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HomeMy WebLinkAboutSierra Pacific West Inc; 2009-07-30; PWS09-24ENG Part 2 of 3SECTION 01300 SUBMITTALS PART 1 - GENERAL 1.1 SUBMITTALS A. The Engineer's approval of submittals shall not relieve the Contractor of the entire responsibility for the correctness of the work covered by the submittal. The Contractor shall assume all responsibility for misfits and deficient work due to errors in the submittals. 1.2 DEFINITIONS A. Or-Equal—Whenever material or equipment is indicated in these specifications by stating names of proprietary items or of particular suppliers, the naming of the item is intended to establish the type, function, and quality required. The Contractor may select any of these named items for use on the project. When the name is followed by the words "or-equal," it indicates that a substitution may be submitted for approval. An "or- equal" item serves the same function; has the same dimensions, appearance, quality, terms of warranty, durability, reliability, cost in service and maintenance; and complies with the same codes and standards as the named item. Further, its substitution will have no effect on project details, cost, and program. B. Substitution—The use of an "or equal" item of material or equipment that meets contract requirements. C. Change or Deviation—The use of an alternative item of material or equipment that does not meet the contract requirements. In this section, the same procedure shall be followed to obtain approval as for substitutions. On the letter of transmittal, substitutions, changes, and deviations are noted as variations. 1.3 REQUIREMENTS FOR SUBMITTALS AND SUBMITTAL PACKAGES A. Submittals will be required for all fabricated articles. B. Submittals required by the specifications sections shall be in accordance with this section unless otherwise specified. Submittals not in accordance with this section and with the section requiring the submittal will be returned to the Contractor as unsatisfactory. C. Prior to transmission to the Engineer, the Contractor shall carefully review each submittal to confirm that it is complete and to verify whether or not the proposed items or work conform to contract requirements. Each submittal shall be dated, signed, and certified by the Contractor as being correct and in conformance with the drawings and the specifications. The Engineer will not review any items which have not been certified by the Contractor. All non-certified submittals will be returned to the Contractor without action taken by the Engineer, and any delays caused thereby shall be the responsibility of the Contractor. 8/13/09 Contract No. 3811 SUBMITTALS PALOMAR AIRPORT ROAD WIDENING 01300-1 D. Items that are not in accordance with the contract requirements shall be conspicuously noted as such. The Contractor shall identify each proposed deviation on the corresponding letter of transmittal and include a written explanation of the necessity for each deviation with the letter of transmittal. Deviations that are not conspicuously marked on both the letter of transmittal and the corresponding drawing or data will be deemed to have been disapproved by the Engineer or not reviewed by the Engineer. E. Number of Copies Required 1. Each Submittal: Unless otherwise specified, The Contractor shall furnish 6 copies of each submittal. Each copy of the submittal shall have the letter of transmittal attached to it. 2. Drawings: Three half-size, direct prints of each original drawing shall be submitted for approval before manufacture or fabrication of the respective articles. 3. Reinforcing Steel Data: Three half-size direct prints of each original reinforcing steel bending diagram, placing list, and placing drawing shall be submitted for review. 4. Catalog sheets, brochures, and other printed sheets: Six copies shall be submitted. 5. Other Data: When the specifications require the submission of certifications, mill test reports, or purchase orders, a minimum of 3 copies shall be submitted to the Engineer, unless otherwise specified. F. Transmittal Format 1. A separate letter of transmittal, in a form acceptable to the Engineer, shall be used to transmit submittals for each specific item or class of material or equipment. An example of an acceptable letter of transmittal is included at the end of this section. a. Submittal of multiple items using a single letter of transmittal will be permitted only when the items taken together constitute a manufacturer's package or are so functionally related that expediency indicates review of the group or package as a whole. If multiple submittal items are transmitted under 1 transmittal letter, then the Contractor shall tab each individual submittal item in the package and provide a table of contents at the beginning of the submittal package. 2. The letter of transmittal for each submittal shall show the transmittal number, date of transmittal, project title, construction contract number, specifications section or drawing number to which the submittal pertains, brief description of the material or equipment submitted, and the company name or the originator of the submittal. Material descriptions shall include the following: type, size, trade name, manufacturer's/supplier's name, and other appropriate summarizing information. Submittal letters for shop drawing descriptions shall include the 8/13/09 Contract No. 3811 SUBMITTALS PALOMAR AIRPORT ROAD WIDENING 01300-2 complete list of drawings/sheet numbers that are included in the submittal package. Each letter of transmittal shall be clearly marked to indicate the cases when the material is being submitted as a variation. 3. The transmittal number shall be indicated on every page of each copy of each submittal, and shall correspond to the number given in the letter of transmittal. Only the first sheet of a bound set of originally published or printed brochures or catalogs shall be numbered. a. Submittals shall be consecutively numbered beginning with the number 1. b. Multiple-page submittals (more than 25 pages) shall be collated into sets, and each set shall be put in a folder or bound before transmittal to the Engineer. c. When material or equipment is resubmitted for any reason, a new letter of transmittal shall have the original submittal number followed by a decimal and a number corresponding to the number of resubmittal. An example is 50.2, where 50 is the submittal number and 2 is the number of times submittal 50 has been resubmitted. The letter of transmittal shall indicate that it is a resubmittal. 1.4 SUBSTITUTIONS A. Submittals of substitutions, changes, and deviations shall be in accordance with this section and may be permitted subject to the following requirements: 1. The proposed substitution, change, or deviation is conspicuously marked on the drawings or data. 2. The corresponding line item on the letter of transmittal is conspicuously marked as a variation. 3. Proof shall be provided of the comparative quality and suitability of alternative equipment or materials for proposed substitutions. Description, information, performance data, and other information as may be required by the Engineer shall be submitted showing the equality of the materials or equipment offered to those specified. 4. A written explanation of the necessity for the proposed change or deviation shall be indicated in the Letter of Transmittal. 5. The Engineer will be the sole judge as to the comparative quality and suitability of alternative equipment or materials, and his decision will be final. B. Prequalified Products: If the specifications state that a specified product has been prequalified by the City, the following applies to that product. 1. A change in the formulation or quality control tolerances of an approved product will necessitate its requalification. ' 8/13/09 Contract No. 3811 SUBMITTALS PALOMAR AIRPORT ROAD WIDENING 01300-3 2. Only those products that have been approved at the time of opening bids will be acceptable for use in the work; except, products may be approved after the bid opening date when there is sufficient time within the contract period to permit testing and qualification. Criteria pertaining to the qualification of products may be obtained from the Engineer. 3. No extension of time will be granted for the purpose of testing and qualifying proposed products. 1 .5 ACTIONS BY THE ENGINEER AND SUBSEQUENT CONTRACTOR ACTIONS AND RESPONSIBILITIES A. The Engineer will reject incomplete submittals as not complying with the contract requirements. B. After receipt of a complete submittal and within the time limits described below, the Engineer will transmit the submittal back to the Contractor marked with the review status. 1 . Product data, drawings, and other items submitted to the Engineer for approval will be returned marked: a. Approved b. Approved as Revised c. Returned for Revision 2. Reinforcing steel drawings and bending diagrams will be reviewed by the Engineer for rebar size, rebar spacing, and lap-splice location. Upon completion of the review, the Engineer will return the drawings marked: a. Reviewed - No corrections noted b. Reviewed - Corrections noted - No resubmittal required c. Reviewed - Resubmittal required 3. Certifications, structural calculations, shoring plans, manuals, test reports, and other plans and procedures submitted to the Engineer for review will be returned marked: a. Reviewed - No corrections noted b. Reviewed - Corrections noted - No resubmittal required c. Reviewed - Resubmittal required 8/13/09 Contract No. 3811 SUBMITTALS PALOMAR AIRPORT ROAD WIDENING 01 300-4 C. For items marked Approved as Revised, the revisions will be marked on the appropriate product data sheets or drawings or will be described in the comment sheet or letter responding to the submittal. These product data sheets or drawings will be considered approved. D. Drawings marked Approved as Revised shall be revised, and new reproducible transparencies and prints shall be submitted within 30 working days. E. In the event the drawings or other data are found unsatisfactory, 1 copy of the submittal will be transmitted to the Contractor with a statement of the deficiencies. The Contractor shall at once revise the drawings or data and resubmit them to the Engineer. F. After approval of submittals, the Contractor shall not deviate from the design, details, or dimensions shown on the approved submittal without the written consent of the Engineer. Fabrication, installation, or other production work performed in advance of the receipt of approval of submittals shall be entirely at the Contractor's risk. 1.6 REVIEW SCHEDULE A. The sequencing and scheduling of submittals shall be in accordance with the priority established in the approved construction schedule. Submittals that affect the critical path and near-critical path work items and large equipment submittals shall be scheduled to provide the greatest amount of float possible. 1. Submittals shall be made far enough in advance of scheduled dates of installation to provide the time for reviews, for securing necessary approvals, for possible revision and resubmittal, and for placing orders and securing delivery. 2. When delay is caused by the need for resubmission of submittals, the Contractor will not be entitled to damages or extension of time on account of the delay. B. In its schedule, the Contractor shall show those submittals on the critical path leading up to the shutdowns. 1.7 SUBMITTAL LOG A. The Contractor shall prepare and maintain an accurate submittal log for the duration of the project. The log shall contain a listing of submittals and shall include the following information for each listed item: 1. Specification section reference 2. Projected submission date 3. Actual submission date 4. Projected need date for approval of the submittal 5. Actual return date from the Engineer ''%•»»*• 8/13/09 Contract No. 3811 SUBMITTALS PALOMAR AIRPORT ROAD WIDENING 01300-5 6. Notation of the Engineer's response 7. Notation if resubmittal or record copy is required 1.8 RECORD COPIES A. Within 30 working days after approval of shop, assembly, or layout drawings, 1 half-size direct copy shall be forwarded to the Engineer. 1. Record copies of approved drawings shall be clean, legible without the use of magnification, and capable of producing copies that are comparable in quality to the original. Drawings which do not meet these criteria will not be accepted by the City. Any record drawing not accepted by the City must be revised and resubmitted until it is acceptable to the City. 1.9 SUBMITTAL FORMAT REQUIREMENTS A. Product Data: Product data shall be annotated or highlighted to show the particular items and options that are proposed for use in the work. B. Drawings 1. Drawings shall be submitted in complete sets together with required data so that sufficient information will be available for a thorough evaluation. 2. Each Contractor's drawing shall include as minimum identification for checking: a. Contractor's name b. Project name c. Applicable subcontractor's name, if any d. Preparer's name e. Submittal number f. Drawing number and date g. The contract and specification number h. Reference contract drawing number i. Drawing title and appropriate subtitles 3. Drawings shall have sufficient blank spaces for making corrections and for the Engineer's review stamp. The minimum blank space for stamping shall be a 3- inch square located at the lower right corner above the title block. Drawings submitted without sufficient information or sufficient spaces for making corrections and stamping will be returned without approval. 8/13/09 Contract No. 3811 SUBMITTALS PALOMAR AIRPORT ROAD WIDENING 01300-6 4. Printed material such as catalog sheets, brochures, or other printed sheets may be submitted in place of drawings, provided that the printed material fully describes the manufactured articles to be installed. If in the opinion of the Engineer the printed material does not adequately describe the item, the printed material will be rejected and a shop drawing shall be submitted. 5. Substitution of tabular computer printouts for layout drawings will not be acceptable; however, the Contractor may submit computer printouts along with the mandatory drawings. CAD drawings are acceptable for submittal. C. Samples 1. Samples of fabricated items shall conform to the specified requirements for tolerance and finish for the work they represent. 2. Samples of materials shall be physically identical to the size, type, color, pattern, and texture of the materials proposed for incorporation in the work. 3. When selection from a range of choices is specified, samples for selection of color, pattern, texture, or other characteristic shall include a full set of the standard range of choices for the material or product. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION (NOT USED) 8/13/09 Contract No. 3811 SUBMITTALS PALOMAR AIRPORT ROAD WIDENING 01300-7 LETTER OF TRANSMITTAL FOR SUBMITTAL NO. CONTRACTOR: ADDRESS: PHONE: FAX: TO: Construction Management & Inspection City of Carlsbad 5950 El Camino Real Carlsbad, CA 92008 DATE: CONTRACT NO: NO: PROJECT: SPEC. WE ARE SUBMITTING THE ENCLOSED: D SHOP DRAWINGS D EQUIPMENT DATA D MATERIAL DATA D SAMPLES D CERTIFICATES OF COMPLIANCE D OTHER FOR YOUR: D APPROVAL D INFORMATION PLEASE RETURN COPIES FOR OUR RECORDS ITEM NO. DESCRIPTION OF ITEM NO. OF COPIES CONTRACT REFERENCE SPEC. SECTION OR DRAWING SHEET NO. # VARIATION REMARKS: All deviations from the construction contract shall be explained in detail. I certify that the above submitted items have been reviewed in detail and are correct and in strict conformance with the contract drawings and specifications except as otherwise stated. NAME/SIGNATURE OF CONTRACTOR DISPOSITION: D APPROVED D REVIEWED—NO CORRECTIONS NOTED D APPROVED AS REVISED D REVIEWED—CORRECTIONS NOTED—NO RESUBMITTAL REQUIRED D RETURNED FOR REVISION D REVIEWED—RESUBMITTAL REQUIRED I I SEE ATTACHED SHEET FOR COMMENTS SIGNATURE AND TITLE OF APPROVING AUTHORITY DATE 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 SUBMITTALS 01300-8 SECTION 02050 DEMOLITION PART 1 - GENERAL 1.1 THE REQUIREMENT A. THE CONTRACTOR shall furnish materials, equipment, and labor necessary to perform and complete demolition work called for in the Contract Documents. B. The WORK includes demolition of landscape, irrigation system, curb, gutter, sidewalk, pavement, fence, storm drain structure, and other items drawn in the plans to facilitate new construction as shown and specified. The WORK also includes the relocation of fence, light poles, traffic signals, signs, and other items as shown in the plans. C. Manufactured articles, materials, equipment, and accessories shall be demolished as shown and in accordance with the manufacturer's specifications and recommendations, and industry standards, unless otherwise shown or specified. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [02110] Clearing, Grubbing, and Stripping. B. Section [02200] Earthwork. C. PROTECTION OF PERSONS AND PROPERTY AND RESTORATION OF EXISTING IMPROVEMENTS of the GENERAL PROVISIONS. D. ENVIRONMENTAL CONTROLS of the GENERAL PROVISIONS. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the applicable reference specifications as specified in the GENERAL PROVISIONS. B. Comply with the Carlsbad City Building Code. 1.4 CONTRACTOR SUBMITTALS A. General: Submittals shall be made in accordance with the GENERAL PROVISIONS. B. Demolition Schedule: The CONTRACTOR shall submit a complete coordination schedule for demolition work, including shut-off and continuation of utility services, with the ENGINEER'S approval prior to start of the work. The schedule shall indicate proposed methods and operations of facility demolition, and provide a detailed sequence of demolition and removal work to ensure uninterrupted operation of occupied areas. 8/13/09 Contract No. 3811 DEMOLITION PALOMAR AIRPORT ROAD WIDENING 02050-1 1.5 QUALITY ASSURANCE A. Comply with the applicable reference specifications as specified in the GENERAL PROVISIONS. 1.6 JOB CONDITIONS A. Condition of Facilities: AGENCY assumes no responsibility for actual condition of facilities to be demolished. The CONTRACTOR shall visit the site and inspect the existing facilities. PART 2 - PRODUCTS (Not Used) PART 3 - EXECUTION 3.1 OCCUPANCY AND POLLUTION CONTROL A. Water sprinkling, temporary enclosures, chutes, and other suitable methods shall be used to limit dust and dirt rising and scattering in the air. Comply with AGENCY regulations pertaining to environmental protection. B. Water shall not be used when it creates hazardous or objectionable conditions such as ice, flooding, or pollution. C. Water contaminated with sediment or hazardous or toxic materials shall not be allowed to run off into the public storm drain system (including street gutters). Such runoff shall be intercepted, collected and disposed of according to existing environmental regulations. 3.2 PROTECTION A. Safe passage of persons around area of demolition shall be ensured. Operations shall be conducted to prevent damage to adjacent buildings, structures, other facilities, and people. B. Interior and exterior shoring, bracing, or supports shall be provided to prevent movement, settlement or collapse of structures to be demolished, and to adjacent facilities to remain. C. Existing landscaping materials, structures, and appurtenances, which are not to be demolished shall be protected and maintained as necessary and in accordance with Section 7-9 PROTECTION AND RESTORATION OF EXISTING IMPROVEMENTS of the GENERAL PROVISIONS. D. The CONTRACTOR shall protect and maintain conduits, drains, sewers, pipes, and wires that are to remain on the property. 8/13/09 Contract No. 3811 DEMOLITION PALOMAR AIRPORT ROAD WIDENING 02050-2 3.3 STRUCTURE DEMOLITION A. Building structures and appurtenances shall be demolished as shown and required to complete work within limitations of governing regulations. B. Small structures may be removed intact when acceptable to the ENGINEER and approved by authorities having jurisdiction. C. Demolition shall proceed in a systematic manner, in accordance with permits and approved submittals. D. Concrete and masonry shall be demolished in sections. Use bracing and shoring to prevent collapse. E. Demolition equipment shall be dispersed throughout structure and demolished materials removed to prevent excessive loads on supporting walls, floors, or framing. 3.4 BELOW-GRADE DEMOLITION A. Footings, foundation walls, traffic signal foundations, below-grade construction and concrete slabs on grade shall be demolished and removed. B. Below-grade areas and voids resulting from demolition of structures shall be completely filled. C. All fill and compaction shall be in accordance with Section [02200], "Earthwork". D. After fill and compaction, surfaces shall be graded to meet adjacent contours and to provide flow to surface drainage structures, or as shown. 3.5 DISPOSAL OF DEMOLISHED MATERIALS A. Demolition and removal of debris shall be conducted to ensure minimum interference with roads, streets, walks; and other adjacent occupied or used facilities which shall not be closed or obstructed without permission from the CITY. Alternate routes shall be provided around closed or obstructed traffic ways. B. Site debris, rubbish, hazardous materials identified in Part 1.1-B herein and other materials resulting from demolition operations shall be removed at the CONTRACTOR'S expense. Burning of removed materials from demolished structures shall not be permitted on site. C. The ENGINEER will provide a list of approved Treatment, Storage and Disposal Facilities (TSDF's) from which the contractor may select one for disposal of hazardous waste. D. The CONTRACTOR shall request from the ENGINEER an EPA Generator ID Number. The ENGINEER will provide the number to the CONTRACTOR. This number will be used on all Hazardous Waste Manifests or Shipping Papers used to transport hazardous waste. Copies of all manifests and shipping papers will be provided to the ENGINEER at 8/13/09 Contract No. 3811 DEMOLITION PALOMAR AIRPORT ROAD WIDENING 02050-3 the time of transport for any Hazardous Waste and completed copies signed by the TSDF will be returned to the ENGINEER within the time frames specified by state and federal regulations. E. The CONTRACTOR shall dispose of the removed landscaping at El Corazon Composting Facility, 3210 Oceanside Blvd., Oceanside, CA 92054, (760) 439-9920, or approved equal. 3.6 PATCHING AND REPAIRING A. The CONTRACTOR shall provide patching, replacing, repairing, and refinishing of damaged areas involved in demolition as necessary to match the existing adjacent surfaces whether shown or not shown, with materials and procedures approved by the ENGINEER. B. The CONTRACTOR shall repair all damages caused to adjacent facilities by demolition as directed by the ENGINEER at no cost to the CITY. C. The CONTRACTOR shall make a detailed inspection after patching and repairing has been completed, and shall carefully remove splattering of mortar from adjoining work (particularly, but not limited to, plumbing fixtures, trim, tile, and finish metal surfaces), and make good any damage caused by such cleaning operations. 3.7 CLEANING A. During and upon completion of work, the CONTRACTOR shall promptly remove unused tools and equipment, surplus materials, rubbish, debris, and dust and shall leave areas affected by work in a clean, approved condition in accordance with the GENERAL PROVISIONS. B. Clean adjacent structures and facilities of dust, dirt, and debris caused by demolition, as directed by the ENGINEER or the INSPECTOR, and return adjacent areas to condition existing prior to start of work. C. The CONTRACTOR shall remove and legally dispose of demolished materials and debris from the site. 8/13/09 Contract No. 3811 DEMOLITION PALOMAR AIRPORT ROAD WIDENING 02050-4 3.8 SALVAGE A. The CONTRACTOR shall tag all salvageable items. The tag shall indicate what the item is, the location and equipment it was removed from, and the date of removal. 1. The "salvaged" and "relocated" items shall be relocated as shown in the drawings. B. All non-salvageable items shall be removed at the CONTRACTOR'S expense. 8/13/09 Contract No. 3811 DEMOLITION PALOMAR AIRPORT ROAD WIDENING 02050-5 SECTION 02110 ^"V CLEARING, GRUBBING, AND STRIPPING - PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work associated with removal of all natural and artificial objectionable material from the designated areas of work as indicated in the Contract Documents. B. This section shall also include the protection from injury and preservation of existing improvements, adjacent property, utility vegetation and existing objects designated to remain. C. Prior to commencing the work, obtain acceptance from the ENGINEER regarding methods to be used and disposal of removed materials. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [02200] Earthwork. B. Section [02050] Demolition. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS ^'•***«>>' A. Comply with the applicable reference specifications of the GENERAL PROVISIONS. 1.4 CONTRACTOR SUBMITTALS A. Submit schedule of clearing, grubbing, and erosion control measures to be put in place for all work scheduled during the rainy season (October - April). 1.5 QUALITY ASSURANCE A. Comply with the applicable Reference Specifications of the GENERAL PROVISIONS. PART 2 - PRODUCTS 2.1 GENERAL A. Clearing shall consist of removing all vegetable growth such as trees, roots, stumps, shrubs, brush, limbs, and other vegetative growth. Remove all evidence of their presence from the growth surface. Clearing shall also include the removal and disposal of trash piles, rubbish, and fencing. 2.2 PRESERVATION OF TREES, SHRUBS, AND OTHER VEGETATION A. Protect trees, shrubbery, and other vegetation not designated for removal from damage resulting from the work. Cut and remove tree branches only where, in the opinion of the ENGINEER, such cutting is necessary to effect construction. Scars resulting from the ^a^ removal of branches shall be treated with an approved tree sealant. .3 8/13/09 Contract No. 3811 CLEARING, GRUBBING, AND STRIPPING PALOMAR AIRPORT ROAD WIDENING 02110-1 2.3 GRUBBING A. Grubbing shall consist of the removal and disposal of wood, stumps or root matter 36 inches below the ground or subgrade surface, whichever is deeper, unless otherwise shown on the Drawings. Clearing shall include stumps, logs, roots, or root systems greater than 1.5 inches in diameter or thickness. 2.4 CLEARING AND GRUBBING FOR TRENCHING A. The CONTRACTOR shall obtain ENGINEER'S approval before beginning excavation. The CONTRACTOR shall complete clearing and grubbing prior to the start of trenching. The CONTRACTOR shall not permit excavated materials to cover vegetation prior to disposal. 2.5 REMOVAL AND DISPOSAL OF CLEARING AND GRUBBING DEBRIS A. General: All materials removed shall be disposed of outside of the right-of-way. No accumulation of flammable material shall remain on or adjacent to the right-of-way. The roadway and adjacent areas shall be left with a neat and finished appearance. B. Bituminous Pavement: Bituminous pavement removal shall be in conformance with SSPWC Section 300-1.3.2. C. Concrete Pavement: Concrete pavement removal shall be in conformance with SSPWC Section 300-1.3.2. D. Concrete Curb, Walk, Gutters, Cross Gutters, Driveways, and Alley Intersections: Concrete removal shall be in conformance with SSPWC Section 300-1.3.2. E. See Section 02050 Demolition for disposal site requirements. 2.6 STRIPPING A. Stripping shall include the removal and disposal of all organic sod, topsoil, grass and grass roots, and other objectionable material remaining after clearing and grubbing from the areas designated to be stripped. The depth of stripping shall be as shown on the Drawings and specified herein. B. Topsoil from the strippings shall be stockpiled and used for the finished site grading. Excess topsoil will be placed in the waste disposal areas designated by the ENGINEER. PART 3 -- EXECUTION 3.1 CLEARING AND GRUBBING A. Clearing and grubbing shall be in conformance with the SSPWC Section 300-1, except 300-1.4. 8/13/09 Contract No. 3811 CLEARING, GRUBBING, AND STRIPPING PALOMAR AIRPORT ROAD WIDENING 02110-2 3.2 STRIPPING A. Prior to beginning any excavation or fill, strip the topsoil to a depth sufficient to remove all organic material. In general, topsoil shall be removed where structures are to be built, trenches dug, and roads, parking lots, walks, and similar improvements constructed within the areas presently covered with topsoil. Topsoil shall be stored clear of the construction area. Take reasonable care to prevent the topsoil from becoming mixed with subsoil. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CLEARING, GRUBBING, AND STRIPPING 02110-3 SECTION 02140 DEWATERING PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall dewater trench and structure excavations, in accordance with the Contract Documents. The CONTRACTOR shall secure all necessary permits to complete the requirements of this Section of the Specifications. B. Ground water will likely be encountered during the construction of the pile foundations for the overhead sign structure. 1.2 CONTRACTOR SUBMITTALS A. Prior to commencement of excavation, the CONTRACTOR shall submit a detailed plan and operation schedule for dewatering of excavations. The CONTRACTOR may be required to demonstrate the system proposed and to verify that adequate equipment, personnel, and materials are provided to dewater the excavations at all locations and times. The CONTRACTOR'S dewatering plan shall have a layout plan of the dewatering system and provide an approved water disposal system. The CONTRACTOR'S dewatering plan shall be reviewed by the Engineer. 1.3 QUALITY CONTROL A. It shall be the sole responsibility of the CONTRACTOR to control the rate and effect of the dewatering in such a manner as to avoid all objectionable settlement and subsidence. B. All dewatering operations shall be adequate to assure the integrity of the finished project and shall be the responsibility of the CONTRACTOR. C. Where critical structures or facilities exist immediately adjacent to areas of proposed dewatering, reference points shall be established and observed at frequent intervals to detect any settlement which may develop. The responsibility for conducting the dewatering operation in a manner which will protect adjacent structures and facilities rests solely with the CONTRACTOR. The cost of repairing any damage to adjacent structures and restoration of facilities shall be the responsibility of the CONTRACTOR. PART 2 - PRODUCTS 2.1 EQUIPMENT A. Dewatering, where required, may include the use of well points, sump pumps, temporary pipelines for water disposal, rock or gravel placement, and other means. Standby pumping equipment shall be maintained on the jobsite. 8/13/09 Contract No. 3811 DEWATERING PALOMAR AIRPORT ROAD WIDENING 02140-1 PART 3 - EXECUTION 3.1 GENERAL REQUIREMENTS A. The CONTRACTOR shall provide all equipment necessary for dewatering. It shall have on hand, at all times, sufficient pumping equipment and machinery in good working condition and shall have available, at all times, competent workmen for the operation of the pumping equipment. Adequate standby equipment shall be kept available at all times to ensure efficient dewatering and maintenance of dewatering operation during power failure. B. Dewatering for structures and pipelines shall commence when groundwater is first encountered, and shall be continuous until such times as water can be allowed to rise in accordance with the provisions of this Section or other requirements. C. At all times, site grading shall promote drainage. Surface runoff shall be diverted from excavations. Water entering the excavation from surface runoff shall be collected in shallow ditches around the perimeter of the excavation, drained to sumps, and be pumped or drained by gravity from the excavation to maintain a bottom free from standing water. D. Dewatering shall at all times be conducted in such a manner as to preserve the undisturbed bearing capacity of the subgrade soils at proposed bottom of excavation. E. If foundation soils are disturbed or loosened by the upward seepage of water or an uncontrolled flow of water, the affected areas shall be excavated and replaced with drain rock. F. The CONTRACTOR shall maintain the water level below the bottom of excavation in all work areas where groundwater occurs during excavation construction, backfilling, and up to acceptance. G. Flotation shall be prevented by the CONTRACTOR by maintaining a positive and continuous removal of water. The CONTRACTOR shall be fully responsible and liable for all damages which may result from failure to adequately keep excavations dewatered. H. If well points or wells are used, they shall be adequately spaced to provide the necessary dewatering and shall be sandpacked and/or other means used to prevent pumping of fine sands or silts from the subsurface. A continual check by the CONTRACTOR shall be maintained to ensure that the subsurface soil is not being removed by the dewatering operation. I. The CONTRACTOR shall dispose of water from the WORK in a suitable manner without damage to adjacent property. CONTRACTOR shall be responsible for obtaining any permits that may be necessary to dispose of water. No water shall be drained into work built or under construction without prior consent of the ENGINEER. Water shall be filtered using an approved method to remove sand and fine-sized soil particles before disposal into any drainage system. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 381 1 DEWATERING 02140-2 J. The release of groundwater to its static level shall be performed in such a manner as to maintain the undisturbed state of the natural foundation soils, prevent disturbance of compacted backfill and prevent flotation or movement of structures, pipelines, and sewers. K. Dewatering of trenches and other excavations shall be considered as incidental to the construction of the WORK and all costs thereof shall be included in the various contract prices in the Bid Forms, unless a separate bid item has been established for dewatering. 8/13/09 Contract No. 3811 DEWATERING PALOMAR AIRPORT ROAD WIDENING 02140-3 SECTION 02200 EARTHWORK PART 1 - GENERAL 1.1 THE REQUIREMENT A. The work of this Section includes all earthwork required for construction of the WORK. Such earthwork shall include, but not be limited to, the loosening, removing, loading, transporting, depositing, and compacting in its final location of all materials wet and dry, as required for the purposes of completing the work specified in the Contract Documents, which shall include, but not be limited to, the furnishing, placing, and removing of sheeting and bracing necessary to safely support the sides of all excavation; all pumping, ditching, draining, dewatering, and other required measures for the removal or exclusion of water from the excavation; the supporting of structures above and below the ground; all backfilling around structures and all backfilling of trenches and pits; the disposal of excess excavated materials; borrow of materials to make up deficiencies for fills; and all other incidental earthwork, all in accordance with the requirements of the Contract Documents. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Division [02] FACILITIES SITEWORK, as applicable. B. Division [15] MECHANICAL, Piping, General. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the applicable reference specifications as specified in the GENERAL PROVISIONS. B. Comply with the current provisions of the following Codes and Standards: 1. Commercial Standards: ASTMC136 Test Method for Sieve Analysis of Fine and Coarse Aggregates. ASTM D 422 Test Method for Particle-Size Analysis of Soils. ASTM D 1556 Test Method for Density of Soil in Place by the Sand-Cone Method. ASTM D 1557 Test Methods for Moisture-Density Relations of Soils and Soil-Aggregate Mixtures Using 10-lb (4.54-kg) Rammer and 18-in (457-mm) Drop. ASTM D 1633 Test Method for Compressive Strength of Molded Soil-Cement Cylinders. ASTM D 2166 Test Method for Unconfined Compressive Strength of Soils. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-1 ASTMD2419 Test Method for Sand Equivalent Value of Soils and Fine Aggregate. ASTM D 2435 Test Method for One-Dimensional Consolidation Properties of Soils. ASTM D 2487 Classification of Soils for Engineering Purposes. ASTM D 2901 Test Method for Cement Content of Freshly-Mixed Soil-Cement. ASTM D 2922 Test Methods for Density of Soil and Soil- Aggregate in Place by Nuclear Methods (Shallow Depth). ASTM D 3017 Test Methods for Moisture Content of Soil & Rock in Place by Nuclear Methods (Shallow Depth). UBC No. 29-2 Test Method for Expansion Index of Soils. 2. Standard Specifications: SSPWC Sections 203-1, 203-2, 203-3 - Bituminous Materials SSPWC Section 211 - Soil and Aggregate Tests SSPWC Section 300 - Earthwork SSPWC Section 306-1 - Open Trench Operations 3. Uniform Building Code: 4. California Labor Code. 1.4 CONTRACTOR SUBMITTALS A. Submittals, including samples of materials, shall be in accordance with the GENERAL PROVISIONS. B. The CONTRACTOR'S attention is directed to the provisions for "Shoring and Bracing Drawings" in Section 6705 of the California Labor Code, and SSPWC Section 306-1.1. The CONTRACTOR, prior to beginning any trench or structure excavation 5 feet deep or over shall submit to the ENGINEER and shall be in receipt of the ENGINEER written acceptance of the CONTRACTOR'S detailed plan showing design of all shoring, bracing, sloping of the sides of excavation, and other provisions for worker protection against the hazard of caving ground during the excavation of such trenches or structure excavation. The plans shall be prepared by a qualified civil or structural engineer licensed in the State of California and employed by an independent engineering firm insured against errors and omissions to the extent required by the ENGINEER. The submittal(s) shall include a site location map referencing existing features; detailed plans; elevations, and various sections indicating all excavation slopes, shoring components and connections and showing all structures and utilities potentially influenced by the performance of shoring, trenching or structure excavation along with supporting calculations; notes 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-2 including sequence of construction, materials, and other clarification as required by the California Labor Code, SSPWC, and the contract documents. 1.5 QUALITY ASSURANCE A. General: All soils testing will be done by a testing laboratory of the ENGINEER'S choice at the AGENCY'S expense except as specified in Paragraph 1.5C below. B. Where soil material is required to be compacted to a percentage of maximum dry density, the maximum dry density at optimum moisture content will be determined in accordance with the latest version of ASTM D 1557. tn-place field density tests will be performed in accordance with ASTM D 1556, (sand cone) and/or ASTM D 2922 and ASTM D 3017 (nuclear gauge). The number and location of field density tests will be determined by the ENGINEER. At least one sand-cone test (ASTM D 1556) will be taken for every [four] nuclear tests (ASTM D 2922 and 3017). C. In case the tests of the fill or backfill show non-compliance with the required density, the CONTRACTOR shall accomplish such remedy as may be required to ensure compliance. Subsequent testing to show compliance shall be by a testing laboratory selected by the ENGINEER and shall be at the CONTRACTOR'S expense. All imported fill material not specified in the contract shall be tested at the CONTRACTOR'S expense and approved by the ENGINEER. D. Where imported fill material is required to possess certain gradation, strength, and settlement properties, the grain size distribution of soils will be determined using ASTM D 422, the gradation of concrete aggregate and base materials will be determined using ASTM C 136, the sand equivalent of soils will be determined using ASTM D 2419, the consolidation of soils will be determined using ASTM D 2435, the unconfmed compressive strength of soils will be determined using ASTM D 2166, and the expansion index of soils will be determined using UBC No. 29-2. 2.1 SUITABLE FILL AND BACKFILL MATERIAL REQUIREMENT A. General: Fill, backfill, and embankment materials shall be suitable selected or processed clean, fine earth, rock, or sand, and free from grass, roots, brush, or other vegetation; contamination; or deleterious material. B. Suitable materials may be obtained from onsite excavations, may be processed onsite materials, or may be imported provided these materials meet all the requirements in the contract documents. If imported materials are required to meet the requirements of this Section or to meet the quantity requirements of the project, the CONTRACTOR shall provide the imported fill materials and the required reports of test results at no additional expense to the AGENCY, unless a unit price item is included for imported materials in the bidding schedule. Unclassified fill shall consist of all fill unless separately designated. Unclassified fill shall conform to the requirements of SSPWC Section 300-4 and the requirements stated in the recommendations of the Geotechnical Report. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-3 The following types of suitable materials are designated and defined as follows: 1. 2. Crushed Aggregate Base (CAB) shall conform to the requirements of SSPWC Section 200-2.2. Crushed Miscellaneous Base (CMB) shall conform to the requirements of SSPWC Section 200-2.4. Drainrock shall be crushed rock or gravel, durable and free from slaking or decomposition under the action of alternate wetting or drying. The material shall be uniformly graded and shall meet the following gradation requirements: Sieve Size 1-inch 3/4-inch 3/8-inch No. 4 No. 8 No. 30 No. 50 No. 200 Percentage Passing 100 90-100 40-100 25-40 18-33 5-15 0-7 0-3 The drainrock shall have a sand equivalent value not less than 75. The finish graded surface of the drainrock immediately beneath hydraulic structures shall be stabilized to provide a firm, smooth surface upon which to construct reinforced concrete floor slabs. The CONTRACTOR shall use, at its option, one of the asphalt types listed below, conforming to SSPWC Section 203-2 or SSPWC Section 203-3. Designation Spray Temperature (°F) Coverage (gal/sq yd) Type 1 SC-70 135-175 0.50 Type 2 SC-250 165-200 0.50 Type 3 RS-1 70-120 0.50 If the surface remains tacky, sufficient sand shall be applied to absorb the excess asphalt. Primary Structural Fill shall conform to the requirements stated in the recommendations of the Geotechnical Report. Structure Backfill material shall conform to the requirements of SSPWC Section 300-3.5.1 and the requirements stated in the recommendations of the Geotechnical Report. Previous Backfill material shall conform to the requirements of SSPWC Section 300-3.5.2 and the requirements in the recommendations stated in the recommendations of the Geotechnical Report. Type A Bedding material shall conform to the requirements for 3/4-inch Crushed Rock, 1/2-inch Crushed Rock, No. 3 Concrete Aggregate, No. 4 Concrete Aggregate, or Portland Cement Concrete Sand in SSPWC Section 200-1 for pipes larger than 24 inches in diameter. Type A Bedding material shall conform to the requirements for Type B Bedding material or the requirements for Portland Cement Concrete Sand in SSPWC Section 200-1 for pipes 24 inches or smaller in diameter. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 EARTHWORK 02200-4 Type B Bedding material shall conform to the requirements for 1/2-inch Crushed Rock or No. 4 Concrete Aggregate in SSPWC Section 200-1. Concrete Pipe Bedding material shall conform to the requirements of SSPWC Section 201-1. Sand-Cement Slurry material shall conform to the requirements of SSPWC Section 201- 1 for Trench Backfill Slurry. Soil Cement material shall conform to the requirements of SSPWC Section 301-3.1. Topsoil material shall conform to the requirements of SSPWC Section 212-1.1. USE OF FILL, BACKFILL, AND EMBANKMENT MATERIAL TYPES C. The CONTRACTOR shall use the types of materials as designated herein for all required fill, backfill, and embankment construction hereunder. D. Where these Specifications conflict with the requirements of any local agency having jurisdiction, or with the requirements of a material manufacturer, the ENGINEER shall be immediately notified. In case of conflict therewith, the CONTRACTOR shall use the most stringent requirement, as determined by the ENGINEER. E. Fill and backfill types shall be used in accordance with the following provisions: 1. Embankment fills shall be constructed of Unclassified Fill material, as defined herein. 2. Pipe zone backfill, as defined under "Pipe and Utility Trench Backfill" herein, shall consist of the following materials for each pipe material listed below. a. Mortar coated pipe, concrete pipe, and uncoated ductile iron pipe shall be provided Type A Bedding, Type B Bedding, or Concrete Pipe Bedding materials as defined herein for pipe zone backfill material. b. Coal tar enamel coated pipe, polyethylene encased pipe, tape wrapped pipe, and other non-mortar coated pipe shall be backfilled with Portland Cement Concrete sand conforming to SSPWC Section 200-1 or Concrete Pipe Bedding material as defined herein for pipe zone backfill material. c. Plastic pipe and vitrified clay pipe shall be backfilled with 3/4-inch Crushed Rock conforming to SSPWC Section 200-1 or Concrete Pipe Bedding material as defined herein for pipe zone backfill material. 3. Trench zone backfill for pipelines as defined under "Pipe and Utility Trench Backfill" shall be Unclassified Fill material as defined herein unless conditions require the use of a designated material as indicated in the Contract Documents. 4. Final backfill material for pipelines under paved areas, as defined under "Pipe and Utility Trench Backfill" shall be Crushed Aggregate Base (CAB) material as defined herein. 5. Trench backfill and final backfill for pipelines under structures shall be the same material as used in the pipe zone, except where concrete encasement is required by the Contract Documents. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-5 6. Aggregate base materials under pavements shall be Crushed Aggregate Base (CAB) material constructed to the thickness shown or specified. 7. Backfill around or behind structures shall consist of Structure Backfill as defined herein unless indicated otherwise in the Contract Documents. 8. Fill materials beneath structures shall be as follows: a. Fill beneath hydraulic structures or other water retaining structures with underdrain systems shall be drainrock material, as defined herein, constructed to the limits and thicknesses shown or specified. b. Fill beneath structures without underdrain systems shall be Primary Structural Fill as defined herein. c. Fill beneath structures where groundwater must be removed to allow placement of concrete shall be Primary Structural Fill as defined herein. 9. Backfill used to replace pipeline trench over-excavation shall consist of Type B Bedding material as defined herein. PART 3 - EXECUTION 3.1 CLEARING, GRUBBING, AND STRIPPING A. Clearing and grubbing shall be performed in accordance with SSPWC Section 300-1. B. Stripping shall include the removal and disposal of all organic sod, topsoil, grass and grass roots, and other objectionable material remaining after clearing and grubbing from the areas designated to be stripped. The depth of stripping shall be as shown on the Drawings and specified herein. C. Topsoil from the strippings shall be stockpiled and may be used for the finished site grading, subject to the approval of the ENGINEER. Excess topsoil will be placed in the waste disposal areas designated by the ENGINEER. D. Prior to beginning any excavation or fill, strip the topsoil to a depth sufficient to remove all organic material. In general, topsoil shall be removed where structures are to be built, trenches dug, and roads, parking lots, walks, and similar improvements constructed within the areas presently covered with topsoil. Topsoil shall be stored clear of the construction area. Take reasonable care to prevent the topsoil from becoming mixed with subsoil. 3.2 STRUCTURE, ROADWAY, AND EMBANKMENT EXCAVATION A. General: Except when specifically provided to the contrary, excavation shall include the removal of all materials of whatever nature encountered, including all obstructions of any nature that would interfere with the proper execution and completion of the work. The removal of said materials shall conform to the lines and grades shown or ordered. Unless otherwise provided, the entire construction site shall be stripped of all vegetation, debris, and all deleterious materials, and such materials shall be removed from the site prior to performing any excavation or placing any fill. The CONTRACTOR shall furnish, place, and maintain all supports and shoring that may be required for the sides of the excavations, and all pumping, ditching, or other measures for the removal or exclusion of 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-6 water, including taking care of storm water, groundwater (dewatering if required), and wastewater reaching the site of the work from any source so as to prevent damage to the work or adjoining property. Excavations shall be sloped or otherwise supported in a safe manner in accordance with applicable Uniform Building Code requirements, State safety requirements, and the requirements of OSHA Safety and Health Standards for Construction (29CFR1926), and the Contract Documents. B. Shoring of Excavations: The CONTRACTOR shall be fully responsible for providing and constructing shoring and bracing to prevent slides or cave-ins and to protect all existing improvements in the vicinity from damage as required. The CONTRACTOR shall submit to the ENGINEER, for approval, shop drawings showing the limits, design criteria, shoring details, sequence of placement and removal, dewatering plans, and other data deemed pertinent by the Engineer to shore the excavation in accordance with the GENERAL PROVISIONS. These shop drawings shall be prepared, signed, and sealed by a qualified Civil or Structural Engineer registered in the State of California. 1. All piling required for shoring shall be installed by drilling. Driven piles of any types will not be allowed without the approval of the ENGINEER. 2. The CONTRACTOR shall not begin excavation operations until the shoring drawings have been reviewed by the ENGINEER. Review of the CONTRACTOR shoring plans shall not be constructed to invalidate other provisions of the GENERAL PROVISIONS (or these Specifications) or relieve the CONTRACTOR of the responsibilities inherent in the pursuance of the work. The CONTRACTOR shall, at its cost and for all its shoring work, obtain permits from the Engineering Department. 3. The CONTRACTOR shall furnish all labor, equipment, and materials to construct, install, and remove the entire shoring system including removal of lagging, soldier beams, and bracing and detensioning of tiebacks. Full compensation for the shoring and its removal shall be considered as included in the Contract Price and no additional compensation will be allowed. 4. Design of shoring shall be in accordance with the applicable requirements of the Uniform Building Code, and the Safety Orders of the Division of Industrial Safety, State of California. The CONTRACTOR shall be responsible for providing more extensive shoring or bracing systems than those required by the Construction Safety Orders when necessitated by conditions indicated on the drawings, specified, or otherwise required by the Work. 5. The shoring and bracing shall be designed in accordance with the data provided in the Geotechnical Investigation Report and shall consider all surcharge loads imposed. 6. Where the shoring support system is within 10 feet of a street, it shall be designed to withstand a minimum surcharge load equivalent to 2 feet in height of earth added to the active earth pressure in the upper 10 feet of shoring. Shoring support systems adjacent to other structures shall be designed to withstand all loads applied to the shoring system from adjacent structures. 7. Where shoring will support adjacent structures or facilities and excessive deflection can lead to structure settlement, braced or tieback shoring shall be utilized. Braced or tieback shoring supporting adjacent nearby facilities shall be designed and constructed to limit the maximum horizontal deflection of the 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-7 "•"I shoring to 1/2-inch or less as directed by the ENGINEER. Deflection of the shoring system shall be monitored on a weekly basis by a licensed surveyor employed by the CONTRACTOR. Monitoring of the shoring shall be performed in the presence of the ENGINEER, with a written report to be submitted to the ENGINEER within 24 hours. 8. Any delay and/or expense incurred due to excess shoring deflection shall be at the CONTRACTOR'S expense. 9. Where tieback anchors are used in shoring excavations, the installation and testing of tieback anchors shall comply as specified herein. 10. The CONTRACTOR shall provide all equipment and instrumentation necessary for verification of the adequacy of the tiebacks. a. A dial gauge capable of measuring displacements to 0.001 inch precision and having 6 inches of travel shall be used to measure tieback movement. b. A hydraulic jack and pump shall be used to apply the test load. The pressure gauge shall be graduated in 100 psi increments or less. The load shall be applied incrementally. The load shall be raised or lowered from one increment to another as determined by the ENGINEER. c. The stressing equipment shall be placed over the anchor tendon in such a manner that the jack, bearing plate, and streesing anchorage are axially aligned with the tendon and the tendon is centered within the equipment. 11. For temporary tieback anchor installation, the number of anchors tested to the 200 percent design load shall be determined by the ENGINEER; however, a minimum of 2 percent of the anchors at each level shall be tested to the 200 percent load and held at a constant tension for a period of time not less than 24 hours. Once the loading for 200 percent of the design load is reached, the axial extension of the anchor assembly shall not exceed 1/2-inch. An axial extension exceeding 1 inch is considered as failure, while axial extensions ranging from 1/2-inch to 1 inch may be assigned partial capacity ratings subject to approval of the structural engineer responsible for the design of the shoring system and the ENGINEER. The total axial anchor extension, measured from the time of initial load application to the termination of the 200 percent load shall not exceed 4 inches. If the total axial extension of the anchor exceeds 4 inches, the ENGINEER may down rate or reject the anchor as unacceptable. 12. All remaining tieback anchors shall be proof tested to at least 150 percent of the design load. Any proof-tested anchor with axial extension exceeding 0.1 inch after 15 minutes under 150 percent of design load or a total axial extension exceeding 4 inches from initial application of load to termination of the test may be down rated or rejected by the ENGINEER. 13. The CONTRACTOR shall submit anchor-testing procedures to the ENGINEER for approval prior to installation of any temporary tieback anchors. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-8 14. Grouted anchors that depend on the maintenance of high grout pressures for ""•»•. their design capacity shall not be permitted. C. Excavation Beneath Structures and Embankments: Except where otherwise specified for a particular structure or ordered by the ENGINEER, excavation shall be carried to the grade of the bottom of the footing or slab. Where shown or ordered, areas beneath structures or fills shall be over-excavated. The subgrade areas beneath embankments shall be excavated to remove not less than the top [8 inches] of native material and where such subgrade is sloped, the native material shall be benched. When such over-excavation is shown, both over-excavation and subsequent backfill to the required grade shall be performed by the CONTRACTOR. When such over-excavation is not shown on the plan and not specified but is ordered by the ENGINEER, such over-excavation and any resulting backfill will be paid for under a separate unit price bid item if such bid item has been established and approved by the ENGINEER prior to commencing the work; otherwise payment will be made in accordance with a negotiated price. After the required excavation or over-excavation has been completed, the exposed surface shall be scarified to a depth of 8 inches, brought to optimum moisture content, and rolled with heavy compaction equipment to obtain the required relative compaction. D. Excavation Beneath Paved Areas: Excavation under areas to be paved shall extend to the bottom of the aggregate base, if such base is called for; otherwise it shall extend to the paving thickness. After the required excavation has been completed, the exposed surface shall be scarified to a depth of at least 12 inches, brought to optimum moisture content, and rolled with heavy compaction equipment to obtain 95 percent of maximum dry density. E. Excavation Subgrade and Below Subgrade: 1. Excavate and shape subgrade to line, grade, and cross-section shown on Drawings. Following receipt of written acceptance for the subgrade by the ENGINEER, compact the subgrade with approved equipment until the top 6-inches is compacted to [95] percent of maximum dry density at optimum moisture content as determined by ASTM D 1557. Remove all soft, loose, or otherwise unsuitable material and replace with suitable sandy material. The finished subgrade shall be firm, hard and unyielding. The subgrade shall be considered to extend over the full width of the base course. Compaction shall extend 18 inches beyond the edge of paving, curb, or form. 2. Where the ENGINEER deems subgrade material to be unsatisfactory, excavation below subgrade will be required to such depths as necessary to remove the unsatisfactory material. Excavation below grade shall be of the same classification as that above it provided it is removed in the same operation as the normal excavation. Special equipment or hand excavation may be required because of the presence of shallow utilities or other unforeseen conditions. F. Notification of ENGINEER; The CONTRACTOR shall notify the ENGINEER at least 2 working days in advance of completion of any structure excavation and shall allow the ENGINEER a review period of at least one day before the exposed foundation is scarified and compacted or is covered with backfill or with any construction materials. 3.3 PIPELINE AND UTILITY TRENCH EXCAVATION A. General: Unless otherwise shown or ordered, excavation for pipelines and utilities shall .•—», be open-cut trenches conforming to SSPWC Section 306-1.1. Trench widths shall be kept as narrow as is practical for the method of pipe zone densification selected by the 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-9 CONTRACTOR, but shall have a minimum width at the bottom of the trench equal to the outside diameter of the pipe plus 18 inches. The maximum width at the top of the pipe shall be in accordance with Table A of Standard Plan S-251. If the maximum trench width is exceeded, the Contractor shall provide substitute installation in accordance with Table B of Standard Plan S-251. B. Trench Bottom: Except when pipe bedding is required, the bottom of the trench shall be excavated uniformly to the grade of the bottom of the pipe. The trench bottom shall be given a final trim, using a string line for establishing grade, such that each pipe section when first laid will be continually in contact with the ground along the extreme bottom of the pipe. Rounding out the trench to form a cradle for the pipe will not be allowed. C. Open Trench: the maximum amount of open trench permitted in any one location shall be 500 feet, or the length necessary to accommodate the amount of pipe installed in a single day, whichever is greater. All trenches shall be fully backfilled at the end of each day or, in lieu thereof, shall be covered by heavy steel plates adequately braced and capable of supporting vehicular traffic in those locations where it is impractical to backfill at the end of each day. The above requirements for backfilling or use of steel plate will be waived in cases where the trench is located further than 100 feet from any traveled roadway or occupied structure. In such cases, however, barricades and warning lights meeting OSHA requirements shall be provided and maintained. D. Trench Over-Excavation: Where the Drawings indicate that trenches shall be over-excavated, they shall be excavated to the depth shown, and then backfilled to the grade of the bottom of the pipe. E. Over-Excavation: When ordered by the ENGINEER, whether indicated on the Drawings or not, trenches shall be over-excavated beyond the depth shown. Such over-excavation shall be to the depth ordered. The trench shall then be backfilled to the grade of the bottom of the pipe. All work specified in this Section shall be performed by the CONTRACTOR when the over-excavation ordered by the ENGINEER is less than 6 inches below the limits shown. When the over-excavation ordered by the ENGINEER is over 6 inches below the limits shown, additional payment will be made to the CONTRACTOR for that portion of the work which is located below said 6 inch distance. Said additional payment will be made under separate unit price bid items for over-excavation and bedding if such bid items have been established; otherwise payment will be made in accordance with a negotiated price. F. Where pipelines are to be installed in embankment or structure fills, the fill shall be constructed to a level at least one foot above the top of the pipe before the trench is excavated. F. Obtain ENGINEER'S approval before beginning excavation. Complete clearing and grubbing prior to the start of trenching. Do not permit excavated materials to cover brush or trees prior to disposal. 3.4 OVER-EXCAVATION NOT ORDERED, SPECIFIED, OR SHOWN A. Any over-excavation carried below the grade ordered, specified, or shown, shall be backfilled to the required grade with the specified material and compaction. Such work shall be performed by the CONTRACTOR at its own expense. