Contractor's address and telephone number. List of equipment, with names and addresses of manufacturer's local representative. Complete operating and maintenance instructions on all major equipment. In addition to the maintenance manuals, the Contractor shall provide the agency maintenance personnel with instructions for major equipment, and show written evidence to the Engineer at the conclusion of the work that this service has been rendered. Add the following section: 308-7.4 Check List. The Contractor shall complete and fonnrard signed and dated checklist to the Engineer before final acceptance of project. The following checklist at the end of the project, using the format shown: a) b) Materials approval c) Plumbing permits (if none required, so note) Pressure mainline test (by whom, and date) e 7/31/02 Contract No. 3907 Page 361 of 414 d) e) 9 g) h) i) j) Record drawings completed (received by, and date) Controller chart completed (received by, and date) Materials furnished (received by, and date) Operation and maintenance manuals furnished (received by, and date) System and equipment operation instructions (received by, and date) Manufacturer warranties (received by, and date) Written guarantee by Contractor (received by, and date) 308-8 MEASUREMENT AND PAYMENT Add the following: The lump-sum or unit prices set forth in the contract documents shall include, but not be limited to, full compensation for furnishing all labor, materials, tools, and equipment and performing all work necessary to complete, maintain, and guarantee the planting and irrigation work described or specified in the contract documents, including soils testing and recommended soil amendments, seed and hydroseed sluny, tree stakes, bark mulch, erosion control matting, plant materials, temporary irrigation and permanent irrigation, including reduced-pressure back-flow preventer, ball valves, drip valve assembly, electric control valves, quick couplers, control wires, pull boxes, valve boxes, all piping and sleeves, electrical conduits, irrigation heads, drip emitters, bubblers, drip irrigation equipment, connection from electrical service to irrigation electrical meter, connection from meter to irrigation controller(s), installation of controller enclosure, concrete pads, preparation, correction, reproduction and lamination of "as-built" drawings, controller charts, assembly and submittal of the check list and operation and maintenance manuals and all appurtenances to the aforementioned items, as well as 120 days' maintenance, water meter fees, and project guarantees. After completion of the project, the Engineer will retain $20,000 of the total contract amount, and will subsequently disburse the $20,000 to the Contractor on a monthly basis of $5,000 per month. The Engineer reserves the right to stop payment until all punch list submitted to the Contractor every month are completed. The Contractor will pay all water meter fees. Add the following section: 308-9 6" PVC IRRIGATION SLEEVE 308-9.1 General. rope in a joint trench as shown in the Plans and as specified herein. This work consists of furnishing and constructing PVC irrigation sleeves with pull 308-9.2 Materials. requirements of Section 212-2, Irrigation System Materials, of the SSPWC. 6" and 2" irrigation crossover sleeves shall be Schedule 80 PVC meeting the 308-9.3 Installation. 6" and 2" irrigation sleeves shall be installed in accordance with Section 308-5.2, Irrigation Pipeline Installation, of the SSPWC. Pull-rope shall be installed in all irrigation sleeves. 308-9.4 Measurement and Payment. 6" PVC Irrigation Sleeve shall be measured and paid by the linear foot of actual 6" PVC sleeve in place. The price paid per linear foot for 6" PVC Irrigation Sleeve shall be considered as full compensation for providing all labor, equipment, materials, tools and incidentals necessary to furnish and install 2", 4" and 6" PVC irrigation sleeves including excavation and backfill of trench, permanent and temporary resurfacing, and all other work necessary to install the sleeves, complete in place. SECTION 309 - MONUMENTS 309-1 DESCRIPTION Add the following: This work shall also include furnishing monuments, as shown on the Plans. 7/31/02 Contract No. 3907 and installing iron pipe street survey Page 362 of 414 309-2 MATERIALS Add the following: Iron pipe shall conform to Section 207-9, ‘Iron Pipe and Fittings,” of the Standard Specifications. 309-4 PAYMENT Add the following: Benchmark-brass plug shall be measured for and paid as Street Survey Monument. 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 final and temporary traffic lanes, directional arrows, guidelines, curbs, parking lines, crosswalks, and other designated markings in accordance with the Plans, or for approved temporary detours essential for safe control of traffic through and around the construction site. The Contractor shall remove by wet grinding all existing or temporary traffic markings and lines that may confuse the public. When temporary detour striping or markings are no longer required, they shall be removed prior to painting the new traffic stripes or markings. 310-5.6.3 Equipment. Delete the ninth paragraph and substitute the following: The Contractor shall provide a wet grinding machine with sufficient capacity to completely remove all existing or temporary traffic striping or markings that conflict with the striping plan, or are contrary to the Traffic Manual, or that may be confusing to the public. The surface produced by grinding the existing or temporary tyffic striping or markings on pavement shall not exceed variations from a uniform plane more, than 3 mm ( /e”) in 3 m (10’) when measured parallel to the centerline of the street or more than 6 mm ( /() in 3 m (IO’) when measured perpendicular to the centerline of the street. The use of any equipment that leaves ridges, indentations or other objectionable marks in the pavement shall be discontinued, and equipment capable of providing acceptable surface shall be furnished by the Contractor. This equipment shall meet all requirements of the air pollution control district having jurisdiction. 310-5.6.6 Preparation of Existing Surfaces. Modify the first paragraph as follows: The Contractor shall remove all existing markings and striping, either permanent or temporary, which are to be abandoned, obliterated or that conflict with the plans by wet grinding methods. Removal of striping by high velocity water jet may be permitted when there is neither potential of the water and detritus from the high velocity water jetting to damage vehicles or private property nor to flow from the street into any storm drain or water course and when approved by the Engineer. The Contractor shall vacuum all water and detritus resulting from high velocity water jet striping removal from the pavement immediately after the water jetting and shall not allow such materials to flow in the gutter, enter the storm drain system or to leave the pavement surface. Surface variation limitations for high velocity water jet striping removal shall be the same as for grinding. The Contractor shall not use dry or wet sandblasting in any areas. Alternate methods of paint removal require prior approval of the Engineer. Obliteration of traffic striping with black paint, light emulsion oil or any other masking method other than a minimum 30mm (0.10’) thick asphalt concrete overlay is not permitted. 31 0-5.6.7 Layout, Alignment, and Spotting. Modify the first paragraph as follows: The Contractor shall establish the necessary control points for all required pavement striping and markings by surveying methods. No layout of traffic striping shall be performed by the Contractor before establishment of the necessary control points. The Contractor shall establish all traffic striping between these points by string line or other method to provide striping that will vary less than 80mm per 100m (1/2 inch in 50 feet) from the specified alignment. The Contractor shall obliterate, straight stripes deviating more than 80mm per 1OOmm (1/ 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. 7/31/02 Contract No. 3907 Page 363 of 414 310-5.6.8 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. A second coat of striping shall be applied two weeks after initial painting. 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 traffic striping, curb markings, pavement markings, thermoplastic pavement marking, and reflective and non-reflective pavement markers as shown on the plans and required by the specifications shall be paid at the unit price bid for Final Traffic Striping (2-coat), Pavement Marker (Reflective), and Pavement Marking (Thermoplastic) and no additional compensation will be allowed therefor. The unit price bid shall include all labor, tools, equipment, materials, and incidentals for doing all work in installing final traffic striping, curb markings, pavement markings, thermoplastic pavement marking, and reflective and non-reflective pavement markers. . Reapplication of temporary stripes and markings shall be repainted at the Contractor's expense, and no additional compensation will be allowed therefor. Add the following Section: 310-6 FINAL SIGNING Add the following Section: 310-6.1 General. Add the following section: permanent traffic control signs at locations shown on plans and as specified herein. The Contractor shall provide and install all final and Add the following section: 310-6.2 Measurement And Payment. Final traffic signing and appurtenances thereto shown on the plans or required in the specifications shall be paid at the unit price bid for Final Traffic Signing. Payment therefor shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals and for doing all the work involved in supplying and installing permanent signing and appurtenances and relocating permanent flashing beacon, complete in place, as shown on the plans, as specified in the Standard Specification and these special provisions, and as directed by the Engineer. Add the following Section: 310-7 PROJECT INFORMATION SIGNS Add the following Section: 310-7.1 General. Before any major physical construction work readily visible to highway users is started on this contract, the Contractor shall modify two Project Information signs at the locations designated in the plans. Modification shall include revising the name of the Contractor shown and relocation of the two existing Project Information signs as directed by the Engineer. The sign message to be used for the Year of Completion of Project Construction will be furnished by the Engineer. The signs shall be kept clean and in good repair by the Contractor. Upon completion of the work, the signs shall be removed and disposed of outside the highway right of way in accordance with the provisions in 300-1.3, "Removal and Disposal of Materials" of the Standard Specifications. Add the following section: 31 0-7.2 Measurement And Payment. Full compensation for revising the Contractor's name shown, relocating, maintaining, and removing and disposing of the project information signs shall be considered as included in the contract price paid for Modify Project Information Signs, and no additional compensation will be allowed therefor. . @ 7/31/02 Contract No. 3907 Page 364 of 414 SECTION 312 - PAVEMENT MARKER PLACEMENT AND REMOVAL 312-1 PLACEMENT Add the following to the third paragraph: 4) If less than 14 days have passed since the placement of the asphalt concrete pavement course on which the pavement markers are to be placed. Add the following section: 312-1.1 Reflective Channelizer Placement and Removal. The Contractor shall place and remove reflective channelizers the same as for pavement marker placement and removal. The Contractor shall place the channelizers uniformly, straight on tangent alignment and on a true arc on curved alignment to the same tolerances of position as for application of paint in Section 310-5.6.8. The Contractor shall perform all layout work necessary to place the channelizers to the proper alignment. If the channelizers are displaced or fail to remain in an upright position, from any cause, the channelizers shall immediately be replaced or restored to their original location, by the Contractor. When reflective channelizers are removed the pavement surface shall be restored to the same color and surface finish as the adjacent pavement. SECTION 313 - TEMPORARY TRAFFIC CONTROL DEVICES Add the following section: 313-1 TEMPORARY TRAFFIC STRIPING AND 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 apputtenances to public traffic. In each stage, after completion of the preceding stage, the first order of work shall be the removal of conflicting pavement delineation. Pavement delineation removal shall be coordinated with new delineation so that lane lines are provided at all times on traveled ways open to public traffic. Removal shall be by grinding unless otherwise approved. Before obliterating any pavement delineation that is to be replaced on the same alignment and location, such pavement delineation shall be referenced by the Contractor, with a sufficient number of control points to reestablish the alignment and location of the new pavement delineation. The references shall also include the limits or changes in striping pattern, including one- and two-way barrier lines, limit lines, crosswalks and other pavement markings. Full compensation for referencing pavement delineation shall be considered as included in the contract prices paid for new pavement delineation and no additional compensation will be allowed therefor. 313-1.2 Temporary Pavement Markers. Temporary reflective raised pavement markers shall be placed in accordance with the manufacturer's instructions. Temporary reflective raised pavement markers shall be cemented to the surfacing with the adhesive recommended by the manufacturer, except epoxy adhesive shall not be used to place temporary reflective raised pavement markers in areas where removal of the markers will be required. Pavement striping, legends and markers which conflict with any traffic pattern shall be removed by grinding as determined by the Engineer. The Contractor shall use temporary reflective raised pavement markers for temporary pavement marking, except when the temporary pavement markers are used to replace patterns of temporary traffic stripe that will be in place for less than 30 days. Reflective pavement markers used in place of the removable-type pavement @ 7/31/02 Contract No. 3907 Page 365 of 414 markers shall conform to the section 312 "Pavement Marker Placement and Removal", except the 144ay waiting period before placing the pavement markers on new asphalt concrete surfacing as specified in section 312-1 "Placemenr, 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: 31 3-2 TEMPORARY TRAFFIC SIGNING Add the following section: 313-2.1 General. The Contractor shall provide and install all temporary traffic control signs, and delineators at locations shown on plans and specified herein. Add the following section: 313-2.2 Maintenance of Temporary Traffic Signs. If temporary traffic signs are displaced or overturned, from any cause, during the progress of the work, the Contractor shall immediately replace the signs in their original approved locations. The Contractor shall maintain all temporary traffic signs used in the Work in a clean, reflective and readable condition. The Contractor shall replace or restore graffiti marked temporary traffic signs and posts used in the Work within 18 hours of such marking being discovered during non-working hours or, when the marking is discovered during working hours, within 2 hours of such discovery of marking. Add the following section: 313-3 TEMPORARY RAILING (NPE K) AND CRASH CUSHIONS Add the following section: 313-3.1 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. Temporary Railing and Crash Cushions. 313-3.1.1 Appearance. Exposed surfaces of new and used units of Temporary railing (Type K) shall be freshly coated with white color paint prior to their first use on the project. The paint shall conform to the provisions in sections 210-1.5 "Paint Systems" and 310 "Painting". Contractor shall be responsible for the removal and cleanup or painting over the graffiti from the K-Rails within 48 hours. The Contractor Shall replace or repaint units of Temporary railing (Type K) or shall remove graffiti, tire or vehicle marks, dirt or any and all materials such that said marks or discoloration mar the appearance of said units when @ 7/31/02 Contract No. 3907 Page 366 of 414 ordered by the Engineer after the units are in place. Add the following section. 313-3.1.2 Manufacture of Temporary Railing. In addition to the requirements herein the temporary railing (TypeK) shall be manufactured per CALTRANS Standard DrawingT3. Concrete used to manufacture Temporary railing (Type K) shall conform to the provisions in sections 201-1, "Portland Cement Concrete" and 303-1 "Concrete Structures". Load tickets and a Certificate of Compliance will not be required. Reinforcing steel shall conform to the provisions sections 201 -1, "Portland Cement Concrete" and 303-1 "Concrete Structures". Steel bars to 'receive bolts at ends of concrete panels shall conform to ASTM Designation: A 36/A 36M. The bolts shall conform to ASTM Designation: A 307. A round bar of the same diameter may be substituted for the end-connecting bolt shown on the plans. The bar shall conform to ASTM Designation: A 36/A 36M, shall have a minimum length of 660 mm and shall have a 75 mm (3") diameter by 9 mm (3/8") thick plate welded on the upper end with a 5-mm (3/1~") 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 (TypeK) 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 (IO') of a traffic lane shall have a reflector installed on top of the rail as directed by the Engineer. Reflectors and adhesive will be furnished by the Contractor. A TypeP 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. When indicated on the plans or required to accommodate pedestrian access during stage construction, the contractor shall provide temporary railing, (bridge rail), above new concrete barrier railing. Add the following section: 31 3-3.2 Temporary Sand-Filled Crash Cushions. Temporary sand-filled crash cushion units shall be "Energite 111" 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 Drawings T1 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 7/31/02 Contract No. 3907 Page 367 of 414 conforming to the requirements of the CALTRANS Traffic Manual shall also be installed at each TSFCC amy as shown in CALTRANS Standard Drawings T1 and T2. Particular care shall be taken to assure that crash cushions are installed with the soil supporting them and the adjacent soil leveled to match the elevation of the bottom of the temporary railing immediately adjacent to the crash cushion. All routes of approach to the TSCFF array shall be graded such that any vehicle diverging from the traveled way to strike the TSCFF will travel on a vertical alignment parallel to the segment of the travel lane that it departed from. Add the following section: 313-4 TEMPORARY SIGNAL SYSTEM Add the following section: 313-4.1 General. Temporary signal system shall conform to Section 3074.2, Temporary Signal Systems, and Section 2-5.3, Shop Drawings and Submittals of the Standard Specifications and these special provisions, and as directed by the Engineer. All materials and equipment for a temporary signal system including, but not limited to, signal heads, mast arms, luminaires, wood poles, conductors, and hardware shall be furnished by the Contractor. Materials and equipment to be used in the temporary signal system shall be either new or used suitable for the intended use. Each signal face shall be oriented to be clearly visible to traffic approaching from signal is intended to control. Add the following section: 313-4.2 Operation. Temporary signal system shall operate at nominal 120 VAC. at 120 VAC or 240 VAC. the direction which the Lighting shall operate Unless othewise directed by the Engineer, the system shall be operated on a continuous 24-hour basis except for the periods when it is necessary to control traffic by flaggers. Timing of a temporary signal system will be performed by the Contractor. Add the following section: 313-4.3 Maintaining Temporary Signal System. Maintaining a temporary signal system shall be the sole responsibility of the Contractor. If components in the temporary signal system are damaged, displaced or cease to operate or function as specified, from any cause during the progress of the work, the Contractor shall immediately repair the components to the original condition or replace the components and shall restore the components to the original location. Components shall include signs, generator, flashing beacons, and signal equipment. In the event the temporary signal system is out of operation, for any reason, the Contractor shall provide flaggers, at the Contractor's expense, to maintain traffic control until the traffic signals are returned to service. 