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-10 3.5 EXCAVATION IN LAWN AREAS A. Where excavation occurs in lawn areas, the sod shall be carefully removed and stockpiled to preserve it for replacement. Excavated material may be placed on the lawn; provided, that a drop cloth or other suitable method is employed to protect the lawn from damage. The lawn shall not remain covered for more than 72 hours. Immediately after completion of backfilling and testing of the pipeline, the sod shall be replaced in a manner so as to restore the lawn as near as possible to its original condition and to the satisfaction of the ENGINEER. CONTRACTOR shall provide new sod if stockpiled sod has remained so for more than 72 hours within the scope of the contract. 3.6 EXCAVATION IN VICINITY OF TREES A. Except where trees are shown to be removed, trees shall be protected from injury during construction operations. No tree roots over 2 inches in diameter shall be cut without express permission of the ENGINEER. Trees shall be supported during excavation by any means previously reviewed by the ENGINEER. 3.9 PROTECTION OF SUBGRADE A. After preparing the subgrade as specified, all traffic on the subgrade shall be avoided. Should it be necessary to haul over the prepared subgrade, the CONTRACTOR shall drag and roll the traveled way as frequently as may be necessary to remove ruts, cuts, and breaks in the surface. All cuts, ruts, and breaks in the surface of the subgrade that are not removed by the above operations shall be raked and hand tamped. All equipment used for transporting materials over the prepared subgrade shall be equipped with pneumatic tires. B. Continued use of sections of prepared subgrade for hauling, so as to cut up or deform it from the true cross-section, will not be permitted. The CONTRACTOR shall protect the prepared subgrade from all traffic. C. The CONTRACTOR will be required to plank the subgrade before hauling materials or equipment over it. D. The subgrade shall be maintained in the finished condition until the first succeeding course or steel or concrete is placed. E. The ENGINEER has the right to test the reworked subgrade and approve or disapprove the subgrade depending on its condition. 3.10 BACKFILL-GENERAL A. Backfill shall not be dropped directly upon any structure or pipe. Backfill shall not be placed around or upon any structure until the concrete has attained specified strength to withstand the loads imposed. Backfill around water retaining structures shall not be placed until the structures have been tested, and the structures shall be full of water while backfill is being placed. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-11 B. Except for drainrock materials being placed in over-excavated areas or trenches, backfill shall be placed after all water is removed from the excavation. 3.11 PLACING AND SPREADING OF BACKFILL MATERIALS A. Backfill materials shall be placed and spread evenly in layers. When compaction is achieved using mechanical equipment, the layers shall be evenly spread in loose lifts not exceeding 8 inches in thickness so that when compacted each layer shall not exceed 6 inches in thickness. B. During spreading, each layer shall be thoroughly mixed as necessary to promote uniformity of material in each layer. Pipe zone backfill materials shall be manually spread around the pipe so that when compacted, the pipe zone backfill will provide uniform bearing and side support. C. Where the backfill material moisture content is below the optimum moisture content, water shall be added before or during spreading until the proper moisture content is achieved. D. Where the backfill material moisture content is too high to permit the specified degree of compaction, the material shall be dried until the moisture content is satisfactory, at or slightly above optimum moisture content. 3.12 EXPORT TO FILL SITE A. Truck loads certified by the inspector shall be used for measurement and payment. The contractor shall have the City Inspector approve each truck load. The Inspector shall keep record of the number of truck loads for payment. 3.13 COMPACTION OF FILL, BACKFILL, AND EMBANKMENT MATERIALS A. Each layer or fill shall be mechanically compacted using proper compaction equipment (not rubber tire or wheel rolling) to the specified percentage of maximum dry density. Equipment that is consistently capable of achieving the required degree of compaction shall be used and each layer shall be compacted over its entire area while the material is at the required moisture content. B. Fill on reservoir and structure roofs shall be deposited at least 30 days after the concrete roof slab has been placed. Equipment weighing more than 10,000 pounds when loaded shall not be used on a roof. A roller weighing not more than 8,000 pounds shall be used to compact fill on a roof. C. Flooding, ponding, or jetting shall not be used to densify and fill materials. D. Equipment weighing more than 10,000 pounds shall not be used closer to walls than a horizontal distance equal to the depth of the fill at that time, but not less than 5 feet. Hand operated power compaction equipment shall be used where use of heavier equipment is impractical or restricted due to weight limitations. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-12 Compaction Requirements: The following compaction test requirements shall be in accordance with ASTM D 1557. Where agency or utility company requirements govern, the highest compaction standards shall apply. "u'l'jf t' ."' ', ' , '/^ J; , " ''"4-%ii '-' • •?•'- Location or Use of Fill -: .•!-••""•-•. Pipe zone backfill portion above bedding for flexiblej>ipe. Pipe zone backfill bedding and over-excavated zones under bedding/pipe for flexible pipe. Pipe zone backfill portion above bedding for rigid pipe. Pipe zone backfill bedding and over-excavated zones under bedding/pipe for rigidj)ipe. Final backfill, beneath paved areas or structures. Final backfill, not beneath paved areas or structures. Trench zone backfill. Embankments. Embankments, beneath paved areas or structures. Backfill beneath structures, hydraulic structures. Backfill around structures, on reservoir or structure roof. Topsoil Aggregate base Percentage of Maximum Density 95 95 95 95 95 95 95 95 95 95 95 85 95 F. Trench Backfill Requirements: The pipe has been structurally designed based upon the trench configuration specified herein. G. The CONTRACTOR shall maintain the indicated trench cross section up to a horizontal plane lying 6 inches above the top of the pipe. H. If, at any location under said horizontal plane, the CONTRACTOR slopes the trench walls or exceeds the maximum trench widths indicated in the Contract Documents, the pipe zone backfill shall be "improved" or the pipe class increased as specified herein, at no additional cost to the AGENCY. "Improved" backfill shall mean sand-cement backfill containing at least 188 pounds of cement per cubic yard or equal materials acceptable to the ENGINEER. I. If the allowable vertical deflection specified for flexible pipe is exceeded, the CONTRACTOR shall expose and re-round or replace the pipe, repair all damaged lining and coating, and reinstall the pipe zone material and trench backfill as specified at no additional expense to the AGENCY. 3.14 PIPE AND UTILITY TRENCH BACKFILL A. Pipe Zone Backfill: The pipe zone is defined as that portion of the vertical trench cross-section lying between a plane 6 inches below the bottom surface of the pipe, i.e., the trench subgrade, and a plane at a point 6 inches above the top surface of the pipe. The bedding for flexible pipe is defined as that portion of pipe zone backfill material between the trench subgrade and the bottom of the pipe. The bedding for rigid pipe is defined as that portion of the pipe zone backfill material between the trench subgrade and a level line which varies from the bottom of the pipe to the spring line as shown. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 EARTHWORK 02200-13 B. Bedding shall be provided for all sewers, drainage pipelines, and other gravity flow pipelines. Unless otherwise specified or shown, for other pipelines the bedding may be omitted if all the following conditions exist. 1. The pipe bears on firm, undisturbed native soil which contains only particles that will pass a one-inch sieve. 2. The trench excavation is not through rock or stones. 3. The trench subgrade soils are classified as suitable fill and backfill materials [per Paragraph 2.1]. 4. The trench subgrade soils have, as a maximum, a moisture content that allows compaction. C. Where bedding is required, after compacting the bedding the CONTRACTOR shall perform a final trim using a string line for establishing grade, such that each pipe section when first laid will be continually in contact with the bedding along the extreme bottom of the pipe. D. The pipe zone shall be backfilled with the specified backfill material. The CONTRACTOR shall exercise care to prevent damage to the pipeline coating, cathodic bonds, or the pipe itself during the installation and backfill operations. E. Trench Zone Backfill: After the pipe zone backfill has been placed as specified above, and after all excess water has completely drained from the trench, backfilling of the trench zone may proceed. The trench zone is defined as that portion of the vertical trench cross-section lying between a plane 6 inches above the top surface of the pipe and a plane at a point 18 inches below the finished surface grade, or if the trench is under pavement, 18 inches below the roadway subgrade. If concrete or sand-cement slurry backfill are used, the pipe shall be filled with water to prevent flotation. 3.15 EMBANKMENT CONSTRUCTION A. The area where an embankment is to be constructed shall be cleared of all vegetation, roots and deleterious materials. Following this, the surface shall be moistened, scarified to a depth of 6 inches, and rolled or otherwise mechanically compacted. Embankment fill material shall be placed and spread evenly in horizontal layers. Each layer shall be moistened or aerated, as necessary. Each layer shall not exceed 6 inches of compacted thickness. The embankment fill and the scarified layer of underlying ground shall be compacted to [95] percent of maximum dry density per the requirements of the recommendations in the Geotechnical Report. B. When an embankment fill is to be made and compacted against hillsides or fill slopes steeper than 4:1, the slopes of hillsides or fills shall be horizontally benched to key the embankment fill to the underlying ground. A minimum of 12 inches normal to the slope of the hillside or fill shall be removed and recompacted as the embankment fill is brought up in layers. Material thus cut shall be recompacted along with the new fill material at the CONTRACTOR'S expense. Hillside or fill slopes 4:1 or flatter shall be prepared in accordance with Paragraph A, above. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-14 C. Where embankment or structure fills are constructed over pipelines, the first 4 feet of fill over the pipe shall be constructed using light placement and compaction equipment that does not damage the pipe. 8/13/09 Contract No. 3811 EARTHWORK PALOMAR AIRPORT ROAD WIDENING 02200-15 SECTION 02223 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING PART 1 - GENERAL 1.1 A. 1.2 A. DESCRIPTION This section includes materials, testing, and installation for trench excavation, backfill, and compaction of piping, conduit, manholes, and vaults. REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. ASTMC131 ASTMC150 ASTM D 75 ASTM 1556 ASTM D 1557 ASTM D 241 9 ASTM D 301 7 ASTM D 3776 ASTM D 4253- ASTM D 4254 ASTM D 4632 ASTM D 4751 CAL-OSHA - - - - - - - - - - - - - Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine Portland Cement Practice for Sampling Aggregates Test Method for Density and Unit Weight of Soil in Place by the Sand-Cone Method Test Method for Moisture-Density Relations of Soils Using a Modified Effort Test Method for Sand Equivalent Values of Soil and Fine Aggregate Test Method for Water Content of Soil and Rock in Place by Nuclear Methods Test Method for Mass Per Unit Area (Weight) of Woven Fabric Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Plate Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density Test Method for Grab Breaking Load and Elongation of Geotextiles Test Method for Determining the Apparent Opening Size of a Geotextile Title 8 General Industry Safety Orders 1.3 A. 1.4 RELATED WORK SPECIFIED ELSEWHERE Standard Specifications 15000, 15044, 15056, and 15064 GEOTECHNICAL TESTING The Contractor shall engage the services of a geotechnical engineering firm or individual licensed in the State of California to monitor soil conditions during earthwork, trenching, bedding, backfill, and compaction operations. Sampling and testing procedures shall be performed in accordance with the Reference Standards and as follows: 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 TRENCHING. EXCAVATION, BACKFILLING, AND COMPACTING 02223-1 A. The soils technician shall be present at the site during all backfill and compaction operations. Failure to have the soils technician present will subject such operations to rejection. B. Density and optimum moisture content of soil shall be determined by the use of the sand cone method, ASTM D 1556, or nuclear density gauge method, ASTM D 2922 & D 3017. Since the composition of the pipe and the walls of the trench have an effect on the nuclear density gauge output, a minimum of 25% of the density and optimum moisture tests shall be made using the sand cone method. C. Determine laboratory moisture-density relations of existing soil by ASTM D 1557, Method C and/or D. D. Determine the relative density of cohesion less soils by ASTM D 1557, Method C and/or D. E. Sample backfill material by ASTM D 75. F. Express "relative compaction" as a percentage of the ratio of the in-place dry density to the laboratory maximum dry density. A report of all soils tests performed shall be stamped and signed by the soils firm or individual and shall be submitted by the Contractor prior to the filling of the Notice of Completion by the ENGINEER. The report shall document the sampling and testing of materials, the location and results of all tests performed, and shall certify that materials and work are in compliance with this specification. 1.5 PIPE ZONE The pipe zone includes the full-width of the trench from 6-inches below the bottom of the pipe to 12-inches above the top of the pipe and extends into manhole or vault excavations to the point of connection to or penetration of such structure. 1.6 TRENCH ZONE The trench zone includes the portion of the trench from the top of the pipe zone to the bottom of the pavement zone in paved areas, or to the existing surface in unpaved areas, and extends into manhole or vault excavations above the pipe zone. 1.7 PAVEMENT ZONE The pavement zone includes the concrete or asphalt concrete pavement and aggregate base section placed over the trench zone and extends into manhole or vault excavations above the trench zone. 1.8 PROTECTION OF EXISTING UTILITIES AND FACILITIES The Contractor shall be responsible for the care and protection of all existing utilities, facilities, and structures that may be encountered in or near the area of the work. 8/13/09 Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING PALOMAR AIRPORT ROAD WIDENING 02223-2 1.9 PROTECTION OF EXISTING LANDSCAPING The Contractor shall be responsible for the protection of all the trees, shrubs, fences, and other landscape items adjacent to or within the work area. 1.10 ACCESS The Contractor shall provide continuous, unobstructed access to all driveways, water valves, hydrants, or other property or facilities within or adjacent to the work areas. 1.11 SAFETY A. Protection of workers within trenches shall be as required by the California Labor Code. B. All excavations shall be performed in a safe manner and shall be protected and supported in accordance with CAL-OSHA regulations. C. Barriers and traffic delineators shall be placed in accordance with the requirements of the agency having jurisdiction. 1.12 BLASTING Blasting for excavation shall not be performed without the written permission of the ENGINEER Procedures and methods of blasting shall conform to all Federal, State, and local laws and ordinances. 1.13 PIPE JACKING Pipe jacking may be permitted in accordance with Section 15125. ENGINEER approval is required in advance of such operations. 1.14 EXCESS EXCAVATED MATERIAL A. The Contractor shall remove and legally dispose of all excess excavated material and demolition debris. B. It is the intent of these specifications that all surplus material shall be legally disposed of by the Contractor. Before acceptance of the work by ENGINEER, the Contractor shall provide the ENGINEER with written releases signed by all property owners with whom the Contractor has entered into agreements for disposing of excess excavated material, absolving the ENGINEER from any liability connected therewith. 1.15 CHANGES IN LINE AND GRADE In the event obstructions not shown on the plans are encountered during the progress of the work, and which will require alterations to the plans, the Engineer shall have the authority to change the plans and order the necessary deviation from the line and grade. The Contractor shall not deviate from the specified line and grade without prior written approval by the ENGINEER. 1.16 HYDROSTATIC TESTING 8/13/09 Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING PALOMAR AIRPORT ROAD WIDENING 02223-3 Pre-testing of the piping system may be performed for the Contractor's convenience at any time. However, the final hydrostatic pressure test, as described in Section 15044, shall be performed following the completion of all backfilling and trench zone compaction with a minimum of 2.5-feet of material over the pipe. PART 2 - MATERIALS 2.1 GENERAL The Contractor shall furnish backfill material as specified below. All materials used in and above the pipe zone shall be capable of attaining the required relative density. 2.2 IMPORTED SAND - PIPE ZONE Imported Granular Material shall be used within the Pipe Zone for installations of PVC Pressure Pipe, Ductile-Iron Pipe, Cement-Mortar Coated Steel Pipe, Tape-Wrapped Steel Pipe, and Paint-Coated Pipe. The Imported Granular Material shall be sand (natural1 or manufactured) or quarry waste (decomposed granite) free from asphalt, clay balls, organic, or other deleterious matter. Material shall have a sand equivalent value of not less than 30 per ASTM D 2419, a coefficient of uniformity of 3 or greater, and shall conform to the following gradation: »$ - U.S. Standard Sieve Size • H 1-Inch 3/4-Inch No. 4 No. 30 No. 200 1 ^Percent Passing by Weight 100 75-100 35-75 10-45 3-9 Resistivity for imported sand shall be not less than 2,000 ohm-cm when measured in accordance with California Test Method 643. Imported sand shall not exceed a maximum chloride concentration of 200 mg/l when measured in accordance with California Test Method 422. 1Native materials may not be used in lieu of Imported Granular Material unless such materials meet all of the requirements specified above. 2.3 CRUSHED ROCK-PIPE ZONE Crushed Rock shall be used in the Pipe Zone on PVC Gravity Sewer Pipe. Crushed rock shall be clean, crushed stone free of organic matter. Crushed rock shall be certified to contain less than 1 % asbestos by weight or volume and shall conform to the following gradation and requirements: 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING 02223-4 t : ' tU.S. Standard Sieve Size -•;• - 1-Inch 3/4-Inch 1/2-Inch 3/8-Inch No. 4 No. 8 ASTM C 131 Testing Grade -?-• Percent Passing by Weight 100 90-100 30-60 0-20 0-5 — B ':& - rTest -'. Percentage Wear 100 Revolutions 500 Revolutions Test Method ASTM C 131 — — Requirement — 15 Maximum 52 Maximum A. Earth backfill is defined as material removed from the required excavations and used as backfill or earth fill. Earth backfill that meets the requirements specified herein may be used for all backfill or fill, except where imported materials are shown on the Plans or specified herein. Do not use stockpiled topsoil for backfill or fill. B. Earth backfill shall be excavated material that is free from organic matter, roots, debris, and rocks larger than 6 inches in the greatest dimension. C. Earth backfill used in the trench zone shall be native granular materials free from roots, debris, and organic matter with less than 50 percent passing the No. 200 sieve and with no more than 60 percent gravel (i.e., not less than 40 percent passing the No. 4 sieve) and rock particles with a maximum dimension no greater than 6 inches. D. Where the onsite materials are determined by the Engineer to be unsuitable, imported fill shall be provided by the Contractor. 2.5 SAND-CEMENT SLURRY Sand-cement slurry shall consist of two sacks, 188 pounds, of Portland cement per cubic yard of sand and sufficient moisture for workability. ENGINEER approval is required for use of slurry as a backfill material. 2.6 FILTER FABRIC Filter fabric shall be manufactured from polyester, nylon, or polypropylene. Material shall be of non-woven construction and shall meet the following requirements: Grab tensile strength (ASTM D 4632): 100 Ibs. minimum for a 1-inch raveled strip Weight (ASTM D 3776): 4.5 oz./yd2) Apparent opening size (ASTM D 4751): 0.006-inch PART 3 - EXECUTION 3.1 CLEARING AND GRUBBING 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING 02223-5 A. Areas where work is to be performed shall be cleared of all trees, shrubs, rubbish, and other objectionable material of any kind, which, if left in place, would interfere with the proper performance or completion of the completed work, would impair its subsequent use, or would form obstructions therein. B. Organic material from clearing and grubbing operations will not be incorporated in the trench backfill and shall be removed from the project site or retained and incorporated into the topsoil. 3.2 PAVEMENT, CURB, AND SIDEWALK REMOVAL Bituminous or concrete pavements, curbs, and sidewalks shall be removed and replaced in accordance with the requirements of the agency having jurisdiction. 3.3 DEWATERING A. 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 excavations or other parts of the work. Dewatering shall be performed by methods that will ensure a dry excavation and preservation of the final lines and grades of the bottoms of excavations. Dewatering methods may include well points, sump points, suitable rock or gravel placed as pipe bedding for drainage and pumping, temporary pipelines, or other means, all subject to the approval of the ENGINEER. The cost of all dewatering activities shall be borne by the Contractor. B. Sewer systems shall not be used as drains for dewatering trenches or excavations, nor for disposal of collected or accumulated groundcover, without the approval of the agency of jurisdiction. C. Concrete shall not be poured in water, nor shall water be allowed to rise around concrete or mortar until it has set at least four hours. D. The Contractor is responsible for meeting all Federal, State, and local laws, rules, and regulations regarding the treatment and disposal of water from dewatering operations at the construction site. 3.4 SHORING AND SHIELDING A. The Contractor's design and installation of shoring shall be consistent with the rules, orders, and regulations of CAL-OSHA. B. Excavations shall be shored, sheeted, and supported such that the walls of the excavation will not slide or settle and all existing improvements of any kind, either on public or private property, will be fully protected from damage. C. The sheeting and shoring shall be arranged so as not to place any stress on portions of the completed work until the general construction has proceeded far enough to provide ample strength. D. Care shall be exercised in the moving or removal of trench shields, sheeting, and shoring to prevent the caving or collapse of the excavation faces being supported. 8/13/09 Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING PALOMAR AIRPORT ROAD WIDENING 02223-6 3.5 CORRECTION OF OVEREXCAVATION Over-excavations shall be corrected by backfilling with approved imported granular material or crushed rock, compacted to 90% relative compaction, as directed by the ENGINEER. 3.6 FOUNDATION STABILIZATION A. When unsuitable soil materials are encountered, the unsuitable material shall be removed to the depth determined necessary in the field by the Soils Technician, and as acceptable to the ENGINEER. The sub-grade shall be restored with compacted Imported Granular Material or crushed rock as recommended by the Soils Technician. Place the appropriate bedding or base material on this restored foundation. B. When rock encroachment is encountered, the rock shall be removed to a point below the intended trench or excavation sub-grade as determined necessary in the field by the Soils Technician, and as acceptable to the ENGINEER. The sub-grade shall be restored with compacted Imported Granular Material as recommended by the Soils Technician. Place the appropriate bedding or base material on this restored foundation. C. When excessively wet, soft, spongy, or similarly unstable material is encountered at the surface upon which the bedding or base material is to be placed, the unsuitable material shall be removed to the depth determined necessary in the field by the Soils Technician, and as acceptable to the ENGINEER. Restore the trench with crushed rock enclosed in filter fabric as directed by the Engineer. Larger size rocks, up to 3-inches, with appropriate gradation, may be used if recommended by the Soils Technician. Place the appropriate bedding or base material on this restored foundation. 3.7 TRENCH EXCAVATION AND PLACEMENT OF BEDDING A. Excavate the trench to the lines and grades shown on the drawings with allowance for 6-inches of pipe bedding material. The trench section shall be as shown on the Standard Drawings. B. The maximum length of open trench shall be 500-feet except by permission of the ENGINEER. The distance is the collective length at any location, including open excavation and pipe laying, which has not been backfilled to the elevation of the surrounding gate. C. Trench walls shall be sloped or shored per the requirements of CAL-OSHA. D. The trench bottom shall be graded to provide a smooth, firm, and stable foundation that is free from rocks and other obstructions. E. Place the specified thickness of bedding material over the full width of the trench. Grade the top of the pipe base ahead of the pipe laying to provide a firm, uniform support along the full length of pipe. F. Excavate bell holes at each joint to permit proper assembly and inspection of the entire joint. 8/13/09 Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING PALOMAR AIRPORT ROAD WIDENING 02223-7 G. Trenches for main pipelines and all appurtenances shall be backfilled with the materials and methods as specified for the Pipe Zone, Trench Zone, and Pavement Zone. H. Trench widths shall be in accordance with the Standard Drawings. Trench depth shall be as required to install pipelines in accordance with the Approved Plans and these Standard Specifications. Unless shown otherwise in the Approved Plans, the minimum cover for pipelines shall be as follows: %&-.?.••< ^Pipeline Application ; V; . Potable Water Recycled Water Sewer Storm Drain Minimum Cover Required 36-inches 48-inches 66-inches 36-inches 3.8 MANHOLE HOLES AND VAULTS A. The Contractor shall prepare an excavation large enough to accommodate the structure and permit grouting of openings and backfilling operations. The walls of the excavation shall be sloped or shored per the requirements of CAL-OSHA. B. Manholes holes and vaults shall be placed at the location and elevation shown on the plans, on undisturbed soils and 6-inches of compacted crushed rock base. C. Manhole hole and vault excavations shall be backfilled with the materials and methods as specified for the Pipe Zone, Trench Zone, and Pavement Zone. 3.9 COMPACTION REQUIREMENTS A. Compaction shall be accomplished by mechanical means. Consolidation by water settling methods such as jetting or flooding is prohibited. B. If the backfill fails to meet the specified relative compaction requirements, the backfill shall be reworked until the requirements are met. All necessary excavations for density tests shall be made as directed by the Soils Technician, and as acceptable to the Engineer. The requirements of the Agency having jurisdiction shall prevail on all public roads. C. Compaction tests shall be performed at random depths, and at random intervals not to exceed 150-feet, as directed by the Soils Technician or ENGINEER. D. Relative compaction shall be determined by the impact or field compaction test made in accordance with ASTM D 1557 Procedure C. E. Unless otherwise shown on the drawings or otherwise described in the specifications for the particular type of pipe installed, relative compaction in pipe trenches shall be. as follows: 8/13/09 Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING PALOMAR AIRPORT ROAD WIDENING 02223-8 1. Pipe zone - 90% relative compaction. 2. Trench zone - 90% relative compaction. 3. Structural section in paved areas - per agency requirements, 95% minimum. 4. Imported Granular Material for over excavation or foundation stabilization - 90% relative density. F. All excavations are subject to compaction tests. 3.10 PIPE ZONE BACKFILL A. Care shall be taken in placing the imported granular backfill material simultaneously around the main pipeline and appurtenance pipes so that the pipe barrel is completely supported and that no voids or uncompacted areas are left beneath the pipe or on the sides of the pipe. Care shall be taken to place material simultaneously on both sides of the pipe to prevent lateral movement. This area shall be mechanically compacted to attain 90% relative density. Care shall be taken when compacting appurtenance laterals 2-inches and smaller to prevent the crushing or denting of the copper lateral. Additional lifts of 12-inches or less thickness may be required on 16-inch or larger diameter pipe to attain complete support of the haunch area. Soils tests may be taken on this layer of backfill. B. After the spring line backfill has been approved by the Soils Technician, backfill of the remainder of the Pipe Zone may proceed. Do not drop sharp, heavy pieces of material directly onto the pipe or the tamped material around the pipe. C. Place and compact the imported granular material at a maximum of 12-inch lifts. Compact all material placed in the Pipe Zone by mechanical methods. Sand cone tests shall be taken on this layer of backfill. D. The use of a backhoe mounted compaction wheel is prohibited within the pipe zone to - 24-inches above the top of the pipe. E. Under no circumstances shall consolidation by water settling or water-setting methods (i.e., jetting, diking, etc.) be permitted. 3.11 TRENCH ZONE BACKFILL A. After the Pipe Zone material has been placed, compacted, approved by the Soil Technician, and accepted by the ENGINEER, backfill in the Trench Zone may proceed. B. Compaction using vibratory equipment, tamping rollers, pneumatic tire rollers, or other mechanical tampers shall be performed with the type and size of equipment necessary to accomplish the work. The backfill shall be placed in horizontal layers of such depths as are considered proper for the type of compacting equipment being used in relation to the backfill material being placed. Each layer shall be evenly spread, properly moistened, and compacted to the specified relative density. The Contractor shall repair or replace any pipe, fitting, manhole, or structure damaged by the installation operations as directed by the ENGINEER. 3.12 PAVEMENT ZONE BACKFILL AND RESTORATION A. After the Trench Zone material has been placed, compacted, approved by the Soil Technician, and accepted by the ENGINEER, backfill in the Pavement Zone may proceed as necessary in accordance with the requirements of the agency having jurisdiction. 8/13/09 Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING PALOMAR AIRPORT ROAD WIDENING 02223-9 B.Replace bituminous and concrete pavement, curbs, and sidewalks removed or damaged during construction in accordance with the requirements of the agency having jurisdiction. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 TRENCHING, EXCAVATION, BACKFILLING, AND COMPACTING 02223-10 SECTION 02232 ,,. PREPARATION OF PAVEMENT SUBGRADE PART 1 - GENERAL 1.1 THE REQUIREMENT A. THE CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work of preparation of subgrade requirements as indicated on the Drawings and specified herein. B. The subgrade will be considered as those areas and surfaces, new or existing, upon which subbase or base material, pavement, curbs and gutters, driveways, or sidewalks are to be placed. C. All underground work in the area of the subgrade shall be completed and properly backfilled and compacted in compliance with Section 02200 "Earthwork" before subgrade work is started. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [02050] Demolition. B. Section [02110] Clearing, Grubbing, and Stripping. C. Section [02200] Earthwork. D. Section [02550] Asphalt Concrete Pavement and Base. E. Section [02527] Concrete Driveway, Sidewalk, Curb and Gutter. 1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Comply with the applicable reference specifications of the GENERAL PROVISIONS. B. Comply with SSPWC Section 301 - 1.4. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL PROVISIONS. 1.5 QUALITY ASSURANCE A. Quality assurance shall be as specified in Section 02200 "Earthwork". PART 2 - PRODUCTS 2.1 EXCAVATION AND EMBANKMENT A. The excavation is unclassified and shall include removal of materials which are "***^ encountered in excavating to the required grades, including existing pavement and curbs 8/13/09 Contract No. 3811 PREPARATION OF PAVEMENT SUBGRADES PALOMAR AIRPORT ROAD WIDENING 02232-1 designated to be removed, or other deleterious materials as required to accomplish the construction. B. Unsuitable material below the processing depth for subgrade shall be excavated and disposed of as directed by the ENGINEER. PART 3 - EXECUTION 3.1 SUBGRADE A. Excavate and shape subgrade to line, grade, and cross-section shown on Drawings. Scarify and compact the top 12 (twelve) inches of subgrade to at least 95 percent of the maximum dry density attainable as determined by ASTM D 1557 except clay soils with a Liquid Limit greater than or equal to 50 percent and a plasticity index greater than or equal to 20 shall be prepared according to the recommendation of the ENGINEER. Remove all soft or otherwise unsuitable material and replace with suitable material as specified in Section 02200 "Earthwork". In sandy soils the moisture content shall be kept at, or slightly above, the optimum moisture content. However, in Clayey and Silty soils, the moisture content shall be kept at about 2% above the optimum moisture content. The finished subgrade shall be firm, hard and unyielding. The subgrade shall be considered to extend over the full-width of the base course. Compaction shall extend at least 18 inches beyond the edge of paving, curb, or form. B. Subgrade tolerances for roadway structures, sidewalk, curb and gutter and driveways shall be in conformance with SSPWC Section 301-1.4. 3.2 EXCAVATION BELOW SUBGRADE A. Where the ENGINEER determines the subgrade material to be unsuitable, excavation below subgrade will be required to such depths as necessary to remove the unsuitable material. Excavation below grade shall be of the same classification as that above it provided it is removed in the same operation as the normal excavation. Special equipment may be required because of the presence of shallow utilities or other unforeseen conditions. B. The over-excavated unsuitable subgrade shall be replaced with suitable material per Section 02200 "Earthwork". 3.3 PROTECTION OF SUBGRADE A. After preparation the subgrade as specified, all traffic on the subgrade shall be avoided. Should it be necessary to haul over the prepared subgrade, the CONTRACTOR shall drag and roll the traveled way as frequently as may be necessary to remove ruts, cuts, and breaks in the surface. All cuts, ruts, and breaks in the surface of the subgrade that are not removed by the above operations shall be raked and hand tamped. All equipment used for transporting materials over the prepared subgrade shall be equipped with pneumatic tires. B. Continued use of sections of prepared subgrade for hauling, so as to cut up or deform it from the true cross-section, will not be permitted. The CONTRACTOR shall protect the preparation subgrade from all traffic. 8/13/09 Contract No. 3811 PREPARATION OF PAVEMENT SUBGRADES PALOMAR AIRPORT ROAD WIDENING 02232-2 C. The CONTRACTOR will be required to plank the subgrade before hauling materials or equipment over it. D. The subgrade shall be maintained in the finished condition as required by Section 3.1 A, until the first succeeding course is placed. 8/13/09 Contract No. 3811 PREPARATION OF PAVEMENT SUBGRADES PALOMAR AIRPORT ROAD WIDENING 02232-3 SECTION 02270 EROSION CONTROL (VEGETATIVE) PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall provide erosion protection including fertilizing, seeding, and mulching for all disturbed areas that are not to be paved or otherwise treated in accordance with the Contract Documents. PART 2 - PRODUCTS 2.1 MATERIALS A. Fertilizer: Fertilizer shall be a commercial, chemical type, uniform in composition, free-flowing, conforming to state and federal laws and suitable for application with equipment designed for that purpose. Fertilizer shall have a guaranteed analysis showing not less than 11 percent nitrogen, 8 percent available phosphoric acid, and 4 percent water soluble potash. B. Seed: Seed shall be delivered in original unopened packages bearing an analysis of the contents. Seed shall be guaranteed 95 percent pure with a minimum germination rate of 80 percent. Seed mix shall be equal parts by weight of native grasses, fescue and barley. C. Mulch: Mulch shall be a fibrous, wood cellulose product produced for this purpose. It shall be dyed green and shall contain no growth or germination inhibiting substances, and shall be manufactured so that when thoroughly mixed with seed, fertilizer, and water, in the proportions specified it will form a homogenous slurry which is capable of being sprayed. The mulch shall be Silva Fiber as manufactured by Weyerhaeuser Company; Conwood Fiber as manufactured by Consolidated Wood Conversion Corp.; or equal. D. Erosion Control Fabric: 1. Materials: jute matting. 2. Anchorage Devices: Nine-inch, 2-legged staples from the Manufacturer or staples of the proper length as recommended by the Manufacturer for specific soil condition. E. Manufacturers, or Equal: 1. North American Green; 2. Bon Terra America. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 EROSION CONTROL (VEGETATIVE) 02270-1 PART 3 - EXECUTION A. Weather Conditions: Fertilizing, seeding, or mulching operations will not be permitted when wind velocities exceed 15 miles per hour or when the ground is frozen, unduly wet, or otherwise not in a tillable condition. B. Soil Preparation: The ground to be seeded shall be graded in conformance with the Drawings and shall be loose and reasonably free of large rocks, roots, and other material which will interfere with the work. C. Method of Application: Fertilizer, seed, and mulch may be applied separately (Dry Method), or they may be mixed together with water and the homogenous slurry applied by spraying (Hydraulic Method), except that all slopes steeper than 3 units horizontal to 1 unit vertical shall be stabilized by the hydraulic method. 3.2 DRY METHOD A. Fertilizing: The fertilizer shall be spread uniformly at the rate of 800 Ibs per acre (approximately 1 Ib per 55 square feet). The fertilizer shall be raked in and thoroughly mixed with the soil to a depth of approximately two inches prior to the application of seed or mulch. B. Seeding: The seed shall be broadcast uniformly at the rate of 60 Ibs/acre (approximately 1 Ib per 730 sq ft). After the seed has been distributed, it shall be incorporated into the soil by raking or by other approved methods. C. Mulch Application: Mulch shall be applied at the rate of 1,500 Ib (air dried weight) per acre (approximately 1 Ib per 30 sq ft). 3.3 HYDRAULIC METHOD A. The hydraulic method consists of the uniform application by spraying of a homogeneous mixture of water, seed, fertilizer, and mulch. The slurry shall be prepared by mixing the ingredients in the same proportions as specified above. The slurry shall have the proper consistency to adhere to the earth slopes without lumping or running. Mixing time of materials shall not exceed 45 minutes from the time the seeds come into contact with the water in the mixer to the complete discharge of the slurry onto the slopes, otherwise the batch shall be recharged with seed. The mixture shall be applied using equipment containing a tank having a built-in, continuous agitation and recirculation system, and a discharge system which will allow application of the slurry to the slopes at a continuous and uniform rate. The application rates of the ingredients shall be the same as those specified for the Dry Method. The nozzle shall produce a spray that does not concentrate the slurry nor erode the soil. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 EROSION CONTROL (VEGETATIVE) 02270-2 3.4 EROSION CONTROL BLANKET A. Placement: 1. Biodegradable erosion control blanket shall be used on all slopes 4H:1V and steeper. 2. The erosion control shall be spread only on prepared, fertilized and seeded surfaces. 3. On all slopes, the erosion control blanket shall be laid up-and-down the slope in the direction of water flow. 4. Waste of erosion control material shall be minimized by limiting overlaps as specified and by utilizing the full length of the netting at roll ends. B. Anchorage: 1. Ends and sides of adjoining pieces of material shall be overlapped 6-inches and 4-inches respectively and stapled. Six anchors shall be installed across ends. A common row of staples shall be used at side joints. Staple through both blankets, placing staples approximately 6-inches apart. 2. The top edge of the erosion control blanket shall be anchored in a 6-inch deep by 6-inch wide trench. Backfill and compact trench after stapling. 3. Anchorage shall be by means of 9-inch long, two-legged staples driven vertically and full-length into the ground. The legs shall be spread 3 inches to 4 inches apart at the ground to improve resistance to pull-out. In loose soils, the use of 18-inch metal/washer pins may be required to properly anchor the blankets. 4. All slopes which are 3:1 or greater shall be stapled with 2 staples per square yard in a triangular pattern. Staples shall be installed per the manufacturer's recommended staple pattern guide. 5. The erosion control blanket shall not be stretched, but should be laid loosely over the ground to avoid the blanket being pulled downslope. 6. The erosion control blanket shall not be rolled out onto ground containing frost within the 9-inch penetration zone of the anchorage staples. Further, no stapling shall be undertaken while any frost exists within the staple penetration zone. 3.5 WATERING A. Upon completion of the erosion control seeding, the entire area shall be soaked to saturation by a fine spray. The new planting shall be kept watered by a sprinkling system on the site during dry weather or whenever necessary for proper establishment of the planting until final project acceptance. At no time shall the planting be allowed to dry out. Care shall be taken to avoid excessive washing or puddling on the surface and any such damage caused thereby shall be repaired by the CONTRACTOR. 8/13/09 Contract No. 3811 EROSION CONTROL (VEGETATIVE) PALOMAR AIRPORT ROAD WIDENING 02270-3 3.6 MAINTENANCE PRIOR TO FINAL ACCEPTANCE A. The CONTRACTOR shall maintain the planted areas in a satisfactory condition until final acceptance of the project. Such maintenance shall include the filling, leveling, and repairing of any washed or eroded areas, as may be necessary, and sufficient watering to maintain the plant materials in a healthy condition. The ENGINEER may require replanting of any areas in which the establishment of the vegetative ground cover does not appear to be developing satisfactorily. 3.7 MAINTENANCE AFTER FINAL ACCEPTANCE A. The CONTRACTOR shall water the permanently planted areas sufficiently to maintain the plant materials in a healthy condition for ninety (90) days following final acceptance. 8/13/09 Contract No. 3811 EROSION CONTROL (VEGETATIVE) PALOMAR AIRPORT ROAD WIDENING 02270-4 SECTION 02372 STORM WATER POLLUTION PREVENTION PART 1 - GENERAL 1.1 SECTION INCLUDES A. Preparation, implementation and monitoring of Storm Water Pollution Prevention Plan (SWPPP) for the purpose of preventing the discharge of pollutants from the Project site into receiving waters. This includes the elimination of pollution discharges such as improper dumping, spills or leakage from storage tanks or transfer areas. B. Compliance with local, state, and federal regulations. C. Payment of application and annual fees required by the State Water Resources Control Board (SWRCB) until the date of Substantial Completion. D. Certification that the Project has met all of the conditions of the General Construction Activity Storm Water Permit (GCASP). 1.2 RELATED SECTIONS A. GENERAL PROVISIONS Section 2-5.3: Submittals B. GENERAL PROVISIONS Section 8: Facilities for Agency Personnel C. GENERAL PROVISIONS Section 9: Measurement and Payment PART 2 - PRODUCTS 2.1 MATERIALS A. Provide the quality, grade, and type of materials as specified in the City of Carlsbad Department of Public Works - Development Best Management Practices - Part A - Construction Activities. PART 3 - EXECUTION 3.1 QUALITY ASSURANCE A. Comply with the following as a minimum requirement: 1. The City of Carlsbad Department of Public Works - Development Best Management Practices in accordance with Order no. 2001-01 SUSMP and General Provisions Section 7-8.6. 3.2 PREPARATION AND SUBMITTAL A. Prepare and submit to the OWNER, within fourteen (14) days after the Effective Date of the Contract, four (4) copies of the completed Storm Water Pollution Prevention Plan and Monitoring Program Checklist (Checklist) and Storm Water Pollution Prevention Plan (SWPPP) as required to comply with storm water pollution regulations for the Project site. 8/13/09 Contract No. 3811 STORM WATER POLLUTION PREVENTION PALOMAR AIRPORT ROAD WIDENING 02372-1 B. Prepare Notice of Intent application. Submit application and application fee made payable to: State Water Resources Control Board. Instructions for completing the application can be found on the State Water Resources Control Board web site. http://www.swrcb.ca.gov/stormwtr/gen const.html#const permit C. Prepare Checklist by downloading instructions from the State Water Resources Control Board web site: http://www.swrcb.ca.gov/stormwtr/gen const.htmlffconst permit D. Prepare SWPPP by downloading template from www.cabmphandbooks.com E. Where land disturbance is less than one (1) acre, a SWPPP is not required, however, any BMP's indicated in the BMP required to prevent or minimize storm water pollution shall be implemented at no cost to OWNER. 3.3 IMPLEMENTATION A. Install perimeter controls prior to starting Work at the Project site. B. Certain on-site storm water on the Project site. Do not drain on-site water directly into the storm drain. C. Designate trained personnel for the proper implementation of the SWPPP. D. Revise SWPPP to suit changing Project site conditions and also when properly installed systems are ineffective. E. Upon Substantial Completion: 1. Leave storm water pollution prevention controls in place when required for post- construction storm water management and remove those that are not needed as determined by OWNER. OWNER will maintain prevention controls left in place. 2. Provide Site Monitoring Reports, SWPPP revisions, Compliance Certifications and related documents to OWNER. Post-construction storm water operation and the management plan as mentioned in the compliance certifications are considered to be in place at Final Completion. 3.4 MONITORING A. Conduct examination of pollution prevention controls on a monthly basis, as well as before and after each storm and each day during extended storm events. Prepare and maintain, at the Project site, a log of each inspection using Site Monitoring Report forms. Notify to RWQCB within 30 days if there is any noncompliance. 8/13/09 Contract No. 3811 STORM WATER POLLUTION PREVENTION PALOMAR AIRPORT ROAD WIDENING 02372-2 3.5 LIABILITIES AND PENALTIES A. Review of the SWPPP and inspection log by OWNER shall not relive CONTRACTOR from liabilities arising from non-compliance of storm water pollution regulations. B. Payment of penalties for non-compliance by CONTRACTOR shall be the sole responsibility of CONTRACTOR. C. Compliance with the Clean Water Act pertaining is the sole responsibility of CONTRACTOR. Any fine against OWNER due to non-compliance by CONTRACTOR, OWNER shall recover all costs of the fine by appropriate assessment. 3.6 CHANGE OF INFORMATION A. Submit to OWNER completed NOI Form for change of information (Construction Site Information and Material Handling/Management Practices). 3.7 ATTACHMENTS A. Attachment A - Compliance Certification. B. Attachment B - Site Monitoring Report. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 STORM WATER POLLUTION PREVENTION 02372-3 OWNER Project Number ATTACHMENT "A" GENERAL CONSTRUCTION ACTIVITY STORM WATER PERMIT COMPLIANCE STATE OF CALIFORNIA STATE WATER BOARD WDID NO. Name of Project: Project Description:Contract Number ANNUAL CERTIFICATION I certify the Project has met the following conditions: All elements of the Storm Water Pollution Prevention Plan are in place; construction materials and equipment maintenance waste have been disposed of properly; and the Project site is in compliance with all local storm water management requirements including erosion/sediment control requirements, and the appropriate use permits have been obtained. CONTRACTOR: Print Name: Signature: Title: Date: FINAL COMPLETION CERTIFICATION I certify the Project has been completed and the following conditions have been met: All elements of the Storm Water Pollution Prevention Plan have been completed; construction materials and equipment maintenance waste have been disposed of properly; the Project site is in compliance with all local storm water management requirements including erosion/sediment control requirements and the appropriate use permits have been obtained; and a post- construction storm water operation, and management plan is in place. CONTRACTOR: Print Name: Signature: Title: Date: 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 STORM WATER POLLUTION PREVENTION 02372-4 OWNER Project Number ATTACHMENT "B" STORM WATER POLLUTION PREVENTION SITE MONITORING REPORT STATE OF CALIFORNIA STATE WATER BOARD WDID NO. Name of Project: Project Description:Contract Number Type of Examination: (Use one form for each type of examination): D Prior to Anticipated Storm Event D After Actual Storm Event D Monthly Event Date Examined: II. Check the response for each SWPPP question below: 1. 2. 3. 4. 5. 6. NO YES Do you have an approved Storm Water Pollution Prevention Plan (SWPPP) and a BMP Handbook on the Project site? Does your SWPPP incorporate an up-to-date erosion control plan? Is the erosion control installed per plan? Is the Work at a stage where the erosion control plan cannot be constructed, is the erosion control at the Maximum Extent Practicable for the stage you are in? Did you observe the presence of any floating materials such as oil, grease, pieces of wood, paper, etc., odor, toxics, and/or sediments? If yes, what is that you observed? D D D III. Check the status of the following items as observed: SWPPP Items Acceptable Not Acceptable Repairs Required Date Repairs Completed 1. De-silting Basins (Cleaned) D 2. Water Quality Basin D 3. Silt Fences D 4. Hay bales/Check dams/Sandbags G 5. Berms and Dikes D 6. Sand/Gravel Inlet D D D D D D D D D D D D D 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 STORM WATER POLLUTION PREVENTION 02372-5 SECTION 02375 CAST-IN-PLACE DRILLED PILES PART 1 - GENERAL 1.1 DESCRIPTION A. Principal Work in this Section: 1. Provide cast-in-place drilled piles, complete, in accordance with Contract Documents, including the latest Caltrans Standard Specification. B. Related Work Specified Elsewhere 1. Section 03200 - Concrete Reinforcement 2. Section 03300 - Cast-in-Place Concrete 3. Section 03310 - Concrete Testing and Inspection 4. Caltrans Standard Specifications 1.2 SYSTEM DESCRIPTION A. Work includes, but is not limited to, the following: 1. Excavation for drilled piles, including soil and rock excavation, removal of existing concrete slabs, foundations and other obstructions as required. 2. Dewatering by pumping and drainage. 3. Steel shells including temporary steel liners as required. Protection of the tops of holes to prevent caving and material entering the hole. 4. Reinforcing steel, furnishing and installing reinforcing steel including reinforcing extending above top of shaft and dowels, as required. 5. Concrete for drilled piles, including mix designs with required supporting testing, furnishing and placing. 6. Disposal of excavated materials. 7. Establishing surveyed elevations and surveyed locations from established building line monuments which will be furnished and installed by a registered land surveyor. 8. Maintaining diameters of shafts. 9. Maintaining top of shaft elevations including removal of laitance. 10. Excavation and filling of trial drilled piles excavation in advance of production drilling for the purpose of review by Contractor and Owner's Geotechnical Consultant of caving potential, equipment suitability, etc. 8/13/09 Contract No. 3811 CAST-IN-PLACE DRILLED PILES PALOMAR AIRPORT ROAD WIDENING 02375-1 A. Quality Assurance: Prepare and execute Quality Assurance program including concrete mix designs, materials report, sampling, and detailed shop drawings for reinforcing which provide no opportunity to complete unsatisfactory cast-in-place drilled pile work. Perform retesting or evaluation by Quality Control personnel due to deficient work, and similar work at no additional cost to Owner. B. Quality Control: Cast-in-place drilled piles work may be subject to evaluation and tests in shop and field by others. Evaluations and testing undertaken by others is strictly for random evaluation. Extent, duration and amount of testing or evaluation is entirely at discretion of others. Use of testing services, or execution of testing or evaluation service by others shall in no way relieve Contractor's sole responsibility to furnish materials and construction in full compliance with Contract Documents. C. Qualifications 1. Contractor engaging work of this section shall have minimum fifteen years experience in work of similar scope and nature to that specified. 2. Contractor shall employ labor and supervisory personnel at least equally experienced in work of similar scope and nature to that specified. D. Consultants 1. Contractor's Soil Consultant: Contractor shall retain at his own expense, the services of a qualified Soils Consultant unless similarly qualified personnel are members of Contractor's staff to advise him on construction techniques involved in this work, including the design, checking and approval of temporary liners and other items pertinent to the work and construction methods for solution of problems which may be encountered during the prosecution of work. Consultant shall be primarily concerned with construction methods which will result in finished piles of quality and strength called for on the drawings and in these specifications and with methods which will prevent settlement and/or damage to surrounding structures, roads, utilities, embankment, etc., both within property lines and on adjoining properties. E. Testing Agencies 1. Inspection/Testing: Coordinate and provide ample notification for inspection and testing agencies and Geotechnical Consultant, so excavation, reinforcing and concrete work occurs in a continuous operation. 2. Contractor's Concrete Testing Agency: Contractor shall employ at his own expense, testing laboratory acceptable to Engineer, to design concrete mixes, conduct tests, and submit reports as are hereinafter specified. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE DRILLED PILES 02375-2 3. Agency's Geotechnical Consultant: Agency will retain, at his own expense, a geotechnical consultant, to conduct tests and inspections of soil conditions and submit reports as are hereinafter specified. Owner's geotechnical consultant will be responsible for inspections and for conducting and interpreting tests. Inspection will take the form of full-time inspection of pile excavation and concreting operations. 4. Agency's Concrete Testing Agency: Agency will retain at his own expense, a testing laboratory, to perform concrete and reinforcing quality control inspection and testing as hereinafter specified. 1.4 REFERENCES A. Except as modified by governing codes and Contract Documents, comply with applicable provisions and recommendations of the following: 1. ACI 2. ASTM 3. PCA 1.5 SUBMITTALS A. Product Data: Submit Product Data and installation instructions for the following items in accordance with General Provisions Section 2-5.3 - SUBMITTALS. Include laboratory test reports and such other data required to show compliance with Contract Documents. 1. Fly ash. 2. Plasticizing admixture. 3. Aggregate for stone concrete, including sodium sulfate soundness test (ASTM CSS) and sieve analysis. 4. Reinforcing steel. 5. Portland cement (including certified mill test reports). B. Shop Drawings: Submit Shop Drawings for the following items in accordance with General Provisions Section 2-5.3 - SUBMITTALS. 1. Provide Shop Drawings which show details and layouts of reinforcing steel in accordance with Section 03200 - Concrete Reinforcing. All tie reinforcing shall have 135 degree hooks around vertical reinforcing at each end of each tie or each piece of continuously wound tie. Vertical reinforcing shall be positioned around pile to clear and coordinate with grade beam reinforcing and anchor bolts/column dowels. C. Furnish to the Owner's Geotechnical Consultant one copy of detailed descriptions of construction procedures, equipment, temporary liners used and drilling methods. 8/13/09 Contract No. 3811 CAST-IN-PLACE DRILLED PILES PALOMAR AIRPORT ROAD WIDENING 02375-3 D. Certificates of Site Examination: Submit, before proceeding with the work, one copy of certification in acceptable form stating that careful examination has been made of the site, existing structures, records of utility lines, test boring records, subsurface exploration reports by the Geotechnical Consultant, drawings and specifications, signed by the Contractor's Soil Consultant (if any), the Installer and the Contractor. E. Test Reports: Test and inspection reports shall be submitted in accordance with General Provisions Section 4 CONTROL OF MATERIALS by the following testing agencies; with one copy to Contractor and others as indicated. 1. Contractor's Concrete Testing Agency a. Report and certification of aggregate for stone concrete, including sodium sulfate soundness test (ASTM C 88) and sieve analysis (may be omitted if available from manufacturer). b. Concrete design mix reports, listing all mixes required together with test results. 2. Owner's Concrete Testing Agency a. Concrete test reports, indicating slump and test strengths at 7 days, 28 days and 56 days (if required) for test samples obtained, together with pertinent information and certification of compliance with strength requirements. b. Ready-Mix Plant Inspection Reports, showing location of plant; mix number and strength; proportioning; source, type and amount of cement; admixtures; aggregates; water added and total water used; slump; air content; capacity and condition of mixing trucks; percent of capacity loading practice; condition of batching equipment; period of inspection and number and size of batches observed. 3. Owner's Geotechnical Consultant: a. Certified, "Drilled Piles Field Record" for each pile recording actual geotechnical data, including the actual elevation of bottom, elevation of bearing strata, final center line location of top, variation of shaft diameters (from those shown), and description of bearing strata over the length of piles shaft. If rock is encountered, indicate depth to rock, rock slope and socket depth. Specific confirmation of the allowable load for the pile shall be included. 4. Record drawings: Update record drawings, to incorporate the above information. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE DRILLED PILES 02375-4 1.6 PROJECT CONDITIONS A. Environmental Conditions 1. Contractor shall examine the site, drawings, records of existing utilities and construction, record of tests borings, and subsurface exploration reports to determine conditions under which the piles will be installed. Records of test borings are for information only and are not guaranteed to represent all conditions that will be encountered. B.Protection 1. During excavation of piles, openings shall be properly protected and covered when work is not in progress. Suitable fences, lights, etc., shall be provided as required. Contractor shall provide a protective cage or casing for inspection and testing of piles and to protect workmen during hand excavation or other operations requiring entry into shaft. The Contractor shall provide access down hole with proper safety equipment for the AGENCY'S Geotechnical Consultant. Coordinate with the Geotechnical Consultant for required safety apparatus, prior to inspection. Holes shall be covered and protected, with casing in place, while tests are being made. Shells as required for construction loads shall satisfy safety requirements of the construction and regulatory agencies. Contractor shall have adequate gas detection devices on site at all times with personnel trained in their proper use. Contractor shall make tests for gas or noxious fumes prior to entry into the shaft and provide continuous monitoring when men are required to be in the shafts. 2. Contractor, piles installer, and Contractor's Soils Consultant shall take particular measures when drilling and constructing along existing buildings. Take all necessary measures to brace, shore, underpin and any other work or sequences to ensure maintaining the strength, stability and cause no damage to existing buildings. 3. Prior to any excavation adjacent to the existing building, record and photograph all existing conditions and send a report to the AGENCY. Monitor by measurement and record and photograph on a regular basis during construction and send reports to the Owner. C. Contractor's bid shall be based on construction of piles to length shown on the drawings. Adjustment will be made on net variation of total quantities, based on the design dimensions for shafts. There will be no additional compensation for excavation or concrete due to overcutting or over lengthening of shafts (i.e., in any dimension) resulting from machine methods of excavation, or any other cause. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE DRILLED PILES 02375-5 PART 2 - PRODUCTS 2.1 MATERIALS A. Portland Cement: ASTM C150, Type II normal Portland cements. B. Fly Ash: ASTM C618. C. Water Reducing and Plasticizing Admixture: ASTM C494, type and quantity recommended by manufacturer depending upon conditions at project site. D. Aggregate for Stone Concrete shall comply with ASTM C 33 size 467 for placement "in-the-dry" and 3/4 inch maximum for tremie concrete and the following: 1. General: Aggregates when subjected to 5 cycles of sodium sulfate soundness test (ASTM C 88) shall not lose more than 15% by weight. Aggregates for the entire job shall come from the same source unless a change is acceptable to the Architect. 2. Fine Aggregates: Natural or artificial hard, clean sand. 3. Coarse Aggregates: Gravel or crushed rock with clean, hard, uncoated particles. E. Mixing Water: Clean, fresh and free from deleterious substances which would impair the work. F. New Billet Steel Bars: ASTM A 615, Grade 60. G. Temporary Steel Liners: Temporary steel liners shall be constructed of ASTM A36 steel plate. Longitudinal and transverse joints shall be full butt welds forming temporary liners to length and diameter required to control caving of shafts during excavation. H. Ready-Mixed Concrete: ASTM C94, of strength as shown on drawings. I. Miscellaneous Materials or Accessories shall be provided as specified hereinafter under the various items of work, as indicated on the drawings, and as required for good construction practice. 2.2 MIX DESIGN A. Contractor's Concrete Testing agency shall design the mix for each type of concrete required in accordance with the requirements of the specifications and drawings. Strength requirements are as noted on drawings. Design mixes shall obtain strength (as determined by test cylinders) at least 15% higher than specified. Allow a minimum of 40 days prior to placing concrete for this work. B. The adequacy of the design shall be verified by tests on a minimum of 9 cylinders; 3 tested at 7 days, 3 at 14 days, and 3 at 28 days in accordance with ASTM C 192 and C39 and by a slump test in accordance with ASTM C143. 8/13/09 Contract No. 3811 CAST-IN-PLACE DRILLED PILES PALOMAR AIRPORT ROAD WIDENING 02375-6 D. Contractor's Agency shall prepare and submit a complete list of design mixes required for the project, together with test results, to Engineer for review before any concrete is placed. Design mixes may be initially submitted for preliminary review with the 7 and 14 day test results but the 28 day test results shall be reported prior to placing concrete. The mix design submittal shall contain at least the following information: gradations for coarse and fine aggregate, cement type, aggregate sources, cement source, admixture data sheet from manufacturer's brochure, mix proportions, strength test results, actual slump of tested concrete mix, batch plant, etc. The submittal shall be signed by the preparer and the registered Civil Engineer experienced in concrete materials that is responsible for the mix design. Contractor shall immediately notify his Concrete Testing Agency (who prepared the mix design and who is performing QA) as well as the Owner's Concrete Testing Agency and Engineer if, at any time during construction, the concrete resulting from the mix design proves to be unsatisfactory for any reason such as: Too much water, lack of sufficient plasticity to prevent segregation, honeycomb, etc., or insufficient strength. Contractor's Concrete Testing Agency shall modify the design, subject to the Engineer's review, until a satisfactory concrete is obtained. Stone Concrete: Proportion in accordance with the following minimum requirements: ign Strength Cement Content*Water. Max •< 4000 5-3/4 5.5 5" min to 7" max per GED * A plasticizing admixture shall be used and minimum cement requirements may be reduced by 1/2 sack per cu. yd. where a maximum of 75 Ibs. of fly ash is substituted per cu. yd. ** Increase slump, provide retardation, etc., as necessary or required for excavation utilizing temporary liners. Tremie Concrete: Proportion in accordance with the following minimum requirements: Design Strength psi 5000 psi Cement Content 705 Ibs. Maximum Slump 7 to 9 inch A plasticizing admixture shall be used and minimum cement requirements may be reduced by 47 Ibs. where a maximum of 75 Ibs. of fly ash is substituted. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE DRILLED PILES 02375-7 PART 3 - EXECUTION 3.1 PREPARATION A. Field Measurements: Verify dimensions before proceeding with work. Obtain field measurements for work required to be accurately fitted to other construction. Be responsible for accuracy of such measurements. B. Equipment: The Contractor shall use equipment of adequate capacity and proven methods for all drilled piles construction work including rock drilling. Drilling shall be accomplished by means of a power driven rotary bucket or auger type foundation drilling machine designed to excavate a plumb cylindrical shaft. C. Methods: The drilling sequences and procedures shall be such as to produce negligible loss of ground as well as squeezing of the hole and consequent settlement. The Contractor shall develop his construction procedure using the guidelines described and provide a description of the procedure for review and approval by Owner's Geotechnical Consultant. 3.2 INSTALLATION/APPLICATION/ERECTION A. Excavation 1. General: Excavated materials shall be removed from the site or utilized on the site in locations in accordance with construction activities as required. The area shall at all times be kept clean and free of spoil and other debris which could affect the progress or safety of the work. 2. Piles with Liners: Machine methods shall be used for the excavation of pile shafts. Temporary steel liners must be used if required to prevent caving of soil and to reduce seepage. The diameter of the bore of the hole shall be such as to reduce the annular space between the wall of the hole and the steel liner to a minimum. a. Liner cutting, loss of temporary liner or portion thereof, extension/addition of piles, etc., shall be at expense of the Contractor. b. Piles shall not be excavated closer than 4 diameters on center unless adjacent piles have been completed 24 hours. c. Piles Shafts: Piles shall be founded in and on bearing strata capable of developing the minimum allowable pile capacity specified on the drawings. If test results indicate that the bearing strata is incapable of providing the required allowable capacity values, the shaft length may be advanced as directed by the Owner's Geotechnical Consultant. d. The AGENCY'S Geotechnical Consultant will perform inspection in order to report quality of bearing strata, penetration into bearing strata, conditions at the bottom and sides of the piles, as well as report the confirmation of design allowable pile capacity. 8/13/09 Contract No. 3811 CAST-IN-PLACE DRILLED PILES PALOMAR AIRPORT ROAD WIDENING 02375-8 B. Installation 1. Placing Concrete: The following procedure shall be followed for placing concrete "in-the-dry". a. Do not start placing of concrete until the excavation and reinforcing for the whole unit to be placed has been completed, cleaned and dried, and inspected and approved by the Owner's Geotechnical Consultant. b. Provide adequate runways, chutes, tremies and other means of conveying concrete into place. Use tremies for placing concrete. Use vertical pipe near the center of the piles extending into the concrete to control concrete placement. c. Place concrete immediately after mixing, and in no case, more than 60 minutes after water has been added. Continue the depositing of concrete in a continuous operation until completion of the piles to top of shaft, and in no case suspend the placing of concrete of a pile more than 30 minutes. Consolidate the concrete by vibrating the top 25' (7.6 m). Laitance and excess water shall be removed. d. Concrete for piles shall be placed "in-the-dry" unless placement under bentonite or other equivalent slurry is determined by the Contractor's Consultant to be necessary and confirmed by written approval of the AGENCY'S Geotechnical Consultant. Standing water in puddles deeper than one (1) inch, loose soil and debris shall be removed from the bottom of shafts before concrete placement. If placement under slurry is necessary, use tremie concrete mix of 1000 psi higher strength than specified on the drawings which is for "in-the-dry" placement. e. Place concrete in piles immediately upon complying with the foregoing requirements and receipt of test results confirming that allowable pile embedment and rock quality have been attained. C. Installation Tolerances 1. The maximum allowable variation of the center of the top of any piles from the required location shall be 4% of the shaft diameter or 3" (75 mm), whichever is less. The shaft shall not be out of plumb by more than 3 inch in 25 feet. If these tolerances are exceeded, additional work shall be performed as directed, at the Contractor's expense. 2. Piles shall have a minimum shaft diameter equal to that shown on the drawings. If the pile's diameter is reduced, the Contractor shall design and furnish additional or corrective construction, acceptable to the Engineer, to compensate for loss of piles section, at no extra cost. The proposed corrective construction which may include additional piles, caps and grade beams shall be submitted to the Engineer for review. 8/13/09 Contract No. 3811 CAST-IN-PLACE DRILLED PILES PALOMAR AIRPORT ROAD WIDENING 02375-9 D. Corrective Methods 1. If test results indicate that the soil is not capable of providing the required minimum allowable piles capacity value, the shaft length shall be advanced and the evaluations for capacity repeated, unless other recommendations are made by the AGENCY'S Geotechnical Consultant, with the concurrence of the Engineer. 2. Loose materials or free water in quantities sufficient to cause settlement or affect concrete strength, as determined by AGENCY'S Geotechnical Consultant shall be removed from the bottom of the shaft. 3. If water or other conditions are found which make excavation through sand or silt strata dangerous to personnel or such as to cause excessive inflow or silt or sand creating voids outside the piles, the work shall be continued using an acceptable stabilization method or other alternative method, which are demonstrated by trial shaft in either case. 4. If concrete placement is suspended before completion of a pile or a construction joint is required for some other reason, show the detail and elevation of the joint on the as-built drawings. 5. If construction joints are required and the reinforcing cage is not required at the joint location, provide dowels of the same size and configuration as the reinforcing cage, suitably tied, with embedment sufficient to develop and bond strength of the bars. 3.3 FIELD QUALITY MONITORING A. Bearing Strata: The AGENCY'S Geotechnical Consultant will perform all tests hereinafter specified and any additional tests as may be required, and will prepare test reports: 1. The bottom elevations, bearing, and lengths of piles as shown on the drawings are estimated from the soil boring data. The actual elevations, pile lengths and load capacities shall be determined by the AGENCY'S Geotechnical Consultant. 2. The Contractor shall notify the AGENCY'S Geotechnical Consultant sufficiently in advance to allow inspection of the shaft excavation and evaluation herein specified as soon as the desired level is reached. 3. The AGENCY'S Geotechnical Consultant shall keep an accurate record of each piles excavation. 4. The bottom of the excavation for all piles shall be inspected as necessary by the AGENCY'S Geotechnical Consultant. 5. The completed piles will be evaluated as directed by the Geotechnicaj Consultant by sonic gamma logging, cross hole logging or other means for voids or other indications of incomplete pile diameter at any elevation. Provide and install a minimum of two tubes in each pile for logging of the diameter and material as directed by the Geotechnical Consultant. Protect the tubes by sealing, filling with water, etc., and flushing out, prior to sonic testing by the Geotechnical Consultant. Provide coring equipment and core the test piles full length to evaluate concrete consistency and strength. Box the core and deliver portions for testing by the AGENCY'S Concrete Testing Agency. Core other piles as directed 8/13/09 Contract No. 3811 CAST-IN-PLACE DRILLED PILES PALOMAR AIRPORT ROAD WIDENING 02375-10 at no additional cost where sonic testing or other evaluations indicate deficiencies in concrete consistency, strength, etc. B. Concrete: The AGENCY'S Concrete Testing Agency shall conduct the following tests and inspections during construction and immediately submit reports thereon to the Engineer. 1. Compression Tests shall be made for each 100 cu. yds. (75 cu.m) of concrete, or fraction thereof, but not less than one set of cylinders for each day's concrete placement of each concrete type. Make 5 standard 6 x 12 (15 x 30 cm) cylinders and test in accordance with ASTM C31 and C39. Test two cylinders at the age of 7 days and two cylinders at the age of 28 days. Keep one cylinder in reserve for 56-day test if 28-day test does not meet requirements. Only one set of tests shall be made from any one batch of concrete and all 5 cylinders shall be made from the same batch. One 7-day cylinder and one 28-day cylinder shall be cured in a pit at the job site to simulate the same curing conditions as the concrete used in the piles. The remaining cylinders shall be cured in the laboratory. Reports of cylinder tests shall state: The location in the structure; laboratory or site curing; compression strength; type of fracture; age at testing; concrete supplier; mix specification strength and any other pertinent information, together with a statement as to whether this concrete complies with the specifications. In addition, one cylinder for 7-day test shall be taken from every truck load. 2. Slump Tests: ASTM C143. Provide a slump cone at the site at all times. Make two (2) test for each 100 cu. yds. (75 cu.m) of concrete, or fraction thereof, but not less than two (2) tests for each day's placement of each type of concrete. Each test shall be from a separate batch. 3. Inspection of Batch Plant operation as required to ensure that concrete delivered to job complies with the specifications and the design mix. Batch plant inspection shall be required once at start of job and thereafter if concrete falls below specification strength or is not satisfactory to the Inspector of Record. C. Additional Tests: If, in the opinion of the Engineer, based on cylinder strengths below specification requirements or visual defects, concrete of poor quality has been placed, additional tests shall be made as directed by the Engineer and at the expense of the Contractor. Tests may be compression tests on cored cylinders, ASTM C42, and/or load tests as outlined in ACI 318, Section 202, or as directed by the Engineer. Complete continuous coring of piles will be required, at the Contractor's expense, where observation of the concrete placing operations indicates cause for suspicion of the quality of the concrete, presence of voids, segregation or other possible defects in the piles. 1. Probe the top 2' (60 cm) of fresh concrete at the top of shaft or where concrete placement is delayed to determine consistency. If laitance, foreign matter, or excess water is in evidence, the Contractor shall remove same. 8/13/09 Contract No. 3811 CAST-IN-PLACE DRILLED PILES PALOMAR AIRPORT ROAD WIDENING 02375-11 SECTION 02485 HYDROSEEDING PART 1 - GENERAL 1.1 WORK INCLUDED A. Weed Eradication B. Hydroseeding C. Maintenance 1.2 RELATED WORK A. The CONTRACTOR is to provide a complete soil analysis test for project site before any hydroseed work begins. The CONTRACTOR is to submit a copy of the test to the ENGINEER or INSPECTOR for evaluation. A soil preparation program will be developed and submitted to the CONTRACTOR for bidding purposes. The CONTRACTOR is to submit a change order for additional labor and materials to implement the suggested soil preparation program. B. Section [02900] Landscaping C. Section [02810] Landscape Irrigation 1.3 QUALITY ASSURANCE A. Installer Qualifications: Fully trained in the preparation and seeding techniques described in this section, and working under the direct supervision of a qualified foreman with not less than five years experience in hydroseeding. B. Pest Control Applicator: Trained and state licensed for application of weed control chemicals. C. Requirements of Regulatory Agencies: Comply with applicable federal, state, and local laws and regulations. 1.4 SUBMITTALS A. Certificates: Submit the following certifications to the INSPECTOR: 1. Seed purity and germination percentages 1.5 PRODUCT HANDLING A. DELIVERY: Deliver all materials in manufacturer's original unopened containers, with each container identified with manufacturer's name, brand or type, contents, weight and guaranteed analysis. 02/17/09 Contract No. 3811 HYDROSEEDING PALOMAR AIRPORT ROAD WIDENING 02485-1 B. Storage: 1. Store materials at a location directed by the Owner. 2. Store materials in an orderly manner. Avoid interference with other construction activities. 3. Store fertilizer above ground and protect from moisture absorption with approved covering. C. Protection: 1. Protect the installed work and materials of other trades. 2. Do not permit workmen to walk on seeded areas unnecessarily before, during, and after seeding operations. 1.6 PROJECT CONDITIONS A. Verify all dimensions and planting area conditions prior to proceeding with work. B. Notify the ENGINEER or INSPECTOR immediately if any discrepancies exist between the drawings, the specifications, and the actual site conditions. C. Do not permit work in any area which is unsuitable for successful plant material establishment until all such conditions have been corrected and approved by the ENGINEER or INSPECTOR. PART 2 - PRODUCTS 2.1 MATERIALS A. Seed: Provide the seed mix specified within these specifications. Seed is to be supplied by Agrono-Tec Seed Company (Ph: 800-543-4109). B. Fertilizer: Commercial grade, granular and uniform in composition, dry and free flowing, with the following constituents: Nitrogen: 16% Phosphoric Acid: 20% Potassium: 0% 1. Each bag labeled with specific NPK rating. 2. Apply at a rate of 500 Ibs. per acre of area. (Step 1 application only). C. Fiber Mulch: Cellulose type 1. Apply at a rate of 1,000 Ibs. per acre of area. (Step 1 application only) 2. Apply at a rate of 2,000 Ibs. per acre of area. (Step 2 application only). 02/17/09 Contract No. 3811 HYDROSEEDING PALOMAR AIRPORT ROAD WIDENING 02485-2 D. Herbicides: 1. As approved by the PEST CONTROL OPERATOR. Provide non-selective, systemic, and contact types as required by type of control required by project conditions. 2. Use only herbicide types which are not harmful to plant species in areas being treated. PART 3 - EXECUTION 3.1 INSPECTION A. Examine surfaces for conditions that will adversely affect execution, permanence and quality of work, including irrigation and graded surfaces. B. Notify the ENGINEER or INSPECTOR in writing, describing all unacceptable conditions. C. Do not proceed with work until such conditions are corrected. 3.2 SLOPE SCARIFICATION A. Cut Slopes: 1. N/A B. Fill Slopes: 1. N/A 3.3 EQUIPMENT A. Use only equipment that has a built-in agitation system and with an operating capacity sufficient to agitate, suspend, and homogenously mix a slurry containing not less than 20 kilos (44 Ibs.) of organic mulching amendment, plus fertilizer additives and solids for each 100 gallons of water. 3.4 HYDROSEEDING A. Perform hydroseeding in a two-step application process as follows: Step 1 LbsJAcre _ Kg/Hectare _ Hydroseed Mix Summary _ 1 ,000 1 ,124 Hydrostraw™ straw and tack mulch See Seed Specification N/A Seed 500 562 6-20-20 commercial fertilizer Step 2 Lbs./Acre _ Kg/Hectare _ Hydroseed Mix Summary _ 2,000 2,250 Hydrostraw™ straw and tack mulch 02/17/09 Contract No. 3811 HYDROSEEDING PALOMAR AIRPORT ROAD WIDENING 02485-3 B. Begin hydroseeding immediately after soils have been prepared and watered as specified. C. Mix proportions: Prepare slurry mixture at the site. Mix components to provide the following application rates: 1. Add water to the tank with the engine at one-half throttle. a. When water reaches the height of the agitator shaft, and good recirculation has been established, add fertilizers to the mixture. b. Tank must be at least 1/3 filled with water at this time. 2. Open engine throttle to full speed when tank is % filled with water. a. Add all organic amendments, fiber, and chemicals when tank is 2/3 to 3/4 full. b. Add seed mix. 3. Begin spraying immediately when tank is full and slurry is thoroughly blended. D. Application: 1. Hydraulically apply mulch in a manner to form a "blotter-like" material uniformly on all scheduled areas. 2. Apply uniformly on all surfaces. Use the dark color of the fiber as a guide to indicate coverage. 3. Direct spray operation so that slurry spray will penetrate the soil surface, and in a manner so as to drill and mix slurry into the soil with maximum impregnation and coverage. 4. Apply slurry in a manner to provide maximum moisture retention in the soils, and stabilize surfaces and inhibit erosion. 5. Do not allow slurry components to remain in the machine for longer than two hours to avoid destruction of seed, except as follows. a. If unused slurry components have been in the machine for two hours after original mixing, add 50 percent more of the specified seed mix to the remaining slurry mix. b. If unused slurry components have been in the machine for eight hours after original mixing, add 75 percent more of the specified seed mix to the remaining slurry mix. c. Do not use slurry mixture which has not been applied within eight hours after original mixing. d. Dispose of rejected slurry material to a legal offsite disposal area. 02/17/09 Contract No. 3811 HYDROSEEDING PALOMAR AIRPORT ROAD WIDENING 02485-4 3.5 MAINTENANCE PERIOD A. Maintain hydroseeded area for a period of 90 days after acceptance of seeded areas by the LANDSCAPE ARCHITECT. B. Irrigation (During Germination Stage): 1. Begin watering sequence approximately 24 hours after hydro mulching is completed. 2. Continue watering long enough to moisten soil thoroughly to the depth of slurry. 3. Exercise care to prevent super saturating and washing away of slurry and seed. 4. Perform frequent and light watering until seedlings have grown beyond the germination stage, usually from 45 to 60 days. 5. Water at the rate required to maintain the optimum moisture content in soils during this period to allow maximum germination. 6. Maintain constant observation of irrigation system during operation. Adjust watering sequence as necessary relative to prevailing air temperature, wind velocity, soil texture, orientation and other influencing logistics. 7. Repair all surfaces damaged and eroded by watering operations. Replace materials to original specifications. C. Irrigation (Establishment Stage): 1. After germination, reduce frequency of watering, while increasing duration of each watering cycle. 2. Provide watering program as approved by the ENGINEER or INSPECTOR. Unless otherwise directed, maintain watering once each day over a 90-day period. D. Irrigation (Hardening-off Stage): 1. At the end of the 90 days, gradually reduce the watering frequency to once every 3 days, and increase the duration of each cycle sufficiently to permit maximum water penetration for the expanding root system. 2. Avoid eroding of soil caused by excessive watering. E. Fertilization: 1. N/A F. Weeding: 1. N/A 02/17/09 Contract No. 3811 HYDROSEEDING PALOMAR AIRPORT ROAD WIDENING 02485-5 G. Re-Seeding: 1. At the end of the maintenance period the hydroseeded areas shall be reviewed by the ENGINEER or INSPECTOR. Any areas that do not have acceptable coverage and growth of the seeded species shall be reseeded either by hand broadcasting or hydroseeding. 3.6 FINAL ACCEPTANCE A. Final approval and acceptance of the work will be given when the following conditions, as determined by the ENGINEER or INSPECTOR are met: 1. At the completion of the 90-day maintenance period, and when 80 percent germination and plant establishment is obtained. 2. After final inspection and acceptance by the ENGINEER or INSPECTOR. 3. The ENGINEER or INSPECTOR reserves the option to extend the maintenance period beyond the 90-days specified, if he determines that further maintenance is necessary to provide the 80 percent coverage required by the contract documents. 4. Approval and acceptance will be given in writing. 3.7 CLEAN UP A. On completion of work described in this section, remove all equipment, containers and debris, from the site. 02/17/09 Contract No. 3811 HYDROSEEDING PALOMAR AIRPORT ROAD WIDENING 02485-6 SECTION 02517 PORTLAND CEMENT CONCRETE PAVING PART 1 - GENERAL 1.1 SUMMARY A. Furnish and install Portland cement concrete paving as shown on the drawings, including curbs, gutters, walkways, and pavement, and other site concrete. B. Material selection: 1. Select materials that have the highest possible recycled content while still meeting performance criteria. 2. Select materials from local manufacturers wherever possible. 1.2 SUBMITTALS A. Provide samples, manufacturer's product data, test reports, and materials' certifications as required in referenced sections for concrete and joint fillers and sealers. B. Mix design: 1. Include the highest percentage of fly ash in concrete mix that will meet the specified performance criteria. 2. Provide manufacturer name and location data for the following materials: a. Concrete: Assembly b. Concrete: Mix Design Report 1) Provide a copy of the plant batch mix report for each different mix design used and batch plant used. 1.3 QUALITY ASSURANCE A. Unless otherwise specified, all materials and work shall be in accordance with "The Standard Specifications for Public Works Construction" (the Standard Specifications), latest edition. B. Base material for concrete shall be CMB per 200-2.4 and shall be placed and compacted per the Standard Specifications. C. Placed concrete shall be class 520-C-2500, maximum 4-inch slump. Pumped concrete shall be class 560-E-2500, maximum 6-inch slump. A complete delivery receipt shall be required for each truckload of concrete delivered. The receipt shall be given to the Contract Administration Inspector. D. Portland Cement Concrete shall be Type II, (201-1.2). 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 PORTLAND CEMENT CONCRETE PAVING 02517-1 PART 2 - PRODUCTS 2.1 MATERIALS A. Forms: Steel, wood, or other suitable material of size and strength to resist movement during concrete placement and to retain horizontal and vertical alignment until removal. Use straight forms, free of distortion and defects. 1. Use flexible spring steel forms or laminated boards to form radius bends as required. B. Coat forms with a nonstaining form release agent that will not discolor or deface surface of concrete. C. Welded Wire Mesh: Welded plain cold-drawn steel wire fabric, ASTM A185, in flat sheets, not rolls. D. Reinforcing Bars: Deformed steel bars, ASTM A 615, Grade 60. E. Joint Dowel Bars: Plain steel bars, ASTM A 615, Grade 60. Cut bars true to length with ends square and free of burrs. F. Concrete Materials: Comply with requirements of applicable Division 3 sections for concrete materials, admixtures, bonding materials, curing materials, and others as required. G. Use high-range water-reducing admixture (HRWR) in pumped concrete, concrete for parking structure slabs, and concrete with water/cement ratios below 0.50. High-Range water-reducing admixture (Super Plasticizer) shall conform to ASTM C 494, Type F or Type G, and be one of the following products: 1. "Super P," Anti-Hydro Co., Inc. 2. "Eucon 37," Euclid Chemical Co. 3. "WRDA 19" or "Daracem," W.R. Grace & Co. 4. "Rheobuild," Master Builders, Inc. 5. Sikament 300," Sika Corp. H. Expansion Joint Sealers: Comply with requirements of applicable Division 7 sections for joint sealers. I. Bituminous Fiber Joint Filler: Preformed strips of asphalt saturated fiberboard, complying with ASTM D 1751. 8/13/09 Contract No. 3811 PORTLAND CEMENT CONCRETE PAVING PALOMAR AIRPORT ROAD WIDENING 02517-2 J. Provide a packaged, integral color, consisting of Portland cement, coloring pigments, and plasticizing admixtures. Use coloring pigments that are nonfading mineral oxides, interground with cement. Color as selected by Architect from manufacturers' standards. Subject to compliance with specified requirements, products that may be incorporated in the work include those of the following manufacturers'. 1. Davis Color, Inc. 2. A. C. Horn, Inc. 3. L & M Construction Chemicals, Inc. 4. Master Builders, Inc. 5. L. M. Scofield Co. 6. Or Equal K. Liquid-Membrane Forming and Sealing Curing Compound: Comply with ASTM C 309, Type I, Class A unless other type acceptable to Architect. Moisture loss no more than 0.055 gr./sq. cm. when applied at 200 sq. ft./gal, as follows: 1. "Clear Seal"; A. C. Horn. 2. "AR-30" W. R. Meadows. 3. "Kure-N-Seal"; Sonnebom-Contech. 2.2 CONCRETE MIX, DESIGN, AND TESTING A. Comply with requirements of applicable Division 3 sections for concrete mix design, sampling and testing, and quality control and as herein specified. B. Design mix to produce normal-weight concrete consisting of Portland cement, aggregate, water-reducing or high-range water-reducing admixture (superplasticizer), air-entraining admixture, and water to produce the following properties: 1. Compressive Strength: As indicated on the drawings, or if not so indicated, compressive strength shall be 3000 psi, minimum at 28 days. 2. Slump Limit: 8 inches minimum for concrete containing high-range water-reducing admixture (superplasticizer); 3 inches for other concrete. 3. Air Content: 5 to 8 percent. PART 3 - EXECUTION 3.1 FORM CONSTRUCTION A. Set forms to required grades and lines, braced and secured. Install forms to allow continuous progress of work and so that forms can remain in place at least 24 hours after placement. B. Check completed formwork for grade and alignment to following tolerances: 1. Top of forms not more than 1/8 inch in 10 feet. 2. Vertical face on longitudinal axis, not more than 1/4 inch in 10 feet. 8/13/09 Contract No. 3811 PORTLAND CEMENT CONCRETE PAVING PALOMAR AIRPORT ROAD WIDENING 02517-3 C. Clean forms after each use and coat with form release agent as required to ensure separation from concrete without damage. D. Slope step treads at 1/4-inch per foot to drain. 3.2 STEEL REINFORCEMENT A. Locate, place, and support reinforcement as specified in Division 3 sections, unless otherwise indicated. 3.3 CONCRETE PLACEMENT A. General: Comply with requirements of Division 3 sections for mixing and placing concrete, and as herein specified. B. Do not place concrete until subbase and forms have been checked for line and grade. Moisten subbase if required to provide a uniform dampened condition at time concrete is placed. Do not place concrete around manholes or other structures until they are at required finish elevation and alignment. C. Place concrete by methods that prevent segregation of mix. Consolidate concrete along face of forms and adjacent to transverse joints with internal vibrator. Keep vibrator away from joint assemblies, reinforcement, or side forms. Use only square-faced shovels for hand-spreading. Consolidate with care to prevent dislocation of reinforcing, dowels, and joint devices. D. Use bonding agent at locations where fresh concrete is placed against hardened or partially hardened concrete surfaces. E. Deposit and spread concrete in a continuous operation between transverse joints as far as possible. If interrupted for more than 1/2 hour, place a construction joint. F. Curbs and Gutters: Automatic machine may be used for curb and gutter placement at Contractor's option. If machine placement is to be used, submit revised mix design and laboratory test results that meet or exceed minimums specified. Machine placement must produce curbs and gutters to required cross-section, lines, grades, finish, and jointing as specified for formed concrete. If results are not acceptable, remove and replace with formed concrete as specified. 3.4 JOINTS A. General: Construct expansion, weakened-plane (contraction), and construction joints true to line with face perpendicular to surface of concrete. Construct transverse joints at right angles to the centerline, unless otherwise indicated. B. When joining existing structures, place transverse joints to align with previously placed joints, unless otherwise indicated. 8/13/09 Contract No. 3811 PORTLAND CEMENT CONCRETE PAVING PALOMAR AIRPORT ROAD WIDENING 02517-4 C. Weakened-Plane (Contraction) Joints: Provide weakened-plane (contraction) joints, sectioning concrete into areas as shown on drawings. Construct weakened-plane joints for a depth equal to at least 1/4 concrete thickness, as follows: 1. Tooled Joints: Form weakened-plane joints in fresh concrete by grooving top portion with a recommended cutting tool and finished edges with a jointer. D. Construction Joints: Use standard metal keyways. Place construction joints at end of placements and at locations where placement operations are stopped for more than 1/2 hour, except where such placements terminate at expansion joints. E. Expansion Joints: Provide premolded joint filler for expansion joints abutting concrete curbs, catch basins, inlets, structures, walks, and other fixed objects. F. Extend joint fillers full width and depth of joint, not less than 1/2-inch or more than 1-inch below finished surface where joint sealer is indicated. If no joint sealer, place top of joint filler flush with finished concrete surface. G. Fillers and Sealants: Comply with requirements of applicable Division 7 sections for preparation of joints, materials, installation, and performance. 3.5 GENERAL CONCRETE FINISHING A. After striking-off and consolidating concrete, smooth surface by screeding and floating. Apply a float finish as a first phase preceeding all other finishes. Use hand methods only where mechanical floating is not possible. Adjust floating to compact surface and produce uniform texture. B. After floating, test surface for trueness with a 10-ft. straightedge. Distribute concrete as required to remove surface irregularities, and refloat repaired areas to provide a continuous smooth finish. C. Work edges of slabs, gutters, back top edge of curb, and formed joints with an edging tool, and round to 1/2-inch radius. D. After floating and when excess moisture or surface sheen has disappeared, complete troweling and finish surface as follows: 1. On level surfaces, broom finish by drawing a fine-hair broom across concrete surface perpendicular to line of traffic. 2. On inclined slab surfaces, provide a coarse, non-slip finish by scoring surface with a stiff-bristled broom, perpendicular to line of traffic. E. Do not remove forms for 24 hours after concrete has been placed. After form removal, clean ends of joints and point-up any minor honeycombed areas. Remove and replace areas or sections with major defects, as directed by Architect. 8/13/09 Contract No. 3811 PORTLAND CEMENT CONCRETE PAVING PALOMAR AIRPORT ROAD WIDENING 02517-5 3.6 WOOD FLOAT FINISH A. Also provide as second stage for other finishes, unless otherwise specified. B. Using approved floating machines or hardwood trowels, float surfaces to required planes and shapes, working just sufficiently to bring surfaces to uniform condition. C. Work no more than necessary to achieve uniform texture free from irregularities and screed marks; except where receiving fills or mortar beds, leave surfaces in roughened, granular condition for good mechanical bond. D. Cut and fill surfaces as necessary to true up. E. When followed by other finishes, floating shall leave small amount of mortar on surfaces without excess of water. F. Do not proceed with subsequent finishes until surface water has absorbed or dried off and concrete has set sufficiently to prevent fines or water from being worked to the surface. G. Finish texture shall be fine-grained and granular to provide good slip-resistance, and shall be reasonably free from directional trowel marks. H. Provide for exterior and interior surfaces of buildings, unless otherwise indicated. 3.7 STEEL TROWEL FINISH A. Using finishing machines or steel trowels, trowel surfaces to produce a dense, hard, smooth steel trowel finish. Commence troweling in 1 pass sufficiently to flatten floated surface. B. Wait until concrete has set sufficiently; then resume steel troweling; continue and repeat as required to obtain a hard steel trowel finish, free of blemishes, ripples, and trowel marks. C. Do Not: 1. Use cement or sand dusting to absorb or otherwise remove surface water. 2. Commence troweling too soon on freshly placed concrete. 3. Overwork surfaces by excessive troweling in an area in one pass. D. Work out lips, uneven levels, and other irregularities prior to final troweling. E. Neatly tool exposed edges, expansion joints, curbs, arises, and other details. F. Surface across joints shall be level and free from offsets. G. Provide for interior surface not otherwise indicated or specified. 8/13/09 Contract No. 3811 PORTLAND CEMENT CONCRETE PAVING PALOMAR AIRPORT ROAD WIDENING 02517-6 3.8 BROOM FINISH A. For exterior flatwork and where indicated. B. Draw a soft-bristled push broom over an initially trowel-finished surface. C. When coarser surfaces are desired, use a stiffer-bristled broom. D. Broom finish shall provide a non-slip surface, even if exposed to rain. 3.9 CURING A. Protect and cure finished concrete paving in compliance with applicable requirements of Division 3 membrane-forming curing and sealing compound. 3.10 REPAIRS AND PROTECTIONS A. Repair or replace broken or defective concrete, as directed by Engineer. B. Protect concrete from damage until acceptance of work. Exclude traffic from pavement for at least 14 days after placement. When construction traffic is permitted, maintain pavement as clean as possible by removing surface stains and spillage of materials as they occur. C. Sweep concrete pavement and wash free of stains, discolorations, dirt, and other foreign material just before final inspection. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 PORTLAND CEMENT CONCRETE PAVING 02517-7 SECTION 02527 CONCRETE DRIVEWAY, SIDEWALKS, CURB AND GUTTER PART 1 - GENERAL 1.1 THE REQUIREMENT A. THE CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work as indicated in the Contract Documents and specified herein. B. This section covers the work necessary to construct the following concrete driveways, sidewalks, and curb and gutters, complete, in place in accordance with the requirements of the Contract Documents. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [02200] Earthwork. B. Section [02232] Preparation of Pavement Subgrade C. Section [03100] Concrete Formwork D. Section [03290] Joints in Concrete E. Section [03300] Cast-ln-Place Concrete F. Section [03370] Concrete Curing 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the applicable reference specifications as specified in the GENERAL PROVISIONS. B. Work of this section shall be performed in accordance with the Standard Specifications for Public Works Construction (SSPWC), unless otherwise specified herein. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL PROVISIONS. 1.5 QUALITY ASSURANCE A. Comply with the applicable Reference Specifications of the GENERAL PROVISIONS. PART 2 - PRODUCTS 2.1 FORMS 8/13/09 Contract No. 3811 CONCRETE DRIVEWAY, SIDEWALKS, CURB & GUTTER PALOMAR AIRPORT ROAD WIDENING 02527-1 A. Form material shall be in conformance with SSPWC Section 303-5.2. 2.2 CRUSHED AGGREGATE BASE A. Crushed Aggregate Base shall conform to 200-2.2 of the Standard Specification for Public Works Construction. 2.3 EXPANSION JOINT FILLER A. Expansion joint filler shall be 1/4-inch thick, preformed asphalt-impregnated, expansion joint material conforming to ASTM D 994. 2.4 CONCRETE A. Refer to Section [03300] "Cast-ln-Place Concrete". 2.5 CURING COMPOUND A. Refer to Section [03370] "Concrete Curing". 2.6 ACCEPTANCE OF MATERIALS A. All materials shall be subject to testing, inspection, and acceptance by the ENGINEER and the INSPECTOR at any time prior to or during the work as applicable. 2.7 EXCAVATION AND BACKFILL A. Refer to Section [02200] "Earthwork". PART 3 - EXECUTION 3.1 EXCAVATION AND BACKFILL A. Excavation and backfill shall be in conformance with Section [02200] "Earthwork". 3.2 PREPARATION OF SUBGRADE A. Preparation of subgrade shall be in conformance with Section [02232] "Preparation of Pavement Subgrade". 3.3 PLACING CRUSHED AGGREGATE BASE A. Crushed Aggregate Base shall be in conformance with the SSPWC Section 301-2.2. B. Crushed Aggregate Base shall be compacted in conformance with SSPWC Section 301-2.3. 3.4 SETTING FORMS A. Setting forms shall be in conformance with SSPWC Section 303-5.2.1. 8/13/09 Contract No. 3811 CONCRETE DRIVEWAY, SIDEWALKS, CURB & GUTTER PALOMAR AIRPORT ROAD WIDENING 02527-2 3.5 SLIP FORMING A. Slip-form equipment shall be in conformance with SSPWC Section 303-5.2.2. 3.6 EXPANSION JOINTS A. Expansion joints shall be constructed in conformance with SSPWC Section 303-5.4.2. 3.7 WEAKENED PLANE JOINTS A. Weakened plane joints shall be placed in conformance with SSPWC Section 303-5.4.3. 3.8 PLACING CONCRETE A. Concrete shall be placed in conformance with SSPWC Section 303-5.3. 3.9 FINISHING A. General: Finishing shall be completed as specified herein for the type work being performed. B. Curb: The stripping of front forms and finishing of curb shall be in conformance with SSPWC Section 303-5.5.2. C. Walk: The finished surface of the walk shall be in conformance with SSPWC Section 303-5.5.3. D. Gutter: The gutter shall be finished in conformance with SSPWC Section 303-5.5.4. E. Access Ramps and Driveways: The Access Ramps and Driveways shall be finished in conformance with SSPWC Section 303-5.5.5. 3.10 CURING A. Refer to Section [03370] Concrete Curing. 8/13/09 Contract No. 3811 CONCRETE DRIVEWAY, SIDEWALKS, CURB & GUTTER PALOMAR AIRPORT ROAD WIDENING 02527-3 SECTION 02530 PAVEMENT MARKING AND SIGNS PART 1 - GENERAL 1.1 SUMMARY A. Extent of painted pavement surface striping is shown on the plans. B. Prepare surface for painting. C. Layout and obtain approval of the proposed striping before starting work. D. Provide templates for stenciled lettering and legend painting. E. Paint surface striping 4" wide, unless otherwise indicated. F. Clean up. G. Furnish and install all traffic control signs, posts, and delineators. 1.2 RELATED DOCUMENTS A. The latest adopted edition of the Standard Specifications for Public Works Construction applies to the work of this section. B. The latest revision to the Caltrans Traffic Manual applies to the work of this section. Applicable plans are stipulated on drawings. C. The latest adopted edition of the Caltrans Specifications, Manuals and Standard Plans apply to the work of this section. 1.3 QUALITY ASSURANCE A. All painted surface striping shall conform to Section 310-5.6 Painting, Traffic Striping, Pavement Markings and Curb Markings of the Standard Specifications for Public Works Construction, latest edition. Where specific items are not addressed in the Standard Specifications, or are required by conditions of a construction permit comply with the State of California Standard Specifications, latest edition, and Caltrans Traffic Manual, latest edition. B. Submit material list and specifications to engineer and City representative for approval. PART 2 - PRODUCTS 2.1 MATERIALS A. Paint for traffic striping, pavement marking and curb marking shall conform to Section 210.16 of the Standard Specifications for Public Works Construction. Paint shall be vinyl-epoxy emulsion based, water thinned, without glass beads; Dunn Edwards "Vin-L-Stripe Traffic Paint W-801", Sinclair Paint "162 Vinyl Traffic Marking Paint", or equal. Accessibility symbol color shall be Federal Standard 595A "Blue #15090". B. Paint shall comply with local environmental regulations. 8/13/09 Contract No. 3811 PAVEMENT MARKING & SIGNS PALOMAR AIRPORT ROAD WIDENING 02530-1 C. Signs: Provide roadside signs complete with posts and braces and sign panel fastening hardware in accordance with the APWA Standard Plans for Public Works Construction, and as shown on the drawings. Provide vandal proof connections. Posts shall be Quik Punch or equal. D. Custom Parking Lot Signs: Signs shall be constructed of reflective aluminum. Locate signs as indicated on the plans. Size and vandal proof mounting hardware shall be in accordance with Caltrans Standard Plans. Provide Western Highway signs or equal. PART 3 - EXECUTION A. Painted traffic striping, pavement markings and curb markings shall comply with Section 301.5.6 of the Standard Specifications for Public Works Construction. 1. Preparation of Surfaces: All surfaces to be painted shall be dry and thoroughly free from oil, grease, and loose material. 2. At no cost to City, any painted traffic striping which is unacceptable (i.e., tire prints, etc.) shall be removed by wet-type sandblasting and repainting. 3. Application rate shall be in accordance with manufacturers' printed recommendations, but not over 400 sq. ft. per gallon. 4. Protection: Protect the painted surfaces from traffic until thoroughly dry, one day minimum. B. Traffic sign installation procedures shall comply with Section 56 of the Caltrans Traffic Manual. C. Cleanup: Remove all splash discoloration, over spray, and other blemishes from adjacent surfaces by wet type sandblasting. Remove excess material, debris, cartons, and containers from premises immediately upon completion of work. 8/13/09 Contract No. 3811 PAVEMENT MARKING & SIGNS PALOMAR AIRPORT ROAD WIDENING 02530-2 SECTION 02550 ASPHALT CONCRETE PAVEMENT AND BASE PART 1 - GENERAL 1.1 THE REQUIREMENT A. THE CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work as indicated in the Contract Documents and specified herein. B. This section covers the work necessary to construct the following street, access road, and parking area, complete, in place, in accordance with the requirements of the Contract Documents. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [02200] Earthwork. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the applicable reference specifications as specified in the GENERAL PROVISIONS. B. Work of this section shall be performed in accordance with the Standard Specifications for Public Works Construction (SSPWC), unless otherwise specified herein. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL PROVISIONS, and the requirements of this section. B. The pavement section shown on the plans is an estimate. The CITY shall employ a Professional Engineer of the State of applied soil mechanics. The CONTRACTOR employed Professional Engineer shall perform "R" valve tests. The "R" valve test and the engineered structural section shall be submitted to the INSPECTOR and ENGINEER for approval a minimum of two (2) working days before the work begins. C. Samples: Prior to the delivery of specified aggregate to the site, the CONTRACTOR shall submit samples of the material for the INSPECTOR'S acceptance in accordance with SSPWC Section 4-1.4. Samples shall be typical of materials to be furnished from the proposed source and in conformance with the specified requirements. D. The CONTRACTOR shall formulate a job-mix formula using the Marshall Method in accordance with SSPWC Section 203-6.3.2 and submit it to the ENGINEER for approval. The resultant mixture shall have Marshall properties conforming to SSPWC Section 203-6.3.2. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 ASPHALT CONCRETE PAVEMENT 02550-1 E. Certificates: 1. Twenty days prior to the delivery of aggregates, asphalt materials, and paving mixes to the project site, the CONTRACTOR shall submit to the ENGINEER certificates and test results of compliance of such materials with these Specifications. 2. Where laboratory testing is specified herein, the CONTRACTOR shall employ an independent testing laboratory to conduct such tests and submit certificates of the test results. 1.5 QUALITY ASSURANCE A. Quality assurance will be provided by the INSPECTOR. The AGENCY will provide inspection at the asphalt plant and laboratory services within 50 miles of the geographical limits of the CITY OF CARLSBAD. B. The CONTRACTOR shall be responsible for quality control. C. After the asphalt concrete is compacted, and when directed by the Engineer, a water test shall be conducted to determine the location of depressions. The CONTRACTOR shall supply all equipment and materials necessary to perform the test. PART 2 - PRODUCTS 2.1 GENERAL A. The CONTRACTOR shall make all tests necessary to locate a source of materials that meet the Specifications. Final approval of the aggregate material will be based on tests of material taken by the CONTRACTOR from the compacted base course. 2.2 BASE COURSE A. Crushed aggregate for the base course shall consist of crushed rock and rock dust and shall conform to the requirements of SSPWC Section 200-2 UNTREATED BASE MATERIALS. Crushed slag base will not be allowed. 2.3 ASPHALT CEMENT A. Asphalt cement for binder shall be PG 64-10 paving asphalt and shall conform to the requirements of SSPWC Section 203-1 PAVING ASPHALT. 2.4 PRIME COAT A. Asphalt to be used for a prime coat shall be liquid asphalt SC-250 and shall conform to the requirements of SSPWC Section 203-2 LIQUID ASPHALT. 2.5 TACK COAT 8/13/09 Contract No. 3811 ASPHALT CONCRETE PAVEMENT PALOMAR AIRPORT ROAD WIDENING 02550-2 A. Asphalt emulsion shall be CSS-1 or CSS-1h and shall conform to the requirements of SSPWC Section 203-3 EMULSIFIED ASPHALT. 2-6 ASPHALT CONCRETE A. Asphalt concrete for paving the designated area shall be Performance Grade PG-64-10 C2-PG 64-1ORAP hot-plant mix. The design mix report shall indicate results of all testing requirements identified in Section 203-1.2 and 203-6.3 of the SSPWC. PART 3 - EXECUTION 3.1 EXCAVATION AND BACKFILL A. Excavation and backfill are specified in Section [02200] "Earthwork". 3.2 PREPARATION OF SUBGRADE A. Shape subgrade to the grades shown on the Drawings and roll with a three-wheeled power roller weighing approximately 10 tons. Compression under the rear wheels shall be at least 325 pounds per inch of wheel width. Other rollers may be used subject to prior acceptance by the ENGINEER. As the rolling of the subgrade proceeds, dig out all soft or spongy areas and fill the resulting holes with suitable material satisfactory to the INSPECTOR. Dispose of excess materials resulting from the grading. Do not use rollers adjacent to structures where such use may cause damage. Where the base course abuts structures and compaction with a roller is not practicable, compact the area with pneumatic tampers or other approved equipment. B. Use of the prepared subgrade for hauling will not be permitted. The CONTRACTOR shall protect the prepared subgrade from all traffic. C. The subgrade shall be maintained in the finished condition until the first succeeding course is placed. 3.3 BASE COURSE A. Place crushed aggregate base in a uniform layer over the entire area to receive base course, without segregation of size, to such loose depth that when compacted with the power roller, the course shall have the required thickness shown on the Drawings. Compact over the full-width until a density of 95 percent as determined by AASHTO T 180 is obtained. Blade the base with a grader and roll, while damp, with the power roller specified above until the course is thoroughly and uniformly compacted and its surface is smooth and conforms to the grade requirements specified. Maintain the surface in its finished condition until the succeeding layer is placed. 3.4 PRIME COAT A. A prime coat shall be applied in conformance with SSPWC Section 302-5.3. 3.5 CONSTRUCTION OF ASPHALT CONCRETE PAVEMENT 8/13/09 Contract No. 3811 ASPHALT CONCRETE PAVEMENT PALOMAR AIRPORT ROAD WIDENING 02550-3 A. Lay asphalt concrete over the aggregate base in accordance with the SSPWC Section 302-5.5. The method of proportioning, mixing, transporting, laying, processing, rolling the material, and the standards of workmanship shall conform to the applicable requirements of SSPWC Section 302-5 ASPHALT CONCRETE PAVEMENT. At no time shall the course aggregate that has segregated from the mix be scattered across the paved mat. B. A tack coat of emulsified asphalt shall be applied to the first lift of the pavement prior to placing the second lift. Application shall be in conformance with SSPWC Section 302-5.4. C. The INSPECTOR will examine the base before the paving has begun. The CONTRACTOR will correct any deficiencies before the paving is started. Roll each lift of the asphalt concrete and compact to 95 percent of the density obtained with the California Kneading Contractor per California Test 304. The grade, line, and cross section of the finished surface shall conform to the Drawings. 3.6 CLEANUP A. Clean all debris and unused materials from the paving operation. Clean all surfaces that have been spattered or defaced as a result of the paving operation. Asphalt or asphalt stains which are noticeable upon surfaces of concrete or materials which will be exposed to view shall be promptly and completely removed. Cleaning shall be done in a manner that will not result in any discharge of contaminated materials into any catch basin. 8/13/09 Contract No. 3811 ASPHALT CONCRETE PAVEMENT PALOMAR AIRPORT ROAD WIDENING 02550-4 SECTION 02556 REINFORCED CONCRETE PIPE (ASTM C76) PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work in accordance with the Contract Documents. B. This Section covers reinforced concrete pipe intended to be used for the construction of storm drains, sewers, and related structures. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [02200] Earthwork. B. Section [03300] Cast-in-Place Concrete. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the reference specifications of the GENERAL PROVISIONS. 1. Commercial Standards ASTMC76 Specification for Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe. ASTMC596 Test Method for Drying Shrinkage of Mortar Containing Portland Cement. 2. Standard Specifications SSPWC Section 207 - 2 Reinforced Concrete Pipe 1.4 CONTRACTOR SUBMITTALS A. Shop drawing submittals shall be made in accordance with the GENERAL PROVISIONS and SSPWC Section 2-5.3.2. 1.5 QUALITY ASSURANCE A. Comply with SSPWC Section 207-2. PART 2 - PRODUCTS 2.1 GENERAL A. Except as modified herein, reinforced concrete pipe shall conform to the requirements of ASTM Designation C 76 for Class IV, Wall B, and Type II cement. Unless otherwise specified, pipe shall have tongue and groove joints designed to be self-centering and to leave a recess on the inside of the pipe for pointing with mortar after jointing. Pipe shall be designed for an external load of 1350-D. 8/13/09 Contract No. 3811 REINFORCED CONCRETE PIPE (ASTM C76) PALOMAR AIRPORT ROAD WIDENING 02556-1 B. The size, type, and D-load of the concrete pipe to be furnished shall be as shown on the Drawings, as specified under the bid item of work for the project, or as stated above. C. When pipe joints of the reinforced concrete collar type of rubber-gasketed type are specified or indicated on the Drawings, joint details shall be submitted to the ENGINEER for acceptance before commencing pipe manufacture. 2.2 MATERIALS A. Except when otherwise permitted by the ENGINEER, no materials shall be used in manufacturing of the pipe other than water, Portland cement, mineral aggregates and steel conforming to ASTM C 76, with the following exceptions: 1. All cement to be used or furnished shall be Type II low alkali Portland cement conforming to ASTM C 150 or Type IP (MS) Portland-pozzolan cement conforming to ASTM C 595, unless otherwise specified. Either cement shall conform to the low alkali requirements of Table IA of ASTM C150. Type IP (MS) cement shall contain no more than 20 percent pozzolan, which shall be interground with the clinker. 2. Aggregates shall be nonreactive when tested in accordance with ASTM C 289 and evaluated in accordance with Appendix A-1 of ASTM C 33. Aggregates found to be potentially reactive may be used only upon written acceptance of the ENGINEER. B. All pipe manufactured under the provisions of this Specification shall contain a minimum of 560 Ib of cement per cubic yard of concrete unless mix designs with a lower cement content meet the requirements of this Specification and approved by the ENGINEER prior to use. C. Cement Mortar: Cement mortar shall consist of a mixture of Portland cement, sand, and water. Cement and sand shall first be combined in the proper proportions, and then thoroughly mixed with the required amount of water. Cement mortar shall be proportioned by loose volume in the proportion of 1 part cement to 2 parts sand. The quantity of water to be used in the preparation of mortar shall be only that required to produce a mixture sufficiently workable for the purpose intended. Mortar shall be used as soon as possible after mixing and shall show no visible signs of setting prior to use. Retempering of mortar will not be permitted. Cement, sand, and water for cement mortar shall conform to Section [03300] Cast-in-Place Concrete. D. Admixtures: No admixtures shall be used in mortar unless otherwise specified or accepted by the ENGINEER. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 REINFORCED CONCRETE PIPE (ASTM C76) 02556-2 E. Quick Setting Grout: Quick setting grout shall be high strength, non-staining grout accepted by the ENGINEER prior to use. It shall reach an initial set within 90 minutes at 70 degrees F and shall reach minimum compressive strength of 2,500 psi within 24 hours. Shrinkage shall be less than 0.1 percent when tested, using the test procedures of ASTM C 596. The grout shall be mixed, handled, and placed in accordance with the manufacturer's written instructions. F. Gaskets for Concrete Pipe: Unless otherwise specified, gaskets shall be manufactured from a synthetic elastomer conforming to SSPWC Section 208 - 3. PART 3 - EXECUTION 3.1 INSTALLATION OF PIPE A. Pjpe shall be laid to plan line and grade, with uniform bearing under the full length of the barrel of the pipe. Pipe shall be installed in accordance with SSPWC Section 306 1.2. Suitable excavation shall be made to receive the socket or collar, which shall not bear upon the subgrade or bedding. Any pipe which is not in true alignment or shows any undue settlement after laying shall be taken up and relaid at the CONTRACTOR'S expense. Pipe shall be laid upgrade with the socket or collar ends of the pipe upgrade unless otherwise authorized by the ENGINEER. Concrete pipe with elliptical reinforcement shall be laid with the minor axis of the reinforcement cage in a vertical position. 3.2 FIELD JOINTING OF REINFORCED CONCRETE PIPE A. Field jointing shall be in conformance with SSPWC Section 306-1.2.4. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 REINFORCED CONCRETE PIPE (ASTM C76) 02556-3 SECTION 02810 LANDSCAPE IRRIGATION PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work as indicated on the Drawings and specified herein. B. This Section covers the construction of an automatic irrigation system, complete and operable, in accordance with the requirements of the Contract Documents. C. The irrigation system shall include, but not be limited to, all pipes, fittings, sprinklers, valves, automatic control valves, controllers, valve boxes, drain valves, hose bibb valves, operating wrenches, riser assemblies, direct burial wires, electrical connections, wiring and other appurtenances, piping, connections, testing, cleanup, maintenance and adjustments necessary for a complete operating system, ready for immediate use upon completion. Minor items necessary for proper construction and functional operation of this system, not specifically described in the Contract Documents, shall be included as a part of the work of this Section. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [02232] Preparation of Subgrade B. Section [02900] Landscaping 1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Comply with the applicable reference specifications as specified in the GENERAL REQUIREMENTS. B. Comply with SSPWC Sections 212-2, and 308-5. C. Comply with Carlsbad Municipal Water District's "Carlsbad Reclamation Rules and Regulations for Construction of Reclaimed Water Mains, June 1991". 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-1 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL PROVISIONS. B. The following submittals and specific information shall be provided. 1. Submit complete lists of irrigation materials and equipment, include manufacturer's name and address, specific trade names, catalog numbers complete with illustrations and/or necessary descriptive literature and clearly mark or underline proposed items. 2. Controller literature, specifications, installation wiring diagram, and circuit breaker information shall be submitted to the ENGINEER for review prior to ordering. 3. Shop drawings are required for any irrigation structure as may be specified. 4. Prior to final inspection, submit "as installed" drawings, showing locations of all valves, pipes (lines), heads, dimensions, controllers, control lines, and electrical wires. Accurately dimension location including depths of all piping, valves, and control equipment as installed. 