313-5 TRAFFIC PLASTIC DRUMS. Traffic plastic drums shall conform to the requirements for traffic control devices in Section 12, "Construction Area Traffic Control Devices," of the Standard Specifications and these special provisions. ' Traffic plastic drums shall be constructed of lowdensity polyethylene material and shall be flexible or collapsible upon impact by a vehicle. The traffic plastic drum shall have a weighted base that will separate from the drum. The base shall be of such shape as to preclude rolling upon impact by a vehicle. The base shall be of sufficient weight to maintain the drum in position and upright. The base or external ballast rings shall not exceed 101.6 mm (0.33 ft) in height, and drum rings shall not exceed @ 7/31/02 Contract No. 3907 Page 368 of 414 965.2 mm (3.17 ft) maximum in diameter. The base or external rings placed over and around the drum, resting on the pavement or ground shall contain the ballast for the drums. Ballast for drums shall be sand or water, except sand shall be used in areas susceptible to freezing. The base shall have drain holes to prevent the accumulation of water. Sand bags shall not be used as ballast for drums. The body of the traffic plastic drum shall be of a fluorescent orange or predominately orange color. Drums shall be a minimum of 914.4 mm (3.00 ft)in height above the traveled way, and have at least an 457.2 mm (1 SO ft) minimum width, regardless of orientation. The markings on drums shall be horizontal, circumferential, alternating orange and white reflective bands 101.6 to 152.4 mm (0.33 to 0.50 ft) wide. Each drum shall have a minimum of 2 orange and 2 white bands. The top of the uppermost reflective band shall be no lower than 152.4 mm (0.50 ft) from the top of the drum. Any non-reflective spaces between the bands shall not exceed 50.8 mm (0.17 ft) in width. The reflective sheeting shall conform to the provisions in "Approved Traffic Products" elsewhere in these special provisions. Only one type of traffic plastic drum shall be used on the project. The type of traffic plastic drum proposed for use on the project shall be submitted to the Engineer for approval, prior to placement on the project. Add the following section: 313-6 MEASUREMENT AND PAYMENT Temporary delineators, traffic plastic drums, type II and type Ill barricade, temporary striping, temporary pavement markers (reflective and non-reflective), temporary signal system, temporary railing (type K), temporary railing (bridge rail), temporary crash cushions, construction area signs, flashing arrow boards, and temporary appurtenances thereto shown on the plans or required in the specifications will be paid at the unit price bid for each item as listed in the bid schedule. 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 delineators, traffic plastic drums, type II and type Ill barricade, temporary striping, temporary pavement markers (reflective and non-reflective), temporary signal system, temporary railing (type K), temporary railing (bridge rail), temporary crash cushions, construction area signs, flashing arrow boards, 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. Payment for relocation of K-rails and crash cushions when not shown on the plans and requested by the Engineer shall be made per Section 3-3, Extra Work, SSPWC. Payment for furnishing all labor, materials, tools, equipment, and incidentals and for doing all the work involved in placing and removing Temporary Asphalt Concrete for Pedestrian Access shall be included in the unit price for each item used for Temporary Traffic Control. Add the following section: 313-7 PORTABLE CHANGEABLE MESSAGE SIGN Add the following section: 313-7.1 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 -2OOC (4OF) to +7OoC (158OF) 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 - G 7/31/02 Contract No. 3907 Page 369 of 414 Add the following section: 313-7.2 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. Add the following section: 313-7.3 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. Add the following section: 313-7.4 Measurement and Payment. The contract unit price for Portable Changeable Message Sign 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, and transporting from location to location, in good working order, and as directed by the Engineer, and no other compensation will be made. SECTION 314 - FENCE CONSTRUCTION Add the following section: 314-1 ENVIRONMENTAL FENCING Add the following section: 3141.1 General. Environmental fence shall be furnished and constructed, maintained, and later removed as shown on the plans, as specified in these special provisions, and as directed by the Engineer. Temporary fences that are damaged from any cause during the progress of the work shall be repaired or replaced by the Contractor at the Contractor's expense. When no longer required for the work as determined by the Engineer, temporary fences shall be removed. Removed facilities shall become the property of the Contractor and shall be removed from the e 7/31/02 Contract No. 3907 Page 370 of 414 site of the work, except as otherwise provided in this section. Removed temporary fence materials that are not damaged may be reused in the permanent work providing such materials conform to all of the requirements specified for the permanent work and such materials are new when used for the temporary fences. Holes caused by the removal of temporary fences shall be backfilled with native material. Add the following section: 314-1.2 Measurement and Payment. Environmental fence will be measured and paid for by the foot. The contract price paid per foot for environmental fence shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved . in environmental fence, complete in place, including maintaining, removing, and disposing of environmental fence, as shown on the plans, as specified in the Standard Specifications and these special provisions, and as directed by the Engineer. SECTION 31 5 - ELECTRICAL AND TELEMETRY FOR PRESSURE REDUCING STATION 315-1 GENERAL 31 5-1 .Ol Scope Of Work. A. B. C. D. The Instrumentation System Supplier (ISS) shall furnish all labor, materials, equipment and incidentals required, and install complete, ready for operation, and field test the Instrumentation and Telemetry System additions as shown on the Drawings and/or specified herein. The Instrumentation System Drawings and Specifications are composed of the Instrumentation Equipment Description, as identified in Section 31 5-2.02 "Instrumentation Equipment Description", of these special provisions, and the Electrical Drawings (included in the project drawing set). The drawings and specifications are not intended to be a complete listing of all components required for a functional instrumentation system. All auxiliary and accessory equipment (including but not limited to power supplies, isolation transmitters, relays, etc.) necessary for system performance shall be provided by the ISS even if not specifically detailed on the drawings or in these specifications. The exact radio antenna location requirements including exact site location and height above grade shall be determined by a field investigation. The ISS shall verify the integrity of radio communication from and to the proposed antenna locations prior to installing the antennas. The survey shall be conducted to optimize the antenna height and location. Approximate locations are shown on the Drawings. A total of up to five different points will be tested. The final results of this testing and the selected antenna location shall be completed within 20 days after initiation of field investigation. The test results shall be submitted within 10 days following the investigation. The maximum cable distance between the radio and the RF antenna connection is limited to 75 feet. 31 5-1.02 Related Work. A. Instrumentation signal cable and alarm and status wiring. B. Equipment mounting hardware shall conform to applicable portions of the plans and these special provisions. C. Process sensing lines and fittings are included on the mechanical drawings. - 315-1.03 Qualifications. @ 7/31/02 Contract No. 3907 Page 371 of 414 A. B. C. D. E. F. G. H. I. The Instrumentation and Telemetry System (Section 13300) shall be supplied by one Instrumentation System Supplier (ISS). The ISS shall perform all work except programming necessary to select, furnish, supervise installation, connect, calibrate, and place into operation all meters, instruments, alarm equipment, telemetry equipment, and accessories as specified and shown on the Drawings. The ISS may be a manufacturer or a "systems house," regularly engaged in the design and the installation of instrumentation and telemetry systems and their associated subsystems as they are applied to the Municipal Water and Wastewater Industry. For the purposes of this specification section, a "systems house" shall be interpreted to mean an organization that complies with the following criteria: 1. Employs personnel on this project who have successfully completed ISA or manufacturers training courses on general process instrumentation. 2. Has performed work of similar or greater complexity on at least five previous projects. 3. Has been actively engaged in the type of work specified in this specification section for a minimum of 5 years. The ISS shall maintain a permanent, fully staffed and equipped service facility within 100 miles of the project site with personnel and equipment required to maintain, repair and calibrate the systems specified herein. Actual installation of the instrumentation system need not be performed by the ISS's employees; however, the ISS as a minimum shall be responsible for the technical supervision of the installation. The ISS shall furnish equipment which is the product of one manufacturer to the maximum practical extent. Where this is not practical, all equipment of a given type shall be the product of one manufacturer. ISS shall be one of the following or equal as approved by the Vallecitos Water District: 1. Freedom Automation, Oceanside (760) 641-2020 2. Team 3 Controls, Simi Valley (805) 955-9200 3. Base 9 Consulting, Carlsbad (760) 436-61 71 4. Syntech Automation Inc., San Diego (858) 712-3460 5. Integrated Controls Inc., Orange (714) 516-9531 Only approved suppliers will be accepted. Proposed system supplier shall be named on the bid document. Qualifications of the ISS shall be submitted with the Contractor's bid. Being listed in this specification does not relieve any potential ISS from meeting the qualifications specified in this Section. The radio survey shall be performed by a company regularly involved in radio communication work, with a minimum of five years experience in the field. 31 5-1.04 Submittals. A. General submittal requirements: 1. Shop Drawings shall fully demonstrate that the equipment and services to be furnished will comply with the provisions of these Specifications and shall provide a true and complete record of the equipment as manufactured and delivered. 2. Submittals shall be bound in separate three-ring binders, shall be complete, neat, orderly with an index and sectional dividers, with all Drawings reduced to a maximum size of 11 -in by 17-in, then folded to 8-1/2-in by 1 l-in for inclusion within the binder. @ 7/31/02 Contract No. 3907 Page 372 of 414 3. Exceptions to the Specifications or Drawings shall be clearly defined by the ISS in a separate section of each submittal package. The submittal shall contain the reason for exception, the exact nature of the exception and the proposed substitution so that a proper evaluation may be made by the Engineer. 4. If, in the opinion of the Engineer, a submittal is not clear or complete, it will be returned to the ISS with the markings "Revise" and "Resubmit". The decision of the Engineer on the acceptability of any submittal shall be final. B. Submittals - Hardware and Shop Drawings 1. Shop Drawings shall be complete; giving at least equipment specifications, details of connections, wiring, I/O address lists, radio/PLC address, range and dimensions. Submittals consisting of only general sales literature will not be acceptable. 2. Submit detailed information for each instrument, power or control device, including manufacturer's descriptive literature and a data sheet for each device which shall include as a minimum: a. Product (item) name and tag number (if applicable) as indicated on the Contract Drawings. b. Manufacturer's name and complete model number. c. InpuUoutput characteristics. d. Range, size, span, setpoint, deadbands, etc. e. Physical size with dimensions, enclosure NEMA classification and mounting details. f. Materials of construction of all components. g. Instrument or control device sizing calculations where applicable. 3. Submit a detailed loop connection diagram for each monitoring and control loop defined. The format shall be based on the Instrument Society of America, Standard for Instrument Loop Diagrams, ISA-S5.4. The loop diagrams shall show all components of the loop including electrical relays, switches, and other devices necessary for the proper operation of the loop. Each loop diagram shall show all wiring and piping details, identify all field termination and grounding points within cabinets and panels and identify connection points on all devices. 4. Submit detailed drawings for control panels including: a. Cabinet assembly and layout drawings to scale. The assembly drawing shall include a bill of material on the drawing with each panel component clearly defined. The bill of material shall be cross-referenced to the assembly drawing so that a non-technical person can readily identify any component of the assembly by manufacturer and model number. Include equipment provided by others (seismic controller, etc.). b. Fabrication and painting specifications. c. Point to point wiring diagrams depicting wiring within the panel as well as connections to external devices. d. Heat calculations for each panel supplied. Heat calculations shall be based on a minimum ambient temperature of 25' F and a maximum ambient temperature of 105oF. 5. PLC and Radio Hardware Submittals a. Catalog cuts and descriptive literature for PLC and radio equipment including central processing unit, input modules, output modules, radios, multiplexers, interface modules, power supplies, etc. 3 +c 7/31/02 Contract No. 3907 Page 373 of 414 C. b. Block diagrams showing the inter-connections between major hardware components, modules, interface devices, radio and plug in circuit boards and a complete inputloutput signal listing. c. Description of communication interfaces between local and remote PLCs. d. Documentation of all hardware switch settings. 6. Results of the Radio Survey. 7. Written indication of any specific exceptions taken to the interconnection and control intent as shown on the Drawings and specified herein. Software submittals: 1. 2. 3. An "Input/Output Record Form", tabulating the module number, channel number, address number, inputloutput designation name and/or number, and description of each item of input and output. A typewritten document containing startup, operation, and maintenance procedures. Details of communication link for RTU operation. Hardware and software configuration information in sufficient detail to verify adequacy of RTU. Include details of any necessary expansion boards, special interface requirements (e.g., cables, jacks, etc.), description of driver and impact of driver on PLC memory configuration. D. Submittals - Test Procedures, Spare Parts, and District Training 1. Test Procedures: Submit the procedures proposed to be followed during each test. Procedures shall include test descriptions, forms, and checklists to be used to control and document the required tests. 2. Test Documentation: Upon completion of each required test, document the test by submitting a copy of the signed off test procedures. Testing documentation shall consist of the following: a. The summary check-off index shall be an index of all PLC and telemetry systems in the project and shall include the following as a minimum for each system: 1) System description. 2) Physical installation check-off box. 3) Functional check-off box for each point. 4) Satisfactory completion check-off box for each point. 5) Comments box. 6) Sign-off area for the ISS, the Engineer, and the District. b. The individual instrument sign-off sheet(s): 1) The instrument tag number. 2) The manufacturer and part number. 3) Description of instrument. 4) Power requirements. 5) Calibration procedure including calibration ideal vs. actual chart for O%, 20%. 6) Calibration range. 7) Calibration data (setpoint, deadband, etc.). 8) Switch settings. 50%, 80%, and 100% of full scale value. G 7/31/02 Contract No. 3907 Page 374 of 414 9) PLC I/O address(es). 1O)Additional comments as required. 11)Signoff space for the ISS, the Engineer, and the District. c. The ISS shall submit the Test Plan and receive a satisfactory review approval by the Engineer before any witnessed testing can occur. 3. The ISS shall submit a training plan. This training plan shall include: a. An overview of the training plan explaining why specific courses are proposed. b. Prerequisite training and experience of attendees. c. Course content - a topical outline. d. Course duration. e. Course location - training center or jobsite. f. The training program shall include operational theory and hands-on instruction for each system supplied. This training shall cover functional operation of the system from the control panel, troubleshooting techniques, removal and replacement of various types of panel devices including modems, PLCs, controllers, indicators, etc., and field devices such as pressure switches, etc. g. The cost of training programs shall be included in the Contract price, and shall be conducted with designated District personnel, covering operation and maintenance of the system. The training and instruction shall be directly related to the System being supplied. E. Submittals - Operations and Maintenance Manuals 1. 2. 3. 4. 