1.5 QUALITY ASSURANCE A. In addition to other inspection as provided by the INSPECTOR, the CONTRACTOR shall give at least 72 hours' notice to the INSPECTOR for scheduling the following special inspections:1 1. The layout of the system. 2. Inspection of trenches, backfilling, and equipment. 3. Pressure tests. 4. Coverage adjustment. 5. Automatic operation. B. The CONTRACTOR shall notify the INSPECTOR at least [72 hours] prior to performing the tests. All tests shall be performed in the presence of the INSPECTOR. Test requirements shall be: 1. After assembly and installation, all water pipes, fittings, automatic equipment, and appurtenances shall be tested at a hydrostatic pressure of 150 psi at the lowest point of the system for not less than 60 minutes. 2. The first test shall be made in such a manner that all valves in the new water pipe sprinkler lines will be tested for watertight closure. Valves may be tested in groups or singly while subjected to 150 psi water pressure for a period of not less than 60 minutes. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-2 3. The second test shall be made by forcing all air from the pipes with water and capping or plugging pipe risers. After the pipe risers have been plugged or capped, all line valves shall be fully opened and the pipe lines subjected to the full static water pressure for a period of not less than 120 minutes. (Pressure pipelines 150 psi). 4. The third test requires that lateral lines be tested at 100 psi for 120 minutes. 5. The fourth test requires that all pressure lines be tested at 120 psi for 24 hours. 6. Water lines and valves which show evidence of leakage or fail to be watertight shall be repaired or replaced. After all repairs or replacements have been made, the above-required tests shall be performed again. 7. When the sprinkler system is completed, the CONTRACTOR, in the presence of the ENGINEER and the INSPECTOR, shall perform a test coverage of water afforded the lawn and planting areas. The CONTRACTOR shall furnish all material and perform all work required to correct any inadequacies of coverage disclosed. The CONTRACTOR shall inform the ENGINEER of any deviation from the Drawings required due to wind, planting, soil, or site conditions that bear on proper coverage. 8. Upon completion of each phase of the work, the CONTRACTOR shall check and adjust each sprinkler head to meet the site requirements and the requirements of the Contract Documents. 1.6 OPERATING MANUALS AND EQUIPMENT A. Furnish the AGENCY with operating and maintenance manuals for all irrigation system equipment such as automatic controllers. B. Explain, in detail, all irrigation equipment operation and maintenance procedures to the personnel directed by the ENGINEER before completion of the project. C. Provide the AGENCY with a reduced legible copy of the "as-installed" irrigation plan hermetically sealed in a plastic cover to be installed in the controller cover. D. Provide one quick coupler key with 1-inch hose swivel for each quick coupler installed. E. Provide one pull box key for each pull box installed. F. Provide one extra, a new electric remote control valve of each size used on this Contract. G. Provide five extra sprinkler heads, including body, nozzle and screen, for each type and arc of sprinkler head installed on this Contract. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-3 1.7 GUARANTEE A. Guarantee the entire irrigation system against defects in materials and workmanship for a period of one year from the date of acceptance of the work. B. Should any deficiencies develop within the specified guarantee period due to inferior or faulty material and workmanship, correct such deficiencies to the satisfaction of the ENGINEER without added expense to the AGENCY. C. The CITY reserves the right to make temporary repairs as necessary to keep the irrigation system equipment in operating condition. The exercise of this right by the AGENCY will not relieve the CONTRACTOR of his responsibilities under the terms of the guarantee. D. Repair any settlement or backfilled trenches, which may occur during a 30-day period after final acceptance by the ENGINEER and the INSPECTOR, to the ENGINEER'S and the INSPECTOR'S satisfaction, without expense to the AGENCY, including the complete restoration of all damaged planting, paving, or other improvements of any kind. 1.8 EXISTING UTILITIES AND CONDITIONS A. Prior to cutting into the soil, the CONTRACTOR shall locate all cables, conduits, sewers, septic tanks, and other such underground utilities, and shall take proper precautions not to damage or disturb such improvements. If a conflict exists between such obstacles and the proposed work, the CONTRACTOR shall promptly notify the ENGINEER. B. The CONTRACTOR shall be responsible for coordinating its work with the operation of existing utilities and new utilities on the Project. The CONTRACTOR shall notify the ENGINEER or its representative when utilities which are in operation require shut-off. C. Due to the scale of Drawings, it is not possible to indicate all offset, fittings, etc., which may be required, the CONTRACTOR shall carefully investigate the structural and finished conditions affecting all its work, and plan its work accordingly, furnishing such fittings, etc., as may be required to meet such conditions. The Contract Documents are generally diagrammatic and indicative of the work to be installed. The work shall be installed in the most direct and workmanlike manner, so that conflicts between sprinkler systems, planting, structures, piping, and etc., will be avoided. D. The CONTRACTOR shall verify the water pressure and the flow available at the site before installation of the system to make sure there is adequate pressure (design pressure [50] psi) to properly operate sprinkler heads and valves, and shall also provide pressure reducing valves if required. If the pressure provided at job site or any other job condition will create problems that will prevent proper operation of the irrigation system, the ENGINEER and the INSPECTOR shall be notified before commencement of any work. Minor additions and adjustments of heads, piping, and circuits shall be made at no additional cost to AGENCY where it is necessary to make the irrigation system operate properly. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-4 1.9 STORAGE OF MATERIALS A. The CONTRACTOR shall be responsible for storage of materials and for damage to the work covered by these Contract Documents before final acceptance of its work. The CONTRACTOR shall securely cover openings into the system, and shall cover all apparatus, equipment, and appliances both before and after being set in place to prevent obstruction in the pipes and the breakage, misuse, or disfigurement of said apparatus, equipment, or appliances. 1.10 SCHEDULING AND COORDINATION A. The CONTRACTOR shall be responsible for making arrangements for the coordination of its construction operations with those of all others on the job. The CONTRACTOR shall permit others engaged in work to accomplish their portion of work without undue interference or delay. B. The CONTRACTOR shall be responsible for the scheduling and coordination of the electrical and water connections and the installation of the piping and equipment in a manner that will affect the earliest completion of the work in conformance with the construction progress schedules. PART 2 - PRODUCTS 2.1 PIPES, TUBES, AND FITTINGS A. Hard Copper Tube: ASTM B 88, Type K, water tube, drawn temper. 1. Copper Pressure Fittings: ASME B16, 18, cast-copper-alloy or ASME B16.22, wrought-copper, solder-joint fittings. Furnish wrought-copper fittings if indicated. 2. Copper Unions: MSS SP-123, cast-copper-alloy, hexagonal-stock body, with ball-and-socket, metal-to-metal seating surfaces and solder-joint or threaded ends. B. Plastic Pipe: Rigid polyvinyl chloride PVC 1120 (Type 1, Grade 2), conforming to ASTM D 1785. (PVC pipe marked with product standard PS-21-70 conforms to ASTM requirements.) C. PVC Pipe: PVC SDR 13.5 compound, Type 1, Grade 1, purple color for recycled water use. C1 31 5 for 2" size and larger irrigation main piping. D. PVC, Pressure-Rated Pipe: PVC compound, SDR 21 , Class 200 purple pipe for recycled water use. E. All pipes shall be homogeneous throughout and free from cracks, holes, foreign materials, blisters, deleterious wrinkles, and dents. F. Use Schedule 40 PVC plastic pipe for installation on the discharge side of control valves and Schedule 80 PVC plastic pipe for continuously pressurized pipe on the supply side of control valves unless otherwise indicated. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 0281 0-5 G. Supply Schedule 80 PVC plastic pipes only, when threaded joints are specified or otherwise permitted by the ENGINEER. H. All pipes shall be permanently marked with the following: manufacturer's name or trademark, size, schedule, and type of pipe, working pressure at 73 degrees F and National Sanitation Foundation (NSF) approval. I. Fittings and Couplings for Plastic Pipe: Threaded or slip-fitting tapered socket solvent weld type. Provide threaded adapters with socket pipe for connections to threaded pipe. Plastic pipe fittings and couplings t shall be PVC I or PVC I/I I material supplied in the same schedule size specified for the pipe the type of plastic materials and schedule size shall be marked on each fitting or coupling. Fittings and couplings shall comply with the following Specifications: Socket Fittings Threaded Fittings Schedule 40 ASTM D 2466, D 1784 Schedule 80 ASTM D 2464 Schedule 80 ASTM D 2467, D 1785 2.2 VALVES AND VALVE BOXES A. General: Provide valves of the type and capacity designated on the plan and with the requirements specified herein. All valves except quick couplers shall be capable of satisfactory performance at a working pressure of 200 psi. Design shall permit disassembly for replacement of the seals without removal of the valve body from the pipeline. B. Shutoff Valves: Sizes 2-inch and smaller shall be bronze ball type (Stpckham, Crane, Nibco, Gee, Kennedy, or equal). Sizes 2-1/2-inch and larger shall be iron body brass trimmed with other features the same as for 2-inch size. C. Remote Control Valves: Electrically operated, brass bodied with resilient solenoid valve seat surface, equipped with flow control adjustment, with capability for manual operation and readily disassembled for servicing, slow opening and adjustable closing speed, and self-cleaning. The valve manufacturer shall submit a written guarantee stating that the valves will operate under dirty water conditions for a period of 1 year after date of final acceptance. D. Quick Coupler Valve and Assembly: Quick couplers shall be of the Acme thread keyway type. Quick couplers shall be constructed of rod brass and cast brass, shall have a maximum capacity of 20 gpm, and shall have a 1-inch bottom female pipe thread and wastewater caution sticker. Install in remote control valve box with remote control valve or individually below grade in a valve box as indicated on the Drawings. Quick-coupling valve assemblies shall include the valve, corresponding key and hose swivel. E. Meter Boxes and Covers shall be polymer-type boxes and lids selected from approved materials list. Meter box sites shall be as follows: Size of Box Meter Box Use 12"x20" 1" Services 17"x30" 2" Services Meter box lids for potable water shall be gray in color. Meter box lids for recycled water shall be purple in color. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-6 G. Remote Control Valve (RCV) Box Lids: Lids shall be marked with the controller letters and station numbers called out on the Drawings. Letters shall be 2 inches in height and made using stencils and black paint. All stencils and paint shall be approved prior to application. 2.3 SPRAY HEADS A. Use types and sizes shown on the plans, of brass and stainless steel except for minor components unless otherwise indicated or as specified in legend. Provide equipment of one type and flow characteristic from the same manufacturer and bearing the manufacturer's name. 2.4 AUTOMATIC CONTROLLERS A. The automatic controllers shall be electrically-timed devices for automatically opening and closing remote control valves. All controllers and remote control valves supplied under this contract shall be of the same manufacturer and have similar operational and adjustment features. B. Each station shall be capable of 7 independent days of programming and selective repeatability. C. Each controller shall be provided with 117-volt and 24-volt circuit breakers. D. Each controller shall contain a station index, a 24-hour time index, and a 7-day index that changes at 6:00 a.m. E. Each controller shall have the capability of programming 0- to 60-minute watering periods for each station. F. The station index shall advance directly to stations programmed to water without delay and shall not repeat until the next scheduled starting time. G. The panel controller shall be able to be operated manually, semiautomatically, and automatically. H. The panel assembly shall be removable from the 117-volt ac source by a quick- disconnect plug. I. The controllers shall be contained in a weatherproof, heavy steel, zinc-plated, acrylic- enameled housing with an integral lock. Keys for covers shall be interchangeable keys. The controller shall be [wall] mounted. 2.5 ELECTRICAL SUPPLY FOR AUTOMATIC IRRIGATION CONTROLLERS A. Conductors: Supply line voltage conductors with THW, 600-volt insulation rating, conforming to the applicable provisions of ASTM D 2219 and 2220. B. Low voltage control conductors shall be UL approved direct burial type U.F., No. 12 AWG solid copper, unless otherwise required, in accordance with the control equipment manufacturer's recommendation. 2.6 ACCESSORIES A. Provide two each special head wrenches for installation, removal, and adjustment for each type and make of sprinkler equipment. Provide two keys each for quick couplers, controller units, and valve boxes. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-7 PART 3 - EXECUTION 3.1 GENERAL A. Inspection: In all cases where inspection of the irrigation system is required and where portions of the work are specified to be performed under the direction and inspection of the INSPECTOR, notify the INSPECTOR at least 48 hours in advance of the times such inspection and direction is required. B. Verifications: All scaled dimensions are approximate. Carefully check and verify all dimensions before proceeding with any work. Immediately notify the ENGINEER should any errors or conflicts in the Drawings and specifications and/or actual jobsite conditions be found which would affect the proper execution of the irrigation work. Do not work in areas where such discrepancies occur until further instructed by the ENGINEER. 3.2 IRRIGATION SYSTEM INSTALLATION A. General: 1. Perform all work on the irrigation system, including hydrostatic and coverage tests, preliminary operational test of the automatic control system, and the backfill and densification of trenches and other excavations after topsoil work and before planting, except as otherwise provided or directed. 2. With the ENGINEER'S approval, make adjustments where necessary to conform to actual field conditions. 3. Make the irrigation system operational with uniform and adequate coverage of the areas to be irrigated, prior to planting. 4. Make water and utility connections as shown on the drawings or designated by the utility company. 5. Where piping on the Drawings is shown under paved areas but running parallel and adjacent to planted areas, the intent of the Drawings is to install piping in the planted areas. B. Trench Excavating and Backfilling: Size trenches and other excavations to accommodate the irrigation system components, conduits, and other required facilities. Provide additional space to assure proper installation and access for inspections. 1. Unless otherwise specified, the minimum depth of cover over pipelines and conduits shall be as follows: a. Electrical conduit - 24-inches (36-inches under roadways). b. Waterlines continuously pressurized - 24-inches (36-inches under roadways). c. Lateral sprinkler lines -12-inches. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-8 2. Make the bottom of trenches true to grade and free of protruding stones, roots, or other matter which would prevent proper bedding of pipe or other facilities. 3. Backfill trenches so that the specified thickness of topsoil is restored to the upper part of the trench. Compact trench backfill through paved areas in 8-inch layers to 95 percent relative compaction up to subgrade to receive asphalt concrete paving and base material. 4. Resurface trenches through paved areas to match an existing pavement. C. Irrigation Pipeline Installation: 1. Install pipe fittings in accordance with the manufacturer's recommendations and these Specifications. When requested by the ENGINEER, furnish the manufacturer's printed installation instructions before pipe installation. 2. Bed pipes in at least 2 inches of finely divided material to provide a firm, uniform bearing. Surround the pipe with additional finely divided material to at least 2-inches over the top of the pipe. 3. Deposit trench backfill sufficient to anchor the pipe before the pipeline pressure testing, except that joints shall remain exposed until satisfactory completion of testing. 4. When two or more pipelines are installed in the same trench, separate the pipelines by a minimum horizontal clear distance of 4 inches. Install equipment so that each pipeline, valve, or other component may be serviced or replaced without disturbing another. 5. Accomplish all assemblies as specified and in accordance with the manufacturer's directions. 6. During installation of pipe, fittings, valves, and other pipeline components, prevent foreign matter from entering the system. Temporarily cap or plug all open ends at cessation of installation operations. 7. Accomplish changes in pipeline size with reducer fittings. 8. Place all mainlines under paving in Schedule 40 PVC sleeves. Oversize the sleeves sufficiently to house the pipe, fittings, and control valves. D. Plastic Pipeline: 1. Joint plastic pipe with socket type solvent welded fittings, threaded fittings, rubber ring fittings, or by other means specified. Install steel pipe first when plastic pipe is jointed to steel pipe. 2. Cut square, externally chamfer approximately 10-15 degrees, and remove all burrs and fins. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-9 3. Make solvent welded joints in accordance with ASTM D 2855. Use the solvent recommended by the pipe manufacturer. 4. Install plastic pipe in accordance with ASTM D 2774 and the requirements herein. 5. Exercise care in assembling a pipeline with solvent welded joints so that stress on previously made joints is avoided. Handling of the pipe following jointing, such as lowering the assembled pipeline into the trench, shall not occur prior to the set times specified in ASTM D 2855. 6. Apply solvent to pipe ends in such a manner that no material is deposited on the interior surface of the pipe or extruded into the interior of the pipe during jointing. Wipe off excess cement on the exterior of the joint immediately after assembly. 7. Plastic pipes shall not be field threaded. 8. Make threaded joints using Teflon tape or other approved jointing material. Do not use solvent with threaded joints. 9. Protect pipe from tool damage during assembly. Use vises with padded jaws and strap wrenches for installation of fittings and nipples. 10. Remove and replace plastic pipe which has been nicked, scarred or otherwise damaged. 11. Snake plastic pipe from side to side in the trench to allow 1 foot of expansion and contraction per 100-feet of straight run. 12. Do not expose pipelines to water for 24 hours after the last solvent welded joint is made. Installation of Valves, Valve Boxes, and Special Equipment: 1. General: Provide and install all valves and other equipment in strict accordance with the details in a normal upright position, a minimum of 6-inches from the edge of curbs, walks, or pavement, in planting areas. Make all equipment readily accessible for operation, maintenance, and replacement. 2. Install valves the same size as the pipeline in which they are installed, unless otherwise indicated. 3. Install gate valves and sectional control valves below ground. House in a covered acceptable box that will permit access for field servicing. Mark covers of shutoff valves "IRRIG. EFFLUENT" and automatic control valve covers "RCV IRRIG. EFFLUENT" in 2-inch cast letters. In addition, with an approved black paint, on the automatic control valve box cover stencil the controller letter and station number 2-inches in height. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-10 4. Quick-coupler valves shall have red covers and shall be installed as detailed on the Drawings. Mark valve box cover "Q.C. IRRIG. EFFLUENT" in 2-inch cast letters. 5. Set valve boxes and valve markers to finish grades on a 12-inch deep layer of 1-inch size crushed rock and set valves at sufficient depth to provide clearance between cover and valve handle or key when the valve is in the fully open position. Place crushed rock below the valve. Do not cover the valve with crushed rock. F. Irrigation Head Installation and Adjustment: 1. General: Flush and pressure test all mains and laterals, including risers, before installing irrigation heads, after which perform a water coverage test. 2. Location, Elevation, and Spacing: a. Do not exceed the maximum irrigation head spacing shown on the Drawings or recommended by the manufacturer. b. Locate irrigation heads projecting above finish grades at least 6-inches away from adjacent curbs, walks, paving, and similar improvements unless otherwise indicated. 3. Riser Installation: a. Install risers perpendicular to finished grade to obtain optimum coverage of the area. b. All risers shall be prethreaded Schedule 80 PVC unless otherwise indicated (length and diameter as required). c. Provide threaded pipe between the connection to the lateral or main and sprinkler head. 4. Irrigation Head Adjustment: a. When all irrigation heads are installed and the irrigation system is operating, adjust and balance each section or unit with all section control valves fully open to obtain uniform and adequate coverage. b. Adjust irrigation heads having adjustable pin nozzles, screws or orifices to provide adequate distribution of water over the coverage pattern. Without additional cost to the CITY, substitute larger or smaller nozzle cores in nonadjustable sprinkler heads as necessary. 02/17/09 Contract No. 3811 LANDSCAPE IRRIGATION PALOMAR AIRPORT ROAD WIDENING 02810-11 3.3 FLUSHING AND TESTING A. Flushing: After completion, and prior to the installation of any terminal fittings, thoroughly flush the entire pipeline system to remove dirt, scale, or other material. B. After flushing, conduct the following tests in the sequence listed below. Provide all equipment, materials, and labor necessary to perform the tests. Conduct all tests in the presence of the ENGINEER and the INSPECTOR. 1. Pipeline Pressure Test: Perform a water pressure test on all pressure mains and laterals before any couplings, fittings, valves, etc., are concealed. Cap all open ends after the water is entering the line in such a manner that all air will be expelled. Test pressure mains with all control valves to lateral lines closed. After the pressure main test, open all valves to test lateral lines. The constant test pressure and the duration of the test are as follows: All pipes shall be pressure tested at 200 psi for two (2) hours. 2. Sprinkler Coverage Test: Perform the coverage test after sprinkler heads have been installed. Demonstrate that each section or unit in the system is balanced to provide uniform and adequate coverage of the areas serviced. Correct any deficiencies. 3. Operational Test: Evaluate the performance of all components of the automatic control system for manual and automatic operation. Make all necessary repairs, replacements, and adjustments until all equipment, electrical work, controls and instrumentation are functioning in accordance with the Contract Documents. 02/17/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 LANDSCAPE IRRIGATION 02810-12 ••»*««<»' SECTION 02830 CHAIN LINK FENCE AND GATE(S) PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work as indicated on the Drawings and specified herein. B. This section covers the work necessary for the chain link fence and gate(s), including removal of a portion of existing fence and reinstalling the chain link fence and gate(s) as shown on the Drawings and specified in the Contract Documents. 1.2 RELATED WORK SPECIFIED ELSEWHERE 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the reference specifications as specified in the GENERAL PROVISIONS. B. SSPWC Sections 206-6 and 304-3: Chain Link Fence. C. Standard Plan S-691. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL PROVISIONS. 1.5 QUALITY ASSURANCE A. Comply with the applicable Reference Specifications of the GENERAL PROVISIONS. PART 2 - PRODUCTS 2.1 GENERAL A. All materials and fittings shall be in conformance with SSPWC Section 206-6. B. All posts, rails, braces, tension wires, fabric, tension rods, fittings and accessories shall be black in color. C. Salvaged material from the existing fence shall be undamaged and acceptable to the ENGINEER prior to reuse or reinstallation. Any material not reused shall be removed as directed by the ENGINEER. D. Like items of materials provided hereunder shall be the end products of one manufacturer in order to achieve standardization for appearance, maintenance, and replacement. 2.2 FABRIC A. Galvanized Fabric: 8/13/09 Contract No. 3811 CHAIN LINK FENCE & GATES PALOMAR AIRPORT ROAD WIDENING 02830-1 1. Chain link fabric shall conform to the requirements of SSPWC Section 206-6.3.1. B. Polyvinyl Chloride (PVC) Coated Fabric: 1. PVC coated chain link fabric shall be in conformance with SSPWC Section 206-6.3.2. 2.3 POSTS, RAILS AND BRACES A. The materials for posts, rails and braces shall be in conformance with SSPWC Section 206-6.2. 2.4 TENSION WIRES AND FABRIC TIES A. Tension wires and ties used to fasten the fabric to posts, rails, and gate frame shall be in conformance with SSPWC Section 206-6.4. 2.5 TRUSS OR TENSION RODS A. Truss or tension rod used in construction shall be in conformance with SSPWC Section 206-6.5. 2.6 FITTINGS A. All required fittings and hardware shall be galvanized and in conformance with SSPWC Section 206-6.6. 2.7 BARBED WIRE A. Barbed wire shall be in conformance with SSPWC Section 206-6.7. 2.8 REPAIR OF DAMAGED COATINGS A. Repairs to abraded or otherwise damaged zinc coating shall be made in conformance with SSPWC Section 206-6.8. 2.9 GATES A. Gates shall be swing or sliding as indicated, complete with latches, stops, keepers, hinges, or rollers and roller tracks. B. Gate frames shall be constructed of tubular members welded at all corners or assembled with fittings. On steel, welds shall be painted with zinc-based paint. Where corner fittings are used, gates shall have truss rods of 5/16-inch minimum nominal diameter to prevent sag or twist. Gate leaves shall have vertical intermediate bracing as required, spaced so that no members are more than 8 feet apart. Gate leaves 10 feet or over shall have a horizontal brace or one 5/16-inch minimum diagonal truss rod. When fence has barbed wire top, the end members of the gate frames shall be extended 1 foot above the top horizontal member to which three strands of barbed wire, uniformly spaced, shall be attached by use by bands, clips, or hook bolts. C. Fabricate frames of standard weight pipe 1.90-inch outside diameter, weight 2.72 pounds per linear foot. 8/13/09 Contract No. 3811 CHAIN LINK FENCE & GATES PALOMAR AIRPORT ROAD WIDENING 02830-2 D. Gate fabric shall be the same type as used in the fence construction. The fabric shall be attached securely to the gate frame at intervals not exceeding 15 inches. E. Gate hinges shall be of adequate strength for gate and with large bearing surfaces for clamping in position. The hinges shall not twist or turn under the action of the gate. The gates shall be capable of being opened and closed easily by one person. F. Gate latches, stops, and keepers shall be provided for all gates. Latches shall have a plunger-bar arranged to engage the center stop, except that for single gates of openings less than 10 feet wide a forked latch may be provided. Latches shall be arranged for locking with padlocks. Center stops shall consist of a device arranged to be set in concrete and to engage a plunger-bar of the latch of double gates. No stop is required for single gates. Keepers shall consist of a mechanical device for securing the free end of the gate when in the full open position. 1. Double Gates: Size and configuration shall be as indicated. Provide gate stops for all double gates, consisting of mushroom type or flush plate with anchors. Set in concrete to engage the center drop rod or plunger bar. Provide locking device and padlock eyes as an integral part of the latch, requiring one padlock for locking both gate leaves. 2. Sliding Gates: Provide manufacturer's standard heavy-duty track, ball-bearing hanger sheaves, overhead framing and supports, guides, stays, bracing, and accessories as required. All sliding gates shall be rolling, cantilever slide, or overhead (top) suspended, as indicated on Drawings. G. Rolling gate track rollers shall be malleable iron or heavy pressed steel construction, with provision for regular grease lubrication. Ground rollers shall have malleable iron or heavy pressed steel hubs with similar provision for lubrication. Gate track shall be Schedule 40 pipe, firmly attached to support posts on 7 foot maximum centers. Gates more than 8 feet in height shall have three tracks. Rolling gate frames shall be constructed similar to swing gates except diagonal bracing shall reflect different support type. H. Cantilever gate rollers shall have heavy malleable rollers, needle or ball bearings with fittings for regular lubrication. Maximum spacing of support posts is 10 feet. Additional weight supporting posts with lower roller shall be provided on 10 foot maximum centers. Support posts shall be 4-inch diameter, Schedule 40, set 36-inch minimum depth. Top and lower rails of gate shall be 2-3/8-inch OD, Schedule 40 pipe. Vertical support posts shall be on 6 foot maximum spacing, 1-7/8-inch OD, Schedule 40 pipe, all diagonal bracing 1-5/8-inch OD, Schedule 40 pipe, all connections welded and painted. I. Keeper: Provide keeper for all vehicle gates, which automatically engages the gate leaf and holds it in the OPEN position until manually released. 2.10 REMOVABLE FENCE PANELS A. Removable fence panels shall be provided as indicated on the Drawings. The total length of any removable fence section shall be divided into equal removable fence panels with panel length not to exceed 10 feet. The posts on either side of removable fence panels shall be hot-dip galvanized pipe, 3-inch OD, 5.71 pounds per linear foot. 2.11 CONCRETE A. Materials as specified in Section [03300] Cast-ln-Place Concrete. Proportions shall be 1:2:4. Compressive strength shall not be less than 2,000 psi at 28 days. 8/13/09 Contract No. 3811 CHAIN LINK FENCE & GATES PALOMAR AIRPORT ROAD WIDENING 02830-3 PART 3 - EXECUTION 3.1 INSTALLATION A. Installation of fencing shall meet the requirements of ASTM F 567. B. Fence Construction shall be in conformance with SSPWC Section 304-3.2 and Standard PlanS-691. C. Installation of Gates shall be in conformance with SSPWC Section 304-3.3 and Standard PlanS-691. 3.2 REMOVAL AND RESETTING OF EXISTING FENCE A. All accessories shall be removed carefully and all materials stored in a safe place until required for resetting. The CONTRACTOR shall provide all new material necessary to replace lost or damaged material and as required for a complete and satisfactory installation. In general, the salvaged fencing shall be reinstalled as specified for new material. All concrete shall be removed from posts before they are reset. The CONTRACTOR may furnish all new materials, rather than salvage and reuse the existing fence. 3.3 CLEANUP A. Upon completion of the fence installation, clean up all waste material resulting from the operation to the satisfaction of the ENGINEER and the INSPECTOR. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CHAIN LINK FENCE & GATES 02830-4 SECTION 02900 LANDSCAPING PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work as indicated in the Drawings as specified herein. B. Landscaping as referred to herein shall include, but not be limited to the following work: soil preparation, installation of headers, weed control, finish grading, furnishing and installing plant materials, tree staking and tying, cleanup, maintenance, guarantee. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [02110] Clearing, Grubbing, and Stripping B. Section [02200] Earthwork. C. Section [02810] Landscape Irrigation. D. Section [02485] Hydroseeding 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the reference specifications of the GENERAL REQUIREMENTS. B. Comply with the SSPWC Sections 212-1 and 308-5. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL REQUIREMENTS. B. General: The CONTRACTOR shall furnish a certificate with each delivery or bulk material delivery, stating source, quantity, and type of material. All materials shall conform to specification requirements. All certificates shall be delivered to the INSPECTOR at the time of each delivery. All bulk delivered materials shall be delivered with level load volume plainly marked on the truck bed. C. Literature on fertilizers, peat, mulch, and seed mixes shall be submitted as specified. D. Certificates of Inspection: Certificates of inspection of plant material, as may be required by Federal, State, or other authorities having jurisdiction, shall be furnished and accompany the shipment. E. Samples: Typical samples, 3 of each variety and size of plants, shall be submitted to the ENGINEER for approval at the site. These samples, if approved, shall be planted and maintained as standards for comparison with plants furnished. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-1 1.5 QUALITY ASSURANCE A. General: All plants furnished by the CONTRACTOR shall be true to type or name as shown in the Contract Documents and shall be tagged in accordance with the standard practice recommended by the Agricultural Code of the State of California; however, determination of plant species or variety will be made by the ENGINEER. B. All plants shall comply with Federal and State laws requiring inspection for plant diseases and infestations. Inspection certificates required by law shall accompany each shipment of plants, and certificates shall be delivered to the ENGINEER. C. All inspections herein specified will be made by the ENGINEER or the INSPECTOR. The CONTRACTOR shall request inspection at least 24 hours in advance of the time inspection work is required. Inspection will be required on the following stages of the WORK: 1. During preliminary grading, soil preparation, and initial weeding. 2. When trees are spotted for planting, but before planting holes have been excavated. 3. When finish grading has been completed. 4. When all specified work, except the maintenance period, has been completed. 5. Final inspection at the completion of the maintenance period. D. Plants shall be subject to inspection and approval or rejection by the ENGINEER at place of growth and upon delivery to site at any time before or during progress of the work based on: 1. Quantity, quality, size, and variety; 2. Ball and root condition; and 3. Latent defects and injuries resulting from handling, disease, and insects. E. Plants approved at pre-planting inspection shall still be subject to rejection during planting if found not to be in compliance with the Specifications. F. Rejected plants shall be identified in an obvious manner, removed from the site and replaced with acceptable equals. G. Plants shall have been grown in nurseries which have been inspected by the governing authorities. Inspection of plant materials required by CITY, County, State, or Federal authorities shall be the responsibility of the CONTRACTOR, who shall have secured permits or certificates prior to delivery of plants to site. 1.6 CLEANUP A. Upon completion of all planting operations, the portion of the project site used for work or storage area by the CONTRACTOR shall be cleaned of all debris, superfluous materials, and equipment. All such materials and equipment shall be entirely removed from the project site. Cleaning shall be done in a manner that will not result in any discharge of contaminated materials into any catch basin. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-2 B. All walks or pavement shall be swept or washed clean upon completion of WORK. C. During the entire Contract period, plant containers that have been cut or removed from plant materials shall be removed from the project site daily. 1.7 90 DAY MAINTENANCE OF LANDSCAPING PLANTING PRIOR TO ACCEPTANCE OF PROJECT (Maintenance period begins once the original work contracted for has been reviewed and approved in writing by the ENGINEER and INSPECTOR). A. General: The CONTRACTOR shall be responsible for protecting, watering, and maintaining all planting and irrigation systems until final acceptance of all work under the contract. B. Watering: Trees and shrubs shall be thoroughly soaked after planting and provided with additional water at intervals as necessary to provide for good health and growth of the planting. C. Upon completion of hydroseeding, the entire area shall be soaked to saturation by a fine spray. The new planting shall be kept moist during dry weather or whenever necessary for proper establishment of the seed. Care shall be taken to avoid excessive washing or puddling on the surface and any such damage caused thereby shall be repaired by the CONTRACTOR at its own expense. D. Protection: The CONTRACTOR shall provide adequate protection to all newly seeded areas including the installation of temporary fences approved by the ENGINEER to prevent trespassing and damage, as well as erosion control, until the end of the one-year correction period. E. The CONTRACTOR shall replace any materials or equipment it has damaged or which have been damaged by its employees or subcontractors. F. Partial utilization of the project by the CITY shall not relieve the CONTRACTOR of any of the requirements contained in the Contract Documents. G. All plants shall be maintained in a vigorous, thriving condition by watering, cultivating, weeding, pruning, spraying, and other operations necessary. No trees or shrubs will be accepted unless they are healthy and show satisfactory foliage conditions. H. All planted areas shall be cultivated at least every 2 weeks and raked smooth, to present a neat appearance, and additional mulch shall be added where necessary. I. Maintenance shall include, in addition to the foregoing, cleaning, edging, repairs to stakes, wire, and wrappings, the repair of erosion, and all other necessary work of maintenance. Sidewalks and other paved areas shall be kept clean while planting and maintenance are in progress. J. Any sprinkler lines broken or disrupted by the CONTRACTOR shall be immediately repaired to proper working order, or replaced and be acceptable to the ENGINEER and the INSPECTOR. 1.8 FINAL INSPECTION AND GUARANTEE A. Final inspection of all hydroseeded areas, and general plantings will be made at conclusion of the specified maintenance period. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-3 B. Written notice requesting final inspection shall be submitted to the ENGINEER at least 10 days prior to the anticipated inspection date. C. Final acceptance of the work prior to guarantee period of the contract will be accepted upon written approval by the ENGINEER and the INSPECTOR, on the satisfactory completion of all work, including maintenance, but exclusive of the replacement of plant material. D. Any delay in the completion of any item of work in the planting operation which extends the planting into more than one season shall extend the correction period in accordance with the date of completion given above. E. The CONTRACTOR shall replace, as soon as weather conditions permit, all plants not in a vigorous, thriving condition which are noted at the end of the one-year correction period. F. Plants used for replacement shall be of the same size and variety specified in the plant list. Plants shall be furnished, planted, staked, and mulched as specified. G. All work done under this contract shall be left in good order to the satisfaction of the ENGINEER. The CONTRACTOR shall, without an additional expense to the CITY, replace any trees, shrubs, or plant material which develop defects or die during the one-year correction period. 1.9 MAINTENANCE AND GUARANTEE FOLLOWING ACCEPTANCE OF PROJECT A. All planting, plant materials, and irrigation systems required under this contract shall be in a condition acceptable to the ENGINEER at the end of the maintenance guarantee period. B. All water required during the maintenance and correction period will be furnished by the CITY. C. The CONTRACTOR shall make any changes or adjustments necessary to the automatic sprinkler system during the maintenance and correction period. D. The CONTRACTOR shall replace any dead or diseased plants during the maintenance and correction period. E. The CONTRACTOR shall clean-up and remove unused or waste materials from the site and leave the area in a neat condition, satisfactory to the ENGINEER, whenever it performs work during the maintenance period. F. Final Inspection: The ENGINEER, the INSPECTOR, and CONTRACTOR shall make a final inspection after the landscaping has been installed. Any plants and materials found defective at time of final inspection shall be replaced within a time agreed upon by both parties. If it is too late in the planting season for replanting, the replacements shall be made during the next planting season even though such planting may run beyond the maintenance and correction period. 02/17/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 LANDSCAPING 02900-4 PART 2 - PRODUCTS 2.1 GENERAL A. All landscaping materials for soil conditioning, weed abatement, or planting shall be first-grade, commercial quality and shall have certificates indicating the source of material, analysis, quantity, or weight attached to each sack or container or provided with each delivery. Delivery certificates shall be given to the ENGINEER as each shipment of material is delivered. A list of the materials used, together with typical certificates of each material, shall be submitted to the ENGINEER prior to the final acceptance of the job. 2.2 TERMINOLOGY AND QUALIFICATIONS A. Plants or plant material having characteristics not conforming to terms as defined will not be accepted. The terms "plant material" or "plants" refer to all vegetation, whether trees, shrubs, ground cover, or herbaceous vegetation. B. Quality refers to structure and form, as evidenced by density and number of canes and branches, compactness, symmetry, and general development without consideration of size or condition. Standard quality indicates the least acceptable quality. Plants shall be typical of the species and variety of good average uniform growth, shall be well formed and uniformly branched, and shall have the minimum number of canes specified, free from irregularities, or shall conform to minimum quality index. Where the number of canes is not specifically stated in describing this grade, the standards of the "Horticultural Standards" as adopted by the American Association of Nurserymen, shall apply. In this case, the number of canes and other factors for the appropriate classification under "quality definition" in the Horticultural Standards shall be the Quality index. Plant material below this standard will be considered "culls" and are not acceptable. Plants shall be nursery grown. C. Specimen means an exceptionally heavy, symmetrical, tightly-knit plant, so trained or favored in its development and appearance as to be outstanding, superior in form, number of branches, compactness, and symmetry. D. Size is the factor controlled by dimensions representing height or spread, or both, without consideration of quality or conditions. For standard quality, a dimension is given for height or container size, or a dimension is given for height as well as container size. E. Height is usually indicated with a tolerance. The smaller dimension is the minimum acceptable. The larger dimension represents the maximum permissible. The average dimension of all plants must equal the average of the tolerance figures shown on each item. F. Condition is the factor controlled by vitality and ability to survive and thrive and be comparable with normal plants of the same species and variety in the vicinity, at the same season of the year. In addition, plants shall be free from physical damage or adverse conditions that would prevent thriving. Conditions also sometimes refer to state of growth, i.e., whether "dormant condition" or "growing condition" and this state shall be comparable to plants of similar species in the vicinity or leaves, formation of buds, and the like. G. Cane means a primary stem which starts from the ground, or close to the ground, at a point not higher than 1/4 the height of the plant. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-5 H. Caliber shall be taken 12 inches above the finish grade or ground, as a guide, or where a dimension in trunk appears to form the head of the tree. I. Foliage line is maximum dimension in case of specimen plants. It measures from ground to lowest part of body of plant. J. Collected plants shall not be used. 2.3 TOPSOIL A. General: Topsoil shall be designated as Class A (imported), Class B (selected) or Class C (unclassified) as specified herein. The ENGINEER shall determine the suitability of topsoil prior to use. Topsoil shall be transported from source to final position unless stockpiling is specified. B. Class A Topsoil: Class A topsoil shall be from a source outside the limits of the project selected by the CONTRACTOR and in compliance with the requirements specified herein. The ENGINEER may make such inspections and perform such tests as deemed necessary to determine that the material meets the requirements. 1. At least 15 days before scheduled use, the proposed topsoil source must be submitted to the ENGINEER for approval. The CONTRACTOR shall submit a written request for approval, accompanied by a written report of a testing agency registered by the State for agricultural soil evaluation which states that the proposed source complies with these specifications. Class A topsoil shall have the same relative composition and structure, a friable sandy loam character, and be free of roots, clods, and stones larger than 1 inch in greatest dimension, pockets of coarse sand, noxious weeds, sticks, brush and other litter. It shall not be infested with nematodes or undesirable insects and plant disease organisms. 2. Class A topsoil shall meet the following additional requirements: a. Gradation Limits: Sand, 50-80 percent, clay 20 percent maximum, and silt, 30 percent maximum. The sand, clay, and silt gradation limits shall be as defined in ASTM D 422. b. Permeability Rate: Not less than 0.5-inches per hour nor more than 2-inches per hour when tested in accordance with ASTM D 2434, California Test 220, or other approved methods. c. Agricultural Stability: The topsoil shall be suitable to sustain the growth of the plants specified. C. Class B Topsoil: Class B topsoil is defined as material which is obtained from sources and in the quantities designated on the plans or in the Specifications and which requires transport to the designated landscape areas. Such designated sources of the Class B topsoil may be within or outside the project limits. The cost of stripping the surface of vegetation and debris at the designated locations and processing of material to a finely divided state, before it is spread, shall be included in the price for hauling and placing. D. Class C Topsoil: Class C topsoil is defined as soil found in place in the designated landscape area, including soil compacted in place as part of the earthwork specified for the project. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-6 2.4 SOIL FERTILIZING AND CONDITIONING MATERIALS A. General: Fertilizing materials shall comply with the applicable requirements of the State Agricultural Code. All fertilizing materials shall be packaged first grade, commercial quality products identified as to source, type of material, weight and manufacturer's guaranteed analysis. Fertilizing material shall not contain toxic ingredients or fillers in quantities harmful to human life, animals or plants. The CONTRACTOR shall furnish a Certificate of Compliance stating that the material meets the specifications. B. Manure: Manure shall be the product of yard fed cattle, free of weed seed, straw, or other inert material, and aged at least 3 months. The manure shall have been processed by grinding and screening and shall be of a consistency that will readily spread with a mechanical spreader. Manures shall be supplied in bulk if the source is approved in advance by the ENGINEER. C. Commercial Fertilizer: Commercial fertilizer shall be a palletized or granular product having a chemical analysis as specified on the plans or in the Specifications. Commercial fertilizer shall be free-flowing material delivered in unopened sacks. Material which becomes caked or otherwise damaged shall not be used. D. Organic Soil Amendment: Organic soil amendment shall be selected from Type 1, 2, or 3 products as described herein. 1. Type 1 organic soil amendment shall be a ground or processed wood product derived from redwood, fir, or cedar sawdust, or from the bark of fir or pine, treated with a non-toxic agent to absorb water quickly, and shall comply with the following requirements: ercentage (Percent) (minimum) No.8 No. Nitrogen Content ( Redwood Fir Cedar Fir Bark Pine Bark percent dry weight) 0.40 - 0.60% 0.56 - 0.84% 0.56 - 0.84% 0.80 - 1.20% 0.80 - 1.20% Salinity Maximum saturation extract conductivity: 6.35 milliohms/inch at 77°F. Wettabilitv When one teaspoon of tap water is applied to 4 cubic-inches (volumetric ratio of 1:15) of the air-dry product, the material shall become completely damp in a period not exceeding 2 minutes. Any wetting agent added shall be guaranteed non-phyto-toxic at the rate used. 02/17/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 LANDSCAPING 02900-7 2. Type 2 organic soil amendment shall be a relatively dry friable organic compost derived from sewage sludge processed for agricultural use. It shall contain at least 1 percent nitrogen by dry weight and comply substantially with the gradation for Type 1 soil amendment. 3. Type 3 soil amendment shall be hay and stable bedding which has been processed and used as the growing medium for the commercial production of mushrooms. It shall contain at least 1 percent nitrogen by dry weight and comply substantially with the gradation for Type 1 soil amendment. E. Mulch: Mulch shall be designated by type in accordance with the requirements herein. Mulch shall be packaged in bales or bags unless the ENGINEER approves a bulk source in advance of delivery to the jobsite. 1. Type 1 mulch (ground wood product), shall comply with the requirements for Type 1 organic soil amendment. 2. Type 2 mulch (sewage sludge product), shall comply with the requirements for Type 2 organic soil amendment. 3. Type 3 mulch (mushroom compost) shall comply with the requirements for Type 3 organic soil amendment. 4. Type 4 mulch (peat), shall be brown compressed sphagnum or hypnum. 5. Type 5 mulch (fir bark chips), shall be fir bark chips in the gradation specified. 6. Type 6 mulch (straw), shall be either threshed new straw or stable bedding material derived from rice, oats, or barley. Straw in an advanced state of decomposition will not be acceptable. 2.5 PLANT MATERIALS A. Plants shall meet requirements of the Contract Documents and shall be in accordance with the botanical names and applicable standards of quality, size, condition, and type. They shall be true to name, genera, species, and variety in accordance with reference publications. B. Plant names are defined in "Standardized Plant Names" and "Bailey's Encyclopedia of Horticulture". When a name is not found in either reference, the accepted name used in the nursery trade shall apply. C. Plants shall be marked for identification. Each bundle of plants and at least 25 percent of each species and variety of separate plants in any one shipment shall have legible labels securely attached before delivery to the site. D. All trees and shrubs shall be measured while their branches are in their normal position. Height and spread dimensions specified refer to the main body of the plant and not from branch or root tip to tip. No trees will be accepted with their leaders cut, or so damaged that cutting is necessary. E. All plants shall be symmetrical and shall conform to the size, age, and condition as specified on the plant list shown in the Contract Documents. Exceptions are as follows: 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-8 1. Plants larger than specified in the plant list may be used if approved by the ENGINEER, but use of such plants shall not increase the contract price. If the use of larger plants is approved, the spread of roots or ball earth shall be increased in proportion to the size of the plant. Bare root plants furnished in size greater than specified shall be balled and burlapped when required by the ENGINEER. 2. Where caliper or other dimensions of any plant materials are omitted from the Plant List, it shall be understood that such plant materials shall be normal stock for type listed. F. Plants shall be of sound health, vigorous, and free from plant disease and shall be well-branched, shall have full foliage when in leaf, and shall have a healthy well- developed normal root system. Cold storage plants will not be accepted. Plants that are sensitive to shock from elevation change shall be grown at elevations close enough to site to alleviate any plant damage due to such change for at least 2 years. G. Bare rooted (BR) plants shall have well-developed branch systems and vigorous root systems. They shall be dug to sufficient depth to ensure full recovery and development of the plants. Roots of these plants shall be covered with a uniformly thick coating of mud being puddle immediately after they are dug. H. Balled and burlapped (BB) plants shall have firm, natural balls of earth, or diameter not less than that specified and of sufficient depth to include all the fibrous and feeding roots. No plant moved with a ball will be accepted if the ball is cracked or broken before or during plant operations, except on special approval of the ENGINEER. I. Roots or balls of all plants shall be adequately protected at all times from sun and drying winds. J. Plants (indicated to be in marked cans, pots, or other containers on the plant list) shall have been grown in the containers for a minimum of 6 months and a maximum of 2 years. Roots shall fill the containers but show no evidence of being or having been root bound. K. Trees shall have straight trunks and all old abrasions and cuts shall be completely callused over. In no case shall trees be topped before delivery. L. Plants shall have been transplanted or root-pruned at least once in the 2 years. Plants shall not be pruned prior to delivery except as authorized by the ENGINEER. 2.6 SEED MIXTURES A. All seed shall conform with applicable CITY, County, State, and Federal regulations. Seed shall be mixed by dealer. The CONTRACTOR shall furnish dealer's guaranteed germination of each variety. Grass seed shall not be delivered to the site until samples have been approved in writing by the ENGINEER or his authorized landscape representative. Approval of samples, however, shall not affect the right of the ENGINEER, or the authorized landscape representative to reject seed upon or after delivery. Seed which has become wet, moldy, or otherwise damaged prior to use will not be accepted. B. Hydroseed mix shall be fresh, clean, and new-crop seed, composed of the following varieties mixed in the proportions by weight, as shown, and tested for the minimum 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-9 percentage of purity and germination specified. The seed rate is to be 10 Ibs. per 1,000 square feet. ' '""> 7^"/;r^J' ' ' '"',. *^f'-.f v*-f ~ - , * ,-.i$8i-.tK. >':•• •>•; :^r •-.-?•• - •"'.-*- -v-'^w"' •* Common Names '• ' - •- Banner Chewings Fescue Azay Sheeps Fescue Hard Fescue English Daisy **',,*' by Weight; (percent) 50 25 24 1 Proportion ^^Purity? v ,v (percent) 90 90 90 90 '- -s ' r Germination " (percent)^ 85 85 85 80 2.9 STAKING MATERIALS A. Stakes for supporting trees shall be sound No. 2 redwood of uniform size not less than 2-inch x 2-inch or 2-1/2-inch min diameter wood posts of lengths specified in staking details. All knots shall be solid. B. Hose for covering wire shall be new or used black or green 2-ply fiber-bearing garden hose, not less than 1/2-inch inside diameter. C. Wire for tree bracing and guying shall be double strand pliable No. 10-gage galvanized steel wire or vinyl-coated steel wire. D. Tree ties of other materials may be used with prior acceptance of ENGINEER. 2.10 MISCELLANEOUS MATERIALS A. Wrapping material for trees, 2-inch diameter or larger, shall be 2 thicknesses of crinkled paper cemented together with bituminous material in strips 4-inch wide. Twine for tying shall be medium or coarse sisal yarn with a light impregnation of oil condensate from asphalt or tar. B. Jute mesh shall be new and shall be of a uniform, open, plain-weave, flame-retardant mesh. The mesh shall be [natural brown-tan] and shall be made from unbleached single jute yarn. The yarn shall be of loosely twisted construction and shall not vary in thickness by more than 1/2 its normal diameter. Jute mesh shall be furnished in rolled strips and shall meet the following requirements: 1. Width - 48-inches, with a tolerance of one-inch wider or narrower. 2. Not less than 78 warp ends per width. 3. Not less than 41 weft ends per yard. 4. Weight shall average 1.22 pounds per linear yard, ± 5 percent. PART 3 - EXECUTION 3.1 GENERAL A. The landscape work shall not be performed at any time when it may be subject to damage by climatic conditions. B. The CONTRACTOR shall carefully scale or otherwise verify all dimensions in the Contract Documents. Any discrepancies or inconsistencies discovered on the plans shall be brought to the attention of the ENGINEER. Dimensions and plant locations shown shall be coordinated with the ENGINEER and final location shall be site-oriented by the planter and the ENGINEER. 02/17/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 LANDSCAPING 02900-10 C. In case of conflict between the plant list totals and total plant count of the Contract Documents, the CONTRACTOR shall provide the higher number of plants. D. Delivery of materials may begin only after samples and tests have been accepted by the ENGINEER. All materials furnished for the work shall be not less than the accepted sample. E. Substitutions for the indicated plant materials may be permitted pursuant to the Contract Documents. F. The CONTRACTOR shall provide temporary fencing, barricades, covering, or other protections to preserve existing landscaping items indicated to remain and to protect the adjacent properties and other structures when they may be damaged by the landscape work. G. The CONTRACTOR shall retain the services of a tree surgeon acceptable to the ENGINEER to repair damage to existing trees. Existing trees which are to be saved and which cannot be restored to full growth, as determined by tree surgeon, shall be removed and replaced with a new similar tree of 24-inch box size of the same species. H. The CONTRACTOR shall remove and/or relocate landscape items such as trees, shrubs, grass, other vegetation, improvements, and obstructions as shown on Drawings or otherwise specified. I. Waste materials shall be removed from the CITY'S property, and disposed of at a designated landfill unless otherwise noted. J. It shall be the responsibility of the CONTRACTOR to avail itself of any information regarding utilities which are in the area of work and to prevent damage to the same. The CONTRACTOR shall provide protection to the utilities as necessary. K. Burning of combustible materials on the site shall not be permitted. L. The CONTRACTOR shall provide protection to structures, sidewalks, pavements, and other facilities in areas of work which are subject to damage during landscape work. Open excavations shall be provided with barricades and warning lights which conform to the requirements of governing authorities and the State's OSHA safety requirements. M. Planting areas include all areas to be landscaped unless specified or shown otherwise. 3.2 SOIL PREPARATION A. The landscape work shall not begin until all other trades have repaired all areas of settlement, erosion, rutting, etc., and the soils have been re-established, recompacted, and refinished to finish grades, to the ENGINEER'S approval. B. Areas requiring grading by the landscaper including adjacent transition areas shall be uniformly level or sloping between finish elevations to within 0.10-ft above or below required finish elevations. C. The landscape work shall not proceed until after walks, curbs, pavings, edging, and irrigation systems are in place. The contract operations shall be completed to a point where the landscape areas will not be disturbed. The subgrade shall be cleaned free of all waste. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-11 D. During grading, waste materials in the planting areas such as weeds, rocks (2-inches and larger) building materials, rubble, wires, cans, glass, lumber, sticks, etc., shall be removed from the site. Weeds shall be dug out by the roots. E. Fertilizers, additives, seed, peat, etc., subject to moisture damage shall be kept in a weatherproof storage place in such a manner that they will be kept dry. F. After removal of waste materials, the planting area subgrade shall be scarified and pulverized to a depth of not less than 6 inches and all surface irregularities below the cover of topsoil removed. G. Finish grading shall consist of: 1. Final contouring of the planting areas. 