5. Operation and Maintenance (O&M) Manuals shall be prepared respective to the Work of this Instrumentation Section. Preliminary and final O&M Manuals shall be submitted for Engineer approval in accordance with Section 2-5.3.3 "Submittals" of the SSPWC. O&M Manuals shall include the following information and documentation (as a minimum): a. Field instrument operation and maintenance information. b. Panel instrument operation and maintenance information. c. As-built field and panel wiring drawings. d. As-built panel layout drawings. e. Configuration documentation. The manuals shall contain all illustrations, detailed drawings, wiring diagrams, and instructions necessary for installing, operating, and maintaining the equipment. The illustrated parts shall be numbered for identification. All information contained therein shall apply specifically to the equipment furnished and shall only include instructions that are applicable. All such illustrations shall be incorporated within the printing of the page to form a durable and permanent reference book. If the ISS transmits any documentation or other technical information which he considers proprietary, such information shall be designated. Documentation or technical information which is designated as being proprietary will be used only for the design, construction, operation, or maintenance of the System and, to the extent permitted by law, will not be published or otherwise disclosed. The minimum requirements for the ISS's O&M Manual are as follows: a. Field and panel instrument operation and maintenance information: This portion of the ISS's O&M Manual shall include information on the installation operation, calibration, . @ 7/31/02 Contract No. 3907 Page 375 of 414 b. C. d. assembly, and disassembly of various field mounted instruments provided under this Specification Section. A replacement parts list with cost and availability data shall be included for every field mounted instrument provided. In addition, the manual shall include the address and phone number of the party from whom replacement parts can be obtained. This portion of the 0&M manual shall be tailored for use by maintenance personnel with technical instrumentation backgrounds. As-built field and panel wiring drawings: This portion of the ISS's O&M Manual shall present previously submitted wiring drawings in as-built form. Wiring diagrams shall be complete in every aspect. All terminals shall be identified. All wires shall be labeled. The direction of all 4-20 mA current flows shall be clearly indicated. I/O termination points shall be labeled and identified as to whether they are an analog input, analog output, discrete input, or discrete output. Additionally, all I/O termination points shall have their software equivalent identifier clearly printed next to the termination point. As-built panel layout drawings: This portion of the ISS's O&M Manual shall present previously submitted panel drawings in as-built form. These drawings shall reflect all changes made since approval drawings were submitted and shall include one copy of all drawings in electronic format on CD-ROM. The exact location of all panel mounted instruments, indicator lamps, selector switches, pushbuttons, etc., shall be indicated and appropriately labeled. PLC configuration, code, setting of all hardware switches, etc. 315-1.05 Identification. A. Each separately packaged instrument shall be marked to identify its location, tag number and function in the system. Identification shall be predominantly displayed on outside of package. B. A permanent stainless steel or other non-corrosive material tag firmly attached and permanently and indelibly marked with the instrument tag number, as given in the instrumentation list, shall be provided on each piece of equipment supplied under this Section. Equipment not identified in the instrumentation list shall be identified with a unique number in conformance with the established instrument identification scheme for this project. 315-1.06 Source Quality Control. A. The manufacturers of the equipment and fabricators of panels and/or cabinets supplied under this Section shall allow the Engineer and/or District to inspect and witness the testing of the equipment at the site of fabrication. Equipment shall include the cabinets, special control systems, flow measuring devices and other pertinent systems and/or devices. Suitable notice shall be provided to allow this work, before any shipments are made. 315-1.07 PIC Inputloutput Listing., DIGITAL INPUT Vault Intrusion RTU Intrusion Station Flooded 315-2 PRODUCTS 315-2.01 Instrumentation General. A. Type @ 7/31/02 ANALOG INPUT 24" Upstream Pressure 24" Downstream Pressure 12" Upstream Pressure 12" Downstream Pressure Contract No. 3907 Page 376 of 414 1. 2. 3. 4. 5. All instrumentation supplied shall be of the manufacturer's latest design and shall produce or be activated by signals which are established standards for the water and wastewater industries. All electronic instrumentation shall be of the solid state type and shall utilize transmission signals of 4 to 20 mAdc (milliampere direct current). However, signals between instruments within the same panel or cabinet may be 1-5 V.dc, or the like. Outputs of equipment that are not of the standard signals as outlined, shall have the output immediately raised and/or converted to compatjble standard signals for remote transmission. No zero based signals will be allowed. All instruments shall be provided with floor stands or wall or panel brackets as shown or required. Equipment enclosures shall be NEMA 4X. .. B. Electrical 1. All equipment shall be designed to operate on a 60 Hertz alternating current power source at 105 to 135 volts, except as noted. All regulators and power supplies required for compliance with the above shall be provided between power supply and interconnected instrument loop. Where equipment requires voltage regulation, constant voltage transformers shall be supplied. 2. Materials and equipment used shall be U.L. approved wherever such approved equipment and materials are available. C. The radio survey shall investigate the radio path between the vault and the Central Facilities. The radio survey contractor shall perform the survey, interpret the results, and prepare a report. The report shall include recommended height, aiming and locations of the antenna poles at each site and other technical information required for proper operation of the radio system. The radio system shall be tuned as required to establish a set of communications channels based on the results of the radio survey and field investigation. 31 5-2.02 Instrumentation Equipment Description. A. Pressure Transmitter 1. 2. 3. 4. 5. 6. Type: bonded strain gauge pressure transmitter; electronic; NEMA 4 case. Operation Purpose: To sense level via gauge pressure and produce a standard current output signal linear with pressure; sensing element - bonded strain gauge; circuitry - solid state. Functional: Power supply - d.c. (from receiver over signal leads); output - 4-20 mA. Physical: wetted parts - 316 stainless steel, Viton; electronics housing - NEMA 4 (weatherproof); process connections - 1/2-in NPT. Performance: Accuracy - plus or minus 0.20% of span over an 8:l range, including combined effects of linearity, hysteresis and repeatability. Manufacturer: Bristol Babcock Signature Model 2808-1 5A-23-1-1-0-1-1-0, no equal. B. Intrusion Alarm Limit Switches 1. Each intrusion alarm limit switch shall transmit a signal when the monitored door or hatch is not in the closed position. 2. Each limit switch shall be SPDT, rated 5 amps. Conduit entrance and terminals shall be epoxy sealed. Limit switch mounting and actuator shall be determined by the contractor to provide a reliable, positive, and accurate indication of entrance. The switch shall be normally closed (actuated open when the door or hatch is closed). Switch shall be mounted for tt- 7/31/02 Contract No. 3907 Page 377 of 414 minimum obstruction of access. Limit switches shall be Telmechanique #XCKJ20541, or equal. - C. Programmable Logic Controller (PLC) 1. Major hardware components of the PLC shall include: a. Central Processing Unit (CPU). b. I/O modules. c. Chassis. d. Power supply. 2. General a. b. C. d. The PLC shall be an intelligent microprocessor based device that can collect data and process control functions. The PLC system shall be an Allen Bradley SLC 503 system to match existing District-owned equipment. No substitutions allowed. All components of the PLC system shall be of normally recognized industry standards and regularly sold for industrial installations. All components shall be assembled by the PLC manufacturer into structurally sound housings. All connecting cables, switches, and other operator-controlled devices shall be constructed so as to withstand, without damage, all normal use and handling. The PLC system shall be of modular design with a plug-in processing unit, power supply unit, bus controller unit, or assemblies. All components shall be marketed and supported by the one manufacturer. All necessary cables shall be included. PLC shall have a 1746-P3 power supply. PLC system power supply shall be fused for overload protection. 3. Central Processing Unit (CPU) a. The PLC CPU shall be supplied with RS232 communications capabilities for interface with the radio. 4. The PLC System shall be supplied with a slotted 110 chassis sized to house the PLC, I/O modules, and communication interfaces. Provide PLC battery. 5. I/O Modules a. General 1) 2) 3) The system shall include 15 percent active output points for future use. Minimum isolation between inpuffoutput and logic voltage shall be 15OOV RMS per NEMA standards via opto-isolation. All outputs, including spare points, shall be furnished with field replaceable fuse protection and blown fuse indicators. Fuses shall be located as near as possible to the relay output modules. All I/O points, including spare points, shall be wired to terminal blocks. b. Discrete input modules shall be 16 point modules type 1746-lV16. Output modules shall be type 1746-OW8. The supplier shall label each input on the module with the appropriate I/O address number. Each output shall be capable of powering a 2 amp continuous load or switching a power load up to 125 VA. For outputs used on loads greater than 2 amps an interposing relay shall be provided. Provide a minimum of one output module with the PLC. c. Analog input and output modules - The analog inpuffoutput block shall accept up to 4 analog inputs or generate up to 4 analog outputs. The unit shall be supplied with an # 7/31/02 Contract No. 3907 Page 378 of 414 internal power supply capable of powering loads up to 300 ohm for each output point. The inputs and outputs shall be 4-20 ma DC. The supplier shall label each I/O point with the appropriate I/O address number. 6. 24 VDC power for powering analog instrument loops shall be provided by the system supplier as a part of the system. D. Radio Equipment 1. 2. 3. 4. 5. 6. Radio equipment shall be a combination radio/modem which operates in a spread-spectrum mode, frequency hopping in the 902 to 928 MHz band, and complies with Part 15 of the FCC rules. Radios shall operate in point-to-point mode, and shall have RS-232 interface to the Allen Bradley PLC. Radio and PLC shall be completely compatible with protocol transparent data communications. The transmitter shall provide 1 watt at the port to the transmission line. The transmitter's spurious and harmonic emission shall be less than 65 dB. The transmitter shall have a carrier stability of at least .0005 percent. The transmitter shall be rated for continuous duty. The receiver local oscillator stability shall be at least .0005 percent. Bit rate errors shall be less than BER 1x10-5 at -105dBm. Radios shall include internal diagnostics with local indicators as well as capability of remote monitoring. Radios shall be programmable. Both diagnostics and programming capability shall be accessible through either an IBM compatible PC or through a handheld terminal. Either a handheld terminal or software to link radio to a PC shall be furnished. Radiolmodems shall be Schlumberger Utilinet, no equal. If conditions necessitate a radio filter, then it shall be a Schlumberger filter compatible with the type of radio. The radio (and filter) will be mounted in the RTU enclosure so that the end of the radio with the serial connections is at least four inches from the nearest obstruction, not blocked in any way and can be easily seen by service technicians standing in front of the open enclosure. E. Antenna and Pole 1. The radio system shall be provided with an omnidirectional antenna, self-supporting metal pole, and other mounting accessories in accordance with the Drawings and the following: a. Square metal pole and all connections shall be fabricated by a manufacturer engaged in the design and production of metal poles on a regular basis, Ameron or equal. b. Pole and anchor bolts shall be engineered to withstand the forces induced on the pole, coaxial cable and equipment from an 80 mph wind with a 1.3 gust and shall meet AASHTO standards. The limiting deflection of the pole tip shall be 7 inches maximum. 2. The antenna used with the radio shall be a ldb, 3db, or 6db omni-directional base station antenna. The required gain of the antenna will be determined by actual field testing to ensure that the radio can communicate' with at least one site to a degree greater than the Schlumberger recommended standards. All hardware shall be stainless steel. Frequency range shall be 890 to 960 MHz (broadband), specifically designed for "spread-spectrum" applications. Antenna shall have foam-potted N-type connectors. All antennas and mast systems shall be grounded per NEC requirements and as shown on the Drawings. 1. The transmission cable shall be furnished and installed as required by the Drawings. Transmission line shall be low VSWR, LDF with N type connectors, with an attenuation of less than 1.10 dB for lengths of 25 to I00 feet. All transmission lines shall be one continuous F. Antenna Transmission Cable a 7/31/02 Contract No. 3907 Page 379 of 414 section without splices or connectors other than at the ends. Transmission cable shall be Andrew Heliax Type LDF4P-50A, or equal. .r % G. Lightning Arrestor 1. Lightning arrestor shall protect the coax cable and radio from lightning strikes, shall have multi-strike capability, low strike throughput energy, flange mounting, N-type connectors. Polyphaser IS-509X-Z2 or equal. 2. Lightning arrestor and ground lug to be mounted in screw cover enclosure outside of the RTU enclosure. H. Power Supplies I. Power supplies shall be furnished as required and shall be capable of supplying the proper voltages for the equipment. 1. The instrument system supplier shall furnish all necessary cables for interconnections between system components. I. Miscellaneous Cables 31 5-2.03 Rtu Enclosure. A. General 1. The enclosure shall be wall mounted, single door deadfront modified NEMA 4X enclosure sized to house all specified equipment. The assembled RTU equipment and panel shall be assembled by a UL panel shop. Provide Hoffman or approved equal. The enclosure shall be furnished with a RTU intrusion switch. B. General Construction Details 1. 2. 3. 4. 5. 6. The panels furnished shall be NEMA 4X of the arrangement and design as required by the Drawings and specifications. Access doors or panels shall have continuous stainless steel hinges and oil resistant gasketing. Fabrication shall be suitably braced internally for structural rigidity and strength. Front panels or sections containing instruments shall be reinforced to prevent warping or distortion. All panel equipment, except as specifically noted, shall be factory mounted on suitable racks or subpanels and wired on or within the cabinet. Wiring shall comply with latest ANSI C1 National Electric Code, grouped in plastic wireways and wired to numbered terminals. Print storage pockets shall be provided on the inside of each panel. Print pockets shall be of sufficient size to hold all of the prints required to service the equipment. The panel shall be factory tested prior to shipment. Factory testing shall functionally test all hardware in the panel for proper operation and confirmation that the devices are connected in accordance with the shop drawings. All wiring within the panel shall be grouped together with harnesses or ducts and secured to the structure. Power and low voltage dc signal wiring shall be routed in separate wireways. Crossing of the two system wires shall be at right angles. Wiring troughs shall not be filled to more than 60 percent visible fill. Wiring trough covers shall be match marked to identify placement. If component identification is shown on covers for visibility, the ID shall also appear on the mounting subpanel. Wiring trough for supporting internal wiring shall be plastic type with snap-on covers. The side walls shall be louvered type to permit wiring changing without disconnecting. All field wiring shall terminate in a master numbered terminal board. The master terminal board shall have a minimum of 25 percent spares. Terminal blocks shall be arranged in vertical rows and separated into groups (120 VAC power or control, and dc signal, etc.). Terminal blocks shall be barrier type with the appropriate voltage rating. They shall be the Contract No. 3907 Page 380 of 414 raised channel mounted type. Terminal strips shall be provided for the purpose of connecting all control and signal wiring. Direct interlock wiring between equipment will not be allowed. Only one side of a terminal block row shall be used for internal wiring. The field wiring side of the terminal shall not be within 6-inches of the side panel or adjacent terminal. Each terminal point shall be provided with an identification strip bearing a unique identification number. 7. Wire shall be as specified in Division 16. Wire color shall be line power - black; neutral or common - white; ac control - red; dc control - blue; equipment or chassis ground - green; externally powered circuits - yellow. 8. All wiring and components shall be numbered in accordance with the numbering system used on the approved shop drawings. 9. Wire and tube markers shall be the heat shrink sleeve type with heat impressed letters and numbers. IO. Wire connectors shall be the hook fork type with insulated barrel for crimp type compression connection to the wire when wiring is terminated on devices other than the specified terminal blocks. 11. Instruments and circuits shall be provided with individual fuses or miniature circuit breakers to minimize service disruption. Miniature circuit breakers shall be suitable for DIN rail mounting with a minimum of 10,000 AIC. 12. Miscellaneous electrical equipment shall be in conformance with applicable Sections of the SSPWC and these special provisions. 13. Panels shall include a power ground bus sized in accordance with the National Electrical Code Article 250. 14.Terminal blocks shall be rail mounted. Terminal blocks and terminal accessories shall be Phoenix Contact, Entrelec, or equal. 31 5-3 EXECUTION 31 5-3.01 Installation. A. General 1. The instrumentation and necessary equipment shall be installed in accordance with the manufacturer's instructions and located as shown on the Drawings or as approved by the Engineer. When manufacturer's installation literature specifies a particular location or orientation in a process line because of measurement accuracy considerations, the installation shall be in conformance with the manufacturer's instructions. 2. All piping to and from field instrumentation shall be provided with test tees and shutoffs. B. Equipment Mounting 1. Field instruments shall be mounted on 2-inch pipe stands unless shown adjacent to a wall or otherwise noted. Instruments attached directly to concrete shall be spaced out from the mounting surface not less than 1/2-inch. Unless othetwise noted, field instruments shall be mounted between 48-in and 60-in above the floor or work area. C. Telemetry Equipment 1. The Contractor shall install the telemetry equipment per the drawings, specifications, and radio survey. 2. Following installation of the telemetry equipment and programming of the PLC's by the District, the ISS shall test the system as noted below. 7131102 Contract No. 3907 Page 381 of 414 31 5-3.02 Configuration. A. 6. C. Communications between the vault and the Operations Building will be on a report by exception basis. Report by exception is defined as follows: The remote site PLC continuously monitors it’s field I/O for changes. Changes in the state of a discrete input or changes in analog values that exceed predefined limits may be considered alarm conditions. When an alarm condition is first detected the remote site PLC will immediately cue up a message and send it to the master PLC located at the Operations Office. Restrictions are built into the PLC code that prevent repeats of the same alarm from being sent more often than once every 30 seconds. When no alarms are present the remote site PLC shall cue up a status message (health check) once every 150 to 200 seconds and send it to the Master PLC. All messages sent from the PLC shall contain a watchdog value that is used by the Master PLC to determine communication failure. The PLC shall communicate with the Schlumberger radio using DF1 Protocol. 