2. Placing all soil additives and fertilizers listed below. The following shall be applied for 1,000 sq. ft. of planting area and mechanically or hand tilled into the soil to a depth of 6" to 8" for all landscaped areas with a slope of 3:1 or less. See hydroseeding specifications for soil preparation for slope conditions. The contractor shall use the following amendment schedule for bidding purposes only. A soil test shall be made as part of this contract, and recommended amendments shall be used for actual installation. Agricultural Gypsum 100 IDS. 18-18-6 Fertilizer 25 Ibs. Iron 10 Ibs. Nitrolized Organic Amendment 5 cubic yards 3. After tilling, bring areas to uniform grades by floating and/or hand raking. 4. Making minor adjustment of finish grades as directed by the ENGINEER. 5. Removing waste materials such as stones, roots, or other undesirable foreign material and raking, disking, dragging, and smoothing soil ready for planting. H. Any unusual subsoil condition that will require special treatment shall be reported to the ENGINEER. I. Surface drainage shall be provided as shown by molding the surfaces to facilitate the natural run-off of water. Low spots and pockets shall be filled with topsoil and graded to drain properly. J. Finish grade of all planting areas shall be 1-1/2-inches below finish grades of adjacent pavement of any kind. 3.3 DELIVERY, STORAGE, AND HANDLING OF PLANT MATERIALS A. No plants other than the required samples shall be dug or delivered to the site until the required inspections have been made and the plant samples are approved. B. Plants shall not be pruned prior to delivery except upon approval by the ENGINEER. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-12 C. Plant material shall be planted on the day of delivery if possible. The CONTRACTOR shall protect the stock in a temporary nursery at the project site where it shall be protected from sun and drying winds and shall be shaded, kept moist, and protected with damp soil, moss, or other acceptable material. Plants shall be planted within 2 days after delivery. D. All balled and burlapped plants which cannot be planted immediately on delivery shall be set on the ground and shall be well protected with soil, wet moss, or other acceptable material. Bare rooted plants, which cannot be planted immediately, shall be planted on heeled-in trenches immediately upon delivery. No material heeled-in more than one week may be used. Bundles of plants shall be opened and the plants separated before the roots are covered. Care shall be taken to prevent air pockets among the roots. E. During planting operations, bare roots shall be covered with canvas, wet straw, or other suitable materials. No plants shall be bound with wire or rope at any time so as to damage the bark or break branches. F. Plants shall not be picked up or moved by stem or branches, but shall be lifted and handled from the sides of the containers. G. Plants shall be lifted and handled from the bottom of the ball or container. Plants with balls cracked or broken before or during planting operations will not be accepted and shall be immediately removed from the site. 3.4 TREE AND PLANT LOCATIONS A. Plant pits, centered on location stakes, shall be excavated circular pits with vertical sides and flat or saucer shape bottom in accordance with the following sizes unless shown otherwise: 1 . Tree pits shall be at least two times the diameter of the rootball for 15 gallon size and smaller, and one and one-half times the diameter of the rootball for 24" box size and larger. The depth is to be equal with the rootball. 2. Shrubs up to 15 gallon in size shall be planted in pits two times the diameter of the rootball and at a depth equal to the rootball. 3.6 PREPARED BACKFILL A. Planting backfill mix for all container plants except ferns, azaleas, camellias, or as noted in plan. On Site Soil 6 cu. yds. Nitrolized Organic Amendment 1 cu. yds. 5-3-1 fertilizer 16 Ibs./c.y. Agricultural gypsum 4 Ibs./c.y. Iron 1 Ib./c.y. B. Tree and shrub pits shall be provided with fertilizer tablets as follows: 1 per one-gallon can plant 3 per 5-gallon can plant 5 per 1 5-gallon can plant 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-1 3 3.7 ROCKS OR UNDERGROUND OBSTRUCTIONS A. In the event that rock or underground obstructions are encountered in the excavation of plant pits, alternative locations shall be selected by the ENGINEER. Moving of trees to alternative locations shall not entail additional costs to the CITY. 3.8 SETTING PLANT MATERIALS A. The soil shall not be worked when the moisture content is so great that excessive compaction will occur, nor when it is so dry that a dust will form in the air or that clods will not break readily. Water shall be applied if necessary to provide ideal moisture for filling and planting as specified. B. Plants shall be set in center of pits as shown in the Contract Documents. They shall be set plumb and straight, and at such a level that after settlement the crown of the plant will be 1-inch above the finished grade. C. Balled and burlapped trees shall have planting soil placed and compacted around base of ball to fill all voids. All burlap ropes or wires shall be removed from the sides and tops of balls. D. Roots of bare root plants shall be properly spread out and planting soil carefully worked in among them. All broken or frayed roots shall be cut off clean. E. All vines shall be removed from stakes, untied, and securely fastened in an approved manner to wall or fence next to which they are planted. F. All ground cover plants shall be evenly spaced, staggered in rows, and set at intervals specified, so as to produce a uniform effect. Plants shall be watered immediately after planting operations have been completed. G. All shrubs and vines shall be pruned to remove damaged branches. All bare root shrubs shall be pruned and shaped to compensate for transplant root loss. H. Planting soil around roots or balls shall be thoroughly compacted and watered. After planting, the soil in the shrub beds shall be cultivated between shrubs, raked smooth, and neatly outlined. Muddy soil shall not be used for backfilling. All broken or frayed roots shall be properly cut off. I. Trees and shrubs on slopes steeper than 6 to 1 shall be provided with watering dams or berms at least 6-inches high and 8-inches wider than planting pit (hole) unless specified or shown otherwise. J. All trees shall be thoroughly watered immediately after planting. K. Remove all tags and labels when directed by ENGINEER. L. Trees shall have trunks wrapped in acceptable tree wrap material from base up to and above at least the second scaffold branch. 3.9 STAKING A. Staking of trees shall be done immediately after they are planted. Plants shall stand plumb after staking. Staking shall be as specified unless shown or indicated otherwise. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-14 B. No balled and burlapped specimen "tree-like" shrubs shall be staked. C. Trees of 2-inch caliper and over shall be guyed at points of branching with 3 wire guys spaced equally around and outside the perimeter of the ball. Guy wires shall be covered with rubber hose at the bark, protected by approved material at points of contact. Each guy shall be positioned below crotches and fastened to a 4-inch diameter by 18-inch wood deadman, 12-inches below grade. One turnbuckle shall be provided for each guy. D. Trees less than 2-inch caliper shall be supported by 2 stakes placed diametrically opposite at perimeter line of ball and to sufficient depth to hold tree rigid. Stakes shall be driven vertically and not twisted or pulled. Trees shall be wired to each stake as indicated on staking details. Trees shall be protected with rubber hose over wires at points of contact. All evergreen trees shall be guyed. 3.10 PRUNING AND MULCHING A. Each tree and shrub shall be pruned in accordance with standard horticultural practice to preserve the natural character of the plant in the manner fitting its use in the landscape design, as approved by the ENGINEER. B. All dead wood or suckers and all broken or badly bruised branches shall be removed by thinning out and shortening branches. Deciduous bare-rooted plants shall have not less than 1/3 of their respective leaf surfaces removed. All cuts shall be made just above a healthy bud. Pruning shall be done with clean, sharp tools. C. Cuts over 3/4-inch diameter shall be painted with an approved tree paint. Paint shall cover all exposed cambium as well as other living tissue. Paint shall be waterproof, adhesive, and elastic antiseptic; shall be free from kerosene, coal tar, creosote, or other materials injurious to the life of the tree; and shall be approved before it is used. D. Plants shall be mulched after planting and cultivating have been completed. A layer of mulch materials, as hereinbefore specified, shall be spread on finished landscaping grade within all planting areas to a depth of 2 inches. The mulch around isolated plants shall be 6 inches greater in diameter than the planting hole. All shrub and ground cover beds shall be completely covered with the mulch. E. All deciduous tree trunks shall be thoroughly sprayed with a methoxychlor or similar insecticide, and wrapped immediately after planting, with wrapping material overlapping (1-1/2-inches, wound from ground line to the second branch, and securely taped in at least 5 places, including the top, middle, and bottom). 3.13 HYDROSEEDING A. See Hydroseeding specifications, Section 02485 3.14 MISCELLANEOUS ITEMS A. Wood chip mulch shall be placed in all shrub areas where shown, spread carefully and evenly to a minimum depth of 4-inches over planted areas. Hydroseeded areas are excluded from this mulching program. 02/17/09 Contract No. 3811 LANDSCAPING PALOMAR AIRPORT ROAD WIDENING 02900-15 SECTION 03100 CONCRETE FORMWORK PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish all materials for concrete formwork, bracing, shoring, and supports and shall design and construct all falsework, all in accordance with the provisions of the Contract Documents. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [03200] Reinforcement Steel. B. Section [03290] Joints in Concrete. C. Section [03300] Cast-in-Place Concrete. D. Section [03315] Grout. E. Section [07920] Sealants and Caulking. F. Caltrans Standard Specifications. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the reference specifications as specified in the GENERAL PROVISIONS. B. Comply with the current provisions of the following Codes and Standards. 1. Government Standards: PS 1 U.S. Product Standard for Concrete Forms, Class I. 2. Commercial Standards: ACI 347 Recommended Practice for Concrete Formwork. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL PROVISIONS. B. The following submittals and specific information shall be provided. 1. Falsework Calculations and Drawings: The CONTRACTOR'S attention is directed to all the latest applicable Sections of the Division of Industrial Safety, Construction Safety Orders, which requires that all falsework or vertical shoring installations where the height of the falsework or vertical shoring, as measured from the top of the sills to the soffit of the superstructure, exceeds 14 feet, or where individual horizontal span lengths exceed 16 feet, or provision for vehicular or railroad traffic through falsework or vertical shoring is made, Plans and Calculations shall be approved and signed by a civil engineer, registered in the State of California; provided further, that a copy of the falsework plan or 8/13/09 Contract No. 3811 CONCRETE FORMWORK PALOMAR AIRPORT ROAD WIDENING 03100-1 shoring layout shall be available on the job site at all times. The Engineer who designed the falsework or vertical shoring shall personally inspect such work and provide a written certification that the work conforms to the design. 2. The CONTRACTOR shall, in accordance with the requirements in GENERAL PROVISIONS submit detailed plans of the falsework proposed to be used. Such plans and calculations shall be in sufficient detail to indicate the general layout, sizes of members, anticipated stresses, grade of materials to be used in the falsework, and typical soil conditions. 1.5 QUALITY ASSURANCE A. Tolerances: The variation from established grade or lines shall not exceed 1/4-inch in 10 feet and there shall be no offsets or visible waviness in the finished surface. All other tolerances shall be within the "Suggested Tolerances" specified in Section 203 of ACI 347. PART 2 -- PRODUCTS 2.1 GENERAL A. Except as otherwise expressly accepted by the ENGINEER, all lumber brought on the job site for use as forms, shoring, or bracing shall be new material. All forms shall be smooth surface forms and shall be of the following materials: Walls - Steel or plywood panel Columns - Steel, plywood or fiber glass Roof and floor - Plywood, steel panels All other work - Steel panels, plywood or tongue and groove lumber 2.2 FORM AND FALSEWORK MATERIALS A. Materials for concrete forms, formwork, and falsework shall conform to the following requirements: 1. Lumber shall be Douglas Fir or Southern Pine, construction grade or better, in conformance with U.S. Product Standard PS20. 2. ' Plywood for concrete formwork shall be new, waterproof, synthetic resin bonded, exterior type Douglas Fir or Southern Pine plywood manufactured especially for concrete formwork and shall conform to the requirements of PS 1 for Concrete Forms, Class I, and shall be edge sealed. 3. Form materials shall be metal, wood, plywood, or other material approved by the ENGINEER that will not adversely affect the concrete and will facilitate placement of concrete to the shape, form, line, and grade shown. Metal forms shall be an approved type that will accomplish such results. Forms for exposed exterior concrete surfaces shall be American Plywood Association (APA) High Density Overlay (HDO) Plyform Class I Ext. 48" X 96" X 3/4" minimum thickness. Forms for other concrete surfaces shall be American Plywood Association (APA) Douglas Fir B-B Plyform Class I Exterior PS 1-76 3/4-inch minimum thickness. 8/13/09 Contract No. 3811 CONCRETE FORMWORK PALOMAR AIRPORT ROAD WIDENING 03100-2 B. Unless otherwise shown, exterior corners in concrete members shall be provided with 3/4-inch chamfers. Re-entrant corners in concrete members shall not have fillets unless otherwise shown. C. Forms and falsework to support the roof and floor slabs shall be designed for the total dead load, plus a live load of 30 psf (minimum). PART 3 - EXECUTION 3.1 GENERAL A. Forms to confine the concrete and shape it to the required lines shall be used wherever necessary. The CONTRACTOR shall assume full responsibility for the adequate design of all forms, and any forms which are unsafe or inadequate in any respect shall promptly be removed from the WORK and replaced at the CONTRACTOR'S expense. A sufficient number of forms of each kind shall be provided to permit the required rate of progress to be maintained. The design and inspection of concrete forms, falsework, and shoring shall comply with applicable local, state and Federal regulations. Plumb and string lines shall be properly installed before concrete placement and shall be maintained during placement. Such lines shall be used by CONTRACTOR'S personnel and by the INSPECTOR and shall be in sufficient number and properly installed. During concrete placement, the CONTRACTOR shall continually monitor plumb and string line form positions and immediately correct deficiencies. B. Concrete forms shall conform to the shape, lines, and dimensions of members as called for on the Drawings, and shall be substantial, free from surface defects, and sufficiently tight to prevent leakage. Forms shall be properly braced or tied together to maintain their position and shape under a load of freshly-placed concrete. If adequate foundation for shores cannot be secured, trussed supports shall be provided. 3.2 FORM DESIGN A. All forms shall be true in every respect to the required shape and size, shall conform to the established alignment and grade, and shall be of sufficient strength and rigidity to maintain their position and shape under the loads and operations incident to placing and vibrating the concrete. Suitable and effective means shall be provided on all forms for holding adjacent edges and ends of panels and sections tightly together and in accurate alignment so as to prevent the formation of ridges, fins, offsets, or similar surface defects in the finished concrete. Plywood, 3/4-inch and greater in thickness, may be fastened directly to studding if the studs are spaced close enough to prevent visible deflection marks in the concrete. The forms shall be tight so as to prevent the loss of water, cement and fines during placing and vibrating of the concrete. Specifically, the bottom of wall forms that rest on concrete footings or slabs shall be provided with a gasket to prevent loss of fines and paste during placement and vibration of concrete. Such gasket may be a 1- to 1-1/2-inch diameter polyethylene rod held in position to the underside of the wall form. Adequate clean-out holes shall be provided at the bottom of each lift of forms. The size, number, and location of such clean-outs shall be as acceptable to the INSPECTOR. 3.3 CONSTRUCTION A. Vertical Surfaces: All vertical surfaces of concrete members shall be formed, except where placement of the concrete against the ground is shown. Not less than 1-inch of concrete shall be added to the thickness of the concrete member as shown where concrete is permitted to be placed against trimmed ground in lieu of forms. 8/13/09 Contract No. 3811 CONCRETE FORMWORK PALOMAR AIRPORT ROAD WIDENING 03100-3 Such permission will be granted only for members of comparatively limited height and where the character of the ground is such that it can be trimmed to the required lines and will stand securely without caving or sloughing until the concrete has been placed. B. Construction Joints: Concrete construction joints will not be permitted at locations other than those shown or specified, except as may be acceptable to the ENGINEER. When a second lift is placed on hardened concrete, special precautions shall be taken in the way of the number, location, and tightening of ties at the top of the old lift and bottom of the new to prevent any unsatisfactory effect whatsoever on the concrete. Pipe stubs and anchor bolts shall be set in the forms where required. C. Form Ties: 1. Embedded Ties: Holes left by the removal of form tie cones shall be clean and rough before being filled with mortar as specified for "Finish of Concrete Surfaces" in Section 03300, "Cast-in-Place Concrete". Wire ties for holding forms will not be permitted. No form-tying device or part thereof, other than metal, shall be left embedded in the concrete. Ties shall not be removed in such manner as to leave a hole extending through the interior of the concrete members. The use of snap-ties which cause spading of the concrete upon form stripping or tie removal will not be permitted. If steel panel forms are used, rubber grommets shall be provided where the ties pass through the form in order to prevent loss of cement paste. Where metal rods extending through the concrete are used to support or to strength forms, the rods shall remain embedded and shall terminate not less than 1-inch back from the formed face or faces of the concrete. 2. Removable Ties: Where taper ties are approved for use in non-water bearing structures, the larger end of the taper tie shall be on the wet side of walls in water retaining structures. After the taper tie is removed, the hole shall be thoroughly cleaned and roughened for bond. A precast neoprene or polyurethane tapered plug shall be located at the wall centerline. The hole shall be completely filled with non-shrink grout for water bearing and below-grade walls. The hole shall be completely filled with non-shrink or regular cement grout for above-grade walls which are dry on both sides. Exposed faces of walls shall have the outer 2-inches of the exposed face filled with a cement grout which shall match the color and texture of the surrounding wall surface. 3.4 REUSE OF FORMS Forms may be reused only if in good condition and only if acceptable to the INSPECTOR. Light sanding between uses will be required wherever necessary to obtain uniform surface texture on all exposed concrete surfaces. Exposed concrete surfaces are defined as surfaces which are permanently exposed to view. In the case of forms for the inside wall surfaces of water retaining structures, unused tie rod holes in forms shall be covered with metal caps or shall be filled by other methods acceptable to the INSPECTOR. 3.5 REMOVAL OF FORMS Careful procedures for the removal of forms shall be strictly followed, and this work shall be done with care so as to avoid damage to the concrete. No heavy loading on green concrete will be permitted. The period of time for formwork removal shall be in accordance with ACI 318, Chapter 6 and Section 303-1.4.1 of Standard Specifications and as follows: 8/13/09 Contract No. 3811 CONCRETE FORMWORK PALOMAR AIRPORT ROAD WIDENING 03100-4 1. In the case of concrete members subject to bending stresses, where the member relies upon forms for vertical support, forms shall remain in place until test cylinders attain a minimum comprehensive strength of 75 percent of the 28-day strength specified in Section [03300], "Cast-in-Place Concrete", provided, that no forms shall be disturbed or removed under individual panel or unit before the concrete in the adjacent panel or unit has attained 75 percent of the specified 28-day strength and has been in place for a minimum of 7 days. 2. Forms for all vertical walls and columns shall remain in place at least 3 days after the concrete has been placed. 3. Formwork removal shall also be subject to the curing requirements of section 3370 of these specifications and as authorized by the ENGINEER. The time required to establish said strength shall be determined by the ENGINEER based on test cylinders made for this purpose from the concrete placed and in accordance with ACI 318 and the curing requirements of section 3370. If the time so determined is more than the minimum time specified above, then that time shall be used as the minimum length of time. Forms for all parts of the WORK not specifically mentioned herein shall remain in place for periods of time as determined by the ENGINEER. 3.6 MAINTENANCE OF FORMS Forms shall be maintained at all times in good condition, particularly as to size, shape, strength, rigidity, tightness, and smoothness of surface. Forms, when in place, shall conform to the established alignment and grades. Before concrete is placed, the forms shall be thoroughly cleaned. The form surfaces shall be treated with a nonstaining mineral oil or other lubricant acceptable to the ENGINEER. Any excess lubricant shall be satisfactorily removed before placing the concrete. Where field oiling of forms is required, the CONTRACTOR shall perform the oiling at least two weeks in advance of their use. Care shall be exercised to keep oil off the surfaces of steel reinforcement and other metal items to be embedded in concrete. 3.7 FALSEWORK A. The CONTRACTOR shall be responsible for the design, engineering, construction, maintenance, and safety of all falsework, including staging, walkways, forms, ladders, and similar appurtenances, which shall equal or exceed the applicable requirements of the provisions of the OSHA Safety and Health Standards for Construction, the requirements of the Construction Safety Orders of the California Division of Industrial Safety, and the requirements specified herein. B. All falsework shall be designed and constructed to provide the necessary rigidity and to support the loads. Falsework for the support of a superstructure shall be designed to support the loads that would be imposed if the entire superstructure were placed at one time. C. Falsework shall be placed upon a solid footing, safe against undermining, and protected from softening. When the falsework is supported on timber piles, the maximum calculated pile loading shall not exceed 20 tons. When falsework is supported on any portion of the structure which is already constructed, the load imposed by the falsework shall be spread, distributed, and braced in such a way as to avoid any possibility of damage to the structure. 8/13/09 Contract No. 3811 CONCRETE FORMWORK PALOMAR AIRPORT ROAD WIDENING 03100-5 3.8 BACKFILL AGAINST WALLS A. Backfill against walls shall not be placed until concrete has attained compressive strength equal to specified 28-day comprehensive strength. B. Place backfill simultaneously on both sides of wall to prevent differential pressures. 8/13/09 Contract No. 3811 CONCRETE FORMWORK PALOMAR AIRPORT ROAD WIDENING 03100-6 SECTION 03200 REINFORCEMENT STEEL PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish, fabricate, and place all concrete reinforcement steel, welded wire fabric, couplers, and concrete inserts for use in reinforced concrete and masonry construction and shall perform all appurtenant work, including all the wires, clips, supports, chairs, spacers, and other accessories, all in accordance with the Contract Documents. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [03100] Concrete Formwork. B. Section [03300] Cast-in-Place Concrete. C. Caltrans Standard Specifications. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the reference specifications of the GENERAL PROVISIONS. B. Comply with the current provisions of the following Codes and Standards. 1. Commercial Standards: ACI 315 Details and Detailing of Concrete Reinforcement. ACI318 Building Code Requirements for Reinforced Concrete. ACI 350 Recommended Practice for Sanitary Structure. WRI Manual of Standard Practice for Welded Wire Fabric. AWS D1.4 Structural Welding Code - Reinforcing Steel. ASTM A 82 Specification for Steel Wire, Plain, for Concrete Reinforcement. ASTM A 185 Specification for Welded Steel Wire Fabric for Concrete Reinforcement. ASTM A 615 Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement. C. The reinforcing steel for the Caltrans Truss Sign Structure shall comply with the Caltrans Standards and Specifications. 8/13/09 Contract No. 3811 REINFORCEMENT STEEL PALOMAR AIRPORT ROAD WIDENING 03200-1 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL PROVISIONS. B. The following submittals and specific information shall be provided. 1. The CONTRACTOR shall furnish shop bending diagrams, placing lists, and drawings of all reinforcement steel prior to fabrication in accordance with the GENERAL PROVISIONS. 2. Details of the concrete reinforcement steel and concrete inserts shall be submitted by the CONTRACTOR at the earliest possible date after receipt by the CONTRACTOR of the Notice to Proceed. Said details of reinforcement steel for fabrication and erection shall conform to ACI 315 and the requirements specified and shown. The shop bending diagrams shall show the actual lengths of bars, to the nearest inch measured to the intersection of the extensions (tangents for bars of circular cross section) of the outside surface. The shop drawings shall include bar placement diagrams which clearly indicate the dimensions of each bar splice. 3. Where mechanical couplers are required or permitted to splice reinforcement steel, the CONTRACTOR shall submit for approval the manufacturer's literature which contains instructions and recommendations for installation for each type of coupler used; certified test reports which verify the load capacity of each type and size of coupler used; and shop drawings which show the location of each coupler with details of how it is to be installed in the formwork. 4. If reinforcement steel is spliced by welding at any location, the CONTRACTOR shall submit mill test reports which shall contain the information necessary for the determination of the carbon equivalent as specified in AWS D1.4. The CONTRACTOR shall submit a written welding procedure for each type of weld for each size of bar which is to be spliced by welding; merely a statement that AWS procedures will be followed is not acceptable. 1.5 QUALITY ASSURANCE A. The CONTRACTOR shall make provisions for sampling reinforcing steel delivered to the job site. Two sampling bars, cut from different bars and 3 feet in length for bar sizes # 3 through # 5 and 5 feet in length for bars sizes #6 and larger, shall be taken from each 25 tons or fraction thereof, of each size and heat number delivered to the job site. When the name of the manufacturer, heat identification number, or chemical analysis is not known, the sampling interval shall be each 5 tons or fraction thereof, of each bar size and heat number. Costs of initial tests will be paid by the AGENCY. Additional tests due to material failing initial tests shall be paid by the CONTRACTOR. B. If reinforcement steel is spliced by welding at any location, the CONTRACTOR shall submit certifications of procedure qualifications for each welding procedure used and certification of welder qualifications, for each welding procedure, and for each welder performing the work. Such qualifications shall be as specified in AWS D1.4. C. The CONTRACTOR shall provide samples of each type, of welded splice used in the work in a quantity and of dimensions adequate for testing. At the discretion of the INSPECTOR, radiographic testing of direct butt welded splices will be performed. The CONTRACTOR shall provide assistance necessary to facilitate testing. The CONTRACTOR shall repair any weld which fails to meet the requirements of AWS D1.4. The costs of testing will be paid by the CITY; except, the costs of all tests which fail to meet specified requirements shall be paid by the CONTRACTOR. 8/13/09 Contract No. 3811 REINFORCEMENT STEEL PALOMAR AIRPORT ROAD WIDENING 03200-2 D. The CONTRACTOR shall provide to the INSPECTOR written identification of reinforcement steel by manufacturer's heat number and mil certification, and the fabricator's release number and type from the point of fabrication to the place of final incorporation of the rebar into the work. PART 2 ~ PRODUCTS 2.1 REINFORCEMENT STEEL A. All reinforcement steel for all cast-in-place reinforced concrete construction shall conform to the following requirements: 1. Bar reinforcement shall conform to the requirements of ASTM A 615 for Grade 60 Billet Steel Reinforcement with supplementary requirement S-1, or as otherwise shown. 2. Welded wire fabric reinforcement shall conform to the requirements of ASTM A 185 and the details shown; provided, that welded wire fabric with longitudinal wire of W9.5 size wire shall be either furnished in flat sheets or in rolls with a core diameter of not less than 10 inches; and provided further, that welded wire fabric with longitudinal wires larger than W9.5 size shall be furnished in flat sheets only. 3. Spiral reinforcement shall be cold-drawn steel wire conforming to the requirements of ASTM A 82. 4. All reinforcements shall be shop fabricated. Bending of reinforcing in the field will not be allowed. 5. Epoxy coated reinforcing steel shall be used where indicated on the drawing. B. Accessories: 1 . Accessories shall include all necessary chairs, slab bolsters, concrete blocks, tie wires, dips, supports, spacers, and other devices to position reinforcement during concrete placement. Slab bolsters shall have gray plastic-coated legs. 2. Concrete blocks (dobies), used to support and position reinforcement steel, shall have the same or higher compressive strength as specified for the concrete in which it is located. Where the concrete blocks are used on concrete surfaces exposed to view, the color and texture of the concrete blocks shall match that required for the finished surface. Wire ties shall be embedded in concrete block bar supports. 2.2 MECHANICAL COUPLERS A. Mechanical couplers shall be approved by the Department of Building and Safety. Location of the Mechanical Couplers shall be approved by the ENGINEER. The couplers shall develop a tensile strength which exceeds 125 percent of the yield strength of the reinforcement bars being spliced at each splice. B. Where the type of coupler used is composed of more than one component, all components required for a complete splice shall be supplied. This shall apply to all mechanical splices, including those splices intended for future connections. 8/1 3/09 Contract No. 381 1 REINFORCEMENT STEEL PALOMAR AIRPORT ROAD WIDENING 03200-3 C. The reinforcement steel and coupler used shall be compatible for obtaining the required strength of the connection. D. Couplers which are located at a joint face shall be a type which can be set either flush or recessed from the face as shown. The couplers shall be sealed during concrete placement to completely eliminate concrete or cement paste from entering. After the concrete is placed, couplers intended for future connections shall be plugged and sealed to prevent any contact with water or other corrosive materials. Threaded couplers shall be plugged with plastic plugs which have an O-ring seal. E. Hot-forged sleeve-type couplers shall not be used. 2.3 WELDED SPLICES A. Welded splices shall be provided where shown and where approved by the ENGINEER. All welded splices of reinforcement steel shall develop a tensile strength which exceeds 125 percent of the yield strength of the reinforcement bars which are connected. B. All materials required to conform the welded splices to the requirements of AWS D1.4 shall be provided. PART 3 - EXECUTION »- 3.1 GENERAL A. All reinforcement steel, welded wire fabric, couplers, and other appurtenances shall be fabricated, and placed in accordance with the requirements of the Building Code and the supplementary requirements specified herein. 3.2 FABRICATION A. General: Reinforcement steel shall be accurately formed to the dimensions and shapes shown, and the fabricating details shall be prepared in accordance with ACI 315 and ACI 318, except as modified by the Drawings. Stirrups and tie bars shall be bent around a pin having a diameter not less than 1-1/2-inch for No. 3 bars, 3-inch for No. 4 bars, and 2-1/2-inch for No. 5 bars. Bends for other bars shall be made around a pin having a diameter not less than 6 times the bar diameter, except for bars larger than 1 inch, in which case the bends shall be made around a pin of 8 bar diameters. Bars shall be bent cold. B. The CONTRACTOR shall fabricate reinforcement bars for structures in accordance with bending diagrams, placing lists, and placing drawings. Said drawings, diagrams, and lists shall be prepared by the CONTRACTOR as specified under GENERAL PROVISIONS. C. Fabricating Tolerances: Bars used for concrete reinforcement shall meet the following requirements for fabricating tolerances: 1. Sheared length: ± 1 inch 2. Depth of truss bars:+ 0, -1/2 inch 3. Stirrups, ties, and spirals: ± 1/2 inch 4. All other bends: ± 1 inch 8/13/09 Contract No. 3811 REINFORCEMENT STEEL PALOMAR AIRPORT ROAD WIDENING 03200-4 3.3 PLACING A. Placing: Reinforcement steel shall be accurately positioned as shown, and shall be supported and wired together to prevent displacement, using annealed iron wire ties or suitable clips at intersections. All reinforcement steel shall be supported by concrete, plastic or metal supports, spacers or metal hangers which are strong and rigid enough to prevent any displacement of the reinforcement steel. Where concrete is to be placed on the ground, supporting concrete blocks (or dobies) shall be used, in sufficient numbers to support the bars without settlement, but in no case shall such support be continuous. All concrete blocks used to support reinforcement steel shall be tied to the steel with wire ties which are embedded in the blocks. For concrete over formwork, the CONTRACTOR shall furnish concrete, metal, plastic, or other acceptable bar chairs and spacers. B. The portions of all accessories in contact with the formwork shall be made of concrete, plastic, or steel coated with a 1/8-inch minimum thickness of plastic which extends at least 1/2-inch from the concrete surface. Plastic shall be gray in color. C. Tie wires shall be bent away from the forms in order to provide the specified concrete coverage. D. Bars additional to those shown which may be found necessary or desirable by the CONTRACTOR for the purpose of securing reinforcement in position shall be provided by the CONTRACTOR at its own expense. E. Placing Tolerances: Unless otherwise specified, reinforcement placing tolerances shall be within the limits specified in Section 7.5 of ACI 318 except where in conflict with the requirements of the Building Code. F. Bars may be moved as necessary to avoid interference with other reinforcement steel, conduits, or embedded items. If bars are moved more than one bar diameter, or enough to exceed the above tolerances, the resulting arrangement of bars shall be as acceptable to the ENGINEER. G. Welded wire fabric reinforcement placed over horizontal forms shall be supported on slab bolsters having gray, plastic-coated standard type legs as specified in Paragraph B herein. Slab bolsters shall be spaced not less than 30 inches on centers, shall extend continuously across the entire width of the reinforcement mat, and shall support the reinforcement mat in the plane shown. H. Welded wire fabric placed over the ground shall be supported on wired concrete blocks (dobies) spaced not more than 3 feet on centers in any direction. The construction practice of placing welded wire fabric on the ground and hooking into place in the freshly placed concrete shall not be used. 3.4 SPACING OF BARS A. The clear distance between parallel bars (except in columns and between multiple layers of bars in beams) shall be not less than the nominal diameter of the bars nor less than 1-1/3 times the maximum size of the coarse aggregate, nor less than one inch. B. Where reinforcement in beams or girders is placed in 2 or more layers, the clear distance between layers shall be not less than one inch. 8/13/09 Contract No. 3811 REINFORCEMENT STEEL PALOMAR AIRPORT ROAD WIDENING 03200-5 C. In columns, the clear distance between longitudinal bars shall be not less than 1-1/2 times the bar diameter, nor less than 1-1/2 times the maximum size of the coarse aggregate, nor less than 1-1/2 inches. D. The clear distance between bars shall also apply to the distance between a contact splice and adjacent splices or bars. 3.5 SPLICING A. General: Reinforcement bar splices shall only be used at locations shown. When it is necessary to splice reinforcement at points other than where shown, the character of the splice shall be as acceptable to the ENGINEER. B. Splices of Reinforcement: The length of lap for reinforcement bars, unless otherwise shown shall be in accordance with ACI 318, Section 12.15.1 for a class B splice. C. Laps of welded wire fabric shall be in accordance with the ACI 318. Adjoining sheets shall be securely tied together with No. 14 tie wire, one tie for each running feet. Wires shall be staggered and tied in such a manner that they cannot slip. D. Splices in column spiral reinforcement, when necessary, shall be made by welding or by a lap of 1-1/2 turns. E. Bending or Straightening: Reinforcement shall not be straightened or rebent in a manner which will injure the material. Bars with kinks or bends not shown shall not be used. All bars shall be bent cold, unless otherwise permitted by the ENGINEER. No bars partially embedded in concrete shall be field-bent except as shown or specifically permitted by the ENGINEER. CLEANING AND PROTECTION The surfaces of all reinforcement steel and other metalwork to be in contact with concrete shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar and other foreign substances immediately before the concrete is placed. Where there is delay in depositing concrete, reinforcement shall be reinspected and, if necessary, recleaned. 8/13/09 Contract No. 3811 REINFORCEMENT STEEL PALOMAR AIRPORT ROAD WIDENING 03200-6 SECTION 03290 JOINTS IN CONCRETE PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall construct all joints in concrete at the locations shown. Joints required in concrete structures are of various types and will be permitted only where shown, unless specifically accepted by the ENGINEER. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [03100] Concrete Formwork. B. Section [03200] Reinforcement Steel. C. Section [03300] Cast-in-Place Concrete. D. Section [07920] Sealants and Caulking. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the reference specifications of the GENERAL PROVISIONS. B. Comply with the current provisions of the following Codes and Standards. 1. Federal Specifications: TT-S-0227E(3) 2. Commercial Standards: ASTM C 920 ASTM D 624 ASTM D 638 ASTM D 746 ASTM D 1752 ASTM D 2240 Sealing Compound, elastomeric type, Multi- component for Caulking, Sealing, and Glazing Buildings and Other Structures). Specification for Elastomeric Joint Sealants. Test Method for Rubber Property - Tear Resistance. Test Method for Tensile Properties of Plastics. Test Method for Brittleness Temperature of Plastics and Elastomers by Impact. Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction. Test Method for Rubber Property - Durometer Hardness. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 JOINTS IN CONCRETE 03290-1 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with GENERAL PROVISIONS. B. The following submittals and specific information shall be provided. 1. Waterstops: Prior to use of the material required under this contract, qualification samples shall be submitted. Such samples shall consist of extruded or molded sections of each size or shape to be used. The material sample shall be representative of the material to be furnished under this contract. The balance of the material to be used under this contract shall not be produced until after the ENGINEER has reviewed and approved the qualification samples. 2. Joint Sealant: Prior to ordering the sealant material, the CONTRACTOR shall submit to the ENGINEER for review and approval, data to show compliance with the requirements of the Contract Documents. Certified test reports from the sealant manufacturer on the actual batch of material being supplied indicating compliance with the above requirements shall be furnished the ENGINEER before the sealant is used on the job. 3. Shipping Certification: The CONTRACTOR shall provide written certification from the manufacturer as an integral part of the shipping form, to show that all of the material shipped to this project meets or exceeds the physical property requirements of the Contract Documents. Supplier certificates are not acceptable. 4. The CONTRACTOR shall submit placement shop drawings showing the location and type of all joints for each structure. 1.5 QUALITY ASSURANCE A. Waterstop Inspection: It is required that all waterstop field joints shall be subject to inspection, and no such work shall be scheduled or started without having made prior arrangements with the INSPECTOR to provide for the required inspections. Not less than 24 hours notice shall be provided to the INSPECTOR for scheduling such inspections. B. All field joints in waterstops shall be free of misalignment, bubbles, inadequate bond, porosity, cracks, offsets, and other defects which would reduce the potential resistance of the material to water pressure at any point. All defective joints shall be replaced with material which shall pass said inspection, and all faulty material shall be removed from the site and disposed of by the CONTRACTOR at its own expense. C. The following waterstop defects represent a partial list of defects which shall be grounds for rejection: 1. Offsets at joints greater than 1/16-inch or 15 percent of material thickness, at any point, whichever is less. 2. Exterior crack at joint, due to incomplete bond, which is deeper than 1/16-inch or 15 percent of material thickness, at any point, whichever is less. 8/13/09 Contract No. 3811 JOINTS IN CONCRETE PALOMAR AIRPORT ROAD WIDENING 03290-2 3. Any combination of offset or exterior crack which will result in a net reduction in the cross section of the waterstop in excess of 1/16-inch or 15 percent of material thickness at any point, whichever is less. 4. Misalignment of joint which result in misalignment of the waterstop in excess of 1/2-inch in 10 feet. 5. Purosity in the welded joint as evidenced by visual inspection. 6. Bubbles or inadequate bonding. D. Waterstop Samples: Prior to use of the waterstop material in the field, a sample of a fabricated metered cross and a tee constructed of each size or shape of material to be used shall be submitted to the ENGINEER for approval. These samples shall be fabricated so that the material and workmanship represent in all respects the fittings to be furnished under this contract. Field samples of fabricated fittings (crosses, tees, etc.) will be selected at random by the INSPECTOR for testing. When tested, they shall have a tensile strength across the joints equal to at least 600 psi. E. Construction Joint Sealant: The CONTRACTOR shall prepare adhesion and cohesion test specimens as specified herein, at intervals of 5 working days while sealants are being installed. F. The sealant material shall show no signs of adhesive or cohesive failure when tested in accordance with the following procedure in laboratory and field tests: 1. Sealant specimen shall be prepared between 2 concrete blocks (1-inch by 2-inch by 3-inch). Spacing between the blocks shall be 1/2-inch. Coated spacers (2-inch by 1-1/2-inch by 1/2-inch) shall be used to ensure sealant cross-sections of 1/2-inch by 2 inches with a width of 1/2-inch. 2. Sealant shall be cast and cured according to manufacturer's recommendations except that curing period shall not exceed 24 hours. 3. Following curing period, the gap between blocks shall be widened to one inch. Spacers shall be used to maintain this gap for 24 hours prior to inspection for failure. 1.6 TYPES OF JOINTS A. Construction Joints: When fresh concrete is placed against a hardened concrete surface, the joint between the two pours is called a construction joint. Unless otherwise specified, all joints in water bearing members shall be provided with a waterstop and sealant groove of the shape specified and as shown on the plans. B. Contraction Joints: Contraction joints are similar to construction joints except that the fresh concrete shall not bond to the hardened surface of the first pour, which shall be coated with a bond breaker. The slab reinforcement shall be stopped 4-1/2 inches from the joint; which is provided with a sleeve-type dowel, to allow shrinkage of the concrete of the second pour. Waterstop and sealant groove shall also be provided. C. Expansion Joints: To allow the concrete to expand freely, a space is provided between the two pours, the joint shall be formed as shown on the plans. This space is obtained by placing a filler joint material against the first pour, which acts as a form for the second 8/13/09 Contract No. 3811 JOINTS IN CONCRETE PALOMAR AIRPORT ROAD WIDENING 03290-3 pour. Unless otherwise specified, all expansion joints in water bearing members shall be provided with an approved type waterstop. Premolded expansion joint material shall be installed with the edge at the indicated distance below or back from finished concrete surface, and shall have a slightly tapered, dressed, and oiled wood strip secured to or placed at the edge thereof during concrete placement, which shall later be removed to form space for sealing material. The space so formed shall be filled with a joint sealant material as specified in the Paragraph in Part 2 entitled "Joint Sealant". In order to keep the two elements in line, the joint shall be provided with a sleeve-type dowel as shown. D. Control Joints: The function of the control joint is to provide a weaker plane in the concrete, where shrinkage cracks will probably occur. A groove, of the shape and dimension as shown on the plans, is formed or saw-cut in the concrete and shall be filled with a joint sealant material as specified in the Paragraph in Part 2 entitled "Joint Sealant". 1.7 GUARANTEE A. The CONTRACTOR shall provide a 5-year written guarantee of the entire sealant installation against faulty and/or incompatible materials and workmanship, together with a statement that it agrees to repair or replace, to the satisfaction of the AGENCY, at no additional cost to the AGENCY, any such defective areas which become evident within said 5-year guarantee period. PART 2 - PRODUCTS 2.1 PVC WATERSTOPS A. General: Waterstops shall be extruded from an elastomeric polyvinyl chloride compound containing the plasticizers, resins, stabilizers, and other materials necessary to meet the requirements of these Specifications. No reclaimed or scrap material shall be used. The CONTRACTOR shall obtain from the waterstop manufacturer and shall furnish to the ENGINEER for review, current test reports and a written certification of the manufacturer that the material to be shipped to the job meets the physical requirements as outlined in the U.S. Army Corps of Engineers Specification CRD-C572 and those listed herein. B. Flatstrip and Center-Bulb Waterstops: Flatstrip and center-bulb waterstops shall be as detailed and as manufactured by: Kirkhill Rubber Co., Brea, California; Water Seals, Inc., Chicago, Illinois; Progress Unlimited, Inc., New York, New York; or equal provided, that at no place shall the thickness of flat strip waterstops, including the center bulb type, be less than 3/8-inch. C. Multi-Rib Waterstops: Multi-rib waterstops, where required, shall be as detailed and as manufactured by Water Seals, Inc., Chicago, Illinois, Progress Unlimited, Inc., New York, New York; or equal. Prefabricated joint fittings shall be used at all intersections of the ribbed-type waterstops. D. Other Types of Waterstops: When other types of waterstops, not listed above are required and shown, they shall be subjected to the same requirements as those listed herein. 8/13/09 Contract No. 3811 JOINTS IN CONCRETE PALOMAR AIRPORT ROAD WIDENING 03290-4 E.Waterstop Testing Requirements: When tested in accordance with the specified test standards, the waterstop material shall meet or exceed the following requirements: Physical Property, Sheet Material Tensile Strength-min (psi) Ultimate Elongation-min (percent) Low Temp Brittleness-max (degreesJF) Stiffness in Flexure-min (psi) Accelerated Extraction (CRD-C572) Tensil Strength-min (psi) Ultimate Elongation-min (percent) Effect of Alkalies (CRD-C572) Change in Weight (percent) Change in Durometer, Shore A Finish Waterstop Tensile Strength-min (psi) Ultimate Elongation-min (percent) Value 1750 350 -35 400 1500 300 +0.25/-0.10 +5 1400 280 ASTMStd. D 6358, Type IV D 638, Type IV D746 D747 D 638, Type IV D 638, Type IV — D2240 D 638, Type IV D 638, Type IV 2.2 A. C. JOINT SEALANT Joint sealant shall be polyurethane polymer designed for bonding to concrete which is continuously submerged in water. B. Joint sealant material shall meet the following requirements: Work Life Time to Reach 20 Shore "A" Hardness (at 77 degrees F, 200 gr quantity) Ultimate Hardness Tensile Strength Ultimate Elongation Tear Resistance (Die C ASTM D 624) Color 45 - 90 minutes 24 hours, maximum 30 - 40 Shore "A" 250 psi, minimum 400 percent, minimum 75 pounds per inch of thickness, minimum Light Gray All polyurethane sealants for waterstop joints in concrete shall conform to the following requirements: 1. Sealant shall be 2-part polyurethane with the physical properties of the cured sealant conforming to or exceeding the requirements of ASTM C 920 or Federal Specification TT-S-00227 E(3) for 2-part material, as applicable. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 JOINTS IN CONCRETE 03290-5 2. For vertical joints and overhead horizontal joints, only "non-sag" compounds shall be used; all such compounds shall conform to the requirements of ASTM C 920 Class B, or Federal Specification TT-S-0027 E(3), Type II. 3. For plane horizontal joints, the self-leveling compounds which meet the requirements of ASTM C 920 Class A, or Federal Specification TT-S-0027 E(3), Type I shall be used. For joints subject to either pedestrian or vehicular traffic, a compound providing non-tracking characteristics, and having a Shore "A" hardness range of 25 to 35, shall be used. 4. Primer materials, if recommended by the sealant manufacturer, shall conform to the printed recommendations of the sealant manufacturer. D. All sealants, wherever shown, or required hereunder shall be [Rubbercalk 2101-1 or 270 as manufactured by Products Research Company; GS 102 or GS 1102 as manufactured by General Sealants Corp; or equal]. E. Sealants for non-waterstop joints in concrete shall conform to the requirements of Section [07900], "Joint Sealants". 2.3 PREFORMED JOINT FILLER A. Preformed joint filler material shall be of the preformed non-extruding type joint filler constructed of cellular neoprene sponge rubber or polyurethane of film texture. Bituminous fiber type will not be permitted. All non-extruding and resilient-type preformed expansion joint fillers shall conform to the requirements and tests set forth in ASTM D 1752 for Type I, except as otherwise specified herein. 2.4 BACKING ROD A. Backing rod shall be an extruded closed-cell, polyethylene foam rod. The material shall be compatible with the joint sealant material used and shall have a tensile strength of not less than 40 psi and a compression deflection of approximately 25 percent at 8 psi. The rod shall be 1/8-inch larger in diameter than the joint width except that a one-inch diameter rod shall be used for a 3/4-inch wide joint. 2.5 BOND BREAKER A. Bond breaker shall be Super Bond Breaker as manufactured by Burke Company, San Mateo, California; Hunt Process 225-TU as manufactured by Hunt Process Co., Santa Fe Springs, California; Select Cure CRB as manufactured by Select Products Co., Upland, California; or equal. It shall contain a fugitive dye so that areas of application will be readily distinguishable. 2.6 BENTONITE WATERSTOP A. Where called for in the Contract Documents, bentonite type waterstop, which shall expand in the presence of water to form a watertight joint seal without damaging the concrete in which it is cast, shall be provided. B. The bentonite waterstop shall be composed of 75 percent bentonite. The balance of the material shall be butyl rubber-hydrocarbon with less than 1.0 percent volatile matter. The waterstop shall contain no asbestos fibers or asphaltics. 8/13/09 Contract No. 3811 JOINTS IN CONCRETE PALOMAR AIRPORT ROAD WIDENING 03290-6 C. The manufacturer's rated application temperature range shall be from 5 to 125 degrees F. The service temperature range shall be from -40 to 212 degrees F. D. The cross sectional dimensions of the unexpended waterstop shall be one inch by 3/4-inch. E. The waterstop shall be provided with an adhesive backing which will provide excellent adhesion to concrete surfaces. PART 3 - EXECUTION 3.1 GENERAL A. Unless otherwise shown, waterstops of the type specified herein shall be embedded in the concrete across joints as shown. All waterstops shall be fully continuous for the extent of the joint. Splices necessary to provide such continuity shall be accomplished in conformance to printed instructions of manufacturer of the waterstops. The CONTRACTOR shall take suitable precautions and means to support and protect the waterstops during the progress of the work and shall repair or replace at its own expense any waterstops damaged during the progress of the work. All waterstops shall be stored so as to permit free circulation of air around the waterstop material. B. When any waterstop is installed in the concrete on one side of a joint, while the other half or portion of the waterstop remains exposed to the atmosphere for more than 2 days, suitable precautions shall be taken to shade and protect the exposed waterstop from direct rays of the sun during the entire exposure and until the exposed portion of the waterstop is embedded in concrete. 3.2 SPLICES IN WATERSTOPS A. Splices in waterstops shall be performed by heat sealing the adjacent waterstop sections in accordance with the manufacturer's printed recommendations and the following requirements: 1. The material not be damaged by heat sealing. 2. The splices have a tensile strength of not less than 60 percent of the unspliced materials tensile strength. 3. The continuity of the waterstop ribs and of its tubular center axis be maintained. B. Butt joints of the ends of two identical waterstop sections may be made while the material is in the forms. C. All joints with waterstops involving more than 2 ends to be jointed together, and all joints which involve an angle cut, alignment change, or the joining of 2 dissimilar waterstop sections shall be prefabricated by the CONTRACTOR prior to placement in the forms, allowing not less than 24-inch long strips of waterstop material beyond the joint. Upon being inspected and approved, such prefabricated waterstop joint assemblies shall be installed in the forms and the ends of the 24-inch strips shall be butt welded to the straight run portions of waterstop in place in the forms. 8/13/09 Contract No. 3811 JOINTS IN CONCRETE PALOMAR AIRPORT ROAD WIDENING 03290-7 3.3 JOINT CONSTRUCTION A. Setting Waterstops: 1. In order to eliminate faulty installation that may result in joint leakage, particular care shall be taken of the correct positioning of the waterstops during installation. Adequate provisions must be made to support the waterstops during the progress of the WORK and to ensure proper embedment in the concrete. The symmetrical halves of the waterstops shall be equally divided between the concrete pours at the joints. The center axis of the waterstops shall be coincident with the joint openings. Maximum density and imperviousness of the concrete shall be ensured by thoroughly working it in the vicinity of all joints. 2. In placing flat-strip waterstops in the forms, means shall be provided to prevent them from being folded over by the concrete as it is placed. Unless otherwise shown, all waterstops shall be held in place with light wire ties on 12-inch centers which shall be passed through the edge of the waterstop and tied to the curtain of reinforcing steel. Horizontal waterstops, with their flat face in a vertical plane, shall be held in place with continuous supports to which the top edge of the waterstop shall be tacked. In placing concrete around horizontal waterstops, with their flat face in a horizontal plane, concrete shall be worked under the waterstops by hand so as to avoid the formation of air and rock pockets. 3. Adequate means shall be provided for anchoring the waterstop in concrete. Waterstops shall be positioned so that they are equally embedded in the concrete on each side of the joint. B. Joint Location: 1. Construction joints, and other types of joints, shall be provided where shown. When not shown, construction joints shall be provided at [25-foot] maximum spacing for all concrete construction, unless noted otherwise. Where joints are shown spaced greater than 25 feet apart, additional joints shall be provided to maintain the [25-foot] maximum spacing. The location of all joints, of any type, shall be submitted for acceptance by the ENGINEER. C. Joint Preparation: Special care shall be used in preparing concrete surfaces at joints where bonding between two sections of concrete is required. Unless otherwise shown, such bonding will be required at all horizontal joints in walls. Surfaces shall be prepared in accordance with the requirements of Section [03300], "Cast-in-Place Concrete." Except on horizontal wall construction joints, wall to slab joints or where otherwise shown or specified, at all joints where waterstops are required, the joint face of the first pour shall be coated with a bond breaker as specified herein. D. Construction Joint Sealant: 1. Construction joints in water-bearing floor slabs, and elsewhere as shown, shall be provided with tapered grooves which will be filled with construction joint sealant. The material used for forming the tapered grooves shall be left in the grooves until just before the grooves are cleaned and filled with joint sealant. After removing the forms from the grooves, all laitance and fins shall be removed, and the grooves shall be sand-blasted. The grooves shall be allowed to become thoroughly dry, after which they shall be blown out; immediately thereafter, they 8/13/09 Contract No. 3811 JOINTS IN CONCRETE PALOMAR AIRPORT ROAD WIDENING 03290-8 shall be primed and filled with the construction joint sealant. The primer used ^«% shall be supplied by the same manufacturer supplying the sealant. No sealant will be permitted to be used without a primer. Care shall be used to completely fill "*"*" the sealant grooves. Areas designed to receive a sealant filler shall be thoroughly cleaned, as outlined for the tapered grooves, prior to application of the sealant. 2. Sealant application shall be in accordance with the manufacturer's printed instructions. The surfaces of the groove for the sealant shall not be coated. Concrete next to waterstops shall be placed in accordance with the requirements of Section [03300], Cast-in-Place Concrete. 3. The primer and sealant shall be placed strictly in accordance with the printed recommendations of the manufacturer, taking special care to properly mix the sealant prior to application. All sealant shall cure at least 7 days before the structure is filled with water. 4. All sealant shall be installed by a competent waterproofing specialty contractor who has a successful record of performance in similar installations. Before work is commenced, the crew doing the WORK shall be instructed as to the proper method of application by a representative of the sealant manufacturer. 5. Thorough, uniform mixing of 2-part, catalyst-cured materials is essential; special care shall be taken to properly mix the sealer before its application. Before any sealer is placed, the CONTRACTOR shall arrange to have the crew doing the WORK carefully instructed as to the proper method of mixing and application by a representative of the sealant manufacturer. -^6. Any joint sealant which after the manufacturer's recommended curing time for the job conditions of the WORK hereunder, fails to fully and properly cure shall be "****" completely removed; the groove shall be thoroughly sandblasted to remove all traces of the uncured or partially cured sealant and primer, and shall be re-sealed with the specified joint sealant. All costs of such removal, joint treatment, re-sealing, and appurtenant work shall be at the expense of the CONTRACTOR. E. Bentonite Waterstop: 1. Where a bentonite waterstop is called for in the Contract Documents, it shall be installed with the manufacturer's instructions and recommendations; except, as modified herein. 