31 5-3.03 Grounding. General: Grounding cable shall be sized by the Contractor in accordance with code requirements when sizes are not specifically called for on the Drawings. The location of ground rods shall be as shown. The length of rods forming an individual ground amy shall be equal in length and shall be of the quantity required to obtain a ground resistance of no more than 5 ohms. Equipment Ground: Ground continuity throughout the facility shall be maintained by installing an electrically- continuous metallic raceway system, or a non-metallic raceway with a grounding conductor when non- metallic raceway is permitted in the Contract Documents. Metallic raceway shall be installed with double lock nuts or hubs at enclosures. Nonmetallic raceway containing dc conductors operating at more than 50 volts to ground, or any ac conductors, shall contain a copper grounding conductor either bare, or green if insulated. Such conductor shall be bonded to terminal and intermediate metallic enclosures. Grounding Electrode System: The Contractor shall install the grounding electrode system with all required components in accordance with National Electrical Code Article 250. Connection to ground electrodes and ground conductors shall be exothermic welded where concealed and shall be bolted pressure type where exposed. Bolted connectors shall be assembled wrench-tight. Insulated rounding bushings shall be employed for all grounding connections to steel conduits in switchboards, in motor control centers, in pullboxes, and elsewhere where conduits do not terminate at a hub or a sheet metal enclosure. Where insulated bushings are required, they shall be installed in addition to double lock-nuts. Copper bonding jumpers shall be used to obtain a continuous metallic ground. 31 5-3.04 Raceways. General: Raceways shall be installed as shown, however, conduit routings shown are diagrammatic. Raceway systems shall be electrically and mechanically complete before conductors are installed. Bends and offsets shall be smooth and symmetrical, and shall be accomplished with tools designed for the purpose intended. Factory elbows shall be used for all 3/4-inch conduit. Bends in larger sizes of metallic conduit shall be accomplished by field bending or by the use of factory elbows. All installations shall be in accordance with the latest edition of the National Electrical Code. - Raceways shall be installed in accordance with the following schedule: Rigid Schedule 40 PVC shall be used for concrete encased duct on earth. PVCaated galvanized rigid steel raceways shall be used on exposed locations in corrosive areas. Q 7/31/02 Contract No. 3907 Page 382 of 414 Galvanized rigid steel (GRS) shall be used on exposed installations in general purpose areas. Rigid Schedule 40 PVC shall be used for conduits embedded in concrete slab on grade and above grade. Rigid Schedule 40 PVC shall be used for area lighting circuits and may not be concrete encased. Galvanized rigid steel shall be used in exposed installations in outdoor areas. Conduits shall be rigidly supported with clamps, hangers, and Unistrut channels. Intervals between supports shall be in accordance with the National Electric Code. Conduit Terminations: Empty conduit terminations not in pullboxes shall be plugged. Exposed raceway shall be installed perpendicular or parallel to buildings except where otherwise shown. Conduit shall be terminated with flush couplings at exposed concrete surfaces. Conduit stubbed up for floor-standing equipment shall be placed in accordance with approved shop drawings. Metallic raceways installed below- grade or in outdoor locations and in concrete shall be made up with a conductive waterproof compound applied to threaded joints. Compound shall be Zinc Clads Primer Coatings No. B69A45, HTL-4 by Crouse- Hinds, Kopr Shield by Thomas & Betts, or approved equal. Conduit Installations: Conduit may be cast integral with horizontal and vertical concrete slabs, providing one-inch clearance is maintained beheen conduit surface and concrete surface. If said clearance cannot be maintained, the conduit shall be installed exposed below elevated slabs; provided, that in the case of slabs on grade, conduit shall be installed below the slab and shall be encased with a minimum cover of 3 inches of concrete. Maximum size of conduit that can be cast in slab above grade shall be 3 inches, in slab on grade shall be 1-1/2 inches. Non-metallic conduit when specified may be cast integral with horizontal slabs with placement criteria as.stated in the previous paragraph. Non-metallic conduit may be run beneath structures or slabs on grade, without concrete encasement. In these instances conduit shall be placed at least 12 inches below the bottom of the structure or slab. Non- metallic conduit may be buried 24 inches minimum below grade, with a 3-inch concrete cover, in open areas or where otherwise not protected by concrete slab or structures. Non- metallic conduit shall be permitted only as required by the Specifications and in concealed locations as described above. Where a run of concealed PVC conduit becomes exposed, a transition to rigid steel conduit is required. Such transition shall be accomplished by means of a factory elbow or a minimum 3-foot length of rigid steel conduit, either terminating at the exposed concrete surface with a flush coupling. Piercing of concrete walls by non-metallic runs shall be accomplished by means of a short steel nipple terminating with flush couplings. Flexible conduit shall be used at dry locations for the connection of equipment such as motors, transformers, instruments, valves, or pressure switches subject to vibration or . movement during normal operation or servicing. Flexible conduit may be used in lengths required for the connection of recessed lighting fixtures; otherwise the maximum length of flexible conduit shall be 18 inches. Connections shall be made using flexible liquid-tight conduit. Equipment subject to vibration or movement which is normally provided with wiring leads, such as solenoid valves, shall be installed with a cast junction box for the make-up of connections. Flexible conduits shall be as manufactured by American Brass, Cablec, Electroflex, or approved equal. G 7/31/02 Contract No. 3907 Page 383 of 414 Conduit penetrations on walls and concrete structures shall be performed in accordance with the following: a. Seal all raceways entering structures at the first box or outlet with oakum or suitable plastic expandable compound to prevent the entrance into the structure of gases, liquids, or rodents. b. Dry pack with nonshrink grout around raceways that penetrate concrete walls, floors, or ceilings aboveground, or use one of the methods specified for underground penetrations. c. Where an underground conduit enters a structure through a concrete roof or a membrane waterproofed wall or floor, provide an acceptable, malleable iron, watertight, entrance sealing device. When there is no raceway concrete encasement specified or indicated, provide such device having a gland type sealing assembly at each end with pressure bushings which may be tightened at any time. When there is raceway concrete encasement specified or indicated, provide such a device with a gland type sealing assembly on the accessible side. Securely anchor all such devices into the masonry construction with one or more integral flanges. Secure membrane waterproofing to such devices in a permanently watertight manner. d. Where an underground raceway without concrete encasement enters a structure through a nonwaterproofed wall or floor, install a sleeve made of Schedule 40 galvanized pipe. Fill the space between the conduit and sleeve with a suitable plastic expandable compound, or oakum and lead joint, on each side of the wall or floor in such a manner as to prevent entrance of moisture. A watertight entrance sealing device as specified may be used in lieu of the sleeve. 31 5-3.05 Wires And Cables. Conductors of No. 1 size and smaller shall be hand pulled. Larger conductors may be installed using power winches. Pulling tensions on the cables shall be within the limits recommended by the cable manufacturer. Wire pulling lubricant, where needed, shall be UL approved. Wire in panels, cabinets, and gutters shall be neatly grouped using nylon tie straps, and shall be fanned out to terminals. Splices and Terminations: The Contractor shall provide, install, and terminate the conductors required for power and controls to electrical equipment and to interconnect incoming annunciator, instrumentation terminal cabinets, control and instrumentation equipment specified in any section of these specifications except as may be otherwise specified in other sections. There shall be no cable splices in underground manhole or pullboxes. Control conductors shall be spliced or terminated only at the locations shown and only on terminal strips or terminal lugs of vendor furnished equipment. "Control Conductors" are defined as conductors operating at 120-volts or less in circuits that indicate equipment status or that control the electric energy delivered to a power consuming device. Solid conductors shall be terminated at equipment terminal screws with proper care that . conductor is tightly wound around screw and does not protrude beyond screw head. Stranded conductors shall be terminated directly on equipment box lugs making sure that all conductor strands are confined within lug. Use forked-tongue lugs where equipment box lugs have not been provided. Splices in 600-volt wire which are not pre-insulated shall be insulated with three layers of tape each half lapped except that splices in below grade pull boxes or in any box subject to flooding shall be made watertight using an epoxy resin splicing kit. e 7/31/02 Contract No. 3907 Page 384 of 414 Splices to motor leads in motor terminal boxes shall be wrapped with mastic material to form a mold and then shall be taped with a minimum of two layers of varnished cambric tape overtaped with a minimum of two layers of high temperature tape. Control devices, such as solenoid operated valves, which are normally supplied with conductor pigtails, shall be terminated as described for control conductors. Continuity Test: All control and instrumentation cables shall be tested for continuity, polarity, undesirable ground, and origination. Such tests shall be performed prior to placing all cables in service. 31 5-3.06 Cable And Equipment Identification. 315-3.06.1 General. The completed electrical installation shall be provided with adequate identification to facilitate proper control of circuits and equipment and to reduce maintenance effort. 315-3.06.2 Cable. The Contractor shall assign to each control and instrumentation wire and cable a unique identification number. Said numbers shall be assigned to all conductors having common terminals and shall be shown on all shop drawings. Identification numbers shall appear within 3 inches of conductor terminals. "Control" shall be defined as any conductor used for alarm, annunciator, or signal purposes: All 120/24O-voh system feeder cables and branch circuit conductors shall be color coded as follows: Line A-black, Line B-red, and Neutral-white. Color coding tape shall be used where colored insulation is not available. Branch circuit switch shall be yellow. Insulated ground wire shall be green, and neutral shall be gray. Color coding and phasing shall be consistent throughout the site, bus bars at panelboard shall be connected Line A-B, top to bottom, or left to right, facing connecting lugs. General purpose ac control cables shall be pink. General purpose dc control cables shall be blue. All spare cables shall be terminated on terminal screws and shall be identified with a unique number as well as with destination. Terminal strips shall be identified by imprinted, varnished, marker strips attached under the terminal strip. 315-3.06.3 Equipment. Equipment and devices shall be identified as follows: Nameplates shall be provided for all panelboards, panels, starters, switches, and pushbutton stations. In addition to the name plates shown, control devices shall be equipped with standard collar-type legend plates. Control devices within enclosures shall be identified as shown. Identification shall be similar to the paragraph above. Toggle switches which control loads out of sight of switch, and all multi-switch locations of more than 2 switches, shall have suitable inscribed finish plates. Empty conduits shall be tagged at both ends to indicate the destination at the far end. Where it is not possible to tag the conduit, destination shall be identified by marking an adjacent surface. The Contractor shall provide typewritten circuit directories for panelboards; circuit directory shall accurately reflect the outlets connected to each circuit. 4w Vd 7/31/02 Contract No. 3907 Page 385 of 414 The Contractor shall install identification tape directly above buried unprotected raceway; install tape 8 inches below grade and parallel with raceway to be protected. Identification tape is required for all buried raceway not under buildings or equipment pads except identification tape is not required for protection of street lighting raceway. c-z . 315-4 TELEMETRY - INSTALLATION AND INSPECTION .315-4.1 General. Inspect each instrument and piece of equipment for damage, defects, completeness and correct operation before installing. Inspect previously installed related work and verify that it is ready for installation of instruments and equipment. 315-4.2 Preparation. Ensure that installation areas are clean and that concrete or masonry operation are completed prior to installing instruments and equipment. Maintain the areas in a broom-clean condition during installation operations. 315-4.3 Instrument Calibration. Provide the services of factory trained instrumentation technicians, tools and equipment to field calibrate each instrument to its specified accuracy in accordance with the manufacturers specifications and instructions for Calibration. Each instrument shall be calibrated at 0 percent, 50 percent and 100 percent of span using test instruments to simulate inputs and read outputs that are rated to an accuracy of at least 5 times greater than the specified accuracy of the instrument being calibrated. Such test instruments shall have accuracies traceable to the National Bureau of Standards, as applicable. Provide a written report to the District on each instrument certifying that it has been calibrated to its published specified accuracy. This report shall include a listing of the published specified accuracy, permissible tolerance at each point of calibration, calibration reading as finally adjusted within tolerances, defects noted, correction action required and correction made. This requirement does apply to all Analog Inputs to the system even though others furnish the devices. Provide certified calibration stamps on instruments with calibration date and next required calibration date. 315-4.4 System Validation. Provide the services of factory trained and field experienced control system engineer(s) to validate each system is operational and performing its intended function. During system validation, make provisional settings on level, alarms, etc. Cause malfunctions to sound alarms or switch to standby to check system operation. Check all systems thoroughly for correct operation. Test equipment for this function shall be specified under "Instrument Calibration". Immediately correct all defects and malfunctions disclosed by tests. Use new parts and materials as required and approved and retest. Provide a report certifying completion of system validation. This report shall indicate that the system meets the complete intent of these specifications. 315-4.5 Final Operational Testing and Acceptance. Upon completion of system validation, test all systems under process conditions. The intent of this test is to demonstrate and verify the operational interrelationship of the system. This testing shall include, but not be limited to, taking process variables to their limits (simulated or process) at the field device to verify all wiring, alarms, failure interlocks, and operational interlocks between systems and/or mechanical equipment. Immediately correct defects and malfunctions with approved methods and materials in each case and repeat the testing. Upon completion of final operational testing, submit certified report indicating that the installation meets all the functional requirements specified herein. Upon agreement that the system is operational and acceptable, the Engineer shall countersign this report and it shall constitute final acceptance of the system. 7/31/02 Contract No. 3907 Page 386 of 414 Testing shall be observed by the Owner or his representative. Notify the Owner in writing a minimum of 72 hours prior to the proposed date for commencing the test. Upon completion of this test the Contractor shall begin or have begun system startup. A. B. C. D. All tests shall be witnessed by the District or it's representative. All tests shall be in conformance with the approved test plans. The ISS shall furnish the services of the manufacturer's service representative, all special tools, calibration equipment and labor to perform the tests. Certified copies of the tests shall be fum- ished in duplicate to the Engineer. All telemetry systems shall be tested to verify that all connected points are correctly received to the satisfaction of the Engineer. The ISS shall make any corrections required at the pressure reducing station, as applicable. 1. The ISS shall coordinate with the District as required to test both the PLC/modem system and the radio telemetry systems. Following initial checkout, the telemetry systems shall be tested on-line for a period of one week. If, during running of the tests, any communication problems occur or any other problems surface with the equipment specified under this section, the manufacturer's field engineer shall make such adjustments or alterations as are necessary to bring equipment up to specification performance. Following such adjustment, the test shall be repeated to insure compliance 31 54.6 Start-up Service. A. The ISS and/or manufacturer of the equipment and accessories supplied in this Section shall include in his contract price the following to be done by a qualified service representative. 1. Checking the installation of all components before power is applied. 2. Placing the equipment into operation and making necessary adjustments. 3. Instruction of the District personnel in the use, operation and maintenance of all equipment shall be provided by a service technician authorized by and factory trained by the particular manufacturer of the equipment for which he will provide instruction. Instruction shall be performed in accordance with the approved training plan. 3154.7 instruction of Engineer. Provide the services of a factory trained and field experienced instrumentation engineer to conduct group training of designated personnel in the operation of each instrument system. This training shall be for the time period of at least 1 day and shall be performed during the operational testing period. Include instruction covering basic system theory, operating principals and adjustments, routine maintenance and repair, and "hands on" operation. The text for this training shall be the operation and maintenance manuals furnished under these specifications. Supplemented text prepared outlining actual operation of the system in practical application. 315-4.8 Mountings. Mount field instruments on pipe mounts or other similar means in accordance with suppliers recommendation. Equipment specified for field mounting shall be suitable for direct pipe mounting or surface mounting, surface-mounted indicators and equipment with calibration adjustments or requiring periodic inspection shall be mounted not lower than 3 feet 6 inches, nor higher than 6 feet above walkways, platforms, catwalks, and the like, unless shown or specified. - All devices shall be accessible to the Engineer for servicing, operating, reading, etc. 7/31/02 Contract No. 3907 Page 387 of 414 SECTION 31 6 - EXISTING HIGHWAY FACILITIES *’ Add the following section: 31 6-1 BRIDGE REMOVAL Add the following section: 316-1.1 General. This work shall consist of removing existing bridges, or portions thereof. The type and general dimensions of the bridges or portions of bridges to be removed is shown on the plans and described in these Special Provisions. When portions of bridges are to be removed, the removal operations shall be conducted so that there will be the least interference to public traffic using the structure involved. When complete bridges are to be removed, removal operations shall not be started until public traffic is no longer routed over the structure to be removed. At least 20 days before beginning bridge removal the Contractor shall submit a complete bridge removal plan to the Engineer per Section 2-5.3.3 detailing procedures and sequence for removing portions of bridge, including all features necessary to remove the bridges in a safe and controlled manner. Prior to removal of the existing bridge the Contractor shall create an area approximately 10 (ten) feet wide and 10 (ten) feet high with dry substrate material, that has visual access from end to end, to allow wildlife movement. The area shall be maintained during removal operations. The bridge removal plan shall be furnished for the existing bridge over San Marcos Creek and shall include the following: The bridge removal sequence for the entire structure, including staging of bridge removal; Equipment locations on the structure during removal operations; Temporary support shoring or temporary bracing; Details and locations of protective covers or other measures to assure that people, property and improvements will not be endangered. Details to assure that the requirements of all applicable permits are satisfied. Temporary support shoring, temporary bracing, and protective covers as required, shall be designed and constructed in conformance with the provisions in Section 303-1.6, “Falsework,” of the Standard Specifications. The assumed horizontal load to be resisted by the temporary support shoring, and temporary bracing, for removal operations only, shall be the sum of the actual horizontal loads due to equipment, construction sequence or other causes and an allowance for wind, but in no case shall the assumed horizontal load to be resisted in any direction be less than 5 percent of the total dead load of the structure to be removed. The Contractor shall submit to the Engineer working drawings, with design calculations, for the proposed bridge removal plan. The bridge removal plan shall be prepared by an engineer who is registered as a Civil Engineer in the State of California. The design calculations shall be adequate to demonstrate the stability of the structure during all stages of the removal operations. Calculations shall be provided for each stage of bridge removal and shall include dead and live load values assumed in design of protective cover. At a minimum, a stage will be considered to be removal of the deck, the soffit, or the girders, in any span; or walls, bent caps or columns at support locations. e 7/31/02 Contract No. 3907 Page 388 of 414 Acceptance by the Engineer of the bridge removal plans or field inspection performed by the Engineer will in no way relieve the Contractor of full responsibility for the bridge removal plan and procedure. Prior to proceeding with bridge removal where bridge removal plan is required, an engineer for the Contractor who is registered as a Civil Engineer in the State of California shall inspect the temporary support shoring, including temporary bracing and protective coverings, for conformity with the working drawings. The Contractor's registered engineer shall certify in writing that the temporary support shoring, including temporary bracing and protective coverings, substantially conform to the details on the working drawings, and that the material and workmanship are satisfactory for the purpose intended. A copy of this certification shall be available at the site of the work at all times. The Contractor's registered engineer shall be present at the bridge site where bridge removal plan is required at all times when bridge removal operations are in progress. The Contractor's registered engineer shall inspect the bridge removal operation and report in writing on a daily basis the progress of the operation and the status of the remaining structure. A copy of the daily report shall be available at the site of the work at all times. Should an unplanned event occur, the Contractor's registered engineer shall submit immediately to the Engineer for approval, the procedure of operation proposed to correct or remedy the occurrence. The Contractor shall provide and maintain adequate safety measures in accordance with Section 7-10, "Public Convenience and Safety" and these Special Provisions. Whenever the Contractor's operations create a condition hazardous to traffic or to the public, he shall, at his expense and without cost to the City, furnish, erect and maintain such fences, temporary railing (Type K), barricades, lights, signs and other devices and take such other protective measures as are necessary to prevent accidents or damage or injury to the public. Such fences, temporary railing (Type K), bamcades, lights, signs, and other devices furnished, erected and maintained by the Contractor, at his expense, are in addition to any construction area traffic control devices for which payment is provided for elsewhere in the specifications. Add the following section: 316-1.2 Preservation of Property. Existing facilities which are to remain in place shall be protected in accordance with Section 7-3, "Liability Insurance," Section 5-2, "Protection," and these Special Provisions. The work involved in Potholing Existing Utilities shall adhere to Section 5-1 of the SSPWC and these special provisions. Due care shall be exercised to avoid injury to existing highway improvements or facilities, utility facilities, adjacent property, and roadside trees, shrubs, and other plants that are not to be removed. Roadside trees, shrubs, and other plants that are not to be removed, and pole lines, fences, signs, markers and monuments, buildings and structures, conduits, pipelines under or above ground, sewer and water lines, all highway facilities, and any other improvements or facilities within or adjacent to the highway shall be protected from injury or damage, and if ordered by the Engineer, the Contractor shall provide and install suitable safeguards, approved by the Engineer, to protect such objects from injury or damage. If such objects are injured or damaged by reason of the Contractor's operations, they shall be replaced or restored at the Contractor's expense. The facilities shall be replaced or restored to a condition as good as when the Contractor entered upon the work, or as good as required by the specifications accompanying the contract, if any such objects are a part of the work being performed under the contract. The Engineer may make or cause to be made such temporary repairs as are necessary to restore to service any damaged highway facility. The cost of such repairs shall be borne by the Contractor and may be deducted from any moneys due or to become due to the Contractor under the contract. - Q4i % 7/31/02 Contract No. 3907 Page 389 of 414 The fact that any underground facility is not shown upon the plans shall not relieve the Contractor of his responsibility under Section 5, 'Utilities." It shall be the Contractor's responsibility, pursuant thereto, to ascertain the location of such underground improvements or facilities which may be subject to damage by reason of his operations. Full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in protecting or repairing property as specified in these Special Provisions, shall be considered as included in the prices paid for the various contract items of work and no additional compensation will be allowed therefor. 316-1.3 Removal Methods. Materials that are to be salvaged shall be carefully removed and stockpiled near the site at a location designated by the Engineer. Stockpiled areas shall be located as far as practical from occupied dwellings. Material which is to be salvaged or used in the reconstructed bridge work and has been damaged or destroyed as a result of the Contractor's operations, shall be repaired or replaced by the Contractor at his expense. All removed materials that are not to be salvaged or used in the reconstruction shall become the property of the Contractor and shall be disposed outside the highway right of way in accordance with the provisions in Section 31 6-1.4, "Disposal of Material Outside the Highway Right of Way," of these Special Provisions. Piling, piers, abutments and pedestals shall be removed to at least one foot below ground line or 3 feet below finished grade, whichever is lower. Flame cutting and saw cutting may be used for removing, widening, or modifying bridges provided the Contractor complies with all protection, safety and damage requirements. Explosives shall not be used for bridge removal. A freely falling mass or a falling mass attached to a cable, rope or chain shall not be used above any area open to the public. Such falling masses shall not be used within 30 feet horizontally of any area open to the public unless adequate protective shields are in place. Protective shields shall be of sufficient size and strength to prevent any debris or equipment from endangering the public. The shields shall be designed and proportioned as required by the size of equipment and method of operations employed, but in no case shall such shields have a strength less than that provided by good, sound 2- inch thick Douglas fir planking supported on posts at 5-fOOt centers. Unless othenrvise provided in the Special Provisions, removed concrete may be buried in adjacent embankments with approval of the Engineer, provided it is broken into pieces which can be readily handled and incorporated into embankments and is placed at a depth of not less than 3 feet below finished grade and slope lines. The removed concrete shall not be buried in areas where piling is to be placed or within 10 feet of trees, pipelines, poles, buildings or other permanent objects or structures, unless permitted by the Engineer. Should the Contractor elect or be required by the Special Provisions to dispose of such material outside the highway right of way, he shall conform to the provisions in Section 316-1.3, "Disposal of Material Outside the Highway Right of Way." Add the following section: 316-1.4 Disposal of Material Outside the Highway Right of Way. If the Contractor elects to dispose of materials at locations other than those where arrangements have been made by the Agency, or, if material is to be disposed of and the Agency has not made arrangements for disposal of such material, the Contractor shall make his own arrangements for disposing of materials outside the highway right of way and he shall pay all costs involved. Arrangements shall include, but not be limited to, entering into agreements with property owners and obtaining necessary permits, licenses and environmental 7131102 Contract No. 3907 Page 390 of 414 clearances. Before disposing of any material outside the highway right of way, the Contractor shall furnish to the Engineer satisfactory evidence that he has entered into agreements with the property owners of the site involved and has obtained said permits, licenses and clearances. When any material is to be disposed of outside the highway right of way, and the Agency has not made arrangements for disposal of such material, the Contractor shall first obtain written authorization from the property owner on whose property the disposal is to be made and he shall file with the Engineer said authorization or a certified copy thereof together with a written release from the property owner absolving the City from any and all responsibility in connection with the disposal of material on said property, and . before any material is disposed of on said property, the Contractor shall obtain written permission from the Engineer to dispose of the material at the location designated in said authorization. When material is disposed of as above provided and the disposal location is visible from a highway, the Contractor shall dispose of the material in a neat and uniform manner to the satisfaction of the Engineer. Where the Agency has made arrangements with owners of land in the vicinity of a project for the disposal of materials on an owner's property, such arrangements are made solely for the purpose of providing all bidders an equal opportunity to dispose of said materials on such property. Bidders or Contractors may, upon written request, inspect the documents evidencing such arrangements between property owners and the City. The Contractor may, if he so elects, exercise any rights that have been obtained, which may be exercised by a Contractor under such arrangements, subject to and upon the conditions hereinafter set forth. Such arrangements are not a part of the contract and it is expressly understood and agreed that the Agency assumes no responsibility to the bidder or Contractor whatsoever in respect to the arrangements made with the property owner to dispose of materials thereon and that the Contractor shall assume all risks in connection with the use of such property, the terms upon which such use shall be made, and there is no warranty or guaranty, either express or implied, as to the quantity or types of materials that can be disposed of on such property. The bidder or Contractor is cautioned to make such independent investigation and examination as he deems necessary to satisfy himself as to the quantity and types of materials which may be disposed of on such property and the rights, duties and obligations acquired or undertaken under such arrangement with the property owner. Notwithstanding that the Contractor may elect to dispose of materials on any such property owner's property, no material may be disposed of on such property unless the Contractor has first either: (1) Executed a document that will guarantee to hold such owner harmless from all claims for injury to persons or damage to property resulting from the Contractor's operations on the property owner's premises and also agree to conform to all other provisions set forth in the arrangement made between the Department and the property owner. Said document will be prepared by the Engineer for execution by the Contractor, or (2) Entered into an agreement with the owner of the disposal site on any terms mutually agreeable to the owner and the Contractor; provided that the Contractor shall furnish to the Engineer a release, in a form satisfactory to the Engineer, executed by the owner, relieving the Agency of any and all obligations under the Agency's arrangement with the owner. If the Contractor elects to dispose of material under (I), the use of such site shall be subject to the terms, conditions and limitations of the arrangement made between the property owner and the Department and the Contractor shall pay such charges as are provided for in the arrangement made by the Department with the property owner, and deductions will be made from any moneys due or that may become due the Contractor under the contract sufficient to cover the charges for such material disposed of. If the Contractor elects to dispose of material under (2), he shall pay such charges as are provided for in 7/31/02 Contract No. 3907 Page 391 of 414 the agreement between the owner and the Contractor and deductions will not be made from any moneys due or that may become due the Contractor under the contract to cover such charges. Before acceptance of the contract, the Engineer may require the Contractor to submit written evidence that the owner of the disposal site is satisfied that the Contractor has satisfactorily complied with the provisions of either - (l), the arrangement between the Department and the owner, or (2). the agreement between the owner and the Contractor, as the case may be. Full compensation for all costs involved in disposing of materials as specified in these Special Provisions, including all costs of hauling, shall be considered as included in the price paid for the contract item of work involving such materials and no additional compensation will be allowed therefor. 316-1.5 Payment. The work to be performed in Section 31 6-1, "Bridge Removal," will be paid for on a lump sum basis as Remove and Dispose of Existing Bridge. The above prices and payments shall include full compensation for furnishing all labor, materials, tools, equipment and incidentals, and for doing all the work involved in removing bridges or portions thereof, in- cluding excavation, backfill, and salvaging materials not to be reused in the project when such salvaging is specified and not otherwise paid for, and creating and maintaining an area of dry substrate to allow wildlife movement, as shown on the plans, as specified in the specifications and these Special Provisions, and as directed by the Engineer. Full compensation for removing and salvaging materials that are to be reused in the project shall be considered as included in the lump sum price paid for remove and dispose of existing bridge, or in such other contract pay items that may be designated in the Special Provisions, and no additional compensation will be allowed therefor. SECTION 317 - ELECTRICAL FOR RECYCLED WATER METERING STATION 317-1 GENERAL 317-1.01 Scope Of Work. The Contractor shall provide all electrical materials and labor to satisfactorily complete all electrical work shown on the Drawings, specified, or neither shown nor specified but necessary for a complete and fully operating recycled water metering station facility. 317-1.02 Quality Assurance. A. Electrical equipment, materials, and installation methods shall conform to all applicable local and state codes as well as the editions of the following in effect on the date of issuance of the Contract Documents. 1. National Electrical Code (NEC) 2. National Electrical Safety Code (NESC) 3. Occupational Safety and Health Act (OSHA) Standards B. Equipment shall conform to the following applicable standards. The revisions of these standards in effect on the date of issuance of the Contract Documents shall apply to the extent referenced herein. 1. American National Standard Institute (ANSI) 2. Institute of Electrical and Electronics Engineers (IEEE) 3. National Electrical Manufacturers Association (NEMA) 4. Instrument Society of America (ISA) e b$ 7/31/02 Contract No. 3907 Page 392 of 414 5. National Fire Protection Association (NFPA). C. UL listing is required for all equipment and materials where such listing is offered by the Underwriters Laboratories. Safety labeling and listing by other organizations, such as ETL Testing Laboratories, may be substituted for UL labeling and listing if acceptable to the authority having code enforcement jurisdiction. D. Provide equipment with service entrance labels in those cases where the NEC requires such labels. E. Series short circuit ratings for protective devices are not allowed. 317-1.03 Drawings. A. The Electrical Drawings are diagrammatic; exact locations of products shall be determined in the field by the Engineer. B. The Contractor shall submit in writing to the Engineer details of any proposed changes in or departures from these contract documents along with the reasons for the change. Make no changes or departures without the prior written favorable review of the Engineer. C. The Contractor shall maintain a set of As-built Drawings which document all changes made. Upon completion of the work, transfer these changes to a clean set of full size Drawings with red ink to indicate additions and green ink to indicate deletions. Submit these full size Drawings to the Engineer. 317-1.04 Submittals. A. Manufacturers' trade names and catalog numbers stated herein are intended to indicate the type and quality of equipment desired. Unless substitution is specifically forbidden, proposed alternates may be submitted for favorable review. Provide sufficient data to allow determination of compliance with these contract documents. List any proposed deviations from these contract documents. B. The Contractor shall submit a single, complete submittal package for all products on the following list. Submit in accordance with the Product Review category of the General Conditions. Submittal package shall be organized by equipment type. Include separators and tabs or other means of identifying each item. 1. Service Pedestal 2. Flowmeter (See Section 17000) 3. Level Switch (See Section 17000) 4. Pressure Transmitter (See Section 17000) 5. Remote Terminal Unit (See Section 17000) C. For the equipment listed in ParagraphB above and pursuant to the seismic anchorage requirements, submit a sketch or description of the anchorage system. D. Operation and Maintenance Manuals: The Contractor shall furnish Operation and Maintenance Manuals, including Instruction Manuals and Part Lists, for equipment provided under this Section. Obtain data from manufacturers, and format and bind as specified. Obtain distribution method instructions from the Owner or his representative. 