2. When requested by the ENGINEER or the INSPECTOR, the CONTRACTOR shall arrange for, the manufacturer to provide technical assistance in the field. 3. The bentonite waterstop shall be located as near as possible to the center of the joint and it shall be continuous around the entire joint. 4. Where a bentonite waterstop is used in combination with PVC waterstop, the bentonite waterstop shall overlap the PVC waterstop for a minimum of 6 inches and shall be placed in contact with the PVC waterstop. 5. The bentonite waterstop shall not be placed when the temperature of the waterstop material is below 40 degrees F. The waterstop material may be jy* warmed so that it shall remain above 40 degrees F during placement; however, ^"ji means used to warm the material shall in no way harm the material or its >*™*# 8/13/09 Contract No. 3811 JOINTS IN CONCRETE PALOMAR AIRPORT ROAD WIDENING 03290-9 properties. The waterstop shall not be installed where the air temperature falls outside the manufacturer's recommended range. 6. The bentonite waterstop shall be secured in place with concrete nails and washers at 12-inch maximum spacing. This shall be in addition to the adhesive backing provided with the waterstop. 8/13/09 Contract No. 3811 JOINTS IN CONCRETE PALOMAR AIRPORT ROAD WIDENING 03290-10 SECTION 03300 CAST-IN-PLACE CONCRETE PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish all materials for concrete with the provisions of this Section and shall form, mix, place, cure, repair, finish, and do all other work as required to produce finished concrete, in accordance with the requirements of the Contract Documents. B. The following types of concrete shall be covered in this Section: 1. Structure Concrete: Concrete to be used in all cases except where noted otherwise in the Contract Documents. 2. Sitework Concrete: Concrete to be used for curbs, gutters, catch basins, sidewalks, pavements, fence and guard post embedment, underground duct bank encasement and all other concrete appurtenant to electrical facilities unless otherwise shown. 3. Lean Concrete: Concrete to be used for thrust blocks, pipe trench cut-off blocks and cradles, where the preceding items are detailed on the Drawings as unreinforced. Concrete to be used as protective cover for dowels intended for future connection. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section [03100] Concrete Formwork. B. Section [03200] Reinforcement Steel. C. Section [03290] Joints in Concrete. D. Section [03315] Grout. E. Section [03370] Concrete Curing. F. Section [07920] Sealants and Caulking. G. Section [16560] Traffic Signals, Lighting, and Traffic Electrical Systems. H. Caltrans Standard Specifications. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the reference specifications of the GENERAL PROVISIONS. B. Comply with the current provisions of the following Codes and Standards. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE CONCRETE 03300-1 1. Federal Specifications: UU-B-790A (Int. Amd. 1) 2. Commercial Standards: ACI 214 ACI 301 ACI 315 ACI 318 ACI 347 ACI 350 ASTM C 31 ASTM C 33 ASTM C 39 ASTM C 40 ASTM C 42 ASTM C 78 ASTM C 88 ASTM C 94 ASTM C 114 ASTM C 131 Building Paper, Vegetable Fiber (Kraft, Waterproofed, Water Repellant and Fire Resistant). Recommended Practice for Evaluation of Strength Test Results of Concrete. Specifications for Structural Concrete for Buildings. Details and Detailing of Concrete Reinforcement. Building Code Requirements for Reinforced Concrete. Recommended Practice for Concrete Formwork. Recommended Practice for Sanitary Structure. Practices for Making and Curing Concrete Test Specimens in the Field. Specification for Concrete Aggregates. Test Method for Compressive Strength of Cylindrical Concrete Specimens. Test Method for Organic Impurities in Fine Aggregates for Concrete. Methods of Obtaining and Testing Drilled Cores and Sawed Beams of Concrete. Specification for Flexural Strength. Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate. Specification for Ready-Mixed Concrete. Method for Chemical Analysis of Hydraulic Cement. Test Method for Resistance to Degradation of Small-Sized Coarse Aggregate by Abrasion. ASTM C 136 ASTM C 143 ASTM C 150 Method for Sieve Analysis of Fine and Coarse Aggregate. Test Method for Slump of Portland Cement Concrete. Specification for Portland Cement. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE CONCRETE 03300-2 ASTMC156 Test Method for Water Retention by Concrete Curing Materials. ASTMC157 Test Method for Length Change of Hardened Hydraulic Cement Mortar and Concrete. ASTM C 172 Specification for Sampling Fresh Concrete. ASTM C 192 Method of Making and Curing Concrete Test Specimens in the Laboratory. ASTM C 260 Specification for Air-Entraining Admixtures for Concrete. ASTM C 289 Test Method for Potential Reactivity of Aggregates (Chemical Method). ASTM C 311 Method for Sampling and Testing Fly Ash or Natural Pozzolans for Use as a Mineral Admixture in Portland Cement Concrete. ASTM C 494 Specification for Chemical Admixtures for Concrete. ASTM C 618 Specification for Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Portland Cement Concrete. ASTM D 1751 Specification for Preformed Expansion Joint Fillers for Concrete Paving and Structural Construction (Non-Extruding and Resilient Bituminous Types). ASTM E 119 Method for Fire Tests of Building Construction and Materials. C. The concrete for the Caltrans truss sign structure pile foundations shall comply with the Caltrans Specifications. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with GENERAL PROVISIONS. B. The following submittals and specific information shall be provided. 1. Mix Designs: Prior to beginning the WORK, the CONTRACTOR shall submit to the ENGINEER, for review, and approval, preliminary concrete mix designs for each class and type of concrete specified herein. The mix designs shall be designed by an independent testing laboratory acceptable to the ENGINEER. All costs related to such mix design shall be borne by the CONTRACTOR. Each concrete mix submittal shall contain the following information: a) Slump on which the design is based. b) Total gallons of water per cubic yard. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-3 c) Brand, type, composition and quantity of cement. d) Brand type, composition and quantity of fly ash. e) Specific gravity and gradation of each aggregate. f) Ratio of fine to total aggregate per cubic yard. g) Weight (surface dry) of each aggregate per cubic yard. h) Brand, type, and ASTM designation, active chemical ingredients and quantity of each admixture. i) Copy of the Building and Safety Research Report Approval for each concrete admixture. j) Air content. k) Compressive strength based on 7-day and 28-day compression tests, including standard deviation calculations, corroborative data (if applicable), and required average comprehensive strength per ACI 318, Sections. I) Time of initial set. m) Certification stamp and signature by a Civil or Structural engineer registered in State of California. n) Certificate of Compliance for Cement. 2. Certified Delivery Tickets: Where ready-mix concrete is used, the CONTRACTOR shall provide certified weighmaster delivery tickets at the time of delivery of each load of concrete. Each certificate shall show the public weighmaster's signature, and the total quantities, by weight of cement, sand, each class of aggregate, admixtures, and the amounts of water in the aggregate and added at the batching plant as well as the amount of water allowed to be added at the site for the specific design mix. Each certificate shall, in addition, state the mix number, total yield in cubic yards, and the time of day, to the nearest minute, corresponding to when the batch was dispatched, when it left the plant, when it arrived at the job, the time that unloading began, and the time that unloading was finished. 3. When a water reducing admixture is to be used, the CONTRACTOR shall furnish mix designs for concrete both with and without the admixture. 4. The CONTRACTOR shall furnish a Certificate of Compliance signed by the supplier identifying the type of fly ash and stating that the fly ash complies with ASTM C 618 and these Specifications, together with all supporting test data prior to the use of the fly ash the sample represents. The supporting data shall also contain test results confirming that the fly ash in combination with the cement and water to be used meets all strength requirements and is compatible with air-entraining agents and other admixtures. 8/1 3/09 Contract No. 381 1 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-4 5. The CONTRACTOR shall submit to the ENGINEER for review the design mix for >-^ fly ash concrete together with the design mix for portland cement (non-fly ash) concrete as specified in this Section. "*"**" 1.5 QUALITY ASSURANCE A. Tests on component materials and for compressive strength and shrinkage of concrete will be performed as specified herein. Test for determining slump will be in accordance with the requirements of ASTM C 143. B. The cost of all laboratory tests on cement, aggregates, and concrete, will be borne by the CITY. However, the CONTRACTOR shall be charged for the cost of any additional tests and investigation on work performed which does not meet the specifications. C. Concrete for testing shall be supplied by the CONTRACTOR at no cost to the CITY, and the CONTRACTOR shall provide assistance and facilities to the INSPECTOR in obtaining samples, and disposal and cleanup of excess material. D. Field Compression Tests: 1. Compression test specimens will be taken during construction from the first placement of each class of concrete specified herein and at intervals thereafter as selected by the INSPECTOR to ensure continued compliance with these specifications. Each set of test specimens will be a minimum of 4 cylinders. x"X2. Compression test specimens for concrete shall be made in accordance with 1 ASTM C 31. Specimens shall be 6-inch diameter by 12-inch high cylinders. "**"**' 3. Compression tests shall be performed in accordance with ASTM C 39. Two test cylinders will be tested at 7 days as necessary and two at 28 days. Any remaining cylinders will be held to verify test results, if needed. E. Evaluation and acceptance of compressive strength concrete shall be based on the following criteria: 1. Drying shrinkage tests shall be provided by the CONTRACTOR for the trial batch specified in the Paragraph in Part 2 entitled "Trial Batch and Laboratory Tests," and during construction to ensure continued compliance with these Specifications. 2. Drying shrinkage specimens shall be 4-inch by 4-inch by 11 -inch prisms with an effective gage length of 10 inches, fabricated, cured, dried and measured in accordance with ASTM C 157 modified as follows: specimens shall be removed from molds at an age of 23 ±1 hours after trial batching, shall be placed immediately in water at 70 degrees F ±3 degrees F for at least 30 minutes, and shall be measured within 30 minutes thereafter to determine original length and then submerged in saturated lime water at 73 degrees F ±3 degrees F. Measurement to determine shrinkage expressed as percentage of base length shall be made and reported separately for 7, 14, 21, and 28 days of drying after 7 days of moist curing. "™<"s 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-5 3. The drying shrinkage deformation of each specimen shall be computed as the difference between the base length (at "0" days drying age) and the length after drying at each test age. The average drying shrinkage deformation of the specimens shall be computed to the nearest 0.0001 at each test age. If the drying shrinkage of any specimen departs from the average of that test age by more than 0.0004-inch, the results obtained from that specimen shall be disregarded. Results of the shrinkage test shall be reported to the nearest 0.001 percent of shrinkage. Compression test specimens shall be taken in each case from the same concrete used for preparing drying shrinkage specimens. These tests shall be considered a part of the normal compression tests for the project. Allowable shrinkage limitations shall be as specified in Part 2, herein. G. Construction Tolerances: The CONTRACTOR shall set and maintain concrete forms and perform finishing operations so as to ensure that the completed work is within the tolerances specified herein. Surface defects and irregularities are defined as finishes and are to be distinguished from tolerances. Tolerance is the specified permissible variation from lines, grades, or dimensions shown. Where tolerances are not stated in the specifications, permissible deviations will be in accordance with ACI 347. H. The following construction tolerances are hereby established and apply to finished walls and slab unless otherwise shown: :iv;J#^§ij.!^r :; <f *£"* > •.feltelli^ "i|pU* * f *> *-' Variation of the constructed linear outline from the established position in plan. Variation from the level or from the grades shown. Variation from the plumb Variation in the thickness of slabs and walls Variation in the locations and sizes of slabs and wall openings /'./".ft-t-^fToIerance : t-l-«. •;•'.;?. In 10 feet: 1/8-inch; In 20 feet or more: 1/4-inch In 10 feet: 1/8-inch; In 20 feet or more: 1/4-inch In 10 feet: 1/8-inch; In 20 feet or more: 1/4-inch Minus 1/8-inch; Plus 1/4-inch Plus or minus 1/8-inch For each class of fly ash, all testing and sampling procedures shall conform with these Specifications and ASTM C 311, including the restriction that one sample weighing 4 pounds shall be taken from at least each 200 tons of fly ash supplied. Separate storage facilities shall be provided for fly ash. Fly ash shall be stored in such a manner as to permit ready access for the purpose of inspection and sampling and suitably protected against contamination or moisture. Should any fly ash show evidence of contamination or moisture or be otherwise unsuitable, the INSPECTOR may reject it and require that it be removed from the site. Each class of fly ash used in concrete for this project shall be from the same source. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-6 .4 PART 2 - PRODUCTS 2.1 CONCRETE MATERIALS A. Materials shall be delivered, stored, and handled so as to prevent damage by water or breakage. Only one brand of cement shall be used. Cement reclaimed from cleaning bags or leaking containers shall not be used. All cement shall be used in the sequence of receipt of shipments. B. All materials furnished for the work shall comply with the requirements of Sections 201, 203, and 204 of ACI 301, as applicable. C. Storage of materials shall conform to the requirements of Section 205 of ACI 301. D. Materials for concrete shall conform to the following requirements. 1. Cement shall be standard brand Portland cement conforming to ASTM C 150 for [Type II or Type V]. Portland cement shall contain not more than 0.60 percent alkalies. The term "alkalies" referred to herein is defined as the sum of the percentage of sodium oxide and 0.658 times the percentage of potassium oxide (Na20 + 0.658 K20). These oxides shall be determined in accordance with ASTM C 114. A single brand of cement shall be used throughout the work, and prior to its use, the brand shall be acceptable to the ENGINEER. The cement shall be suitably protected from exposure to moisture until used. Cement that has become lumpy shall not be used. Sacked cement shall be stored in such a manner so as to permit access for inspection and sampling. Certified mail test reports for each shipment of cement to be used shall be submitted to the INSPECTOR. Concurrent with strength design criteria, concrete shall also be proportioned to provide the requisite durability to satisfy the exposure conditions imposed by either environment and/or service. Durability, in this context, refers to the ability of the concrete to resist deterioration from the environment or service in which it is placed. Concrete proportioned in accordance with ACI 318, chapter 4, Durability Requirements, will meet this criteria. 2. Water shall be potable, clean, and free from objectionable quantities of silty organic matter, alkali, salts and other impurities. The water shall be considered potable, for the purposes of this Section only, if it meets the requirements of the local governmental agencies. 3. Aggregates shall be obtained from pits acceptable to the INSPECTOR, shall be non-reactive, and shall conform to ASTM C 33. Maximum size of coarse aggregate shall be as specified herein. Lightweight sand for fine aggregate will not be permitted. a. Coarse aggregates shall consist of clean, hard, durable gravel, crushed gravel, crushed rock or a combination thereof. The coarse aggregates shall be prepared and handled in two or more size groups for combined aggregates with a maximum size greater than 3/4-inch. When the aggregates are proportioned for each batch of concrete, the two size 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-7 groups shall be combined. See the Paragraph in Part 2 entitled "Trial Batch and Laboratory Tests" for the use of the size groups. b. Fine aggregates shall be natural sand or a combination of natural and manufactured sand that are hard and durable. c. Combined aggregates shall be well graded from coarse to fine sizes, and shall be uniformly graded between screen sizes to produce a concrete that has optimum workability and consolidation characteristics. Where a trial batch is required for a mix design, the final combined aggregate gradations will be established during the trial batch process. d. When tested in accordance with ASTM C 289, the ratio of silica released to reduction in alkalinity shall not exceed 1.0. e. When tested in accordance with ASTM C 40, the fine aggregate shall produce a color in the supernatant liquid no darker than the reference standard color solution. f. When tested in accordance with ASTM C 131, the coarse aggregate shall show a loss not exceeding 42 percent after 500 revolutions, or 10.5 percent after 100 revolutions. g. When tested in accordance with ASTM C 88, the loss resulting after five cycles shall not exceed 10 percent for fine or coarse aggregate when using sodium sulfate. 4. Ready-mix concrete shall conform to the requirements of ASTM C 94. 5. Admixtures: The ENGINEER may require the use of admixtures or the CONTRACTOR may propose to use admixtures to control the set, effect water reduction, and increase workability. In either case, the addition of an admixture shall be at the CONTRACTOR'S expense. The use and continued use of an admixture shall be approved by the ENGINEER. Admixtures specified herein, other than calcium chloride, shall conform to the requirements of ASTM C 494. The required quantity of cement shall be used in the mix regardless of whether or not an admixture is used. Admixtures shall contain no free chloride ions, be non-toxic after 30 days, and shall be compatible with and made by the same manufacturer as the air entraining admixture. These admixtures shall not be used in greater doses than those recommended by the manufacturer or permitted by the ENGINEER. The permitted dosage of the admixture shall not exceed that which will result in an increase in the driving shrinkage of the concrete in excess of 20 percent when used in precast or prestressed concrete, or 10 percent when used in any other structural concrete. The strength of concrete containing the admixture in the amount of proposed shall, at the age of 48 hours and longer be not less than that of similar concrete without the admixture. The admixture shall not adversely affect the specified air content, unless permitted by the ENGINEER. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-8 a. Set controlling admixture shall be either with or without water-reducing properties. Where the air temperature at the time of placement is expected to be consistently over 80 degrees F, a set retarding admixture such as Sika Chemical Corporation's Plastiment, Master Builder's Pozzolith 300R, or equal shall be used. Where the air temperature at the time of placement is expected to be consistently under 40 degrees F, a set accelerating admixture such as Sika Chemical Corporation's Plastocrete 161FL, Master Builder's Pozzolith 50C, or equal shall be used. b. Low range water reducer shall conform to ASTM C 494, Type A. It shall be either a hydroxylated carboxylic acid type or a hydroxylated polymer type. The quantity of admixture used and the method of mixing shall be in accordance with the manufacturer's instructions and recommendations. c. High range water reducer shall be sulfonated polymer conforming to ASTM C 494, Type F or G. If the high range water reducing agent is added to the concrete at the batch plant, it shall be second generation type, Daracem 100, as manufactured by W.R. Grace & Co.; Pozzolith 430R, as manufactured by Masterbuilders; or equal. High range water reducer shall be added to the concrete after all other ingredients have been mixed and initial slump has been verified. If the high range water reducer is added to the concrete at the job site, it shall be used in conjunction with a low range water reducer and shall be Pozzolith 400N and Pozzolith MBL82, as manufactured by Masterbuilders; WRDA 19 and WRDA 79, as manufactured by W.R. Grace & Co.; or equal. Concrete shall have a slump of 3-inches ± /4-inch prior to adding the high range water reducing admixture at the job site. The high range water reducing admixture shall be accurately measured and pressure injected into the mixer as a single dose by an experienced technician. A standby system shall be provided and tested prior to each day's operation of the job site system. Concrete shall be mixed at mixing speed for a minimum of 30 mixer revolutions after the addition of the high range water reducer. d. Air-entraining agent meeting the requirements of ASTM C 260, shall be used. Sufficient air-entraining agent shall be used to provide a total air content of 3 to 4 percent; provided that, when the mean daily temperature in the vicinity of the worksite falls below 40 degrees F for more than one day, the total air content provided shall be 5 to 6 percent. The CITY reserves the right, at any time, to sample and test the air-entraining agent received on the job by the CONTRACTOR. The air-entraining agent shall be added to the batch in a portion of the mixing water. The solution shall be batched by means of a mechanical batcher capable of accurate measurement. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-9 '%«*.»" 6. Calcium Chloride: Except as otherwise provided herein, calcium chloride will not be permitted to be used in concrete. 7. Fly ash/pozzolan shall conform to ASTM C 618, including the requirements of Table 1A, therein, section 2.5 D of this section and the following supplementary requirements: a. Class C fly ash • Loss on ignition, maximum 2 percent • S03 content, maximum 4 percent • Moisture content, maximum 1 percent • R = (CaO - 5%)/(Fe203), maximum 4.5 b. Class F fly ash • Loss on ignition, maximum 4 percent • S03 content, maximum 3 percent • Moisture content, maximum 1 percent • R = (CaO - 5%)/Fe203), maximum 0.75 2.2 CURING MATERIALS A. Materials for curing concrete as specified herein shall conform to the following requirements: 1. Concrete curing compound shall conform to the requirements of ASTM C309 Type 1-D (clear or translucent with a fugitive dye), Class B (Resin Type Only), except the loss of water shall not exceed 0.15 kilograms per square meter in 24 hours nor 0.45 kilograms per square meter in 72 hours when tested in accordance with ASTM C 156. the CONTRACTOR shall provide, when requested by the ENGINEER, certified copies of vendor's test report showing compliance with ASTM C 309 and these specifications. The testing and the report shall be supplied without cost to the Agency. All compounds shall be furnished by the CONTRACTOR in sealed original containers labeled in accordance with ASTM C 309 and with the date of manufacture. 2. Polyethylene sheet for use as concrete curing blanket shall be white and conform to ASTM C 171. The loss of moisture when determined in accordance with the requirements of ASTM C 156 shall not exceed 0.055 grams per square centimeter of surface. 3. Polyethylene-coated waterproof paper sheeting for use as concrete curing blanket shall consist of white polyethylene sheeting free of visible defects, uniform in appearance, having a nominal thickness of 2 mils and permanently bonded to waterproof paper conforming to the requirements of Federal Specification UU-B-790A (Int. Amd. 1). The loss of moisture, when determined in accordance with the requirements of ASTM C 156, shall not exceed 0.055 gram per square centimeter of surface. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-10 4. Polyethylene-coated burlap for use as concrete curing blanket shall conform to ASTM C 171. The loss of moisture, when determined in accordance with the requirements of ASTM C 156, shall not exceed 0.055 grams per square centimeter of surface. 5. Curing mats for use in Curing Method 6 as specified herein, shall be heavy shag rugs or carpets or cotton mats quilted at 4-inches on center. Curing mats shall weigh a minimum of 12 ounces per square yard when dry. 6. Evaporation retardant shall be a material such as Confilm as manufactured by Masterbuilders, Cleveland, OH; or equal. 2.3 NON-WATERSTOP JOINT MATERIALS A. Materials for non-waterstop joints in concrete shall conform to the following requirements: 1. Preformed joint filler shall be a non-extruding, resilient, bituminous type conforming to the requirements of ASTM D 1751. 2. Elastomeric joint sealer shall conform to the requirements of Section [07900], "Joint Sealants". 3. Mastic joint sealer shall be a material that does not contain evaporating solvents; that will tenaciously adhere to concrete surfaces; that will remain permanently resilient and pliable; that will not be affected by continuous presence of water and will not in any way contaminate potable water; and that will effectively seal the joints against moisture infiltration even when the joints are subject to movement due to expansion and contraction. The sealer shall be composed of special asphalts or similar materials blended with lubricating and plasticizing agents to form a tough, durable mastic substance containing no volatile oils or lubricants and shall be capable of meeting the test requirements set forth hereinafter, if testing is required by the ENGINEER. 2.4 MISCELLANEOUS MATERIALS A. Floor sealer/hardener shall be a colorless, aqueous solution of zinc and/or magnesium fluosilicate or of sodium silicate, and shall be as manufactured by Masterbuilders Company, W.R. Grace Co., or equal. The solution shall be delivered ready for use in the manufacturer's original sealed containers. Each gallon of the fluosilicate solution shall contain not less than 2 pounds of crystals. B. Dampproofing agent shall be an asphalt emulsion, such as Sonneborn Hydrocide 660, Flintkote C-13-E Foundation Coating, or equal. C. Epoxy adhesives shall be the following products for the applications specified: 1. For bonding freshly-mixed, plastic concrete to hardened concrete, Sikadur Hi-Mod Epoxy Adhesive, as manufactured by Sika Chemical Corporation; Concresive 1001-LPL, as manufactured by Adhesive Engineering Company; or equal. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-11 2. For bonding hardened concrete or masonry to steel, Colma-Dur Gel, Sikadur Hi- Mod Gel, or equal. 2.5 CONCRETE DESIGN REQUIREMENTS A. B. C. D. General: Concrete shall be composed of cement, admixtures, aggregates and water. These materials shall be of the qualities specified. The exact proportions in which these materials are to be used for different parts of the work will be determined during the trial batch. In general, the mix shall be designed to produce a concrete capable of being deposited so as to obtain maximum density and minimum shrinkage and, where deposited in forms, to have good consolidation properties and maximum smoothness of surface. Mix designs with more than 41 percent of sand of the total weight of fine and coarse aggregate shall not be used. The aggregate gradations shall be formulated to provide fresh concrete that will not promote rock pockets around reinforcing steel or embedded items. The proportions shall be changed whenever necessary or desirable to meet the required results at no additional cost to the CITY. All changes shall be subject to review by the ENGINEER. Water-Cement Ratio and Compressive Strength: The minimum compressive strength and cement content of concrete shall be not less than that specified in the following tabulation. Note: One sack of cement equals 94 Ib. Adjustments to Mix Design: The mixes used shall be changed whenever such change is necessary or desirable to secure the required strength, density, workability, and surface finish and the CONTRACTOR shall be entitled to no additional compensation because of such changes. Fly ash/pozzolan may be used when approved by the ENGINEER as a partial cement replacement in concrete as follows: 1. Fly ash shall replace not more than 10 percent by weight of the Portland cement in the design mix. The design mix shall contain a minimum of 7 sacks of cement per cubic yard before the replacement is made. 2. Fly ash for hydraulic/liquid containing structures shall be Class F fly ash only. Fly ash for all other structures shall be Class C or F fly ash. 2.6 CONSISTENCY The quantity of water entering into a batch of concrete shall be just sufficient, with a normal mixing period, to produce a concrete which can be worked properly into place without segregation, and which can be compacted by the vibratory methods herein 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE CONCRETE 03300-12 specified to give the desired density, impermeability and smoothness of surface. The quantity of water shall be changed as necessary, with variations in the nature or moisture content of the aggregates, to maintain uniform production of a desired consistency. The consistency of the concrete in successive batches shall be determined by slump tests in accordance with ASTM C 143. The slumps shall be as follows: ^^-^'^Mssm Footings and slabs 3-inches + 1 /2-inch, -1-inch Other work 3-inches ± 1-inch With high range water reducer added 8-inches max 2.7 TRIAL BATCH AND LABORATORY TESTS A. Before placing any concrete, a Department of Building and Safety testing laboratory approved by the ENGINEER shall prepare, within 30 calendar days after the date of the Notice to Proceed, a trial batch of each class of concrete having a 28-day strength of 4,000 psi or higher, based on the preliminary concrete mixes submitted by the CONTRACTOR. During the trial batch the aggregate proportions may be adjusted by the testing laboratory using the two coarse aggregate size ranges to obtain the required properties. If one size range produces an acceptable mix, a second size range need not be used. Such adjustments shall be considered refinements to the mix design and shall not be the basis for extra compensation to the CONTRACTOR. All concrete shall conform to the requirements of this Section, whether the aggregate proportions are from the CONTRACTOR'S preliminary mix design, or whether the proportions have been adjusted during the trial batch process. The trial batch shall be prepared using the aggregates, cement and admixture proposed for the project. The trial batch materials shall be of a quantity such that the testing laboratory can obtain 3 drying shrinkage, and 10 compression test specimens from each batch. The cost of not more than 3 laboratory trial batch tests for each specified concrete strength shall be borne by the CONTRACTOR. Any additional trial batch testing required shall be performed at the expense of the CONTRACTOR. B. The determination of compressive strength will be made by testing 6-inch diameter by 12-inch high cylinders; made, cured and tested in accordance with ASTM C 192 and ASTM C 39. 5 compression test cylinders shall be tested at 7 days and 5 at 28 days. The average compressive strength for the 5 cylinders tested at 28 days for any given trial batch shall not be less than the appropriate sections of ACI 318 of the specified compressive strength. C. A sieve analysis of the combined aggregate for each trial batch shall be performed according to the requirements of ASTM C 136. Values shall be given for percent passing each sieve. 2.8 SHRINKAGE LIMITATION A. The maximum concrete shrinkage for specimens cast in the laboratory from the trial batch, as measured at 21-day drying age or at 28-day drying age shall be 0.036 percent or 0.042 percent, respectively. The CONTRACTOR shall only use a mix design for construction that has first met the trial batch shrinkage requirements. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-13 >•*••'' B. The maximum concrete shrinkage for specimens cast in the field shall not exceed the trial batch maximum shrinkage requirement by more than 25 percent. C. If the required shrinkage limitation is not met during construction, the CONTRACTOR shall take any or all of the following actions, at no additional cost to the CITY, for securing the specified shrinkage requirements. These actions may include changing the source or aggregates, cement and/or admixtures; reducing water content; washing of aggregate to reduce fines; increasing the number of construction joints; modifying the curing requirements; or other actions designed to minimize shrinkage or the effects of shrinkage. 2.9 MEASUREMENT OF CEMENT AND AGGREGATE The amount of cement and of each separate size of aggregate entering into each batch of concrete shall be determined by direct weighing equipment furnished by the CONTRACTOR and acceptable to the ENGINEER; provided that, where batches are so proportioned as to contain an integral number of conventional sacks of cement, and the cement is delivered at the mixer in the original unbroken sacks, the weight of the cement contained in each sack may be taken without weighing as 94 pounds. 2.10 MEASUREMENT OF WATER The quantity of water entering the mixer shall be measured by a suitable water meter or other measuring device of a type acceptable to the ENGINEER and capable of measuring the water in variable amounts within a tolerance of one percent. The water feed control mechanism shall be capable of being locked in position so as to deliver constantly any specified amount of water to each batch of concrete, and the meter shall include a set-back register with a readily visible vertical face and double hands indicating in cubic feet and decimals thereof. A positive quick-acting valve shall be used for a cut- off in the water line to the mixer. The operating mechanism must be such that leakage will not occur when the valves are closed. 2.11 READY-MIXED CONCRETE A. At the CONTRACTOR'S option, ready-mixed concrete may be used meeting the requirements as to materials, batching, mixing, transporting, and placing as specified herein and in accordance with ASTM C 94, including the following supplementary requirements. B. Ready-mixed concrete shall be delivered to the site of the work, and discharge shall be completed within 90 minutes after the addition of the cement to the aggregates or before the drum has been revolved 300 revolutions, whichever is first. In hot weather, or under conditions contributing to quick stiffening of the concrete, or when the temperature of the concrete shall not exceed 90 degrees F. C. Truck mixers shall be equipped with electrically-actuated counters by which the number of revolutions of the drum or blades may be readily verified. The counter shall be of the resettable, recording type, and shall be mounted in the driver's cab. The counters shall be actuated at the time of starting mixers at mixing speeds. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-14 D. Each batch of concrete shall be mixed in a truck mixer for not less than 70 revolutions of the drum or blades at the rate of rotation designated by the manufacturer of equipment. Additional mixing, if any, shall be at the speed designated by the manufacturer of the equipment as agitating speed. All materials including mixing water shall be in the mixer drum before actuating the revolution counter for determining the number of revolution of mixing. E. Truck mixers and their operation shall be such that the concrete throughout the mixed batch as discharged is within acceptable limits of uniformity with respect to consistency, mix, and grading. If slump tests taken at approximately the 1/4 and 3/4 points of the load during discharge give slumps differing by more than one inch when the specified slump is 3-inches or less, or if they differ by more than 2-inches when the specified slump is more than 3-inches, the mixer shall not be used on the work unless the causing condition is corrected and satisfactory performance is verified by additional slump tests. All mechanical details of the mixer, such as water measuring and discharge apparatus, condition of the blades, speed of rotation, general mechanical condition of the unit, and clearance of the drum, shall be checked before a further attempt to use the unit will be permitted. F. Each batch of ready-mixed concrete delivered at the job site shall be accompanied by a certified weighmaster delivery ticket furnished to the INSPECTOR in accordance with the Paragraph in Part 1 entitled "Certified Delivery Tickets". G. The use of non-agitating equipment for transporting ready-mixed concrete will not be permitted. Combination truck and trailer equipment for transporting ready-mixed concrete will not be permitted. The quality and quantity of materials used in ready-mixed concrete and in batch aggregates shall be subject to continuous inspection at the batching plant by the INSPECTOR. PART 3 - EXECUTION 3.1 PROPORTIONING AND MIXING A. Proportioning: Proportioning of the concrete mix shall conform to the requirements of Chapter 3 "Proportioning" of ACI 301; provided, that the maximum slump for any concrete shall not exceed 4-inches except when the use of high range water reducer is permitted which increases the maximum slump to 8-inches. B. Mixing: Mixing of concrete shall conform to the requirements of Chapter 7 of said ACI 301 Specifications. C. Slump: Maximum slumps shall be as specified herein in Section 2.6. D. Retempering: Retempering of concrete or mortar which has partially hardened will not be permitted. 3.2 PREPARATION OF SURFACES FOR CONCRETING A. General: Earth surfaces shall be thoroughly wetted by sprinkling, prior to the placing of any concrete, and these surfaces shall be kept moist by frequent sprinkling up to the 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-15 time of placing concrete thereon. The surface shall be free from standing water, mud, and debris at the time of placing concrete. B. Joints in Concrete: Concrete surfaces upon or against which concrete is to be placed, where the placement of the old concrete has been stopped or interrupted so that, as determined by the ENGINEER, the new concrete cannot be incorporated integrally with that previously placed, are defined as construction joints. The surfaces of horizontal joints shall be given a compacted, roughened surface for good bond. Except where the Drawings call for joint surfaces to be coated, the joint surfaces shall be cleaned of all laitance, loose or defective concrete, and foreign material. Such cleaning shall be accomplished by sandblasting followed by thorough washing. All pools of water shall be removed from the surface of construction joints before the new concrete is placed. C. After the surfaces have been prepared, all approximately horizontal construction joints shall be covered with a layer of mortar approximately two-inch thick. The mortar shall have the same proportions of cement and sand as the regular concrete mixture. The water-cement ratio of the mortar in place shall not exceed that of the concrete to be placed upon it, and the consistency of the mortar shall be suitable for placing and working in the manner hereinafter specified. The mortar shall be spread uniformly and shall be worked thoroughly into all irregularities of the surface. Wire brooms shall be used where possible to scrub the mortar into the surface. Concrete shall be placed immediately upon the fresh mortar. When casting deep walls (more than 6 feet high) over slabs or footings, in lieu of the two-inch thick mortar, a 6-inch lift of a rich pea gravel mix with the same water-cement ratio as the wall concrete shall be placed and spread uniformly. Wall concrete shall follow immediately and shall be placed upon the fresh pea gravel mix. D. Embedded Items: No concrete shall be placed until all formwork, installation of parts to be embedded, reinforcement steel, and preparation of surfaces involved in the placing have been completed and ACCEPTED by the INSPECTOR at least 24 hours before placement of concrete. All surfaces of forms and embedded items that have become encrusted with dried grout from concrete previously placed shall be cleaned of all such grout before the surrounding or adjacent concrete is placed. E. All inserts or other embedded items shall conform to the requirements herein. F. All reinforcement, anchor bolts, sleeves, inserts, and similar items shall be set and secured in the forms where shown or by shop drawings and shall be acceptable to the INSPECTOR before any concrete is placed. Accuracy of placement is the responsibility of the CONTRACTOR. G. Where concrete is to be cast against old concrete, (greater than 60 days of age), the surface of the old concrete shall be thoroughly cleaned and roughened by sand-blasting, exposing the aggregate. In concrete shear-walls, suspended slabs and roof slabs, the interface surface at construction joints shall be roughened to a full amplitude of one quarter inch. The hardened surface shall be cleaned of all latent foreign material and washed clean, prior to the application of an epoxy bonding agent. H. No concrete shall be placed in any structure until all water entering the space to be filled with concrete has been properly cut off or has been diverted by pipes, or other means, and carried out of the forms, clear of the work. No concrete shall be deposited 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-16 underwater nor shall the CONTRACTOR allow still water to rise on any concrete in such manner and at such velocity as will injure the surface finish of the concrete. Pumping or other necessary dewatering operations for removing ground water, if required, will be subject to the review of the ENGINEER. I. Corrosion Protection: Pipe, conduit, dowels, and other ferrous items required to be embedded in concrete construction shall be so positioned and supported prior to placement of concrete that there will be a minimum of 2-inches clearance between said items and any part of the concrete reinforcement. Securing such items in position by wiring or welding them to the reinforcement will not be permitted. J. Openings for pipes, inserts for pipe hangers and brackets, and the setting of anchors shall, where practicable, be provided for during the placing of concrete. K. Anchor bolts shall be accurately set, and shall be maintained in position by templates while being embedded in concrete. L. Cleaning: The surfaces of all metalwork to be in contact with concrete shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar, and other foreign substances immediately before the concrete is placed. 3.3 HANDLING, TRANSPORTING, AND PLACING A. General: Placing of concrete shall conform to the applicable requirements of ACI 301 and the requirements of this Section. B. Non-Conforming Work or Materials: Concrete which upon or before placing is found not to conform to the requirements specified herein shall be rejected and immediately removed from the work. Concrete which is not placed in accordance with these Specifications, or which is of inferior quality, shall be removed and replaced by and at the expense of the CONTRACTOR. C. No concrete shall be placed except in the presence of duly authorized representative of the INSPECTOR. The CONTRACTOR shall notify the INSPECTOR in writing at least 48 hours in advance of placement of any concrete. D. Placement in Wall Forms: Concrete shall not be dropped through reinforcement steel or into any deep form, whether reinforcement is present or not, causing separation of the coarse aggregate from the mortar on account of repeatedly hitting rods or the sides of the form as it falls, nor shall concrete be placed in any form in such a manner as to leave accumulation of mortar on the form surfaces above the placed concrete. In such cases, some means such as the use of hoppers and, if necessary, vertical ducts of canvas, rubber, or metal shall be used for placing concrete in the forms in a manner that it may reach the place of final deposit without separation. In no case shall the free fall of concrete exceed 4 feet below the ends of ducts, chutes, or buggies. Concrete shall be uniformly distributed during the process of depositing and in no case after depositing shall any portion be displaced in the forms more than 6 feet in horizontal direction. Concrete in forms shall be deposited in uniform horizontal layers not deeper than 2 feet; and care shall be taken to avoid inclined layers or inclined construction joints except where such are required for sloping members. Each layer shall be placed while the 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-17 previous layer is still soft. The rate of placing concrete in forms shall not exceed 5 feet of vertical rise per hour. E. Casting New Concrete Against Old: An approved epoxy adhesive bonding agent shall be applied to the old surfaces according to the manufacturer's written recommendations. This provision shall not apply to joints where waterstop is installed, see Section [03290], "Joints in Concrete". F. Conveyor Belts and Chutes: All ends of chutes, hopper gates, and all other points of concrete discharge throughout the CONTRACTOR'S conveying, hoisting and placing system shall be so designed and arranged that concrete passing from them will not fall separated into whatever receptacle immediately receives it. Conveyor belts, if used, shall be of a type acceptable to the ENGINEER. Chutes longer than 50 feet will not be permitted. Minimum slopes of chutes shall be such that concrete of the specified consistency will readily flow in them. If a conveyor belt is used, it shall be wiped clean by a device operated in such a manner that none of the mortar adhering to the belt will be wasted. All conveyor belts and chutes shall be covered. Sufficient illumination shall be provided in the interior of all forms so that the concrete at the places of deposit is visible from the deck or runway. G. Placement in Slabs: Concrete placed in sipping slabs shall proceed uniformly from the bottom of the slab to the top, for the full width of the pour. As the work progresses, the concrete shall be vibrated and carefully worked around the slab reinforcement, and the surface of the slab shall be screeded in an up-slope direction. H. Temperature of Concrete: The temperature of concrete when it is being placed shall be not more than 90 degrees F nor less than 40 degrees F in moderate weather, and not less than 50 degrees F in weather during which the mean daily temperature drops below 40 degrees F. Concrete ingredients shall not be heated to a temperature higher than that necessary to keep the temperature of the mixed concrete, as placed, from falling below the specified minimum temperature. If concrete is placed when the weather is such that the temperature of the concrete would exceed 90 degrees F, the CONTRACTOR shall employ effective means, such as preceding of aggregates and mixing water using ice or placing at night, as necessary to maintain the temperature of the concrete, as it is placed, below 90 degrees F. The CONTRACTOR shall be entitled to no additional compensation on account of the foregoing requirements. I. Cold Weather Placement: Earth foundations shall be free from frost or ice when concrete is placed upon or against them. Fly ash concrete shall not be placed when the air temperature falls below 50 degrees F. 3.4 PUMPING OF CONCRETE A. General: If the pumped concrete does not produce satisfactory end results, the CONTRACTOR shall discontinue the pumping operation and proceed with the placing of concrete using conventional methods. B. Pumping Equipment: The pumping equipment must have 2 cylinders and be designed to operate with one cylinder only in case the other one is not functioning. In lieu of this requirement, the CONTRACTOR may have a standby pump on the site during pumping. C. The minimum diameter of the hose (conduits) shall be 4-inches.* ' 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-1 8 D. Pumping equipment and hoses (conduits) that are not functioning properly, shall be >«%, replaced. E. Aluminum conduits for conveying the concrete will not be permitted. F. Proportioning: Minimum compressive strength, cement content, and maximum size of aggregates shall be as specified herein. G. Gradation of coarse aggregates shall conform to ASTM C 33 and shall be as close to the middle range as possible. H. Gradation of fine aggregate shall conform to ASTM C 33, with 15 to 30 percent passing the number 50 screen and 5 to 10 percent passing the number 100 screen. The fineness modulus of sand used shall not be over 3.00. I. Water and slump requirements shall conform to the requirements of this Section. J. Cement and admixtures shall conform to the requirements of this Section. K. Field Control: Concrete samples for slump per ASTM C 143 and test cylinders per ASTM C 31 and C 39. 3.5 ORDER OF PLACING CONCRETE A. The order of placing concrete in all parts of the work shall be acceptable to the ENGINEER. In order to minimize the effects of shrinkage, the concrete shall be placed in ^. units as bounded by construction joints shown. The placing of units shall be done by '^^ placing alternate units in a manner such that each unit placed shall have cured at least "***' 7 days before the contiguous unit or units are placed, except that the corner sections of vertical walls shall not be placed until the 2 adjacent wall panels have cured at least 14 days. B. The surface of the concrete shall be level whenever a run of concrete is stopped. To ensure a level, straight joint on the exposed surface of walls, a wood strip at least 3/4-inch thick shall be tacked to the forms on these surfaces. The concrete shall be carried about 1/2-inch above the underside of the strip. About one hour after the concrete is placed, the strip shall be removed and any irregularities in the edge formed by the strip shall be leveled with a trowel and all laitance shall be removed. 3.6 TAMPING AND VIBRATING A. As concrete is placed in the forms or in excavations, it shall be thoroughly settled and compacted, throughout the entire depth of the layer which is being consolidated, into a dense, homogeneous mass, filling all corners and angles, thoroughly embedding the reinforcement, eliminating rock pockets, and bringing only a slight excess of water to the exposed surface of concrete during placement. Vibrators shall be high speed power vibrators (8,000 to 10,000 rpm) of an immersion type in sufficient number and with (at least one) standby units as required. B. Care shall be used in placing concrete around waterstops. The concrete shall be carefully worked by rodding and vibrating to make sure that all air and rock pockets have "*^ been eliminated. Where flat-strip type waterstops are placed horizontally, the concrete 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-19 shall be worked under the waterstops by hand, making sure that all air and rock pockets have been eliminated. Concrete surrounding the waterstops shall be given additional vibration, over and above that used for adjacent concrete placement to assure complete embedment of the waterstops in the concrete. C. Concrete in walls shall be internally vibrated and at the same time rammed, stirred, or worked with suitable appliances, tamping bars, shovels, or forked tools until it completely fills the forms or excavations and closes snugly against all surfaces. Subsequent layers of concrete shall not be placed until the layers previously placed have been worked thoroughly as specified. Vibrators shall be provided in sufficient numbers, with standby units as required, to accomplish the results herein specified within 15 minutes after concrete of the prescribed consistency is placed in the forms. The vibrating head shall be kept from contact with the surfaces of the forms. Care shall be taken not to vibrate concrete excessively or to work it in any manner that causes segregation of its constituents. 3.7 FINISHING CONCRETE SURFACES A. General: Surfaces shall be free from fins, bulges, ridges, offsets, honeycombing, or roughness of any kind, and shall present a finished, smooth, continuous hard surface. Allowable deviations from plumb or level and from the alignment, profiles, and dimensions shown are defined as tolerances and are specified in Part 1, herein. These tolerances are to be distinguished from irregularities in finish as described herein. Aluminum finishing tools shall not be used. B. Formed Surfaces: No treatment is required after form removal except for curing, repair of defective concrete, and treatment of surface defects. Where architectural finish is required, it shall be as specified or as shown. C. Uniformed Surfaces: After proper and adequate vibration and tamping, all uniformed top surfaces of slabs, floors, walls, and curbs shall be brought to a uniform surface with suitable tools. The classes of finish specified for unformed concrete surfaces are designated and defined as follows: 1. Finish U1 - Sufficient leveling and screeding to produce an even, uniform surface with surface irregularities not to exceed 3/8-inch. No further special finish is required. 2. Finish U2 - After sufficient stiffening of the screeded concrete, surfaces shall be float finished with wood or metal floats or with a finishing machine using float blades. Excessive floating of surfaces while the concrete is plastic and dusting of dry cement and sand on the concrete surface to absorb excess moisture will not be permitted. Floating shall be the minimum necessary to produce a surface that is free from screed marks and is uniform in texture. Surface irregularities shall not exceed 1/4-inch. Joints and edges shall be tooled where shown or as determined by the ENGINEER. 3. Finish U3 - After the floated surface (as specified for Finish U2) has hardened sufficiently to prevent excess of fine material from being drawn to the surface, steel troweling shall be performed with firm pressure such as will flatten the sandy texture of the floated surface and produce a dense, uniform surface free 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-20 from blemishes, ripples, and trowel marks. The finish shall be smooth and free of all irregularities. 4. Finish U4 - Steel trowel finish (as specified for Finish U3) without local depressions or high points. In addition, the surface shall be given a light hairbroom finish with brooming perpendicular to drainage unless otherwise shown. The resulting surface shall be rough enough to provide a nonskid finish. D. Uniformed surfaces shall be finished according to the following schedule: UNIFORM SURFACE FINISH SCHEDULE '••>,»,&• ivj-U'-r-" - ."-,^.:^f, "Area - ' ' '~ • • - Grade slabs and foundations to be covered with concrete or fill material Floors to be covered with grouted tile or topping grout Slabs which are water bearing with slopes 10 percent and less Sloping slabs which are water bearing with slopes greater than 1 0 percent Slabs not water bearing Slabs to be covered with built-up roofing Interior slabs and floors to receive architectural finish Finish U1 U2 U3 U4 U4 U2 U2 E. Floor Sealer Hardener (Surface Applied): 1. Floors to receive hardener shall be cured, cleaned, and dry with all work above them completed. Apply zinc and/or magnesium fluosilicate evenly, using 3 coats, allowing 24 hours between coats. 2. The first coat shall be 1/3 strength, second coat 1/2 strength, and third coat 2/3 strength. Each coat shall be applied so as to remain wet on the concrete surface for 15 minutes. If sodium silicate is used, it shall be applied evenly, using 3 coats, allowing 24 hours between coats, and the material shall be applied full strength at the rate of one gallon per 300 square feet. Approved proprietary hardeners shall be applied in conformance with the manufacturer's instruction. After the final coat is completed and dry, surplus hardener shall be removed from the surface by scrubbing and mopping with water. 3. Floor hardener shall be applied where shown. 3.8 ARCHITECTURAL FINISH A. Smooth Concrete Finish: Immediately after the forms have been stripped, the concrete surface shall be inspected and all poor joints, voids, rock pockets, or other defective areas shall be repaired and all form-tie fastener holes filled as specified herein. B. After the concrete has cured at least 10 days, the surface shall be wetted, and a grout shall be applied with a brush. The grout shall be made by mixing one part Portland cement and one part of fine sand that will pass a No. 16 sieve with sufficient water to give it the consistency of thick paint. The cement used in said grout shall be 1/2 gray and 1/2 white portland cement, as determined by the ENGINEER. White portland cement shall be [Atlas white], or equal, furnished by the CONTRACTOR. Calcium chloride in the amount of 5 percent by volume of the cement shall be used in the brush coat. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE CONCRETE 03300-21 The freshly applied grout shall be vigorously rubbed into the concrete surface with a wood float filling all small air holes. After all the surface grout has been removed with a steel trowel, the surface shall be allowed to dry and, when dry, shall be vigorously rubbed with burlap to remove completely all surface grout so that there is no visible paint-like film of grout on the concrete. The entire cleaning operation for any area shall be completed the day it is started, and no grout shall be left on the surface overnight. C. Surface Overnight: Cleaning operations for any given day shall be terminated at panel joints. It is essential that the various operations to carefully timed to secure the desired effect which is a light-colored concrete surface of uniform color and texture without any appearance of a paint or grout film. D. Before beginning any of the final treatment on exposed surfaces, the CONTRACTOR shall treat in a satisfactory manner a trial area of at least 200 square feet in some inconspicuous place selected by the ENGINEER and shall preserve said trial area undisturbed until the completion of the job. E. All architecturally-treated concrete surfaces shall conform to the accepted sample in texture, color, and quality. It shall be the CONTRACTOR'S responsibility to maintain and protect the concrete finish. F. Sandblasted Concrete Finish: Sandblasting shall be done in a safe manner acceptable to local authorities, SCAQMD and per OSHA requirements. The sandblasting shall be a light sandblast to remove laitance and to produce a uniform fine aggregate surface texture with approximately 1/32- to 1/16-inch of surface sandblasted off. Corners, patches, form panel joints, and soft spots shall be sandblasted with care. The sandblasting work shall not proceed until after treatment of surface defects as specified herein, are completed. G. A 3-sq ft sample panel of the sandblasting finish shall be provided by the CONTRACTOR for acceptance by the ENGINEER prior to starting the sandblasting work. The sample panel shall include a corner, plugs, and joints and shall be marked after approval. All other sandblasting shall be equal in finish to the sample panel. H. Protection against sandblasting shall be provided on all surfaces and materials not requiring sandblasting but within or adjacent to areas being sandblasted. After sandblasting, the concrete surfaces shall be washed with clean water and excess sand removed. 3.9 CURING AND DAMPPROOFING General: All concrete shall be cured for not less than 10 days after placing, in accordance with the methods specified herein for the different parts of the work, and described in detail in the following paragraphs: 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-22 •>v, ,^.1; '.,?i-v?*"^T'? i«^^,iB«niiceao'WB-\*urtHi>,er-it»ainpproofea?t«i»^fss-^*,>> - •> Unstripped forms Wall sections with forms removed Construction joints between footings and walls, and between floor slab and columns Encasement concrete and thrust blocks All concrete surfaces not specifically provided for elsewhere in this paragraph Floor slabs on grade Roof and slabs not on grade Exterior buried surfaces of roof slabs [and basement walls] All liquid and water retaining structures , ; meinoa 1 6 2 3 4 5 6 7 2 Method 1: Wooden forms shall be wetted immediately after concrete has been placed arid shall be kept wet with water until removed. If steel forms are used, the exposed concrete surfaces shall be kept continuously wet until the forms are removed. If forms are removed within 10 days of placing the concrete, curing shall be continued in accordance with Method 6, herein. Method 2: The surface shall be covered with burlap mats which shall be kept wet with water for the duration of the curing period, until the concrete in the walls has been placed. No curing compound shall be applied to surfaces cured under Method 2. Method 3: The surface shall be covered with moist earth not less than 4 hours, nor more than 24 hours, after the concrete is placed. Earthwork operations that may damage the concrete shall not begin until at least 7 days after placement of concrete. Method 4: The surface shall be sprayed with a liquid curing compound. 