1. Schedule: Deliver at least two (2) copies of manuals in 3-ring binders (8-112 by 1 l-inch format) not later than the equipment shipment date. 2. Contents: Include in manuals not less than the following information, as applicable, for each instrument, equipment, subsystem and/or control loop: e 7/31/02 Contract No. 3907 Page 393 of 414 a. b. C. d. e. f. 9. h. 1. General, introduction and overall description, purpose, functions, simplified theory of Specifications (including equipment specification data sheet as described above under Shop Drawings), sufficiently detailed for reordering exact duplicates of the original items. Installation instructions, procedures, sequences, tolerances, and precautions. Operational procedures. Shutdown procedures. Maintenance, calibration, and repair instructions. Parts list and spare parts recommendations. As-built Drawings. Software programs (RTU Ladder Logic, BASIC, or Source Code). operations, etc. .-. 3. Format: a. Use Drawings and pictorials to illustrate the text to the extent necessary to insure a clear, concise presentation. If manuals have been written to cover a family of similar instruments or equipment, strike out inapplicable information in a neat fashion or emphasize applicable portion by heavily weighted arrows, circles or boxes; whichever provides the clearest and neatest presentation. b. Group manuals by system control panels, including field instrumentation connected or associated with the panel. Where identical instruments are used in more than one control loop or subsystem, include only one instruction manual, per panel grouping; however, an index by tag number for all instruments shall identify its location in that manual. c. Provide control loop and/or subsystem operational descriptions to identify the function of each instrument and its relation to the other instruments in the loop. 4. Binding: Bind each manual in a cover which indicates the panel or process area to which it applies, manufacturer's name, local address and telephone number, and year of purchase. Punch and bind manuals in standard three ring binders and include system name and subcontractor's name on binding. E. As-Built Drawings: Submit a revised set of Contract Drawings that incorporates all change orders and modifications made during performance of the work. In addition to updated loop diagrams, interconnect diagrams and elementary diagrams, submit equipment and device wiring diagrams and other sketches as necessary to depict the "as-built" condition of equipment. 31 7-1.05 Locations. A. The Contractor shall provide equipment, materials, and wiring methods suitable for the locations in which they are to be installed, as defined in Paragraph B herein. B. Definitions of Types of Locations: 1. Dry locations: All those indoor areas which do not fall within the definitions below for wet or damp locations and which are not otherwise designated on the Drawings. 2. Wet Locations: All locations exposed to the weather, either under a roof or not, unless otherwise designated on the Drawings. 3. Damp locations: All indoor spaces wholly or partially underground, or having a wall or ceiling forming part of a channel or tank, unless otherwise designated on the Drawings. C. Unless specified otherwise in Part 2, provide enclosures as follows: 1. Dry Locations: NEMA 12 @ 7/31/02 Contract No. 3907 Page 394 of 414 2. Wet Locations: NEMA 4 or 3R 3. Damp Locations: NEMA 12 31 7-1.06 Materials. A. The Contractor shall provide all first quality, new materials, free from defects, and suitable for the intended use and space. Where two or more units of the same class of material are required, provide products of a single manufacturer. B. Unless otherwise indicated, the Contractor shall provide materials and equipment that are the standard products of manufacturers regularly engaged in the production of such materials and equipment. Provide the manufacturer's latest ,standard design that conforms to these specifications. 317-2 PRODUCTS 317-2.01 Conduit And Wireways (Including Couplings, Elbows, And Nipples). A. The minimum size conduit shall be 3/4-inch. B. Galvanized Rigid Steel (GRS) conduit shall be hotdip galvanized after fabrication and shall conform to ANSI C80.1 and UL 6. C. PVC coated GRS shall conform to ANSI C80.1 and UL 6 and shall have a 40 mil thick PVC coating. D. Flexible conduit: Liquidtight with PVC jacket over galvanized flexible steel conduit. E. Rigid nonmetallic conduit: PVC Schedule 40, rated 9O"C, conforming to UL 651. F. For GRS and PVC coated GRS conduit systems, provide threaded fittings; set-screw type and compression type are not acceptable. G. Bushings shall be insulated type. Bushings for GRS and PVC coated GRS conduit systems shall be insulated grounding type. 317-2.02 Wire And Cable. A. All low voltage conductors shall be copper, Type THWN. B. Cable manufacturer shall be Okonite; Cablec; or equal. C. Twisted Shielded Pairs (TSP) shall be UL listed Type PLTC cable with two #18 AWG copper conductors, 2-inch or shorter lay, and 100% foil shield. Insulation shall be rated 600 volts. Provide Alpha; Dekoron; or equal. D. Conductors for equipment grounding shall be stranded copper sized to meet the NEC. Conductors shall have green Type TW insulation. 317-2.03 Outlet, Junction, And Pull Boxes. A. In dry and damp locations, provide sheet metal units conforming to UL 50 with hotdip galvanizing conforming to ASTM A1 23. B. In wet locations provide cast metal FS type units conforming to UL 514. 317-2.04 Wiring Devices. A. Receptacles shall be 20ampere, 125volt conforming to NEMA5-20. Color shall be brown 'in industrial areas and ivory or white in office and other areas. Devices shall have nylon composition face with a nylon or melamine body. Units shall comply with Federal 7/31/02 Contract No. 3907 Page 395 of 414 Specification W-C-596 and UL 498. Weatherproof receptacles shall be mounted in a cast metal box with gasketed, weatherproof, cast metal cover plate and a separate cap over each opening. Each cap shall be provided with a spring hinged flap, stainless steel springs and rubber gaskets. B. Line voltage switches shall be rated 20 amperes at 120 Vac. Units shall be quiet operating type. Handle color shall be brown industrial areas. Units shall conform to Federal Specification W-S- 896, UL 20, and NEMA WD1. C. Device plates shall be of the style and color to match the wiring devices. Plates shall conform to NEMA WD1, UL 514, ANSI C73 and Federal Specification W-P-4552. Plates and boxes on finished walls and in corrosive areas shall be nonmetallic or stainless steel. 317-2.05 Service Pedestal. A. B. C. D. E. F. G. H. General: The Contractor shall provide a free standing outdoor weatherproof service pedestal consisting of a meter compartment, load center compartment, and monitoring compartment. Enclosure: Enclosure shall be constructed of 12-gage steel, factory assembled and tested for NEMA 3R rating. The enclosure shall have three hinged doors with a window on one door to view utility metering. Provide wireways for utility and distribution circuits. The enclosure shall have a dry powder electrostatically applied coating baked at 380 deg F. The doors shall be lockable. Meter Compartment: The meter compartment shall consist of all components required by the electric utility for metering of the electrical service. The panel door shall be padlockable and shall include a meter viewing window. Load Center Compartment: The control cabinet shall be supplied with an 8-circuit load center and main disconnect breaker. Breakers shall be provided in the quantities and ratings shown on the drawings. Monitoring Compartment: The monitoring compartment shall contain the necessary components for providing a complete flow control facility. Components shall include, but not limited to the following: programmable logic controller (PLC), telephone backboard, and RTU equipment as shown on the drawings. The RTU shall be as described herein and in Section 17000. The Contractor shall provide the application for service and pay for all fees and costs for installation of service pedestal. Provide conduit for utility transformer and dedicated leased line. Coordinate with the Owner for additional requirements. Manufacturer: TESCO; or equal. 31 7-2.06 Underground Electrical Work. A. Materials: Conduits shall be as specified in Paragraph 2.01 I B. Comply with the requirements of General Order 128 of the California PUC. 31 7-2.07 Grounding. A. Ground rods shall be copper-clad steel, not less than 3/4-inch diameter by 10-foot length. B. Buried conductors shall be medium-hard drawn bare copper; all other conductors shall be soft drawn copper. C. Exposed ground connections shall be high copper alloy bolted pressure types. Buried connections and connections in ground rod boxes shall be exothermic weld type. . @ 7/31/02 Contract No. 3907 Page 396 of 414 .. D. Ground rod boxes shall be %inchdiameter by IZinchdeep precast concrete with hotdip galvanized traffic covers embossed with the words "Ground Rod". Assembly shall be suitable for AASHTO HS20 loading. 317-2.08 Control Devices. A. B. Control (CR) and alarm (AR) relays shall be machine tool type with convertible NEMAA600 contacts. Cutler-Hammer (Westinghouse) Type AR Series; Square D Class 8501, Type R; or Limit switch shall be provided to sense limiting position of equipment as shown on the Drawings. The limit switch shall be SPDT. The switch shall be rated for 5 amperes minimum at 120 VAC and shall be enclosed in a NEMA 4 housing. Provisions shall be made for a 1M-inch electrical conduit connection. Mounting brackets shall be fabricated appropriate to the mechanical equipment being monitored. Switch shall Square D XCK-J; or equal. equal. *. 31 7-3 EXECUTION 317-3.01 General. A. B. C. D. E. F. G. H. All work shall be performed by craftsmen skilled in their trade. All work shall present a neat, finished appearance. The Contractor shall install all equipment in strict accordance with the manufacturer's instructions unless directed otherwise by the Engineer. Wherever a conflict occurs between manufacturer's instructions, codes and regulations, or these contract documents, follow Engineer's decision at no additional cost to the Owner. Keep a copy of manufacturer's installation instructions on the job site available for review at all times. All indoor floor-mounted or freestanding electrical equipment shall be on 3-inch, reinforced concrete pads with nonshrink grout as required between concrete pad and equipment base. All equipment shall be level or plumb. The Contractor shall provide protection for materials and equipment and/or against loss or damage. Protect everything from the effects of weather. Prior to installation, store all items in indoor locations. In addition, items subject to corrosion under damp conditions, and items containing insulation such as transformers, motors and control, shall be stored in indoor, heated, dry locations. Following installation, protect materials and equipment from corrosion, physical damage, and the effects of moisture on insulation. Cap conduit runs during construction with manufactured seals. Keep openings in boxes or equipment closed during construction. Where existing equipment of any kind is removed or relocated, all exposed materials no longer needed, such as studs, straps, conduits, and wires, shall be removed. Where such equipment is removed from walls, floors, or other surfaces, the surface shall be repaired to conform to the finish of the surrounding surface in a neat and workmanlike manner by skilled craftsmen of the trades involved at no additional cost to the Owner. The Contractor shall lay out work carefully in advance. Do not cut or notch any structural member or building surface without specific approval of Engineer, Carefully carry out any cutting, channeling or drilling of floors, walls, partitions, ceilings, paving, or other surfaces required for the installation, support, or anchorage of conduit, raceways, or other electrical materials and equipment. Following such work, restore surfaces neatly to original condition using skilled craftsmen of the trades involved at no addition cost to the Owner. The Contractor shall keep the premises free from accumulation of waste material or rubbish. Upon completion of work, remove materials, scraps, and debris from premises and from interior and exterior of all devices and equipment. Touch up scratches, scrapes, or chips in interior and - 7/31/02 Contract No. 3907 Page 397 of 414 exterior surfaces of devices and equipment with finishes matching as nearly as possible the type, color, consistency, and type of surface of the original finish. 317-3.02 Condiut And Wireway. A. The Contractor shall install conduit types in accordance with Conduit Use Tables: B. C. D. F. G. H. I. J. K. L. M. N. t Provide ground wire sized per NEC requirements for all circuits. Signal circuits are those subject to radio-frequency interference or induced current. MSPs, TSPs, telephone cable, coaxial cable, and manufacturer's cables specially designed for low level signals are all presumed to be part of signal circuits. From pull-point to pull-point, the sum of the angles of all of the bends and offsets shall not exceed 270 degrees. Store rigid PVC conduit on a flat surface shielded from the sun. At all boxes and equipment, provide insulated type metallic grounding bushings for metallic conduits. Bond all conduits together to provide continuity of the equipment grounding system. Size bonding conductor per NEC. For connections to motors, transformers, valves, and any equipment subject to vibration or relative movement, provide flexible conduit in lengths of not less than 18 inches. Flexible conduit shall not be considered as a grounding conductor. Use flexible conduit only in exposed and accessible locations. Run all conduits exposed except in finished areas or as otherwise shown on the Drawings. Install all exposed conduits as unobtrusively as possible, avoiding windows, and run parallel to building lines. Install conduits so as not to interfere with the operation of valves or any other equipment, and keep at least 6 inches clear of any pipe or equipment which may operate at more than 100°F. Ream all GRS to remove burrs after cutting. Treat cut surfaces or damaged ends of all raceways with a corrosion-resistant coating such as Devcon Z, prepared by Subox Coatings; Galvanox Type I, prepared by Pedley-Knowles; or equal, following manufacturer's recommendations. Properly support all conduits as required by the NEC. Slope all underground conduits to provide drainage to a pullbox. After completing an underground conduit run, prove the integrity of the run by pulling through it a mandrel 1/4-inch smaller than the inside diameter of the raceway. In each handhole, pullbox, cabinet, or other equipment enclosure identify each conduit using the conduit number shown on the Drawings by means of a stamped brass tag affixed with stainless steel wire; where affixing tag is not feasible, identify conduits by stenciling. Stencil each exposed conduit for identification at least once in each room. . 317-3.03 Wire And Cable. A. For wire 600 volts or less, use type as follows: 1. Circuits for receptacles, switches, and light fixtures having screw-type terminals: solid copper sizes #12 and #10 AWG. 4- r(ls 7/31/02 Contract No. 3907 Page 398 of 414 B. C. D. E. F. - G. H. I. 2. Circuits for motors, power feeders, and power branch circuits: stranded copper #I2 AWG and larger. 3. Circuits for motor control: stranded copper #I4 AWG and larger. 4. Connections to fixtures in which the temperature may exceed the rating of branch circuit conductors: fixture wire. Provide color coding as follows: 1. Neutral: white or gray 2. Grounding conductor: green 3. Isolated ground conductor: green with orange tracer 4. Ungrounded conductors: a. 208Y/120V, 3 Phase: red, black, and blue b. 480Y/27N, 3 Phase: yellow, brown, and black c. 120/240V, 1 Phase: red and black Pulling Wires and Cables. The raceway construction shall be complete and protected from the weather before the conductors are pulled into it. Swab conduits before installing conductors. Exercise care in pulling wires and cables into conduits or wireways so as to avoid kinking, putting undue stress, or otherwise abrading or damaging them. No grease will be permitted in pulling conductors. Do not exceed conductodcable minimum bending radius. Install feeder cables in one continuous length without splices wherever possible. The Contractor shall provide an equipment grounding conductor, whether or not it is shown on the Drawings, in any flexible conduit or any raceway in which all or any portion of a run consists of non-metallic duct or conduit. For flexible conduit, an external bonding jumper is an acceptable alternative. In panels, bundle incoming wire and cables, ##6 AWG and smaller, lace at intervals not greater than 6 inches, neatly spread into trees, and connect to their respective terminals. Allow sufficient slack for alterations in terminal connections. For lacing use plastic cable ties or linen lacing twine. Lacing is not necessary where conductors are properly installed in plastic panel wiring duct. For cables crossing hinges, utilize extra flexible stranded wire, make up into groups not exceeding 12, and arrange so that they will be protected from chafing when the hinged member is present. Splices in wire and cable rated 600 volts or less: q. Solid conductors: Use insulated wire nuts. 2. Stranded conductors #I4 through ##8 AWG: Use crimp type connectors and insulating tape. 3. Stranded conductors, MAWG and larger: Use bolted pressure type connectors and insulating tape. 4. Splices in handholes: Use watertight epoxy resin splice kits. 5. Install all conductors without splices unless necessary as determined by the Engineer. All splices in pull boxes below grade shall be watertight. All cable must be kept dry and free of contaminants while storing, pulling and terminating. Terminate all low voltage stranded conductors using spade type terminals unless box lug terminals are on the equipment. Identify each wire or cable at each termination point using preprinted heat-shrinkable wire markers. Use only soapstone, talc, or UL listed pulling compound. -* % 7/31/02 Contract No. 3907 Page 399 of 414 J. K. L. M. N. 0. P. Q. R. S. Signal cable shall be installed by personnel who have had a minimum of 3 years experience in terminating and splicing twisted shielded conductors and co-axial cables. Adequate care shall be exercised by the installers to prevent cable damage or sheath distortion. Bending radius shall not be less than 10 times the cable O.D. Immediately after placement, the cable shall be tagged with permanent, properly encoded, heat shrinkable tags. Signal cable shielding shall be grounded at one end only of the cable. Bonding shall be to a single ground point only. Bonding from cable to cable in multiple run installations shall not be permitted. Heat shrinkable sleeving shall be installed on all cables to insulate shielding at the ungrounded cable terminations. Connectors and splices shall conform to Federal Specification WS-610. Shielded cable carrying analog and digital signals shall be installed in GRS metallic conduit. Where installed in control consoles containing power circuits, maintain a minimum of 2-inch separation between power and control cables. Color coding shall be strictly observed throughout the installations. Manufacturer's cable pulling tension shall not be exceeded. Each cable shall be tested for continuity and for freedom from shorts or grounds prior to connection to sensors, signal conditioners, or instruments. Analog signal loop resistance shall not exceed manufacturer's recommendations for the instruments served. 317-3.04 Wiring Devices. A. Wiring Device Mounting: 1. Dry locations: Install device in flush mounted box with washers as required to bring device mounting strap even with finished wall surface. 2. Damp or wet locations: Install devices and enclosures suitable for these locations. 31 7-3.05 Circuit Breakers And Switches. A. Set all breaker trip settings per instructions. B. Perform circuit continuity tests with a low powered dc test source before energizing the protected equipment. C. Demonstrate that the protected circuit can be manually controlled by the installed equipment. 31 7-3.06 Underground Electrical Work. A. Underground conduit: 1. Thoroughly clean conduits before laying. During construction and after completion, plug conduit ends to prevent dirt and mud from entering the conduit. 31 7-3.07 Grounding. A. Ground all equipment for which a ground connection is required per ANSI C1 whether not specifically shown on the Drawings. e 7/31/02 Contract No. 3907 Page 400 of 414 B. C. D. E. F. Bond metallic water pipe at its entrance into each building. Ground separately derived electrical system neutrals to the metallic water piping in addition to the system driven ground, per ANSI C1 requirements. Provide a ground wire in every conduit carrying a circuit of over 150 volts to ground. Make embedded or buried ground connections, taps and splices with exothermic welds. Effectively bond structural steel for buildings to the grounding system. Conduct ground resistance tests using a ground megohmmeter with a scale reading of 25 ohms maximum. Test methods shall conform to IEEE Standard 81 using the three electrode method. Conduct tests after a period of not less than 48 hours of dry weather. Furnish to the Engineer a test report with recorded data for each ground rod location. 317-3.08 Lighting. A. Install luminaires in accordance with manufacturer's instructions, complete with lamps, ready for operation as indicated. Align, mount, and level the luminaires uniformly. Avoid interference with equipment. In case of conflict, change the location of the luminaire by the minimum distance necessary. All fixtures and luminaires shall be clean and lamps shall be new at the time of acceptance. B. Mount luminaires per the contract plans and these special provisions. Anchor luminaire supports to the structural slab or structural members as indicated. Surface mounted fixtures shall be rigidly bracketed from mounting surfaces. C. Mount fluorescent fixtures level and securely. After installation of fixtures, operate and check circuits to ensure lamps are being operated per manufacturer's recommendations. 317-3.09 Control Devices. A. Where exposed to weather, provide each device with a weatherproof plastic cover. B. Provide an escutcheon plate for each pushbutton, selector switch and indicator light indicating its function. Provide a nameplate for each service or group of devices associated with a piece of mechanical equipment engraved with the name of that equipment. Securely attach each nameplate to the mounting surface with stainless steel screws. 317-3.10 Field Tests. A. B. C. D. E. Perform tests in accordance with applicable procedures as described in NETA Acceptance Testing Specifications. Give sufficient notice to the Engineer prior to any test to permit witnessing the test. Retesting will be required for all unsatisfactory tests after the equipment or system has been repaired. Retest all related equipment and systems if required by the Engineer. Repair and retest equipment and systems which have been satisfactorily tested but later fail, until satisfactory performance is obtained. Putting Equipment and Cables into Service: Submittal and favorable review of the specified factory and field tests shall occur before the Contractor is permitted to place the respective equipment or cable into service. Miscellaneous Tests: 1. Insulation Resistance, Continuity, Rotation: Perform routine insulation resistance, continuity and rotation tests for all distribution and utilization equipment including all motors 112 horsepower. All testing shall be performed in the presence of the Engineer. Any system @ 7/31/02 Contract No. 3907 Page 401 of 414 material or workmanship which is found defective on the basis of acceptance tests shall be reported directly to the Engineer. The Contractor shall maintain a written record of all tests and upon completion of project, assemble and certify a final test report. 2. Motor Current: Measure and record current in each phase for each new motor. Include measurement of the motor terminal voltages and motor currents when the motor is being operated at normal operating loads. Operationally test all circuits to demonstrate that the circuits and equipment have been properly installed, adjusted and are ready for full-time service. Demonstrate the proper functioning of circuits in all modes of operation, including alarm conditions, and demonstrate satisfactory interfacing with the data acquisition and alarm systems. 3. Operational Tests: SECTION 318 - INSTRUMENTATION AND CONTROLS FOR RECYCLED WATER METERING STATION 318-1 GENERAL 31 8-1.01 Scope Of Work. A. Contractor Shall: 1. 2. 3. 4. 5. Provide all tools, equipment, materials, and supplies and be responsible for all labor required to complete the installation, startup and operational testing of a complete and operable Instrumentation and Control (lac) System. Provide all the necessary equipment components and interconnections along with the services of manufacturers' engineering representatives necessary to ensure that the Owner receives a completely integrated and operational system as specified herein. Provide all field instruments, control panels and control devices specified herein. Provide all terminations for wiring at field-mounted instruments, equipment enclosures, alarms and status contacts. Provide all Instrumentation and Control wire required for a fully functioning Instrumentation and Controls System. 31 8-1.02 Reference Standards. A. American National Standard Institute (ANSI) Publications: 1. Y14.15a Drafting Practice 2. C62.1 Surge Arrestors B. Instrumentation Society of America (ISA) Publications: 1. s5.4 Instrument Loop Diagrams 2. s20 Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves 31 8-1.03 Quality Assurance. A. Standard of Quality: The Contractor shall provide equipment of the types and sizes specified that have been demonstrated to operate successfully. Provide equipment that is new and of recent proven design. B. Compatibility: The supplier shall be responsible to see that all components of the instrumentation system, including equipment specified under other Divisions, are completely compatible and 7/31/02 Contract No. 3907 Page 402 of 414 function properly as a system. Provide such additional equipment, accessories, etc., as are necessary to meet these objectives at no cost to the Owner. 31 8-1.04 Inspections. A. The Engineer may inspect the fabricated equipment at the factory before shipment to job site. Provide the Engineer with sufficient prior notice so that an inspection can be arranged at the factory. 6. Inspection of the equipment at the factory by the Engineer will be made after the manufacturer has performed satisfactory checks, adjustments, tests and operations. Favorable review of the equipment and factory testing (see paragraph 3.05) at the factory only allows the manufacturer to ship the equipment to the project site. 318-1.05 Submittals. A. Shop Drawings: Submit shop drawings for review in complete bound sets indexed by Specification number, with exterior tabs marked by subject. Submit manufacturer's catalog cuts for each item for which shop drawings are not required. Manufacturer's catalog cuts, specifications or data sheets shall be clearly marked to delineate the options or styles to be furnished. Show dimensions, physical configurations, methods of connecting instruments together, mounting details, and wiring schematics. Drawings shall be complete with device tag numbers, wire numbers and terminal board numbers. Submit fabrication details, nameplate legends, and control panel internal wiring and piping schematic drawings. Submit panel graphic drawings where applicable. Include material specification lists where applicable. 6. Loop Diagrams: 1. Submit Instrument Loop Diagrams per ISA S5.4 to provide necessary detail for connection of analog instrument and control system components including those components specified in other sections of these Specifications. 2. Provide with the Instrumentation Diagrams all instrument model numbers, ranges, set points, sizes, process fluids, specification reference numbers, and all other information listed as "desirable and optional items of information" per ISA S5.4. C. Interconnection Diagrams: Submit point-to-point type interconnection diagrams conforming to ANSI Y14.15a; include each conduit run, with wirefill noted for each run. Include electric panel and circuit numbers for all sources of 120 Vac power. Show wiring interconnections between each control panel, instrument, RTU, valve actuator, and other field-mounted device. For the format of these diagrams, see below under As-Build Drawings. D. Operation and Maintenance Manuals: Furnish Operation and Maintenance Manuals, including Instruction Manuals and Part Lists in accordance with Section 01 300. 1. Schedule: Deliver at least two (2) copies of manuals in %ring binders (8-1/2 by 1 l-inch format) not later than the equipment shipment date. 2. Contents: Include in manuals not less than the following information, as applicable, for each instrument, equipment, subsystem and/or control loop: a. General, introduction and overall description, purpose, functions, simplified theory of operations, etc. b. Specifications (including equipment specification data sheet as described above under Shop Drawings), sufficiently detailed for reordering exact duplicates of the original items. c. Installation instructions, procedures, sequences, tolerances, and precautions. d. Operational procedures. e. Shutdown procedures. @ 7/31/02 Contract No. 3907 Page 403 of 414 f. Maintenance, calibration, and repair instructions. g. Parts list and spare parts recommendations. h. Calibration curves, rating tables and any other data showing the relationship of the variable inputs and the calibrated output of all measuring devices and controlled equipment. 3. Format: a. b. C. Use drawings and pictorials to illustrate the text to the extent necessary to insure a clear, concise presentation. If manuals have 'been written to cover a family of similar instruments or equipment, strike out inapplicable information in a neat fashion or emphasize applicable portion by heavily weighted arrows, circles or boxes; whichever provides the clearest and neatest presentation. Group manuals by system control panels, including field instrumentation connected or associated with the panel. Where identical instruments are used in more than one control loop or subsystem, include only one instruction manual, per panel grouping; however, an index by tag number for all instruments shall identify its location in that manual. Provide control loop and/or subsystem operational descriptions to identify the function of each instrument and its relation to the other instruments in the loop. 4. Binding: Bind each manual in a cover which indicates the panel or process area to which it applies, manufacturer's name, local address and telephone number, and year of purchase. Punch and bind manuals in standard three-ring binders and include system name and subcontractor's name on binding. E. Accessory and Maintenance Materials: Submit data for the following items: 1. Special Tools and Accessories: Special tools, instruments, and accessories for maintaining instruments and equipment requiring periodic repair and adjustment as specified elsewhere herein. Also, furnish special lifting and handling devices for equipment requiring such devices. 2. Maintenance Materials and Spare Parts: Submit a list of manufacturer recommended spare parts for each item specified. F. RTU Submittals: 1. 2. 3. 4. 5. 6. 7. Catalog cuts for the central processing unit, input modules, output modules, magnetic program storage device, interfacing equipment, power supply voltage regulation transformer, and power line surge protection device. Heat load data for the power line voltage regulation transformer. A layout drawing of the enclosure. An "InputlOutput Record Form," tabulating the module number, channel number, address number, input/output designation name and/or number, and a textual description for each item of input and output. A "Constant Memory Assignment Record," tabulating the area (C), location number, and textual description for each variable stored in memory. A "Variable Memory Assignment Record," tabulating the area (V), location number, and textual description for each variable stored in memory A brief description on a page preceding the ladder diagram listings, describing all symbols and functions used on the succeeding diagrams. 4m 'E9 7/31/02 Contract No. 3907 Page 404 of 414 318-1.06 UI Label. A. Enclosure shall bear the UL label. If required in order to be UL labeled, provide ground fault interrupters, isolation transformers, fuses, and any other necessary equipment even though such equipment is not called for on the Drawings. 31 8-1.07 Product Delivery, Storage And Handling. A. Box, crate, or otherwise enclose and protect instruments and equipment during shipment, handling, and storage. Keep all equipment dry and covered from exposure to weather, moisture, corrosive liquids and gases or any element that could degrade the equipment. Protect painted surFaces against impact, abrasion, discoloration, and other damage. Notify the Engineer in writing in the event that any equipment or material is damaged. Obtain prior favorable review by the Engineer before making repairs to damaged products. 318-2 PRODUCTS 318-2.01 Materials And Standard Specifications. A. The Contractor shall provide instruments, equipment and materials suitable for service conditions and meeting standard specifications such as ANSI, ASTM, ISA, and SAMA. The intent of this Specification is to secure instruments and equipment of a uniform quality and manufacture throughout. All instruments of the same type shall be made by the same manufacturer. 318-2.02 Nameplates. A. For each piece of equipment, provide a manufacturer's nameplate showing his name, location, the pertinent ratings and the model designation. B. Identify each piece of equipment and related controls with a rigid laminated engraved phenolic nameplate. Engrave nameplates with the inscriptions indicated on the Drawings and, if not so indicated, with the equipment name. Securely fasten nameplates in place using two stainless steel screws with epoxy cement. Where no inscription is indicated on the Drawings, furnish nameplates with an appropriate inscription furnished by the Engineer after review of submittals. C. Each control device, including pushbuttons, control switches, and indicating lights, shall have an integral legend plate or nameplate indicating the device function. These shall be inscribed as indicated on the Drawings or as favorably reviewed by the Engineer. D. Provide CAUTION or SAFETY nameplates to alert operators of special conditions that may result in faulty equipment operations. Devices containing batteries that must be replaced periodically must be clearly identified. Nameplates are not required if the device senses and displays a low battery warning. 31 8-2.03 Name Tags. A. All instrumentation and equipment items or systems shall be identified by name tags. Field equipment shall be tagged with the assigned instrumentation tag number. B. Name tags shall be stainless steel with engraved or stamped black characters of 3/16-inch minimum height. Tags shall be attached to equipment with a tag holder and stainless steel .band with a worm screw clamping device. Use 20-gauge stainless steel wire where banding is impractical. For field panels or large equipment cases use stainless steel screws: however, such permanent attachment shall not be on an ordinarily replaceable part. - 31 8-2.04 Electronic Equipment. A. If the equipment is electronic in nature, provide solid state equipment to the extent applicable. Select components of construction for their suitability and reliability. Employ adequate a 7/31/02 Contract No. 3907 Page 405 of 414 component derating to preclude failures because of transients and momentary overloads reasonably expected in normal operation. Design units for operation without forced cooling, unless such cooling is an integral part of the device. 31 8-2.05 Equipment Operating Conditions. A. All equipment shall be rated for normal operating performance with varying operating conditions over the following minimum ranges: 1. Electrical Power: 120 Vac *lo%, 60 Hz, unregulated. 2. Field Instruments: Indoor Unheated Areas: a. Ambient Temperature: +50°F to +140°F b. Ambient Relative Humidity: 10% to 90%, non-condensing 31 8-2.06 Analog Signal Indicated Units. A. For all instruments with local or remote indicators, provide indicators scaled in actual engineering units, i.e., gallons per minute, feet, psi, etc., rather than 0 to loo%, unless noted otherwise on the Drawings. 31 8-2.07 Signal Transmission. A. Analog: Signal transmission between electric or electronic instruments shall be 4-20 mA and shall operate at 24Vdc. Signal output from all transmitters and controllers shall be current regulated and shall not be affected by changes in load resistance within the unit's rating. Where practical, milliampere signals from the field shall be converted to a voltage signal at the external terminals of each panel, and all instruments within a panel shall be parallel wired. B. Discrete: All alarm and status signals shall be 120 Vac or 24 (ac or dc). Proprietary data highway or serial bit transmissions such as RS232C shall be allowed to the extent specified. 31 8-2.08 RackEnclosure Bay Ac Power Supplies. A. Provide each main rack and/or enclosure bay with a separate isolation transformer to prevent ground loops between the instrument and electrical power grounds. These transformers may be nonshielded control power type. 318-209 Tubing, Pipe, Fittings And Supports. A. Copper Tubing: Soft-annealed copper tubing shall be %inch O.D. x 0.030-inch wall, 3/8-inch O.D. x 0.032-inch wall, or %-inch O.D. x 0.032-inch wall as shown on the Drawings. Copper tubing shall be seamless copper, Type DHP, bright annealed after coiling, dehydrated and sealed in 50-foot aluminum. B. Stainless Steel: Stainless tubing shall be Type 304 seamless, cold drawn and annealed per ASTM A269. Sizes shall be 1/4-inch O.D. x 0.045inch wall, 3/&inch O.D. x 0.035-inch wall or %-inch O.D. x 0.035-inch wall. C. Pneumatic Tubing: Pneumatic tubing for panel intemals shall be 1/4 or 3/&inch O.D. rigidwall, clear polyethylene, 250 psi rating. Tubing shall be supported in plastic duct or conduit Where appropriate. 1. Copper Tube: Solder joint fittings shall be seamless wrought copper per ASTM B75. 2. Stainless Steel Tube: Weld joint fittings shall be Type 304 stainless. Compression fittings e 7/31/02 Contract No. 3907 Page 406 of 414 - . D. Fittings: Compression fittings shall be Brass equal to Imperial or Swagelok. shall be Type 316 stainless steel equal to Imperial or Swagelok. 3. Supports for Tubing: Supports located in areas exposed to the weather or corrosive atmosphere shall be Type 304 stainless steel Unistrut or equal or made of steel conforming to ASTM A276. Supports not exposed to the weather or corrosive atmosphere shall be carbon steel painted. 4. Pipe, Pipe Fittings and Valves: Main-line piping material and root valves for instrumentation shall be as specified in Section 15050. 5. Weld joint fittings shall be permitted for header and branch service only. Instrument and valve connections shall be compression-type only. Use unions on as necessary to simplify instrument removal. 