1. Curing compound shall be applied in 2 coats according to the manufacturer's printed instructions. The direction of application of the second coat shall be perpendicular to the first. The second coat shall be applied when the first coat is dry to touch, but not to exceed 4 hours. Each coat shall be applied at a rate not more than 200 square feet per gallon and in such a manner as to cover the surface with a uniform film which will seal thoroughly. 2. Where the curing compound method is used, care shall be exercised to avoid damage to the seal during the curing period. The CONTRACTOR shall maintain and monitor the curing compound membrane for a minimum of 10 days. Should the seal be damaged or broken before the expiration of this curing period, the break shall be repaired immediately by the application of additional curing compound over the damaged portion. 3. Wherever curing compound may have been applied by mistake to surfaces against which concrete subsequently is to be placed and to which it is to adhere, said compound shall be entirely removed by wet sandblasting just prior to the placing of new concrete. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE CONCRETE 03300-23 4. Application of the curing compound to the concrete shall commence as soon as the finished surface of the concrete reaches a uniformly damp appearance with no free water on the surface. Curing compound shall also be applied no later than 2 hours after removal of forms from contact with formed surfaces or after the placement of concrete on the subgrade. At any point, the application rate shall be within 50 square feet per gallon of the nominal rate and the average application rate shall be within 25 square feet per gallon of the nominal rate specified when tested in accordance with California Test 535. 5. Repairs required to be made to formed surfaces shall be made within the said 2-hour period; provided, however, that any such repairs which cannot be made within the said 2-hour period shall be delayed until after the curing compound has been applied. When repairs are to be made to an area on which curing compound has been applied, the area involved shall first be wet-sandblasted to remove the curing compound, following which repairs shall be made as specified herein. 6. At the time of use, pigmented curing compounds shall be maintained in a thoroughly mixed condition. Containers of curing compound shall remain air-tight when not in use. 7. The CONTRACTOR shall apply curing compound in the presence of the INSPECTOR. Curing compound shall be applied to form a continuous and uniform membrane. Method 5: Immediately after the concrete has been screeded, it shall be treated with a liquid evaporation retardant. The retardant shall be used again after each work operation as necessary to prevent drying shrinkage cracks. 1. Immediately after each square foot of the concrete has been finished, it shall be given a coat of curing compound in accordance with Method 4, herein. Not less than one hour nor more than 4 hours after the coat of curing compound has been applied, the surface shall be wetted with water delivered through a fog nozzle, and concrete-curing blankets shall be placed on the slabs. The curing blankets shall be polyethylene sheet, polyethylene-coated waterproof paper sheeting or polyethylene-coated burlap. The blankets shall be laid with the edges butted together and with the joints between strips sealed with 2-inch wide strips of sealing tape or with edges lapped not less than 3-inches and fastened together with a waterproof cement to form a continuous watertight joints. 2. The curing blankets shall be left in place during the 10-day curing period and shall not be removed until after concrete for adjacent work has been placed. Should the curing blankets become torn or otherwise ineffective, the CONTRACTOR shall replace damaged sections. During the first 3 days of the curing period, no traffic of any nature and no depositing, temporary or otherwise, of any materials shall be permitted on the curing blankets. During the remainder of the curing period, foot traffic and temporary depositing of materials that impose light pressure will be permitted only on top of plywood sheets 5/8-inch minimum thickness, laid over the curing blanket. The CONTRACTOR shall add water under the curing blanket as often as necessary to maintain damp concrete surfaces at all times. 8/1 3/09 Contract No. 381 1 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-24 Method 6: Concrete slabs shall be treated with an evaporation retardant as specified in Method 5. The concrete shall be kept continuously wet by the application of water for a minimum period of at least 10 consecutive days beginning immediately after the concrete has been placed or forms removed. Heavy curing mats shall be used as a curing medium to retain the moisture during the curing period. The curing medium shall be weighted or otherwise held in place to prevent being dislodged by wind or any other causes. Until the concrete surface is covered with the curing medium, the entire surface shall be kept damp by applying water using nozzles that atomize the flow so that the surface is not marred or washed. The curing blankets and concrete shall be kept continuously wet by the use of sprinklers or other means both during and after normal working hours. Immediately after the application of water has terminated at the end of the curing period, the curing medium shall be removed and curing compound immediately applied in accordance with Method 4, herein. The CONTRACTOR shall dispose of excess water from the curing operation to avoid damage to the work. Method 7: 1. Method 6 shall be used for curing. 2. Immediately after completion of curing, the surface shall be sprayed with a dampproofing agent consisting of an asphalt emulsion. Application shall be in 2 coats. The first coat shall be diluted to 1/2 strength by the addition of water and shall be sprayed on so as to provide a maximum coverage rate of 100 square feet per gallon of dilute solution. The second coat shall consist of an application of the specified material, undiluted, and shall be sprayed on so as to provide a maximum coverage rate of 100 square feet per gallon. Dampproofing material shall be as specified herein. 3. As soon as the asphalt emulsion, applied as specified herein, has taken an initial set, the entire area thus coated shall be coated with whitewash. Any formula for mixing the whitewash may be used which produces a uniformly coated white surface and which so remains until placing of the backfill. Should the whitewash fail to remain on the surface until the backfill is placed, the CONTRACTOR shall apply additional whitewash. 3.10 PROTECTION The CONTRACTOR shall protect all concrete against injury until final acceptance by the CITY. Fresh concrete shall be protected from damage due to rain, hail, sleet, or snow. The CONTRACTOR shall provide such protection while the concrete is still plastic and whenever such precipitation is imminent or occurring. Immediately following the first frost in the fall, the CONTRACTOR shall be prepared to protect all concrete against freezing. After the first frost, and until the mean daily temperature in the vicinity of the worksite falls below 40 degrees F for more than one day, the concrete shall be maintained at a temperature not lower than 50 degrees F for at least 72 hours after it is placed. 3.11 CURING IN COLD WEATHER A. Water curing of concrete may be reduced to 6 days during periods when the mean daily temperature in the vicinity of the worksite is less than 40 degrees F; provided that, during 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-25 the prescribed period of water curing, when temperatures are such that concrete surfaces may freeze, water curing shall be temporarily discontinued. 6. Concrete cured by an application of curing compound will require no additional protection from freezing if the protection at 50 degrees F for 72 hours is obtained by means of approved insulation in contact with the forms or concrete surfaces; otherwise, the concrete shall be protected against freezing temperatures for 72 hours immediately following 72 hours protection at 50 degrees F. Concrete cured by water curing shall be protected against freezing temperatures for 3 days immediately following the 72 hours of protection at 50 degrees F. C. Discontinuance of protection against freezing temperatures shall be such that the drop in temperature of any portion of the concrete will be gradual and will not exceed 40 degrees F in 24 hours. In the spring, when the mean daily temperatures rises above 40 degrees F for more than 3 successive days, the specified 72-hour protection at a temperature not lower than 50 degrees F may be discontinued for as long as the mean daily temperature remains above 40 degrees F; provided, that the concrete shall be protected against freezing temperatures for not less than 48 hours after placement. D. Where artificial heat is employed, special care shall be taken to prevent the concrete from drying. Use of unvented heaters will be permitted only when unformed surfaces of concrete adjacent to the heaters are protected for the first 24 hours from an excessive carbon dioxide atmosphere by application of curing compound; provided, that the use of curing compound for such surfaces is otherwise permitted by these Specifications. 3.12 TREATMENT OF SURFACE DEFECTS A. As soon as forms are removed, all exposed surfaces shall be carefully examined and any irregularities shall be immediately rubbed or ground in a satisfactory manner in order to secure a smooth, uniform, and continuous surface. Plastering or coating of surfaces to be smoothed will not be permitted. No repairs shall be made until after inspection by the ENGINEER. In no case will extensive patching of honeycombed concrete be permitted. Concrete containing minor voids, holes, honeycombing, or similar depression defects shall have them repaired as specified herein. Concrete containing extensive voids, holes, honeycombing, or similar depression defects, shall be completely removed and replaced. All repairs and replacements herein specified shall be promptly executed by the CONTRACTOR at its own expense. B. Defective surfaces to be repaired shall be cut back from trueline a minimum depth of 1/2-inch over the entire area. Feathered edges will not be permitted. Where chipping or cutting tools are not required in order to deepen the area properly, the surface shall be prepared for bonding by the removal of all laitance or soft material, and not less than 1/32-inch depth of the surface film from all hard portions, by means of an efficient sandblast. After cutting and sandblasting, the surface shall be wetted sufficiently in advance of shooting with shotcrete or with cement mortar so that while the repair material is being applied, the surfaces under repair will remain moist, but not so wet as to overcome the suction upon which a good bond depends. The material used for repair purposes shall consist of a mixture of one sack of cement to 3 cubic feet of sand. For exposed walls, the cement shall contain such a proportion of Atlas white portland cement as is required to make the color of the patch match the color of the surrounding concrete. 8/13/09 Contract No. 3811 CAST-IN-PLACE CONCRETE PALOMAR AIRPORT ROAD WIDENING 03300-26 C. Holes left by tie-rod cones shall be reamed so as to leave the surfaces of the holes clean and rough. These holes then shall be repaired in an approved manner with non-shrink grout. Holes left by form-tying devices having a rectangular cross-section, and other imperfections having a depth greater than their least surface dimension, shall not be reamed but shall be repaired in an approved manner with non-shrink grout. D. All repairs shall be built up and shaped in such a manner that the completed work will conform to the requirements of this Section, as applicable, using approved methods which will not disturb the bond, cause sagging, or cause horizontal fractures. Surfaces of said repairs shall receive the same kind and amount of curing treatment as required for the concrete in the repaired section. E. Prior to filling any structure with water, all cracks that may have developed shall be repaired to the satisfaction of the ENGINEER. This repair method shall be done on the water bearing face of the members. Prior to backfilling, faces of members in contact with fill, which are not covered with a waterproofing membrane, shall also have cracks repaired as specified herein. 3.13 CARE AND REPAIR OF CONCRETE General: The CONTRACTOR shall protect all concrete against injury or damage from excessive heat, lack of moisture, overstress, or any other cause until final acceptance by the CITY. Particular care shall be taken to prevent the drying of concrete and to avoid roughening or otherwise damaging the surface. Any concrete found to be damaged, or which may have been originally defective, or which becomes defective at any time prior to the final acceptance of the completed work, or which departs from the established line or grade, or which, for any other reason, does not conform to the requirements of the Contract Documents, shall be satisfactorily repaired or removed and replaced with acceptable concrete at the CONTRACTOR'S expense. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 CAST-IN-PLACE CONCRETE 03300-27 SECTION 03370 CONCRETE CURING PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work as indicated on the Drawings and specified herein. B. This section covers the work necessary for the concrete curing requirements. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section 03300 Cast-ln-Place Concrete 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Comply with the reference specifications of the GENERAL REQUIREMENTS. B. The work of this section shall be performed in accordance with Standard Specifications for Public Works Construction Section 303-1.10. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the GENERAL PROVISIONS. 1.5 QUALITY ASSURANCE A. Quality Control Data: 1. Curing Compound: Manufacturer's Certification of Compliance, to include statement that product meets ASTM C 309, additional permeability requirement, and coverage. 2. Retardant for Exposed Aggregate Finish on Formed Surface: Manufacturer's Certification of Compliance including statement that product is suitable for and will meet job requirements. 3. Curing method, procedures and method of application to be used shall be in compliance with the requirements as specified herein. PART 2 - MATERIALS 2.1 CURING COMPOUND A. Curing compound shall consist of a liquid which, when applied to fresh concrete by means of a spray gun, will form an impervious membrane over the exposed surfaces of the concrete. 8/13/09 Contract No. 3811 CONCRETE CURING PALOMAR AIRPORT ROAD WIDENING 03370-1 B. The membrane may be either asphaltic or paraffin derivatives to which other waterproofing materials may have been added. Concrete curing compounds shall be designated by type as follows: Type 1 - Clear or translucent with red fugitive dye Type 2 - White pigmented Type 3 - Light gray pigmented Type 4 - Black pigmented C. All curing compounds shall be furnished by the Contractor and shall be delivered ready- mixed in sealed original containers bearing the manufacturer's name and product identification. D. Provide curing compound meeting requirements of ASTM C 309, with additional requirement that permeability not exceed 0.039 gm/square cm/72 hours. E. Provide evaporation retardant where required to prevent rapid evaporation of water from fresh exposed concrete. F. When pigmented curing compounds are used, at the time of use, the compound shall be thoroughly mixed, with the pigment uniformly dispensed throughout the mixture. G. Unless otherwise specified, Type 1 curing compound shall be used. ^^ 2.2 FLOOR HARDENER (SURFACE-APPLIED) A. Floor hardener shall be a colorless, aqueous solution of zinc and/or magnesium fluosilicate. B. Each gallon of fluosilicate solution shall contain minimum of 2 pounds of crystals. C. All hardeners shall be furnished by the CONTRACTOR and shall be delivered ready mixed in sealed original containers bearing the manufacturer's name and product identification. PART 3 - EXECUTION 3.1 CURING OF CONCRETE A. As soon after the completion of the specified finishing operations as the condition of the concrete will permit without danger of consequent damage thereto, all exposed surface shall either be sprinkled with water, covered with plastic sheet, or covered with earth, sand or burlap, or when not required to be painted, sprayed with Type 1 curing compound conforming with Article 1.1, Curing Compound of this section. B. Concrete that is water cured must be kept continuously wet for at least 10 days after being placed; preferably being covered, if possible, with at least two layers of not lighter ^^ than 7-ounce burlap. Handrail, base rail, railing posts, tops of walls, and similar parts of ***** 8/13/09 Contract No. 3811 CONCRETE CURING PALOMAR AIRPORT ROAD WIDENING 03370-2 the structure, if water cured, must be covered with burlap as prescribed above, immediately following the finishing treatment specified therefore, and such covering shall not be removed in less than 4 days. Roadway areas, floors, slabs, curbs, walks, and the like, that are water cured may be covered with sand to a depth of at least 2 inches in lieu of the burlap as prescribed above, as soon as the condition of the concrete will permit, and such covering shall remain wet and in place for at least 10 days, unless otherwise directed by the Engineer or prescribed by the Specifications. C. When an impervious membrane (curing compound) is used, it shall be applied under pressure through a spray nozzle in such manner and quantity as to entirely cover and seal all exposed surfaces of the concrete with a uniform film. The membrane shall not be applied to any surface until all of the finishing operations have been completed; such surfaces being kept damp, until the membrane is applied. All surfaces on which a bond is required, such as construction joint, shear planes, reinforcing steel, and the like, shall be adequately covered and protected before starting the application of the curing compound in order to prevent any of the compound from being deposited thereon; and any such surface with which the compound may have come in contact shall immediately thereafter be cleaned. Care shall be exercised to prevent any damage to the membrane seal during the curing period. Should the seal be damaged before the expiration of 10 days after the placing of the concrete, additional impervious membrane shall be immediately applied over the damaged area. D. The top surface of highway bridge decks shall be cured by both the curing compound method, and by the water method except that the curing compound shall be either Pigmented Curing Compound-Chlorinated Rubber Base Type (State Specification 8030- 71D-04), or Pigmented Curing Compound Chlorinated Rubber Base white or Tinted (State Specification 8030-71D-05). The curing compound shall be applied progressively during the deck finished operations immediately after finishing operations are completed on each individual portion of the deck. The water cure shall be applied not later than 4 hours after completion of deck finishing or, for portions of the decks on which finishing is completed after normal working hours, the water cure shall be applied not later than the following morning. E. Should any forms be removed sooner than 10 days after the placing of the concrete, the surface so exposed shall either be immediately sprayed with a coating of the curing compound, or kept continuously wet by the use of burlap or other suitable means until such concrete has cured for at least 10 days. F. When tops of walls are cured by the curing compound method, the side forms, except for metal forms, must be kept continuously wet for the 10 days following the placing of the concrete. G. If there is any likelihood of the fresh concrete checking or cracking prior to the commencement of the curing operations (due to weather conditions, materials used, or for any other reason), it shall be kept damp, but not wet, by means of an indirect fine spray of water until it is not likely that checking or cracking will occur, or until the curing operations are started in the area affected. 8/13/09 Contract No. 3811 CONCRETE CURING PALOMAR AIRPORT ROAD WIDENING 03370-3 3.2 CURING METHODS ^+± ',1 A. Walls: 1. General: Where walls are to receive coatings, painting, cementitious material, or other similar finishes, do not use curing compounds. Use only water curing procedures. 2. Method 1: Leave concrete forms in place and keep sufficiently damp at all times to prevent opening of joints and drying of concrete. 3. Method 2: Apply specified curing compound, where allowed, immediately after removal of forms. 4. Method 3: Continuously sprinkle exposed surfaces. B. Slabs, Curb, and Roadway Areas: 1. Method 1: Protect surface by ponding. 2. Method 2: Cover with two layers of burlap or cotton mats and keep continuously wet. 3. Method 3: Cover with 2-inch layer of wet sand, earth, or sawdust, and keep continuously wet. —<^^% 4. Method 4: Continuously sprinkle exposed surface. """^ 5. Other agreed upon method that will provide moisture to be present and uniform at all times on entire surface of slab. C. The Engineer will determine the permissible rate of coverage of a curing compound. 3.3 EVAPORATION RETARDANT APPLICATION A. Spray onto surface of fresh concrete immediately after screeding to react with surface moisture. B. Reapply after smoothing surface with a bull float to ensure continuous, compacted monomolecular layer until final finishing is completed. C. After finishing, apply water curing as specified. 3.4 CURING AND PROTECTION IN COLD WEATHER A. Concrete shall not be placed during cold weather where conditions would require procedures as specified in ACI 306. B. The Engineer, at his option, may allow cold weather placement of concrete if an extended period of cold weather is anticipated. *\ 3.5 CLEAR HARDENER APPLICATION (SURFACE APPLIED) ^, 8/13/09 Contract No. 3811 CONCRETE CURING PALOMAR AIRPORT ROAD WIDENING 03370-4 A. Before application, thoroughly cure floors to receive hardener for minimum 28 days, keep clean, unpainted, free from membrane curing compounds, and dry with all work above them completed. B. Do not use curing compounds where floor hardeners are specified. Use water curing only. C. Apply hardener evenly, using three coats, allowing 24 hours between coats as follows: 1. First Coat: 1/3 strength, second coat 1/2 strength, and third coat 2/3 strength, mix with water. 2. Apply each coat so as to remain wet on surface for 15 minutes. 3. Apply approved hardeners in accordance with manufacturer's instructions. 4. After final coat is completed and dry, remove surplus hardener from surface by scrubbing and mopping with water. 8/13/09 Contract No. 3811 CONCRETE CURING PALOMAR AIRPORT ROAD WIDENING 03370-5 SECTION 05500 MISCELLANEOUS METALWORK PART 1 - GENERAL 1.1 THE REQUIREMENT A. 1.2 A. B. The CONTRACTOR shall provide miscellaneous metalwork and appurtenances, complete and in place, in accordance with the Contract Documents. REFERENCE SPECIFICATIONS, CODES, AND STANDARDS Federal Specifications MIL-G-18015A(3) MIL-A-907E Commercial Standards AA-M32C22A41 AASHTO HS-20 AISC AISI ASTM A 36 ASTM A 48 ASTM A 53 ASTM A 123 ASTM A 153 ASTM A 193 ASTM A 194 ASTM A 307 ASTM A 325 ASTM A 500 8/13/09 PALOMAR AIRPORT ROAD WIDENING (Ships) Aluminum Planks (6063-T6) Antiseize Thread Compound, High Temperature Aluminum Assn. Truck Loading Manual of Steel Construction Design of Light Gauge, Cold-Formed Steel Structural Members Carbon Structural Steel Gray Iron Castings Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products Zinc Coating (Hot-Dip) on Iron and Steel Hardware Alloy Steel and Stainless Steel Bolting Materials for High Temperature Service Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes o 3 Contract No. 3811 MISCELLANEOUS METALWORK 05500-1 ASTM A 992 Steel for Structural Shapes for Use in Building Framing ANSI/AWS D1.1 Structural Welding Code - Steel ANSI/AWS D1.2 Structural Welding Code - Aluminum ANSI/AWS QC1 Qualification and Certification of Welding Inspectors 1.3 CONTRACTOR SUBMITTALS A. Shop Drawings: Shop Drawings of all miscellaneous metalwork shall be submitted in accordance with the GENERAL PROVISIONS Section 2-5.3.1. B. Layout drawings for grating shall be submitted showing the direction of span, type and depth of grating, size and shape of grating panels, seat angle details, and details of grating hold down fasteners. Load and deflection tables shall be submitted for each style and depth of grating used. C. An ICBO report listing the ultimate load capacity in tension and shear for each size and type of concrete anchor shall be submitted. CONTRACTOR shall submit manufacturer's recommended installation instructions and procedures for adhesive anchors. Upon review by ENGINEER, these instructions shall be followed specifically. D. No substitution for the indicated adhesive anchors will be considered unless accompanied with ICBO report verifying strength and material equivalency, including temperature at which load capacity is reduced to 90 percent of that determined at 75 degrees F. 1.4 QUALITY ASSURANCE A. All weld procedures and welder qualifications shall be available in the CONTRACTOR'S field office for review. B. All welding shall be inspected by a CONTRACTOR-furnished inspector qualified in accordance with AWS requirements and approved by the ENGINEER. PART 2 - PRODUCTS 2.1 GENERAL REQUIREMENTS A. Steel Wide Flange Shapes Shapes, Plates, Bars Pipe, Pipe Columns, Bollards HSS ASTM A 992 ASTM A 36 ASTM A 53, Type E or S, Grade B standard weight unless noted otherwise ASTM A 500 Grade B 8/13/09 Contract No. 3811 MISCELLANEOUS METALWORK PALOMAR AIRPORT ROAD WIDENING 05500-2 B. Corrosion Protection: Unless otherwise indicated, fabricated steel metalwork which will be used in a corrosive environment and/or will be submerged in water/wastewater shall be coated in accordance with Section 09800 - Protective Coating and shall not be galvanized prior to coating. All other miscellaneous steel metalwork shall be hot-dip galvanized after fabrication. C. Stainless Steel: Unless otherwise indicated, stainless steel metalwork and bolts shall be of Type 316 stainless steel. D. Aluminum: Unless otherwise indicated, aluminum metalwork shall be of Alloy 6061-T6. Aluminum in contact with concrete, masonry, wood, porous materials, or dissimilar metals shall have contact surfaces coated in accordance with Section 09800. E. Cast Iron: Unless otherwise indicated, iron castings shall conform to the requirements of ASTM A 48, Class SOB or better. 2.2 METAL STAIRS A. Metal Stairs: Metal stairs shall be composed of steel or aluminum stringers and supports, be fabricated in accordance with standard practice of the National Association of Ornamental Metal Manufacturers, and be as indicated. Steel stair members shall be hot-dip galvanized after fabrication. 2.3 GRATING STAIR TREADS A. Grating stair treads shall be designed to support a live load of 100 psf or a concentrated load at mid-span of 1000 pounds, whichever creates the higher stress. The maximum deflection due to the uniform live load shall be as required for metal grating below. All grating stair treads shall have an integral non-slip nosing. 2.4 SAFETY STAIR NOSINGS A. Safety stair nosing shall be provided on all concrete stairs and other locations as indicated. The nosing shall be 3-inch wide, extruded aluminum with cast-in abrasive strips and wing anchor with bolt and nut. The color of the cast abrasive shall be as selected by the ENGINEER from the manufacturer's standard colors. The nosing shall be American Safety Tread Company, Inc., Style "3511", equivalent product of American Abrasive Metals Company, or equal. 2.5 LADDERS A. Ladders which may be partially or wholly submerged, or which are located inside a hydraulic structure, shall be entirely of Type 316 stainless steel. All other ladders shall be of aluminum. B. Every ladder that does not have an exterior handhold shall be equipped with a pop-up extension. Pop-up extension device shall be manufactured of the same material and finish as the ladder with telescoping tubular section that locks automatically when fully extended. Upward and downward improvement shall be controlled by stainless steel spring balancing mechanisms. Units shall be completely assembled with fasteners for securing to the ladder rungs in accordance with the manufacturer's instructions. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 MISCELLANEOUS METALWORK 05500-3 2.6 METAL GRATING A. General: Metal grating shall be of the design, sizes, and types indicated. Grating shall be completely banded at all edges and cutouts using material and cross section equivalent to the bearing bars. Such banding shall be welded to each cut bearing bar. Grating shall be supported on all sides of an opening by support members. Where grating is supported on concrete, embedded support angles matching grating material shall be used on all sides, unless indicated otherwise. Such angles shall be mitered and welded at comers. 1. All pieces of grating shall be fastened in two locations to each support. 2. Where grating forms the landing at the top of a stairway, the edge of the grating, which forms the top riser, shall have an integral non-slip nosing, width equal to that of the stairway. 3. Where grating depth is not given, grating shall be provided which will be within allowable stress levels, and which shall not exceed a deflection of 1/4-inch or the span divided by 180, whichever is less. For standard duty plank, and safety grating, the loading to be used for determining stresses and deflections shall be the uniform live load of the adjacent floor or 100 psf, whichever is greater or a concentrated load of 1000 pounds. For heavy duty grating, the loading used for determining stresses and deflections shall be AASHTO HS-20. B. Material 1. Except where indicated otherwise, bar grating shall be fabricated entirely of aluminum as follows: Bearing and banding bars, alloy 6061-T6; cross bars, alloy 6063-T5. 2. Safety grating shall be fabricated of aluminum alloy 5052-H32. 3. Plank grating shall be fabricated of aluminum alloy 6063-T6. 4. Grating which may be partially or wholly submerged shall be fabricated entirely of stainless steel, Type 316. C. Standard-Duty Grating 1. No single piece of grating shall weigh more than 80 pounds, unless indicated otherwise. Standard duty grating shall be serrated bar grating. 2. Cross bars shall be welded or mechanically locked tightly into position so that there is no movement allowed between bearing and cross bars. D. Safety Grating 1. Safety grating shall be made of sheet metal punched into an open serrated diamond pattern and formed into plank sections. The open diamond shapes shall be approximately 1-7/8 inch by 11/16-inch in size. Safety grating shall be Grip Strut by Metal Products Division, United States Gypsum Company; Deck Span by I KG Industries, or equal. E. Plank Grating 8/13/09 Contract No. 3811 MISCELLANEOUS METALWORK PALOMAR AIRPORT ROAD WIDENING 05500-4 1. Plank grating shall be extruded in 6-inch widths with a minimum of 6 integral 1-bar type bearing bars per plank. The top surface shall be solid with raised ribs, unless indicated otherwise. Where punched grating is required, the top surface shall be provided with a pattern of S-inch by 19/32-inch rectangular openings spaced at 4 inches on center. The planks shall have continuous tongue and groove type interlock at each side, except that interlocking planks shall be arranged so that any 4-foot wide section may be removed independently from the other grating sections. 2. Plank grating shall be provided with a clear anodized finish, except that punched grating may have standard mill finish. 2.7 CHECKERED PLATE A. Checkered plate shall have a pattern of raised lugs on one face and shall be smooth on the opposite face. Lugs shall be a minimum of one inch in length and raised a minimum of 0.050 inch above the surface. The lugs shall be located in a pattern in which the lugs are oriented at 90 degrees from the adjacent lugs in two orthogonal directions. The rows of lugs shall be oriented at 45 degrees from the edges of the plates. B. Where no plate material is indicated on the Drawings, aluminum shall be provided. Unless indicated otherwise, the minimum plate thickness shall be as required to limit deflection resulting from a live load of 100 psf to 1/4-inch or the span divided by 240, whichever is less. 2.8 FLOOR HATCHES A. Where access hatches are mounted on a floor slab (including top slabs which are not covered with a roofing membrane) or on a concrete curb, the hatch shall be a flush type as indicated herein. Hatches mounted on a roof surface which has a membrane or other roofing material covering it shall be the integral raised curb type in accordance with Section 07720 - Roof Accessories. B. Hatches shall be fabricated from Aluminum 6061 T6, unless otherwise indicated. Hatch hardware shall be Type 316 stainless steel. Hatches shall be gutter-type; Bilco Type "J" or "JD" Babcock-Davis type "FT" or "AM" or equal. C. The design live load shall be 300 psf, unless indicated otherwise. D. Hatch opening sizes, number and swing direction of door leaves, and locations, shall be as indicated. Sizes are for the clear opening. Where the number of leaves is not given, openings larger than 42 inches in either direction shall have double-leaf doors. Unless indicated otherwise, hinges shall be located on the longer dimension side. Unless indicated otherwise, ladder hatches shall be a minimum of 30-inches wide by 36-inches long, with the ladder centered on the shorter dimension, and the door hinge opposite the ladder. E. Door leaves shall be a minimum of 1/4-inch thick checkered pattern plate. Channel frames shall be a minimum of 1/4-inch material with an anchor flange around the perimeter. Hatches shall be provided with an automatic hold-open arm with release handle. Hatches shall be designed for easy opening from both inside and outside. F. Hatches shall be designed to be water-tight and shall be equipped with a joint gutter and moat-type edge drain. A minimum of 1-1/2 inch diameter drain connection shall be provided, located by the manufacturer. 8/13/09 Contract No. 3811 MISCELLANEOUS METALWORK PALOMAR AIRPORT ROAD WIDENING 05500-5 G. Hatches for submersible pump stations shall include a unistrut channel around the frame perimeter. The face of the unistrut channel shall be flush with the face of the frame and be compatible with the upper guide rail bracket of the submersible wastewater pump manufacturer. H. Hatches shall include a recessed hasp for a padlock that is covered by a hinged lid flush with the surface. I. Unless indicated otherwise, hatch nets shall be installed on floor hatches. Hatch nets shall conform to OSHA requirements and shall be Hatch Net 121, as manufactured by Safe Approach, Inc., Auburn, ME, or equal. 2.9 IRON CASTINGS A. Iron castings shall be of uniform quality, free from blowholes, porosity, hard spots, shrinkage, distortion, or other defects. They shall be smooth and well cleaned by shotblasting. B. Covers and grates shall fit together evenly, so that the cover fits flush with the surrounding finished surface and so that the cover does not rock or rattle when loading is applied. Round covers and frames shall have machined bearing surfaces. C. Covers and grates with matching frames shall be designed to support the following loadings: 1. Where located within a structure, the design loading shall match that required for the adjacent floor area, or, if no floor loading is given, a minimum of 300 pounds per square foot. 2. Exterior covers and grates shall be designed for AASHTO HS-20 loading unless indicated otherwise. 2.10 BOLTS AND ANCHORS A. Standard Service (Non-Corrosive Application): Unless otherwise indicated, bolts, anchor bolts, washers, and nuts shall be of steel as indicated herein. Threads on galvanized bolts and nuts shall be formed with suitable taps and dies such that they retain their normal clearance after hot-dip galvanizing. Except as otherwise indicated, steel for bolt material, anchor bolts and cap screws shall be in accordance with the following: 1. Structural connections: ASTM A 307, Grade A or B, hot-dip galvanized. 2. Anchor Bolts: ASTM A 307, Grade A or B, or ASTM A 36, hot-dip galvanized. 3. High strength bolts where indicated: ASTM A 325. 4. Pipe and equipment flange bolts: ASTM A 193, Grade B-7. B. Corrosive Service: All bolts, nuts, and washers in the locations listed below shall be stainless steel as indicated below. 1. All buried locations. 8/13/09 Contract No. 3811 MISCELLANEOUS METALWORK PALOMAR AIRPORT ROAD WIDENING 05500-6 2. All submerged locations. 3. All locations subject to seasonal or occasional flooding. 4. Inside hydraulic structures below the top of the structure. 5. Inside buried vaults, manholes, and structures, which do not drain through a gravity sewer or to a sump with a pump. 6. All chemical handling areas. 7. Inside trenches, containment walls, and curbed areas. 8. Locations indicated by the Contract Documents or designated by the ENGINEER to be provided with stainless steel bolts. C. Unless otherwise indicated, stainless steel bolts, anchor bolts, nuts, and washers shall be Type 316 stainless steel, Class 2, conforming to ASTM A 193 for bolts and to ASTM A 194 for nuts. All threads on stainless steel bolts shall be protected with an antiseize lubricant suitable for submerged stainless steel bolts, to meet government specification MIL-A-907E. Buried bolts in poorly drained soil shall be coated the same as the buried pipe. D. Bolt Requirements 1. The bolt and nut material shall be free-cutting steel. 2. The nuts shall be capable of developing the full strength of the bolts. Threads shall be Coarse Thread Series conforming to the requirements of the American Standard for Screw Threads. All bolts and cap screws shall have hexagonal heads and nuts shall be Heavy Hexagon Series. 3. Bolts and nuts shall be installed with washers fabricated of material matching the base material of bolts; except that hardened washers for high strength bolts shall conform to the requirements of the AISC Specification. Lock washers fabricated of material matching the bolts shall be installed where indicated. 4. The length of each bolt shall be such that after the joint is made up, the bolt extends through the entire nut, but in no case more than 1/2-inch beyond the nut. E. Adhesive Anchors: Unless otherwise indicated, all drilled, concrete or masonry anchors shall be adhesive anchors. No substitutions will be considered unless accompanied with ICBO report verifying strength and material equivalency. 1. Epoxy adhesive anchors are required for drilled anchors for indoor installations, in submerged, wet, splash, overhead, and corrosive conditions, and for anchoring handrails and reinforcing bars. Epoxy shall comply with Section 03315 - Grout. Threaded rod shall be galvanized for general-purpose applications and stainless steel Type 316 for corrosive applications. Epoxy anchors shall not be permitted in areas where the concrete temperature is in excess of 100 degrees F or higher than the limiting temperature recommended by the manufacturer, whichever is lower. Epoxy anchors shall not be used where anchors are subject to vibration or fire. Embedment depth shall be as the manufacturer recommends for the load to be supported. 8/13/09 Contract No. 3811 MISCELLANEOUS METALWORK PALOMAR AIRPORT ROAD WIDENING 05500-7 2. Unless otherwise indicated, glass capsule, polyester resin adhesive anchors will be permitted in locations not included above and shall be Hilti HVA or Cobra Anchors. Threaded rod shall be galvanized steel. F. Expanding-Type Anchors: Expanding-type anchors if indicated or permitted, shall be galvanized steel expansion-type ITW Ramset/Redhead "Trubolt" anchors; McCullock Industries "Kwick-Bolt;" or equal. Lead caulking anchors will not be permitted. Size shall be as indicated. Embedment depth shall be as the manufacturer recommends for the load to be supported. Expansion-type anchors, which are to be embedded in grout, may be of steel. Non-embedded buried or submerged anchors shall be stainless steel. G. Non-Shrink Grouted Anchors: Anchors, if indicated or permitted, shall be grouted with a non-shrink cementitious grout in accordance with the manufacturer's recommendation. Embedment depth shall be as the manufacturer recommends for the load to be supported. Non-shrink grout material shall be Class B or C in accordance with Section 03315 - Grout. 2.11 POWDER-DRIVEN PINS A. Materials: Powder-driven pins for installation in concrete or steel shall be heat-treated steel alloy. If the pins are not inherently sufficiently corrosion-resistant for the conditions to which they are to be exposed, they shall be protected in an acceptable manner. Pins shall have capped or threaded heads capable of transmitting the loads the shanks are required to support. Pins that are connected to steel shall have longitudinal serrations around the circumference of the shank. 2.12 IMPACT ANCHOR A. Impact anchor shall be an expansion-type anchor in which a nail-type pin is driven to produce the expansive force. The pin shall have a zinc sleeve with a mushroom style head and stainless steel nail pin. Anchors shall be Metal Hit Anchors, manufactured by Hilti, Inc., Rawl Zamac Nailin, manufactured by the Rawlplug Company; or equal. PART 3 - EXECUTION 3.1 FABRICATION AND INSTALLATION REQUIREMENTS A. Fabrication and Erection: Except as otherwise indicated, the fabrication and erection of structural steel shall conform to the requirements of the American Institute of Steel Construction "Manual of Steel Construction." B. Floor Hatches: Unless otherwise indicated, the CONTRACTOR shall provide a 1/2-inch drain line to the nearest floor drain for all floor hatches. C. Powder-Driven Pins: Powder-driven pins shall be installed by a craftsperson certified by the manufacturer as being qualified to install the manufacturer's pins. Pins shall be driven in one initial movement by an instantaneous force that has been carefully selected to attain the required penetration. Driven pins shall conform to the following requirements where "D" = pin's shank diameter: 8/13/09 Contract No. 3811 MISCELLANEOUS METALWORK PALOMAR AIRPORT ROAD WIDENING 05500-8 •r.'.'iiyfaterialiA:^ Pe|ietrated '-^-'fl^'iPi n .-,:.'. Concrete Steel Material - Minimum - ; Thickness 16D 1/4-inch Pin Shank Penetration in Supporting • '•-- Material 6D minimum Steel thickness Minimum Space from Pin's CL to Edge of Penetrated Material 14D 4D Minimum Pin Spacing 20D 7D 3.2 WELDING A. Method: Welding shall be by the metal-arc method or gas-shielded arc method as described in the American Welding Society's "Welding Handbook" as supplemented by other pertinent standards of the AWS. Qualification of welders shall be in accordance with the AWS Standards governing it. B. Quality: In assembly and during welding, the component parts shall be adequately clamped, supported, and restrained to minimize distortion and for control of dimensions. Weld reinforcement shall be as indicated by the AWS Code. Upon completion of welding, weld splatter, flux, slag, and burrs left by attachments shall be removed. Welds shall be required to produce a workmanlike appearance, with uniform weld contours and dimensions. All sharp corners of material, which is to be painted or coated, shall be ground to a minimum of 1/32-inch on the flat. 3.3 GALVANIZING A. Structural steel plates, shapes, bars, and fabricated assemblies required to be galvanized shall, after the steel has been thoroughly cleaned of rust and scale, be galvanized in accordance with the requirements of ASTM A 123. Any galvanized part that becomes warped during the galvanizing operation shall be straightened. Bolts, anchor bolts, nuts and similar threaded fasteners, after being properly cleaned, shall be galvanized in accordance with the requirements of ASTM A 153. B. Field repairs to damaged galvanizing shall be made by preparing the surface and applying a coating. 1. Surface preparation shall consist of removing oil, grease, soil, and soluble material by cleaning with water and detergent (SSPC SP1) followed by brush off blast cleaning (SSPC SP7), over an area extended at least 4-inches in all directions into the undamaged area. 2. Coating shall be applied to at least 3 mils dry film thickness. Use Zinc-Clad XI by Sherwin-Williams, Galvax by Alvin Products, or Galvite by ZRC Worldwide. 3.4 DRILLED ANCHORS A. Drilled anchors and reinforcing bars shall be installed in strict accordance with the manufacturer's instructions. Holes shall be roughened with a brush on a power drill, cleaned and dry. Drilled anchors shall not be installed until the concrete has reached the required 28-day compressive strength. Adhesive anchors shall not be loaded until the adhesive has reached its indicated strength in accordance with the manufacturer's instructions. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 MISCELLANEOUS METALWORK 05500-9 SECTION 09900 PAINTING AND COATING PART 1 - GENERAL 1.1 DESCRIPTION This section described the requirements for the preparation of surfaces and subsequent application of protective coatings. The Contractor shall furnish all labor, materials and equipment required for satisfactory completion of all items contained herein. The Contractor shall furnish all necessary safety equipment and protective clothing, as well as be responsible for proper instruction and supervision of their use. Requirements for steel storage reservoirs are specified elsewhere in the Specifications. 1.2 RELATED WORK DESCRIBED ELSEWHERE The Contractor shall refer to the following Specification section(s) for additional requirements: A. General Piping System & Appurtenances: 15000 1.3 SUBMITTALS Contractor shall furnish submittals in accordance with the requirements described in General Provisions Section 2-5.3 Submittals. The following submittals are required: A. Submit a chart of the manufacturer's available colors for color selection well in advance of painting operation. B. Submit manufacturer's data sheets showing the following information: 1. Recommended surface preparation. 2. Minimum and maximum recommended dry-film thicknesses per coat for prime, intermediate, and finish coats. 3. Percent solids by volume. 4. Recommended thinners. 5. Statement verifying that the selected prime coat is recommended by the manufacturer for use with the selected intermediate and finish coats. 6. Application instructions including recommended application, equipment, humidity, and temperature limitations. 7. Curing requirements and instructions. C. Submit certification that all coatings conform to applicable local Air Quality Management District rules and regulations for products and application. 8/13/09 Contract No. 3811 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-1 1.4 PAYMENT Payment for the Work in this section shall be included as part of the lump-sum or unit-price bid amount for which such Work is appurtenant thereto. PART 2 - MATERIALS 2.1 GENERAL All materials shall be those of current manufacture and shall meet all applicable regulations for the application and intended service. All coats of any particular coating system shall be of the same manufacturer and shall be approved by the manufacturer for the intended service. In the event that a product specified herein is no longer manufactured or does not meet current regulations, the Contractor shall provide a substitute, currently manufactured product of at least equal performance which meets all applicable regulations subject to Engineer's approval, at no additional cost. All materials shall be delivered to the Project Site in their original, unopened containers bearing the manufacturer's name, brand, and batch number. Standard products of manufacturers other than those specified will be accepted when it is proved to the satisfaction of the Engineer they are equal in composition, durability, usefulness and convenience for the purpose intended. Paint listed in the system refers to products of the following manufacturers and distributors: Ameron Corrosion Control Division, Brea, CA I.C. Devoe, Louisville, KY Engard Coating Corporation, Long Beach, CA I. DuPont de Nemours & Company, Los Angeles, CA Tnemec Company, Inc., Kansas City, MO 64141 All surfaces to be coated or painted shall be in the proper condition to receive the material specified before any coating or painting is done. No more sandblasting or surface preparation than can be coated or painted in a normal working day will be permitted. All sharp edges, burrs, and weld spatter shall be removed. All concrete and masonry surfaces shall cure 30 days prior to coating or painting. Surface preparation, prime coatings, and finish coats for the various systems are specified herein. Unless otherwise noted, all intermediate and finish coats shall be of contrasting colors. It is the intent that the coating alternates specified herein serve as a general guide for the type of coating desired. 2.2 VALVES A. Exterior Coating: Coat metal valves located above ground, in vaults or in structures the same as the adjacent piping. If the adjacent piping is not coated, then coat valves per this Specification section unless otherwise noted. Apply the specified prime coat at the place of manufacture. Apply intermediate and finish coats in the field. Finish coat shall match the color of the adjacent piping. Coat handwheels and floor stands the same as the valves. Coat the exterior of buried metal valves at the place of manufacture per this specification. 8/1 3/09 Contract No. 381 1 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-2 B. Coating (Devoe Alternate): Prime coat shall be BarRust 231 or Devran 200 applied at 2 to 3 mils dry-film thickness. Intermediate coat shall be Devran 224H Epoxy applied at 2 to 4 mils dry-film thickness. Finish coat shall be 379 Urethane applied at 2 to 3 mils dry-film thickness. C. Interior Lining: Valves 4-inches and larger shall be coated on their interior metal surfaces excluding seating areas and bronze and stainless-steel pieces. Sandblast surfaces in accordance with SSPC-SP-10 (near white blast cleaning). Remove all protuberances which may produce pinholes in the lining. Round all sharp edges to be coated. Remove any contaminants which may prevent bonding of the lining. Coat the interior ferrous surfaces using one of the following methods: 1. Apply powdered thermosetting epoxy per the manufacturer's application recommendations to a thickness of 10 to 12 mils. 2. Apply two coats of polyamide epoxy to a dry-film thickness of 10 to 12 mils total. Follow the manufacturer's application recommendations including minimum and maximum drying time between the required coats. 3. Apply two coats of Tnemec Series 140 (for potable water) or Series 69 (for non- potable water), or equal, to a dry film thickness of 10 to 12 mils total. Follow manufacturer's application recommendations including minimum and maximum drying time between required coats. 4. Apply two coats of Devoe Bar-Rust 233H Epoxy applied to a dry-film thickness of 6 to 8 mils, each. Total dry-film thickness shall be 10 to 12 mils minimum. All epoxy lining shall be applied at the factory by the manufacturer of the valve, and shall meet current Volatile Organic Compound (VOC) content regulations. Epoxy lining for potable water valves shall also be listed by National Sanitation Foundation (NSF) for contact with potable water. Test the valve interior linings at the factory with a low-voltage holiday detector. The lining shall be holiday free. 2.3 METAL, INTERIOR AND EXTERIOR, NORMAL EXPOSURE A. General: The Contractor shall paint all exposed steelwork, non-galvanized handrails, exposed pipework, fittings, all mechanical equipment, pumps, motors, doors, door frames and window sash with this coating system. All metalwork previously given a shop prime coat approved by the Owner's Representative shall be touched up as required in the field with Tnemec Series 4 Versare Primer or equal. B. Surface Preparation: All exterior metal surfaces which are to be painted shall be commercial blast cleaned per Specification SP-6 (commercial blast cleaning) except as otherwise specified, in locations where sandblasting would damage previously coated surfaces and installed equipment, and in locations where dry sandblasting is prohibited. The above locations in which SP-6 commercial sandblasting is not possible shall be given a SP-3 power tool cleaning. This sandblasting shall be done not more than 8 hours ahead of the painting, subject to humidity and weather conditions between the time of sandblasting and painting operations. If any rusting or discoloration of sandblasted surfaces occurs before painting, such rusting or discoloration shall be removed by additional sandblasting. Sandblasted surfaces shall not be left overnight before painting. 8/13/09 Contract No. 3811 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-3 C. Coating (Tnemec Alternate): Prime coat or spot prime coat as required shall be Tnemec Series 4 Versare primer applied to a dry-film thickness of 2 to 3.5 mils. Two or more finish coats of Tnemec Series 2H Tneme-Gloss enamel shall be applied to a thickness of 1.5 to 3.5 mils. Total dry-film thickness of the complete system shall be 7 mils, minimum. D. Coating (Devoe Alternate): Prime coat or spot prime as required shall be 4140 Q.D. Alkyd Primer. Two or more finish coats of Devshield 4328 Alkyd applied to a dry-film thickness of 1.5 to 2 mils, each. Total dry-film thickness of the complete system shall be 5 mils, minimum. 2.4 METAL, SUBMERGED OR INTERMITTENTLY SUBMERGED A. General: All submerged metalwork, gates, equipment, valves, exposed pipework and all other metalwork within areas which will be submerged, except as noted hereinafter, shall be painted with this coating system. B. Surface Preparation: All metal surfaces shall be field sandblasted according to SSPC-SP- 10 (near white blast cleaning). C. Coating (Tnemec Alternate): Prime coat shall be Tnemec Series 69 Epoxoline II applied to a dry-film thickness of 4 to 6 mils. Two finish coats of Tnemec Series 69 Epoxoline II shall be applied to a dry-film thickness of 4 to 6 mils each coat. Total try-film thickness of the complete system shall be a minimum of 12 mils. D. Coating (Devoe Alternate): Apply two coats of Bar-Rust 233H Epoxy applied to a dry-film thickness of 6 to 8 mils each coat. Total dry-film thickness of the complete system shall be a minimum of 12 mils. 2.5 METAL, SEVERE EXPOSURE TO MOISTURE OR CHEMICAL FUMES A. Surface Preparation: All metal surfaces shall be field sandblasted according to SSPC-SP- 10 (near white blast cleaning). B. Coating (Tnemec Alternate): Prime coat shall be Tnemec Series 104 H.S. Epoxy to a dry- film thickness of 6 to 10 mils. One or more finish coats of Tnemec Series 104 H.S. Epoxy topcoat shall be applied. Total dry-film thickness shall be a minimum of 12 mils. C. Coating (Devoe Alternate): Prime coat shall be Catha-Coat 304V Zinc, 2 to 3 mils dry-film thickness. Intermediate coat shall be Devran 224H Epoxy applied at 4 to 6 mils dry-film thickness. Finish coat shall be Devthane 379 Urethane applied at 2 to 3 mils dry-film thickness. Total dry-film thickness shall be 8 mils minimum. 2.6 METAL, HIGH-TEMPERATURE EXPOSURE A. General: Engine mufflers, exhaust systems and other metal surfaces subjected to high temperatures shall be coated with this system. B. Surface Preparation: Surface shall be field sandblasted in accordance with SSPC-SP-10 (near white blast cleaning). 8/13/09 Contract No. 3811 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-4 C. Coating (Tnemec Alternate): One coat of Tnemec Series 90-96 Tneme-Zinc to a minimum total dry-film thickness of 2 to 3.5 mils. D. Coating (Devoe Alternate): One coat of Catha-Coat 304V Zinc to a dry-film thickness of 2 to 4 mils. 2.7 METAL, GALVANIZED, ALUMINUM, COPPER, OR BRASS A. Surface Preparation: Surfaces shall be solvent cleaned in accordance with SSPC-SP-1 (solvent cleaning) and SSPC-SP-2 (hand tool cleaning). B. Coating: Pre-treatment prime coat shall be Tnemec Series 32-1215 Tneme-Grip or Sinclair 7113 Wash Primer. Next, apply recommended coating or paint for the particular surface to be coated. C. Coating (Devoe Alternate): Pre-treatment prime coat shall be Devoe BarRust 231 primer applied at 3 mil dry-film thickness. Next, apply recommended coating or paint for the particular surface to be coated. 2.8 METAL, BURIED A. General: The Contractor shall coat all buried metal which includes valves, bolts, nuts, structural steel and fittings. It does not include steel storage reservoirs. B. Surface Preparation: Sandblast to SSPC-SP-6 (commercial blast cleaning) C. Coating (Tnemec Alternate): Prime none. Finish with two coats of Tnemec Series 46-465 H.B. Tnemecol or equal at 10 to 12 mils dry-film thickness, each. Total dry-film thickness shall be 20 mils minimum. D. Coating (Devoe Alternate): Prime with Devtar 221 (5A) Epoxy applied at 8 mil dry-film thickness. Two coats of Devtar (5A) Epoxy applied at 8 mils dry-film thickness, each. Total dry-film thickness shall be 24 mils, minimum. PART 3 - EXECUTION 3.1 GENERAL The Contractor shall arrange with the Owner's Representative so that all surface preparation may be inspected and approved prior to the application of any coatings. The Contractor is hereby notified that the Engineer will inspect the Work prior to the expiration of the warranty period and all defects in workmanship and material shall be repaired by the Contractor, at his own expense. 8/13/09 Contract No. 3811 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-5 3.2 WORKMANSHIP It is the intent of the Specifications that finishes shall be provided which meet standards for best grades of painting. Drop cloths shall be placed where required to protect floors, surfaces and equipment from spatter and dropping, not to receive paint or coatings. The Contractor shall take all necessary precautions to protect all adjacent Work and all surrounding property and improvements from any damage whatsoever as a result of the painting and coating operation. Only good, clean brushes and equipment shall be used and all brushes, buckets, and spraying equipment shall be cleaned immediately at the end of each painting period. Each coat of paint shall be of the consistency as supplied by the manufacturer, or thinned, if necessary, and applied in accordance with manufacturer's instructions. Each coat shall be well brushed, rolled or sprayed to obtain a uniform and evenly applied finish. Work shall be free from "runs", "bridges", "shiners", or other imperfections due to faulty intervals. Particular care shall be taken to obtain a uniform unbroken coating over all bolts, threads, nuts, welds, edges and comers. Paint shall not be applied in extreme heat, in dust or smoke laden air, or in damp or humid weather, unless written permission of the Engineer is obtained. If paint is applied by spray, the air pressure used shall be within the ranges recommended by both the paint and spray equipment manufacturers. Spray painting shall be conducted under controlled conditions and the Contractor shall be fully responsible for any damage occurring from spray painting. Care shall be exercised not to damage adjacent Work during sandblasting operations. Stainless steel need not be sandblasted. Blasted surfaces shall not be left overnight before coating. All dust shall be removed from the surface following sandblasting. 3.3 APPLICATION PROCEDURES A. Surfaces to be Coated: All surfaces of materials furnished and constructed are to be painted or coated per the Specifications except as indicated below. B. Surfaces Not To Be Coated: The following surfaces shall not be coated unless otherwise noted on the Plans and shall be fully protected when adjacent areas are painted. Aluminum grating Grease fittings Nameplates on Aluminum surfaces Hardware machinery Bearings Lighting fixtures Machined Pipe interior* Brass and copper tubing, surfaces Shafts submerged* Metal letters Stainless steel Buried pipe Mortar-coated pipe and fittings Switch plates Couplings * unless specifically required on the Plans or elsewhere in the Specifications C. Protection of Surfaces Not To Be Coated: Surfaces not intended to be painted shall be removed, masked, or otherwise protected. Drop cloths shall be provided to prevent paint materials from falling on or marring adjacent surfaces. Working parts of mechanical and electrical equipment shall be protected from damage during surface preparation and painting process. Openings in motors shall be safely masked to prevent paint and other materials from entering the motors. All masking materials shall be completely removed and surfaces cleaned at completion of painting operations. 8/13/09 Contract No. 3811 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-6 D. Weather Conditions: Paint shall not be applied in the rain, wind, snow, mist, and fog or when steel or metal surface temperatures are less than 5°F above the dew point. Paint shall not be applied when the relative humidity is above 80%, the air temperature is above 90°F, or the temperature of metal to be painted is above 125°F. Alkyd, chlorinated rubber, inorganic zinc, silicone aluminum, or silicone acrylic paints shall not be applied if air or surface temperature is below 50°F or expected to be below 50°F within 24 hours. Epoxy, coal tar epoxy, acrylic latex, and polyurethane paints shall not be applied on an exterior or interior surface if air or surface temperature is below 50°F or expected to drop below 50°F within 24 hours. 