318-2.10 Magnetic Flowmeter - Induction Type (Fit-1). A. B. C. D. E. General: Magnetic meter shall utilize the principle of electromagnetic induction to produce an output proportional to the rate of fluid flow. A set of pulsed dc, electrically powered coils shall generate a magnetic field which in turn induces a voltage in the flowing fluid which is sensed by a pair of electrodes in contact with the fluid. 1. Protect coils from contact with the fluid. The electrodes shall be made of Type 31 6 stainless steel. The meter shall be housed in a NEMA 4 enclosure. The metering tube shall be lined with hard rubber. Meter shall be resistant to electrode coating. The probe sensor shall be designed to be inserted in water pipes and shall not be affected by solids, air bubbles, oil or coating. The probe sensor wetted parts shall be of Type 316 stainless steel. 2. The meter shall be designed to operate from a 120 volt ac, 60 cycle, single phase power supply. A 10% variation in power line voltage or frequency shall not affect the meter output accuracy in excess of 1 % of full scale. 3. Provide magnetic flowmeter suitable for fluids with conductivities as low as 5.0 micromho/cm. 4. Each magnetic flow meter system shall have accuracy within 1% of actual for flow velocities between 10% and 100% of full scale. Meters shall have repeatability within 0.25% of full scale. 5. The magnetic flow meter shall be equipped with a signal converter to transmit an analog 4- 20 mAdc signal proportional to flow rate. Output span and zero shall be manually adjustable. Provide span adjustment capable of producing 100% strength analog at flow rates that are 30% of maximum. Signal shall be linear with flow within the accuracy specified above. The converter shall be mounted remotely from the meter. Provide interconnecting cable between the meter and the converter. Converter shall be housed in a NEMA 4X, permanent submergence-proof enclosure and shall use HART digital communications protocol. 6. The signal converter shall have the capability of positive zero return for shutdown conditions. The magnetic flow meter shall have flanged end connections or as shown on the Drawings. Field coils shall be either completely encapsulated in the meter lining material or a protective shield shall be provided suitable for withstanding the scouring velocities of the process fluid at the maximum flow rates. Grounding: Provide a grounding circuit for the magnetic meter. Furnish and install grounding rings or a protective shield when the meter is installed in a nonconductive line or if required by the manufacturer. Settings: 1. Meter size: 16-inch 2. Calibration Range: 0-1 0.000 gpm Manufacturer: Meter and signal converter shall be Sparling Tigermag; Foxboro; or equal. 7/31/02 Contract No. 3907 Page 407 of 414 A. B. C. I.. F. Special Tools: Furnish special tools necessary for the replacement of parts and the adjustment of the equipment. 318-2.11 Level Switch - Float Type, Sump Duty (Lsh-1). General: Level switch shall use the movement of a float, the weight of whose moving parts is less than that of the displaced process liquid, to actuate switches as the level changes. The switch shall be integrally mounted within the float and connected to a terminal box by a waterproof electric cable. A movable weight shall be mounted on the cable to keep the cable immersed in the liquid. The switch operating levels shall be easily adjusted by moving the weight along the cable or altering the height of the cable fixing point. 1. The switch covering shall be made of indestructible polypropylene material. The cable shall be PVC coated. 2. The switch shall be reversible such that the switching action operates on rising or falling level. 3. The switch actuating points shall be per the manufacturer's recommendation. 4. The float shall be rated for 150 psi (10.5 kg/cm2) pressure and 140°F (60°C) temperature. The float shall not be greater than 7 inches (1 78 mm) in diameter. 5. The switch shall be rated for 250volts ac or dc and 5amperes minimum, and shall be terminated with 14 AWG wires in a NEMA 4X terminal box. Manufacturer: Float type sump level switches shall be as manufactured by Flygt Corporation; Consolidated Electric Company; or equal. 31 8-2.1 2 Pressure Transmitters - Electronic. A. General: 1. Electronic indicating-type pressure transmitters shall convert a gauge or absolute pressure measurement to a 4-20 mAdc linear electrical output signal capable of transmission into at least a 600 ohm maximum load at 24 Vdc or less. Signal and power transmission shall be provided on a single pair of wires. Operating ambient temperature limits shall be at least -40" to +82"C. 2. Range shall be as indicated on the Drawings. Overrange protection shall be at least 1-1/2 times span without degradation of accuracy. Reference accuracy shall be *1/2 percent 'or better. 8. Construction: 1. The transmitter enclosure shall be NEMA 4X rated. The process connection for clean liquid service shall be 1/4-inch NPT. Enclosure and wetted surface material shall be corrosion resistant and suitable for the process fluid. 2. Transmitters shall be liquid-filled employing diaphragm where shown on the Drawings. Use optional remote seal with capillary length selected to suit installation needs, such as location, elevation, or orientation. Standard seal flange shall be a 3-inch 150-pound USAlS lap joint flange. A mating transmitter ANSI flange shall be provided with each transmitter. C. Manufacturers: Endress + Hauser PMC 133, or equal, to match Owner's standards. 318-2.13 Instrument Manifolds. A. General: Test valve manifolds shall be used with all pressure transmitters installed in clean liquid (no entrained solids) service. Test manifolds shall be corrosion resistant with integral 2- valve assembly (block and bleed) for pressure transmitter installation. 9. Mounting: Pipe mounting brackets shall be provided with each manifold. 7/31/02 Contract No. 3907 Page 408 of 414 C. Manufacturer: Anderson-Greenwood Company, M Series, Hoke, or equal. c- 318-2.14 Remote Terminal Unit. A. General: Furnish, install, test, and place the RTU into satisfactory operation as required by the Drawings and Specifications. B. Manufacturer: Opto-22 Type SNAP-63000 with SNAP I/O modules: or equal to match Owner's standards. C. Remote Terminal Unit: Provide each RTU with the following hardware. 1. 2. 3. Central Processing Unit: The Central Processing Unit (CPU) shall be powered by 5 Vdc supply, and shall have the following: a. b. C. d. e. f. Remote 1/0 connections to Opto-22 snap system. &slot I/O rack: SNAP 83000 BRAIN system. RTU software with extend math functions and on lineloff line programming functions. Communications port for RS-232 and Ethernet communications. Battery-backed (10-year lithium) CMOS RAM Rack power supply: 5 Vdc, SNAP-PS5. Power supply: 24-volt dc with on-off switch. SNAP-PS24 lnputloutput modules: Provide a &channel rack with interconnect port to connect to SNAP RTU . a. Analog inputs (AI) shall meet the following requirements: 1) 4 to 20 mAdc inputs, 250 ohm impedance maximum, 2 inputs per module. 2) Accuracy of *0.05% of span. 3) Common Mode Rejection of 120 dB. 4) Provide SNAP-AIM-I. b. Discrete inputs (DI) shall meet the following requirements: C. d. e 7/31/02 1) Unpowered contact inputs or power inputs at 120 Vac. 2) Input isolation shall meet or exceed IEEE-472. Relay isolation is unacceptable. 3) Discrete inputs shall be powered by the RTU by 120 Vac. Power supply shall be current limited to conform with NEC Class 2 remote control and signal wiring circuits. 4) Modules with 4 inputs with common ground terminals. Voltage input modules shall have their channels fully isolated. 5) Provide SNAP-IAC5. Analog outputs (AO) shall meet the following requirements. 1) Output: 4-20 mAdc into a 0 to 500 ohm load; 2 isolated output configuration. 2) Isolation: From the multiplexer ground. 3) Accuracy: *O.l% of span. 4) Provide SNAP-AOA-23. Provide spare inputs and outputs so that a minimum of 25% of each type is spare, functional, and installed in the mounting racks. Permanently label each input and output on each module by the tag number and description given in the InputlOutput Schedule as shown on the Drawings. Contract No. 3907 Page 409 of 414 4. 5. 6. 7. e. Provide at least two spare slots for future modificationdadditions. Cables: Provide a full complement of cables for connecting to the programming terminal and interface devices. Interfacing Relays, Instruments, and Switches: Provide equipment as required for compliance with the functional requirements. a. For analog signals, provide relays and switches with gold flashed silver contacts. Provide analog loop isolators where required to eliminate "ground loops." Power Line Voltage Regulation Transformer: Provide a UL recognized power line voltage regulation transformer to provide 11 5 Vac power for the RTU, in addition to any isolation transformer(s) required for UL labeling of the RTU enclosure. a. The voltage regulation transformer may be of any of the following types: 1) Saturated core transformer. 2) Ferroresonant transformer. 3) SCR (Silicon Controlled Rectifier) automatic tap-changing transformer. b. Provide voltage regulation such that the output voltage to the RTU is maintained at 1 15 Vac k10 Vac for input voltages to the transformer varying from 85 to 130 Vac. c. Submit heat load data. d. If an automatic SCR tap-changing transformer is to be provided, submit data to demonstrate that electrical switching noise produced by the tap-changing circuitry will not adversely affect the performance of the RTU. Power Line Surge Protection Device: Provide a UL listed power line surge protection device in the 115 Vac power supply lines for the RTU, to limit both steady-state and transient power line disturbances. Install the device between the power line and the voltage regulation transformer. a. Provide a surge protection device with the following specifications: 1) Maximum steady-state and transient voltage clamping at 140 Vac RMS (200 volt 2) Voltage clamping energy dissipation at 50 joules (watt-seconds). 3) Transient impulse filtering of 5 dB at 100 kHz and 40 dB at 30 mHz. b. Provide a surge protection device with the following features as a minimum: 1) Fuse protection of the load if input surge exceeds the capacity of the surge protector. Provide externally mounted fuseholder. 2) Series inductor chokes rated for the full line current of the RTU. peak). Communication Interfaces: Equip the RTU with a serial modem interface for communication to the Owner's existing SCADA system. D. RTU Programming: 1. RTU programming shall be by the Owner. The Contractor shall coordinate with the Owner and provide any technical information regarding the RTU, communication, arrangement and addressing. E. Spare Parts: Provide the following spare parts. 1. One input/output module for each type provided. 2. Power supply. 7/31/02 Contract No. 3907 Page 410 of 414 F. Inputloutput List: As shown on the Drawings. G. Control Strategy: See Appendix A of this section. A. B. C. D. 31 8-3 EXECUTION 318-3.01 Mountings. Equipment specified for field mounting shall be suitable for direct pipe mounting or surface mounting and non-inline indicators and equipment with calibration adjustments -or requiring periodic inspection shall be mounted not lower than 3feet nor higher than 5feet above walkways, platforms, catwalks, and the like. Manufacturers of all process instrument panels and instruments shall certify that their equipment, when installed and anchored, will safely transfer seismic forces through the equipment to the anchorage without failure of equipment or components. Detail drawings shall be provided showing sway bracing design and anchorage requirements for their equipment. All devices shall be accessible to operators for servicing, operating, reading, etc. The Contractor shall provide platforms or remote meters and/or control switches to assure devices are accessible for operation. 31 8-3.02 Process Connections. A. B. Contractor shall provide instrument impulse piping, tubing, and capillary tubing to meet the intended process service and ambient environmental condition for corrosion resistance, etc. Slope lines according to service to promote selfdraining or venting back to the process. Terminate connection to process lines or vessels in a service rated block valve, provided under other Divisions that will permit closing off the impulse line or removal of the element without requiring shut down of the process. Include blowdown of drip legs and valves for terminations of impulse lines at the instruments. Process vessels, line penetrations, and root valves shall be furnished and installed under other Divisions of these Specifications. Instrument tubing manifolds and devices are installed as part of this Specification. 318-3.03 Electromagnetic Interference (Emi). A. Construction shall proceed in a manner which minimizes the introduction of noise into the I&C System. B. Cross signal wires and wires carrying ac power or control signals at right angles. C. Separate signal wires from wires carrying ac power or switched addc control signals within control panels, terminal cabinets, telemetry equipment, multiplexer cabinets, and data loggers as much as possible. Provide the following minimum separations within such equipment unless indicated otherwise on the Drawings: Power Wirina CaDacity SeDaration finches) 120 volts ac or 10 amps 240 volts ac or 50 amps 480 volts ac or 200 amps 12 18 24 318-3.04 Grounding. A. Provide for single-point grounding system for instrument signals in all control panels. This system does not use building steel or conduit systems for its ground path. e 7/31/02 Contract No. 3907 Page 411 of 414 B. Ground all signal shields, signal grounds, and power supplies at the single-point ground termination in each control panel. The far ends of these signal cables must be disconnected (floated) from any ground to prevent ground loops. C. Provide for connecting each single-point ground with insulated copper wire of size 8AWG or larger. 31 8-3.05 Factory Testing Of Control Panels. A. Verify, at the factory, wiring continuity and equipmentldevicelinstrument operation by simulating inputs and outputs. Factory testing of panels shall be accomplished in accordance with an approved factory test procedure. Upon completion of factory testing, submit a report certifying that the control panels are operable and meet the specifications. 318-3.06 Instrument Calibration. A. B. Provide the services of factory trained instrumentation technicians, tools, and equipment to field calibrate each instrument to its specified accuracy in accordance with the manufacturets specifications and instructions for calibration. Each instrument shall be calibrated at 0%, 25%, 50%, 75% and 100% of span using test instruments to simulate inputs and read outputs that are rated to an accuracy of at least 5 times greater than the specified accuracy of the instrument being calibrated. Such test instruments shall have accuracies traceable to the National Bureau of Standards, as applicable. Submit a written report to the Engineer on each instrument certifying that it has been calibrated to its published specified accuracy. This report shall include a listing of the published specified accuracy, permissible tolerance at each point of calibration, calibration reading as finally adjusted within tolerances, defects noted, correction action required, and correction made. This report shall list instrument readings in actual engineering units such as gallons per minute, feet, psi, etc., rather than 0 to 100%. 31 8-3.07 System Verification. A. Provide the services of factory trained and field experienced instrumentation engineers to verify that each instrument is operational and performing its intended function within system tolerance. B. Cause malfunctions to sound alarms or switch to standby to check system operation. Check all systems thoroughly for correct operation. Test equipment for this function shall be as specified under "Instrument Calibration." C. Immediately correct all defects and malfunctions disclosed by tests. Use new parts and materials as required and approved and retest. Submit a report certifying completion of verification of each instrument system. This report shall indicate calculated system tolerances, verification that system meets these tolerances, and any provisional settings made to devices. This report shall list instrument readings in actual engineering units such as gallons per minute, feet, psi, etc., rather than 0 to 100 percent. 31 8-3.08 Final Operational Testing And Acceptance. A. Provide the services of a factory trained and field experienced instrumentation engineer to plant operational testing. The purpose of this testing is to support in making final adjustments of settings on the instrument systems in the presence of the Owner or designated representative to assure systems are ready for beneficial occupancy. B. Each test shall be witnessed, documented, and signed off upon completion by the Engineer. Notify the Engineer in writing a minimum of 48 hours prior to the proposed date for commencing the test. 7/31/02 Contract No. 3907 Page 412 of 414 3183.09 Instruction Of Owner's Personnel. .-- A. Provide the services of a factory trained and field experienced instrumentation engineer to conduct group training of Owner's designated personnel in the operation of each instrument system. This training shall be for the time period of 2 working days and shall be performed during the operational testing period. Include instruction covering basic system theory, operating principles and adjustment, routine maintenance and repair, and "hand on" operation. The text for this training shall be the Operation and Maintenance Manuals furnished under these Specifications. 318-3.10 Rtu Control Strategies 318-3.10.01 Control Strategy 1 : Motorized Valve Control. Related Equipment: FCV-1, FIT-1 A. General: This control strategy interface logic with the motorized valve and magnetic flowmeter in the new recycled water metering station. All RTU programming shall be by the Owner. Control strategies are included for information only. The interface includes controlling and monitoring motorized valve FCV-1. A remote controller shall activate the analog output when the equipment is in the "AUTO" mode only. When the equipment is put in 'MAN" mode, a remote controller shall de-activate the discrete output. The motorized valve is used for modulating service. 1. RTU shall monitor "READY" status of valve for automatic control. 2. To open or close the valve, the RTU shall issue a command to valve controls. 3. The RTU shall monitor the valve positions for "OPEN" (ZSO-I) and "CLOSED" (ZSC-1). 4. The RTU shall monitor the valve status after an "OPEN" or "CLOSE" command. If the valve does not achieve the required status after an adjustable delay 0-60 seconds, issue a valve "FAIL". 5. For each valve, set points for valve controls such as deadbands and selected data shall be available. C. Flow Control Loop (FC-1) Description: 1. A feedback loop using PID (Proportional Integral and Derivative) shall be implemented in the RTU with displays of various signals on a loop view template including settings of tuning parameters. Loop shall include a bumpless transfer feature from Auto to Manual. The loop view shall include: a. Process variable indicator in engineering units. b. Set point indicator. c. Set point selection: local/remote. d. Output signal: 0-1 00%. B. Automatic Valve Interface: e. ManuaVAuto selection: This allows a manual control of output signal. f. PI&D tuning monitoring and setting. 2. The flow set point (FK-1) to the flow control loop (FC-1) is received from an operator input. The process variable (FI-I) is the signal from magnetic flowmeter FIT-1. FC-1 modulates FCV-1 to maintain the flow set point. 7/31/02 Contract No. 3907 Page 413 of 414 318-3.10.02 Control Strategy 2: Alarms. Related Equipment: All A. General: This strategy describes the monitoring and display of alarm conditions. B. Description: 1. Alarms shall be discrete input alarms. Whenever a discrete input alarm is detected, the RTU shall annunciate an alarm after an adjustable delay 0-5 seconds. 2. Alarms shall include the following: a. Vault Intrusion, ZS-1 b. Cabinet Loss of Power, YA-1 c. Valve Fully Open, ZSO-1 d. Valve Fully Closed, ZSC-1 e 7/31/02 Contract No. 3907 Page 414 of 414