3.4 SURFACE PREPARATION A. General: Sandblast or prepare only as much surface area as can be coated in one day. All sharp edges, burrs, and weld spatter shall be removed. Epoxy-coated pipe that has been factory coated shall not be sandblasted. B. SSPC Specifications: Wherever the words "solvent cleaning", "hand tool cleaning", "wire brushing", or "blast cleaning" or similar words are used in the Specifications or in paint manufacturer's specifications, they shall be understood to refer to the applicable SSPC (Steel Structures Paint Council, Surfaces Preparation Specifications, ANSI A159.1) Specifications listed below: SP-1 Solvent Cleaning SP-6 Commercial Blast Cleaning SP-2 Hand Tool Cleaning SP-7 Brush-Off Blast Cleaning SP-3 Power Tool Cleaning SP-8 Pickling SP-5 White Metal Blast Cleaning SP-10 Near White Blast Cleaning Oil and grease shall be removed from aluminum and copper surfaces in accordance with SSPC SP-1 using clean cloths and cleaning solvents. Weld spatter and weld slag shall be removed from metal surfaces. Rough welds, beads, peaked corners, and sharp edges including erection lugs shall be ground smoothly in accordance with SSPC SP-2 and SSPC SP-3. Welds shall be neutralized with a chemical solvent that is compatible with the specified coating materials using clean cloths and chemical solvent. C. Abrasive Blast Cleaning: Dry abrasive blast cleaning shall be used for metal surfaces. Do not recycle or reuse contaminated blast particles. Dry clean surfaces to be coated by dusting, sweeping, and vacuuming to remove residue from blasting. Apply the specified primer or touch-up coating within the period of an 8-hour working day. Do not apply coating over damp or moist surfaces. Reclean prior to application of primer or touch-up coating any blast cleaned surface not coated within said 8-hour period. Prevent damage to adjacent coatings during blast cleaning. Schedule blast cleaning and coating such that dust, dirt, blast particles, old coatings, rust, mill scale, etc., will not damage or fall upon wet or newly coated surfaces. 8/13/09 Contract No. 3811 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-7 3.5 PROCEDURES FOR THE APPLICATION OF COATINGS The recommendations of the coating manufacturer shall be followed, including the selection of spray equipment, brushes, rollers, cleaners, thinners, mixing, drying time, temperature and humidity of application, and safety precautions. Coating materials shall be kept at a uniform consistency during application. Each coating shall be applied evenly, free of brush marks, sags, runs, and other evidence of poor workmanship. A different shade or tint shall be used on succeeding coating applications to indicate coverage where possible. Finished surfaces shall be free from defects or blemishes. Only thinners recommended by the coating manufacturer shall be used. If thinning is allowed, do not exceed the maximum allowable amount of thinner per gallon of coating material. Apply a brush coat of primer on welds, sharp edges, nuts, bolts, and irregular surfaces prior to the application of the primer and finish coat. The brush coat shall be done prior to and in conjunction with the spray coat application. Apply the spray coat over the brush coat. Apply primer immediately after blast cleaning and before any surface rusting occurs, or any dust, dirt, or any foreign matter has accumulated. Reclean surfaces by blast cleaning that have surface colored or become moist prior to coating application. A. Paint Mixing: Multiple-component coatings shall be prepared using all the contents of each component container as packaged by the paint manufacturer. Partial batches shall not be used. Multiple-component coatings that have been mixed beyond their pot life shall not be used. Small quantity kits for touch-up painting and for painting other small areas shall be provided. Only the components specified and furnished by the paint manufacturer shall be mixed. For reasons of color or otherwise, additional components shall not be intermixed, even within the same generic type of coating. B. Field Touch Up of Shop-Applied Prime Coats: Organic Zinc Primer: Surfaces that are shop primed with inorganic zinc primers shall receive a field touch up of organic zinc primer to cover all scratches or abraded areas. Organic zinc coating system shall have a minimum volume solids of 54% and a minimum zinc content of 14 pounds per gallon. Coating shall be of the converted epoxy, epoxy phenolic, or urethane type and shall be manufactured by the prime coat and finish coat manufacturer. Other Primers: Surfaces that are shop primed with other than organic zinc primer shall receive a field touch up of the same primer used in the original prime coat. 3.6 DRY-FILM THICKNESS TESTING AND REPAIR A. Special Instructions to the Contractor: The Contractor shall furnish to the Owner at no charge for use during execution of the Work, necessary dry-film thickness gauge and electrical flaw detection equipment. The Contractor shall perform the holiday (pinholes) inspection in the presence of the Owner's Representative, and the Contractor shall monitor wet film measurements throughout the application of each coat of coating. 8/13/09 Contract No. 3811 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-8 B. Coating Thickness Testing: Coating thickness specified for steel surfaces shall be measured with a magnetic-type dry-film thickness gauge. Dry-film thickness gauge shall be provided as manufactured by Mikrotest or Elcometer. Each coat shall be checked for the correct dry-film thickness. Measurement shall not be made until a minimum of eight hours after application of the coating. Non-magnetic surfaces shall be checked for coating thickness by micrometer measurement of cut and removed coupons. Contractor shall repair coating at all locations where coupons are removed. C. Holiday Testing: The finish coat (except zinc primer and galvanizing) shall be tested by the Contractor in the presence of the Engineer for holidays and discontinuities with an electrical holiday detector of the low-voltage, wet-sponge type. Detector shall be provided as manufactured by Tinker, Rasor, K-D Bird Dog, or approved equal. D. Repair: If the item has an improper finish, color, insufficient film thickness, or holidays, the surface shall be cleaned and top-coated with the specified paint material to obtain the specified color and coverage. Visible areas of chipped, peeled, or abraded paint shall be hand or power-sanded, feathering the edges. The areas shall then be primed and finish coated in accordance with the Specifications. Work shall be free of runs, bridges, shiners, laps, or other imperfections. 3.7 CLEANUP Upon completion of all painting and coating Work, the Contractor shall remove all surplus materials and rubbish. The Contractor shall repair all damage and shall leave the premises in a clean and orderly condition. 8/13/09 Contract No. 3811 PAINTING & COATING PALOMAR AIRPORT ROAD WIDENING 09900-9 SECTION 09902 PETROLATUM WAX TAPE COATING PART 1 - GENERAL 1.1 SCOPE This section covers the work necessary to furnish and install petrolatum wax tape coating on pipe, pipe flanges, fittings or other buried pipeline appurtenances, complete, as indicated on the drawings and specified herein. 1.2 SUBMITTALS DURING CONSTRUCTION Submit manufacturer's technical product data, details, installation instructions and general product recommendations. 1.3 PRODUCT IDENTIFICATION The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired only. Products of other manufacturers will be considered in accordance with the Contract Documents. PART 2 - MATERIALS 2.1 GENERAL Wrap all exposed surfaces of buried ferrous pipe, flanges, couplings and other pipeline appurtenances (including bolts, nuts, etc.) with petrolatum wax tape, unless another corrosion protection system (other than a factory-installed paint coating) is otherwise specified or indicated by the Contract Drawings. Exposed piping shall be wrapped only where specifically called out on the Drawings. Ductile iron pipe encased with polyethylene sheathing shall not be wrapped with this product. 2.3 PRIMER Exposed surfaces shall be prime coated with a blend of petrolatum, plasticizer, and corrosion inhibitor having a paste-like consistency. The material shall have the following properties: Pour Point Flash Point Approximate Coverage Color 400-100° F 350° F minimum 1 gal/100 square feet Brown The primer shall be Trenton Wax-Tape Primer or equivalent. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 PETROLATUM WAX TAPE COATING 09902-1 2.3 WAX TAPE Two types of petrolatum wax tape shall be available from the manufacturer: one type for buried installations and another type for above-ground installations. A. Buried Installations: The covering material shall be a plastic-fiber felt tape, saturated with a blend of petrolatum, plasticizers, and corrosion inhibitors that is easily formable over irregular surfaces. The tape shall have the following properties: Color: Brown Saturant Pour Point 115° - 125°F Thickness 70-90 mils Dielectric Strength 170 volts/mil Tape Width 6 inches Wax tape shall be Wax-Tape #1 as manufactured by The Trenton Corporation (Ann Arbor, Michigan), or approved equal. 2.4 OUTER COVERING The primed and wax-tape wrapped surface shall be wrapped with a plastic tape covering consisting of three (3) layers of 50 gauge, clear, polyvinylidene chloride, high cling membranes wound together as a single sheet. The material shall have the following properties: Width 6 inches Thickness 1.5 mils Dielectric Strength 2000 volts/mil Water Absorption Negligible Color Clear The outer covering shall be Trenton Poly-Ply or approved equal. 2.5 OTHER PETROLATUM WAX TAPE SYSTEM COMPONENTS Any components not listed above, but required for a complete petrolatum wax tape coating system as recommended for this application by the manufacturer shall be provided at no additional cost to Owner. PART 3 - EXECUTION 3.1 GENERAL The petrolatum wax tape system shall be installed in conformance with the manufacturer's recommendations. 8/13/09 Contract No. 3811 PETROLATUM WAX TAPE COATING PALOMAR AIRPORT ROAD WIDENING 09902-2 SECTION 10900 OVERHEAD SIGN STRUCTURE PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall use the 2006 Caltrans Standard Specifications for all work related to the Caltrans Truss Sign Structure including foundations, sign structure, guide signs, and lighting. REFERENCE STANDARDS A. Caltrans Standard Specification Section 49: Piling B. Caltrans Standard Specification Section 52: Reinforcement Caltrans Standard Specification Section 55: Steel Structures Caltrans Standard Specification Section 56: Signs 1.2 1.3 1.4 C. D. E.Caltrans Standard Specification Section 86: Signals, Lighting and Electrical Systems SUBMITTALS A. Submittals shall be made in accordance with GENERAL PROVISIONS and as required per the Caltrans Specifications. B. The CONTRACTOR may submit the Caltrans Standard spread footing design for consideration. The spread footing design submittal shall include all the necessary calculations and assumptions performed by a licensed Engineer in the state of California. The calculations and drawings shall be submitted to Engineer for approval. The bids for this portion of work shall be based on the assumption that pile foundations will be used. PAYMENT A. Payment for the Work in this section shall be included a part of the lump-sum or unit-price bid amount for which such Work is appurtenant thereto. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 OVERHEAD SIGN STRUCTURE 10900-1 SECTION 15000 GENERAL PIPING SYSTEM AND APPURTENANCES PART 1 - GENERAL 1.1 DESCRIPTION This Section describes the requirements and procedures for piping systems and appurtenances that apply to a number of other complimentary Specification Sections. The items are listed in this Section to avoid repetition in Sections elsewhere. This Section includes, but is not limited to: Temporary above ground piping (high line), wet taps, flexible pipe couplings, grooved and shouldered end couplings, joint restraint system, field touch up, bolts, nuts, polyethylene wrap, warning/identification tape, tracer wire, gate well and extension stems, meter boxes, abandonment and removal of existing facilities, and salvage. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. A. American National Standards Institute (ANSI) B. American Society for Testing and Materials (ASTM) 1.3 RELATED WORK SPECIFIED ELSEWHERE A. CMWD Standard Drawings B. SECTIONS 15041, 15044 AND 15056 1.4 SUBMITTALS Submit manufacturers' catalog data showing dimensions, materials of construction by ASTM reference and grade and coatings. 1.5 LINING CONTAMINATION PREVENTION Volatile organic compounds present in the linings of items in contact with potable water or recycled water shall not exceed concentrations allowed by the latest requirements of the State Office of Drinking Water and Department of Health Services. Some products and materials may also require proof of NSF certification on the lining materials to be used. 1.6 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) High line piping, where shown on the Approved Plans or required by the District Engineer, shall be furnished, installed, disinfected, connected, maintained, and removed by the Contractor. Bacteriological sampling and testing shall be performed by a State of California Certified testing laboratory. The Contractor shall provide a submittal to the 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-1 District showing pipe layout, materials, sizing, flow calculations, schedule and duration of use, and disinfection for all high line piping. The submittal shall be reviewed and approved by the Engineer prior to ordering or delivery of any materials. 1.7 PIPE TAPPING (WET TAP) All pipe tap (wet tap) connections to existing pipelines, whether for mainline extensions or service laterals, shall be performed by the Contractor under the inspection of the District. The Contractor shall provide materials and labor to excavate, pour thrust block, backfill, compact, and repair pavement as indicated in this Section. 1.8 JOINT RESTRAINT SYSTEM Joint Restraint Systems may be used for PVC or ductile-iron pipe only with prior approval of the District Engineer. Joint restraint systems shall be used in the place of, or in conjunction with, concrete thrust blocks as directed. Contractor shall submit shop drawings, calculations, and catalog data for joint restraint systems. Splined gaskets, also known as joint restraint gaskets, may be used for PVC or ductile- iron pipe located within casings, or for PVC pipe casings, only. 1.9 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be used for all ferrous metal materials not otherwise protectively coated. A. Polyethylene wrap shall be used for the protection of buried ductile-iron fittings and valves. B. Polyethylene sleeves shall be used for the protection of buried ductile iron pipe. C. Polyethylene wrap or sleeves may also be installed around buried PVC pipe for recycled water identification. 1.10 WARNING/IDENTIFICATION TAPE Warning/identification tape shall be used to identify location of underground utilities and to act as a warning against accidental dig-ins of buried utilities. Warning/identification tape shall be used on all underground water and recycled water mains, potable and recycled water irrigation systems, sewer mains, and all related appurtenances. Warning/identification tape shall also be used on cathodic protection wiring systems and tracer wire brought into and out of access ports. 1.11 GATE WELLS Gate Wells shall be used for buried valves 50mm (4") and larger, unless otherwise indicated on the Standard Drawings. Gate well box and lid shall be used on all gate wells. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES 15000-2 1.12 VALVE STEM EXTENSION Valve Stem Extensions shall be installed when the valve operating nut is more than 1.5m (5') below grade. Stem extensions shall be of sufficient length to bring the operating nut to a point between 300mm (12") and 450mm (18") below the gate well lid. 1.13 METER BOXES A. Meter boxes shall be used for 25mm (1") and 50mm (2") water meters. B. Meter boxes shall be sized for the specific meter size or size as indicated on the Standard Drawings. 1.14 RECYCLED WATER IDENTIFICATION Facilities installed for the use of recycled water shall be identified with purple color coating, identification labels, or signs. 1.15 CURB IDENTIFICATION MARK FOR SERVICES The Contractor shall mark the location of all potable water, recycled water and sewer laterals at the curb crossing by stamping the face of the curb in 50mm (2") high letters as described below: A. Potable water laterals shall be stamped with a letter "W". B. Recycled water laterals shall be stamped with a letter "RW". C. Sewer laterals be stamped with a letter "S". PART 2 - MATERIALS 2.1 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) High line piping layout, materials and appurtenances shall be as indicated on the approved submittal. 2.2 FLEXIBLE PIPE COUPLINGS Flexible pipe couplings shall be in accordance with the Approved Materials List and as described below: A. Steel Couplings shall have middle rings made of steel conforming to ASTM A 36/A 36M, A 53 (Type E or S), or A 512 having a minimum yield strength of 207 MPa (30,000 psi). Follower rings shall be ductile-iron per ASTM A 536, or steel per ASTM A 108, Grade 1018 or ASTM A 510, Grade 1018. Minimum middle ring length shall be 175 mm (7") for pipe sized 150 mm (6") through 600 mm (24"). B. Sleeve bolts shall be made of stainless steel per ASTM A193 and shall have a minimum yield strength of 276 MPa (40,000 psi), an ultimate yield strength of 414 MPa (60,000 psi), and shall conform to AWWA C111. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-3 2.3 GROOVED END OR SHOULDERED COUPLINGS FOR DUCTILE IRON OR A STEEL PIPE ^J Groove end or shouldered couplings shall be in accordance with the Approved Materials List and as described below: A. Use square-cut shouldered or grooved ends per AWWA C606. Grooved-end couplings shall be malleable iron per ASTM A 47, or ductile iron per ASTM A 536. Gaskets shall be per ASTM D 2000. B. Bolts in exposed service shall conform to ASTM A 183, 69 MPa (10,000 psi) tensile strength. 2.4 JOINT RESTRAINT SYSTEM Joint Restraint Systems shall be ductile-iron and shall consist of a split-ring restraint with machined (not cast) serrations - on the inside diameter, a back-up ring, and connecting bolts, and shall be selected from the Approved Materials List. Splined gaskets, also known as joint restraint gaskets, shall be a rubber-ring type with stainless steel locking segments vulcanized into the gasket. 2.5 FIELD TOUCH-UP APPLICATIONS All surfaces of metallic appurtenances in contact with potable water and not protected ,**t. from corrosion by another system shall be shop-coated by the manufacturer. Appurtenances with damaged coatings shall be repaired or replaced as directed by the "**"*" Engineer. Touch-up of damaged surfaces, when allowed by the Engineer, shall be performed in accordance with the manufacturer's recommendations. 2.6 BOLTS AND NUTS Bolts and nuts shall be as indicated below. A. Cadmium-plated or zinc-plated bolts and nuts shall be used for the installation of pipelines up to 500mm (20") diameter and shall be carbon steel conforming to ASTM A307, Grade A, unless otherwise indicated on the approved drawings. Bolts shall be standard ANSI B1.1, Class A coarse threads. Nuts shall be standard ANSI B1.1, Class 2H coarse threads. B. Stainless steel bolts and nuts shall be used for the installation of pipelines 600mm (24") diameter and larger and for submerged flanges. Bolts and nuts shall be Type 316 stainless steel conforming to ASTM A193, Grade B8M for bolts, and Grade 8M for nuts. Use lubricant for stainless steel belts and nuts. Lubricant shall be Husky Lube "O" Seal by Husk-ITT Corporation or equal C. All bolt heads and nuts shall be hexagonal, except where special shapes are required. Bolts shall be of such length that not less than 6.4mm (1/4") or more than 12.7mm (1/2") shall project past the nut in tightened position. ^^ 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-4 D. Provide a washer under each nut and under each bolthead. Use washers of the same materials as the nuts. 2.7 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be as indicated below and shall be selected from the Approved Materials List. Polyethylene materials shall be kept out of direct sunlight exposure. A. Polyethylene sleeves shall be a minimum 0.305mm (0.012" or 12 mil) thick polyethylene plastic in accordance with AVWVA C105. B. Polyethylene wrap shall be a minimum 0.203mm (0.008" or 8 mil) thick polyethylene plastic in accordance with AWWA C105. C. Polyethylene wrap and sleeves shall be clear for use with potable water and purple for use with recycled water. D. Polyethylene or vinyl adhesive tape a minimum of 50mm (2") wide or plastic tie straps shall be used to secure polyethylene encasement. 2.8 WARNING/IDENTIFICATION TAPE Warning/identification tape shall be as indicated below and in accordance with the Approved Materials List. A. Tape shall be an inert plastic film or metallic formulated for prolonged underground use that will not degrade when exposed to alkalies, acids and other destructive substances commonly found in soil. B. Tape shall be puncture-resistant and shall have an elongation of two times its original length before parting. C. Tape shall be colored to identify the type of utility intended for identification. Printed message and tape color shall be as follows: Printed Message Tape Color Caution: Waterline Buried Below Blue Caution: Recycled Waterline Buried Below Purple Caution: Cathodic Protection Cable Buried Below Red Caution: Electric Line Buried Below Red Ink used to print messages shall be permanently fixed to tape and shall be black in color with message printed continuously throughout. D. Tape shall be minimum 0.102mm (0.004" or 4 mil) thick x 150mm (6") wide with a printed message on one side. Tape used with the installation of onsite potable and recycled water irrigation systems shall be a minimum of 75mm (3") wide. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-5 2.9 INSULATING UNIONS & COUPLINGS A. For insulating unions, use a molded nylong sealing sleeve mounted in a three-piece malcable-iron body (ASTM A47 or A197). Use thread ends when connecting to steel piping, and copper solder joint when connecting to copper piping. Minimum working pressure shall be 150 psi. B. Threaded insulating couplings shall provide dielectric protection from electrolytic corrosion at points where piping of dissimilar metals is joined. 2.10 GATE WELLS Valve gate wells shall be as indicated below in accordance with the Approved Materials List. A. Valve gate well size and material shall be as follows: - •£%'- • • Valve Size . .-•••, : • • ' Larger than 100mm (4") Gate Well Size and Material 200mm (8") diameter Class 150, C-900 PVC 1. PVC gate wells for use in recycled water system applications shall be white. 2. PVC gate wells for use in potable water system applications shall be white or blue. B. Gate well lids shall be as indicated below in accordance with the Approved Materials List. 1. Gate well box lids shall be circular ductile-iron, and shall include a skirt for a close fit inside the upper portion of the gate well. Lids shall be cast with the AGENCY NAME (CMWD) and the word WATER for use on potable water systems, and Recycled Water for recycled water systems. 2. Lids shall be Brooks 4TT with long skirt or approved equal. 3. Normally closed potable water valves and recycled water valves shall use box lids by Brooks 3RT or approved equal. 4. Lid sizes shall be as follows: Valves Larger than 100mm (4") where the speed limit is 56 km/h (35 mph) or greater Gate Well Lid Machined ductile-iron frame and 200mm (8") lid with 150mm (6") long skirt 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES 15000-6 2.11 VALVE STEM EXTENSIONS Stem extensions shall be complete with operating nut, location ring, and lower socket to fit valve-operating nut. The configuration of the extension stem nut shall match that of the valve it operates. A. Stem extensions shall be square fiberglass tubing glued together to make a continuous one-piece unit used to a maximum length of 2.4m, eight feet (81). B. Steel stem extensions shall be used where the maximum length of the extension exceeds 2.4m (8') or at the request of the District Engineer. Steel stem extensions may be round or square hot-dipped galvanized steel tubing of solid design (no pinned couplings permitted) with guides. 2.12 METER BOXES Meter boxes shall be polymer-type boxes with lids selected from the Approved Materials List. A. Meter box sizes shall be as follows: , ; Mis| ;, v- Meter Box Size 250mm x 500mm (12" x 20") 425mm x 750mm (17" x 30") Meter Box Uses 25mm (1") water services 50mm (2") water services B. Meter box lids for use in potable water system applications shall be gray. C. Meter box lids for use in recycled water system applications shall be purple. 2.13 RECYCLED WATER IDENTIFICATION Materials used to identify pipe and appurtenances used for recycled water, not manufactured in purple color, shall be as described in Carlsbad Reclamation Rules & Regulation for Construction of Reclaimed Water Mains. PART 3 - EXECUTION 3.1 TEMPORARY ABOVEGROUND PIPE (HIGH LINE) A. All high line piping, fittings, and service connections shall be furnished, installed, and maintained by the Contractor, and the Contractor shall make connections to a water source designated by the District Engineer. B. All pipe, valves, fittings, hose and connections furnished by the Contractor shall be of good quality, clean, and suitable for conveying potable water in the opinion of the District Engineer. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-7 C. The high line pipe shall be installed in such a manner that it will not present a hazard to traffic and will not interfere with access to homes and driveways along its route. D. Valves shall be installed at 60m (200') intervals or as directed by the District Engineer. The use of pressure reducing valves (PRV) may be required as directed by the District Engineer. E. The Contractor shall be responsible for disinfecting all high lines, connections, and flushing. F. Following disinfection and acceptance of the high line as a potable water system, the Contractor shall maintain continuous service through the high line piping to all consumers normally served both directly and indirectly by the pipeline. G. Upon completion of the work, the Contractor shall remove the high line piping and appurtenances. H. If progress in making repairs to the high line is inadequate, the District Engineer, may order necessary corrective measures. Corrective measures may consist of directing District personnel or another contractor to complete the work. All costs for corrective measures shall be borne by the Contractor. 3.2 CONNECTION TO EXISTING FACILITIES (WET TAPS AND CUT-IN INSTALLATIONS) The Contractor shall furnish the tapping sleeve or tee, valves and all other materials as called for in the Standard Specifications in accordance with the Approved Materials List. The Contractor shall provide all equipment and labor required for the excavation and installation of the connection including, but not limited to, backfill and pavement replacement. In certain circumstances the Contractor may be required to provide a water truck, high line, and fittings as part of the equipment for making the connections. In addition, the Contractor shall assist the District in alleviating any hardship incurred during a shutdown for connections. Emergency standby equipment or materials may be required of the Contractor by the District Engineer. Wet taps or cut-in tee and valve installations shall be performed as follows: A. Prior to construction, Contractor shall pothole the existing pipe at the location of the proposed connection. The District shall inspect the pothole prior to Contractor's repair of trench. Contractor shall record the following information on as-built drawings: 1. Pipe size, outside diameter. 2. Pipe type such as ACP, PVC, Ductile-Iron or Steel. 3. Pipe class and/or pressure rating. 4. Elevation, grade, and alignment. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-8 5. Location of collars, pipe bells, fittings or couplings, if found. Note: Collars, bells, fittings, or couplings shall not be within 18-inches of the outer dimension of the tapping saddle. 6. Potential conflicts with existing utilities. B. To facilitate the proposed connection and allow for slight adjustments in alignment, the Contractor shall leave a minimum 3.0m (10') gap between the new pipe installation and the proposed connection point at the existing water main. The Contractor shall leave a gap longer than 3.0m (10') if conditions warrant, or if directed by the Engineer. C. The new pipeline shall have successfully passed pressure testing in accordance with Section 15044 and disinfection and bacteriological testing in accordance with Section 15041 prior to proceeding with the connection to the existing pipeline. D. After the City Engineer has given approval to proceed with the connection, the Contractor shall schedule with the District for the wet tap or cut-in installation. 1. Shutdowns will be scheduled at the convenience of the District. Shutdowns may be scheduled for nights or weekends if required. 2. The Contractor shall give the District a minimum of 5 working days notice prior to any proposed excavation or shutdown of existing mains or services. Scheduling shall be subject to approval by the District Engineer. 3. The District may postpone or reschedule any shutdown operation if, for any reason, the District Engineer believes that the Contractor is improperly prepared with competent personnel, equipment, or materials to proceed with the connection. 4. If progress in completing the connection within the time specified is inadequate, the Engineer may order necessary corrective measures. Corrective measures may consist of directing District personnel or another contractor to complete the work. All costs for corrective measures shall be borne by the Contractor. E. Contractor may proceed with excavation only after potholing has been completed, materials have been approved and delivered, and wet tap or cut-in installation has been scheduled with approved Connection Permit. 1. The Contractor shall saw-cut pavement, excavate and provide and install shoring and steel plating, when necessary, one day prior to the wet tap or cut-in installation. 2. The Contractor shall provide lights, barricades and traffic control in accordance with the agency of jurisdiction and as deemed necessary for the excavation by the Engineer. 3. The Contractor shall de-water existing mains in full compliance with NPDES standards where cut-in installations are required and shall be done in the presence of the Engineer and in accordance with Section 15041. Only District personnel are authorized to operate existing valves. The Contractor shall be 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-9 responsible for any and all damage resulting from unauthorized operation of existing District facilities. 4. The Contractor under the inspection of the City shall perform the following work for wet taps and cut-in installations: a. Wet taps: Disinfect and install and tapping saddle and tapping valve and perform tapping operations. b. Cut-ins: Cut and remove portions of existing mains, and disinfect and install tees, valves, couplings, and appurtenances required to complete the closure. The Contractor shall discard pipe and appurtenances removed from service in accordance with this Section. 5. After the Contractor has performed tapping or cut-in operations, and the Engineer has given approval to proceed, the Contractor shall complete the installation as shown on the Approved Plans in accordance with the Standard Specifications including, but not limited to: a. Disinfecting and installing the pipe section(s) necessary to make the closure to the new system. b. Installing and setting the valve gate well(s) in accordance with the Standard Drawings. c. Installing thrust and anchor blocks in accordance with the Carlsbad's Engineer Standards. d. Completing all backfill and compaction of the trench in accordance with Section 02223. e. Repairing or replacing pavement as necessary. 3.3 FLEXIBLE PIPE COUPLINGS Flexible pipe couplings shall be installed in accordance with the manufacturers recommendations and as described below: A. Use plain-end pipe with flexible couplings per AWWA C200. Provide joint harnesses per AWWA M11 for aboveground applications or where indicated on the Approved Plans. B. Flexible couplings may be used only where indicated on the drawings. C. Clean oil, scale, rust, and dirt from the pipe ends and touch-up the epoxy coating and allow time for curing before installing the coupling. Clean the gaskets before installing. D. Follow the manufacturer's recommendation for installation and bolt torque using a properly calibrated torque wrench. E. Lubricate the bolt threads with graphite prior to installation. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-10 3.4 GROOVED-END OR SHOULDERED COUPLINGS FOR DUCTILE IRON OR STEEL PIPE Grooved-end or shouldered couplings shall be installed in accordance with the manufacturer's recommendations and as described below: A. Grooved-end or shouldered joint couplings shall be installed per AWWA C606 and the manufacturer's recommendations. B. Clean loose scale, rust, oil, grease, and dirt from the pipe or fitting groove and touch-up the epoxy coating as necessary, allowing time for curing before installing the coupling. C. Clean the gasket before installation. Apply a lubricant selected from the Approved Materials List to the gasket exterior including lips, pipe ends, and housing interiors. D. Fasten the coupling alternately and evenly until the coupling halves are seated. Follow the manufacturer's recommendation for bolt torque using a properly calibrated torque wrench. 3.5 JOINT RESTRAINT SYSTEM Joint Restraint Systems shall be installed in accordance with the manufacturers recommendations and as described below: A. Length of pipe to be restrained on each side of bends, tees, reducers and other fittings shall be determined by the Private Engineer or manufacturer of the restraint device. B. Split ring restraint shall be installed on the spigot end of pipe, connected to a back-up ring which seats behind the bell of the adjoining pipe or fitting. C. Restraint devices can be installed prior to lowering pipe into the trench. D. Splined gaskets, also known as joint restraint gaskets, shall be installed in accordance with the manufacturer's recommendations. 3.6 BOLTS AND NUTS A. All bolts and nuts shall be new and unused. B. Bolts and nuts shall be cleaned, if needed, by wire brushing and lubricated prior to assembly. C. Tighten nuts uniformly and progressively. D. Buried bolts and nuts shall receive a heavy coat of protective non-oxide grease coating selected from the Approved Materials List prior to being wrapped with polyethylene. E. All stainless steel bolts shall be coated with an anti-seize compound selected from the Approved Materials List. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-11 F. Bolts and nuts shall not be reused once tightened. Used bolts and nuts shall be discarded and removed from the job. 3.7 POLYETHYLENE ENCASEMENT A. Polyethylene encasement shall completely encase and cover all metal surfaces. Pipe: All ductile-iron pipe shall be encased with polyethylene sleeves in accordance with Method A described in AWWA C105, or with polyethylene wrap in accordance with Method C described in AWWA C105. Fittings: Fittings such as tees, bends and reducers shall be encased with polyethylene wrap in accordance with AWWA C105. Valves: Valves shall have only the stem and operating nut exposed and the wrap shall be attached so that valve operation will not disturb the wrapping or break the seal. B. Polyethylene sleeves shall be secured with polyethylene or vinyl adhesive tape or plastic tie straps at the ends and quarter points along the sleeve in a manner that will hold the sleeve securely in place during backfill. Polyethylene wrap shall be secured with polyethylene or vinyl adhesive tape in a manner that will hold the wrap securely in place during backfill. 3.8 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be installed as described below in accordance with the Standard Drawings. A. Tape shall be placed at the top of the pipe zone 300mm (12") above and centered over the utility intended for identification. Tape used with onsite potable and recycled water irrigation systems shall be installed at 150mm (6") above the pipe. 6. Tape shall be installed with the printed side up and run continuously along the entire length of the utility intended for identification. Tape shall be installed on the main piping and all appurtenant laterals, including blowoffs, air valve assemblies, fire hydrants, and services. Tape splices shall overlap a minimum of 600mm (24") for continuous coverage. C. Tape shall be installed prior to placement of the Trench Zone Backfill. 3.9 GATE WELLS AND VALVE STEM EXTENSIONS Gate wells shall be installed as shown on the Standard Drawings and as described below: A. Valve Stem Extensions shall be installed when the valve operating nut is more than 1.5m (5') below grade. Stem extensions shall be of sufficient length to bring the operating nut to a point between 300mm (12") and 450mm (18") below the gate well lid. Valve stem extensions shall be installed in accordance with the Standard Drawings. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-12 3.10 METER BOX INSTALLATION Meter boxes shall be installed at the elevations and locations shown on the Approved Plans and in accordance with the Standard Drawings. Near the completion of the project, a final meter box adjustment to finish grade may be required. Water meters shall not be installed until final adjustments are made to the meter box and approved by the District. 3.11 ABANDONMENT OR REMOVAL FROM SERVICE OF EXISTING FACILITIES Before excavating for new mains that are to replace existing pipes or services, the Contractor shall make provisions for the continuation and maintenance of service to customers as directed by the District Engineer. Abandonment or removal from service of existing mains, appurtenances or water services shown on the Approved Plans or as called for by the District Engineer shall be as directed by the District Engineer. Abandonment or removal from service of existing mains, appurtenances or water services shown on the Approved Plans or as called for by the District Engineer shall be as indicated below and in accordance with the Standard Drawings: A. Abandonment in place: 1. Existing pipe 100mm (4") and smaller shall have a short section of pipe removed and pipe ends encased in concrete. 2. Existing pipe 150mm (6") through 350mm (14") shall be cut and plugged with concrete or shall be pressure-grouted at intervals of 60m (200') as recommended by the Engineer. 3. Existing pipe 400mm (16") and larger shall be entirely filled by pressure-grouting or by blown sand as determined by the Engineer. 4. Existing pipe ends shall be filled with concrete. 5. All valves shall be removed with remaining pipe or fittings permanently sealed with blind flange or concrete plug. 6. Gate wells shall be cut 600mm (24") below grade and filled with 1-2 slurry sack concrete or removed and replaced with compacted backfill. 7. Water service corporation stops shall be closed. Meter boxes and curb stops shall be removed. Service laterals shall be cut back a minimum of 24-inches below the finish grade. 8. Water services to be abandoned that are connected to pipelines that will remain in service shall be abandoned in-place. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-13 9. Sewer laterals shall be cut and plugged with concrete or capped at the main as x*^ directed by the Engineer for the specific circumstance and material type ^J) identified. 10. Sewer access holes shall have the cover and frame, concrete ring, grade rings and cone section removed. Inlet and outlet piping shall be plugged with concrete, manhole void shall be filled with sand, and a 300mm (12") thick, reinforced concrete slab shall be poured over the top of remaining manhole. The Contractor shall backfill hole to ground surface with compacted select fill. B. Removal by excavation: 1. Existing pipe and appurtenances shall be removed from the ground as indicated on the Approved Plans or as directed by the District Engineer. 2. Contractor shall provide measures that allow for the removal of existing sewer mains and appurtenances with no leakage of raw sewage. Transportation of sewer mains and appurtenances removed from service shall be in waterproof trucks to prevent raw sewage from leaking on public streets. 3. Removal of asbestos-cement pipe (ACP) and sewer mains and appurtenances shall be in accordance with all applicable State and Federal requirements. Legal disposal is the responsibility of the Contractor. Obtain approval from the agency having disposal jurisdiction with respect to disposal sites. 4. Backfill, compaction, and surface repair of all excavations for removal of pipe and appurtenances shall be made in accordance with the Approved Plans, Section s**r 02223 of the Standard Specifications, and the Standard Drawings. 3.12 SALVAGE When the Contractor is required to remove existing pipe and appurtenances, or portions thereof, from the ground, such material may, at the discretion of the Engineer, be considered salvage. All materials identified as salvage are considered property of the District. A. The Contractor shall remove and temporarily stockpile all materials identified as salvage in a safe location that will not disrupt traffic or shall deliver salvage to the District's Field Operations Yard as directed by the District Engineer. B. The Contractor shall legally dispose of all other materials in an appropriate manner. Disposal is the responsibility of the Contractor. Obtain concurrence from the agency having disposal jurisdiction with respect to disposal sites and transportation methods. 3.13 RECONNECTIONS A. The Contractor may encounter unused service laterals or appurtenant piping connected to an existing pipeline being replaced. Laterals and appurtenance piping that will not be connected to the new pipeline shall be abandoned as described in Section 3.11. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-14 B. Existing service laterals or appurtenances to be connected to new pipelines shall be installed as shown on the Approved Plans or as directed by the District Engineer in accordance with the Standard Drawings. 8/13/09 Contract No. 3811 GENERAL PIPING SYSTEM & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15000-15 SECTION 15041 DISINFECTION OF PIPING PART 1 - GENERAL 1.1 DESCRIPTION This section describes requirements for disinfection by chlorination of potable and recycled water mains, services, pipe appurtenances and connections. 1.2 REFERENCED STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. A. American Water Works Association (AWWA) B300 Standard for Hypochlorites B301 Standard for Liquid Chlorine C651 Disinfecting Water Mains 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Specifications 15000, 15044, 15056, 15057, 15061, and 15064 1.4 SERVICE APPLICATION A. All water mains and appurtenances taken out of service for inspection, repairs, or other activity that might lead to contamination shall be disinfected before they are returned to service. B. All new water mains and temporary high lines shall be disinfected prior to connection to the District's existing system. C. All components incorporated into a connection to the District's existing system shall be disinfected prior to installation. 1.5 SUBMITTALS A. A written disinfection and dechlorination plan signed by a certified chlorinator shall be submitted to the Engineer for review and approval prior to starting disinfection or dechlorination operations. Plan for disinfection method and procedure shall include equipment used to inject the chlorine solution, gauges or scales to measure the rate at which chlorine is injected, qualifications of personnel, testing location and schedule, source of water and water disposal locations. Personnel performing the disinfection shall demonstrate a minimum of five years experience in the chlorination and dechlorination of pipelines. B. Qualification of certified testing laboratory. C. Emergency Response Plan. 8/13/09 Contract No. 3811 DISINFECTION OF PIPING PALOMAR AIRPORT ROAD WIDENING 15041-1 3 L Lt-O^t-J^.jSJ^p^^tljs 1.6 DELIVERY, STORAGE AND HANDLING Chlorination and dechlorination shall be performed by competent individuals knowledgeable and experienced in the operation of the necessary application and safety equipment in accordance with applicable Federal, State and Local laws and regulations. The transport, storage and handling of these materials shall be performed in accordance with Code of Federal Regulations (CFR) 1910.120 Hazardous Waste Operations and Emergency Response, CFR 49.172 Hazardous Materials Regulations, and the General Industry Safety Orders of the California Code of Regulations, Title 8, Section 5194. 1.7 CONCURRENT DISINFECTION AND HYDROSTATIC TESTING The specified disinfection of the pipelines may be performed concurrently with the hydrostatic testing in accordance with Section 15044. In the event repairs are necessary, as indicated by the hydrostatic test, additional disinfection may be required by the Engineer in accordance with this specification. 1.8 CONNECTION TO EXISTING MAINS Prior to connection to existing mains, disinfection and bacteriological testing shall be performed in accordance with this specification, and hydrostatic testing shall be performed per Section 15044. A District Connection Permit is required authorizing connection to an existing system shall and be given only on the basis of acceptable hydrostatic, disinfection and bacteriological test results. Connection to existing mains shall be performed in accordance with Section 15000. PART 2 - MATERIALS 2.1 CHLORINE (GAS) A. Liquid chlorine contains 100-percent available chlorine and is packaged in steel containers in net weights of 68.1kg (150 Ib.) or 907.2kg (1 ton). B. Liquid chlorine shall be used with appropriate gas flow chlorinators, heaters, and injectors to provide a controlled, high-concentration solution feed to the water. The chlorinators and injectors shall be the vacuum-operated type. 2.2 SODIUM HYPOCHLORITE (LIQUID) Sodium hypochlorite is available in liquid form in glass or plastic containers, ranging in size from 0.95 L (1 Qt.) to 18.93 L (5 Gal.). The solution contains approximately 10% to 15% available chlorine. 2.3 TABLET OR GRANULAR HYPOCHLORITE Tablet or granular hypochlorite may be used if a solution container is utilized to provide a continuous feed method. 8/13/09 Contract No. 3811 DISINFECTION OF PIPING PALOMAR AIRPORT ROAD WIDENING 15041 -2 PART 3 - EXECUTION 3.1 GENERAL A. Disinfection of pipelines shall not proceed until all appurtenances and any necessary sample ports have been installed and the Engineer provides authorization. B. Every effort shall be made to keep the water main and its appurtenances clean and dry during the installation process. C. All piping, valves, fittings, and appurtenances which become contaminated during installation shall be cleaned, rinsed with potable water, and then sprayed or swabbed with a 5 percent sodium hypochlorite disinfecting solution prior to installation. D. Water mains under construction that become flooded by storm water, runoff, or groundwater shall be cleaned by draining and flushing with metered potable water until clear water is evident. Upon completion, the entire main shall be disinfected using a method approved by the Engineer. 3.2 METHODS A. Chlorine (Gas) 1. Only vacuum-operated equipment shall be used. Direct-feed chlorinators, which operate solely from gas pressure in the chlorine cylinder, shall not be permitted. The equipment shall incorporate a backflow prevention device at the point of connection to the potable water source used to fill the line being tested. 2. The chlorinating agent shall be applied at the beginning of the system to be chlorinated and shall be injected through a corporation stop, a hydrant, or other approved connection to ensure treatment of the entire system being disinfected. 3. Only a certified, licensed chlorination and testing contractor shall perform gas chlorination work. The chlorination contractor must also possess a Grade II Treatment Plant Operator Certification from the State of California if required by the Engineer. B. Sodium Hypochlorite Solution (Liquid) 1. Sodium hypochlorite solution shall be used for cleaning and swabbing piping and appurtenances immediately prior to installation and for disinfecting all components of connections to the District's existing system. 2. Sodium hypochlorite solution may be used for the initial disinfection of newly installed water mains. The solution shall be applied at a terminus of the system to be chlorinated using an injector which can adjust the amount of solution being injected into the piping system. The solution shall be injected in the appropriate concentration to achieve the specified concentration range of chlorine throughout the entire piping system. Where pumping equipment is used in conjunction with an injector, an integral backflow prevention device shall be used and connected to the potable water supply. 8/13/09 Contract No. 3811 DISINFECTION OF PIPING PALOMAR AIRPORT ROAD WIDENING 15041-3 3. Water trucks, pumping equipment, piping, appurtenances and all other equipment in contact with potable water shall be disinfected prior to use. 4. Sodium hypochlorite solution may also be used to increase the total chlorine residual if the concentration from the initial chlorination of the system is found to be low. The solution shall be added to the system in sufficient amounts at appropriate locations to ensure that the disinfecting solution is present at a concentration within the specified range throughout the piping system. 3.3 PROCEDURE FOR DISINFECTING WATER MAINS AND APPURTENANCES A. The pipeline shall be filled at a rate not to exceed 1,135 liters per minute (300 GPM) or a velocity of 0.3m per second (1 foot per second), whichever is less. B. Disinfection shall result in a total chlorine concentration of not less than 25-mg/l. This concentration shall be evenly distributed throughout the system to be disinfected, using a continuous feed method of chlorination. C. All valves shall be operated with the disinfection solution present in the pipeline. All appurtenances such as air-vacuum relief valves, blowoffs, hydrants, backflow prevention devices, and water service laterals shall be flushed with the treated water a sufficient length of time to ensure a chlorine concentration within the specified range in all components of each appurtenance. (Note the limitations for discharge of chlorinated water outlined below.) D. The Engineer will verify the presence of the disinfection solution throughout the system by sampling and testing for acceptable chlorine concentrations at the various appurtenances and/or at the test ports provided by the Contractor. Areas of the system found to be below the specified chlorine concentration level shall receive additional flushing as noted above and/or additional disinfection solution as necessary. (Note the limitations for discharge of chlorinated water outlined below.) Addition of disinfection solution after the initial charging of the line shall be made by either the liquid chlorine (gas) method, or the sodium hypochlorite method as directed by the Engineer. E. The chlorinated water shall be retained in the system for a minimum of 24 hours. The District Engineer will test the total chlorine residual. The system shall contain a total chlorine residual of not less than 80% of the initial total chlorine residual before the 24-hour soaking period began. If the total chlorine residual has decreased more than 20%, the system shall be soaked for an additional 24-hour period. If the total chlorine residual has not deceased after this additional 24-hour period, the system shall be flushed in accordance with the procedure detailed herein. If the total chlorine residual has decreased, the system shall be flushed in accordance with the procedure detailed herein, and shall be re-disinfected. 8/13/09 Contract No. 3811 DISINFECTION OF PIPING PALOMAR AIRPORT ROAD WIDENING 15041-4 F. Following a successful retention period as determined by the District Engineer, the chlorinated water shall be flushed from the system at its extremities and at each appurtenance, using potable water from a source designated by the District Engineer. The minimum water velocity during flushing shall be 0.9 meters per second (3 feet per second) or as directed by the Engineer. Flushing shall continue until the replacement water in the new system is equal in chlorine residual to the potable source of supply as verified by the District. (Note the limitations for discharge of chlorinated water outlined below.) G. The Contractor shall contract with a State certified sampling laboratory to perform sampling, transport samples and perform bacteriological sampling and testing as specified herein. 3.4 DISCHARGE OF CHLORINATED WATER A. Indiscriminate onsite disposal or discharge to sewer systems, storm drains, drainage courses or surface waters of chlorinated water is prohibited. In locations where chlorine neutralization is required, the reducing agent shall be applied to the water as it exits the piping system. The Developer shall monitor the chlorine residual during the discharge operations. Total residual chlorine limits in these locations, and for the discharge of chlorinated water from the testing of pipelines to surface waters of the San Diego Region are as follows: Total Residual Chlorine Effluent Limitations ^^k >^*J30-Day Average - 0.002 mg/l >**r Average Daily Maximum - 0.008 mg/l Instantaneous Maximum - 0.02 mg/l The various methods of dechlorination available can remove residual chlorine to concentrations below standard analytical methods of detection, 0.02 mg/l, which will assure compliance with the effluent limit. The Developer will perform all necessary tests, keeping and providing records to the Engineer to ensure that the total residual chlorine effluent limitations listed above are met. B. In locations where no hazard to the environment is evident based on the joint examination described above, the chlorinated water may be broadcast for dust control on the surface of the immediate site. Care shall be exercised in broadcasting the water to prevent runoff. 3.5 BACTERIOLOGICAL TESTING The Contractor shall employ a State certified laboratory to perform bacteriological sampling and testing of all new system installations. The testing methodology employed by the District shall be as set forth in "Standard Methods for the Examination of Water and Waste Water" (current edition). Testing requirements are as set forth in the California Domestic Water Quality and Monitoring Regulations and commensurate with current requirements for surface water testing. The testing laboratory will analyze the samples for the presence of coliform bacteria and heterotrophic-type bacteria ^^ *^^&r 8/13/09 Contract No. 3811 DISINFECTION OF PIPING PALOMAR AIRPORT ROAD WIDENING 15041 -5 (heterotrophic plate count). The evaluation criteria employed by the District for a passing test sample is as follows: A. Coliform bacteria: no positive sample, and B. Heterotrophic plate count (HPC): 500 colony forming units/ml or less. 3.6 REDISINFECTION If the initial disinfection fails to produce satisfactory bacteriological test results, the pipeline system shall be re-flushed and re-sampled. If the second set of samples does not produce satisfactory results, the pipeline system shall be re-chlorinated, flushed, and re-stamped. The chlorination, flushing, and sampling procedure shall continue until satisfactory results are obtained. Re-disinfection and retesting shall be at the Contractor's expense. 3.7 DISINFECTING TIE-INS AND CONNECTIONS Pipes, fittings, valves and all other components incorporated into connections with the District's existing system shall be spray disinfected or swabbed with a liquid chlorine solution in accordance with AWWA C651 and as specified herein. Upon connection to the main, the line shall be flushed as directed by the District Engineer. Disinfection by this method is generally limited to assemblies of 6m (20') or less in length. Alternate methods such as "predisinfection" prior to installation in accordance with AWWA C651 may be required at the discretion of the District Engineer. 8/13/09 Contract No. 3811 DISINFECTION OF PIPING PALOMAR AIRPORT ROAD WIDENING 15041 -6 SECTION 15044 HYDROSTATIC TESTING OF PRESSURE PIPELINES PART 1 - GENERAL 1.1 DESCRIPTION This section describes the requirements and procedures for pressure and leakage testing of all pressure mains. 1.2 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 15000, 15041, 15056, 15061, and 15064 1.3 REQUIREMENTS PRIOR TO TESTING A. Provide testing procedure submittal including testing pressure, testing schedule, test bulkhead locations, and water supply details. B. All piping, valves, fire hydrants, services, and related appurtenances shall be installed prior to testing. C. The pipe trench shall have trench zone backfill placed and compacted with a minimum of 0.76m (2.5') of material over the pipe. D. All concrete anchor blocks shall be allowed to cure a sufficient time to develop a minimum strength of 13.79 MPa (2,000 psi) before testing. E. Pressure tests on exposed and aboveground piping shall be conducted only after the entire piping system has been installed and attached to pipe supports, hangers or anchors as shown on the Approved Plans. F. Steel pipelines shall not be tested before the mortar lining and coating on all pipe lengths within the line have been in place for a minimum of fourteen (14) days. Cement-mortar lined pipe shall not be filled with water until a minimum of eight hours has elapsed after the last joint has been mortared. 1.4 CONCURRENT HYDROSTATIC TESTING AND DISINFECTION OF PIPELINES Hydrostatic testing of pipelines shall be performed prior to or concurrently with the disinfection operations in accordance with Section 15041. In the event repairs are necessary, as indicated by the hydrostatic test, the District may require additional disinfection in accordance with Section 15041. 1.5 CONNECTION TO EXISTING MAINS Hydrostatic testing shall be performed prior to connections to existing mains. A District Connection Permit authorizing connection to the existing system shall be given only on the basis of acceptable hydrostatic, disinfection and bacteriological test results. Connection to existing mains shall be performed in accordance with Section 15000. 8/13/09 Contract No. 3811 HYDROSTATIC TESTING OF PRESSURE PIPELINES PALOMAR AIRPORT ROAD WIDENING 15044-1 PART 2 - MATERIALS 2.1 WATER A. Potable water shall be used for hydrostatic testing of potable and recycled water mains. B. Potable water shall be supplied by a District-approved source. Make-up water for testing shall also be potable water. C. A chlorinated water solution, in accordance with Section 15041, shall be used to charge the line and for make-up water when hydrostatic testing and disinfection operations are combined. D. Meet all applicable state and local requirements for disposal of testing water. 2.2 CONNECTIONS A. Testing water shall be supplied through a metered connection equipped with a backflow prevention device in accordance with Section 15112 at the point of connection to the potable water source used. B. The Contractor shall provide any temporary piping needed to deliver potable water to the piping that is to be tested. Temporary piping shall be in accordance with Section 15000. PART 3 - EXECUTION 3.1 GENERAL A. All water systems shall be pre-tested to insure passage of test prior to scheduling official test with inspector. B. The Contractor shall provide the District with a minimum of 48 hours' notice prior to the requested date and time for hydrostatic tests. C. The Contractor shall furnish all labor, materials, tools, and equipment for testing. D. Temporary blocking during the tests will be permitted only at temporary plugs, caps or where otherwise directed by the District. E. All valves and appurtenances shall be operated during the test period. The test shall be conducted with valves in the open position. The Contractor is not permitted to operate any valves on the District's system. F. At the onset of testing, all valves, air vacuum assemblies, blowoffs, and services shall be monitored for possible leakage and repairs made, if necessary, before the test proceeds. The appurtenances shall be monitored through the duration of the testing. G. For pipe with porous lining, such as cement mortar, the pipe shall be filled with water and placed under a slight pressure for a minimum of forty-eight (48) hours prior to the actual hydrostatic test. 8/13/09 Contract No. 3811 HYDROSTATIC TESTING OF PRESSURE PIPELINES PALOMAR AIRPORT ROAD WIDENING 15044-2 H. Testing shall be made before connecting the new line with the existing District pipes and mains. I. The pipeline should be filled at a rate such that the velocity of flow is less than 1 fps. J. Maximum length of pipe to be included in any one (1) test shall not exceed 2,500 linear feet or vertical elevation difference of 58 feet. 3 3.2 FlELD TEST PROCEDURE A. Before applying the specified test pressure, care shall be taken to release all air within the pipe and appurtenances to be tested. Air shall be released through services, fire hydrants, air release valves, or other approved locations. 6. The leakage shall be considered as the total amount of water pumped into the pipeline during the test period. C. Apply and maintain the test pressure by means of a hydraulic force pump. D. Maintain the test pressure for the following duration by restoring it whenever it falls an amount of 5 psi: Pipe Diameter (inches) 18 and less 20 to 36 Greater than 36 Hours 4 8 24 E. After the test pressure is reached, use a meter to measure the additional water added to maintain the pressure. This amount of water is the loss due to leakage in the piping system. The allowable leakage for various sizes of PVC & DIP with rubber gaskets are shown in the following table: TYPE OF PIPE: CLASSES: P.V.C. & D.I.P. 150&200 Pipe Sizes (inches) 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" Allowable Leakage Gals/4 hrs/1000' of pipe .33 Gals .50 Gals .66 Gals .83 Gals. .99 Gals. 1.16 Gals. 1.32 Gals. 1.49 Gals. 1.66 Gals. 1.98 Gals. 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING HYDROSTATIC TESTING OF PRESSURE PIPELINES 15044-3 F. The allowable leakage for welded steel pipe shall be zero gallons. G. The allowable leakage for piping having threaded, brazed, or welded (including solvent welded) joints shall be zero gallons. H. Repair and retest any pipes showing leakage rates greater than that allowed in the above criteria. 3.3 TEST PRESSURE Pipe sizes 16" diameter and less shall be tested at 75 p.s.i. in excess to the pressure class of the pipeline. Pressure shall be maintained for a duration shown in section 3.2 and shall be repumped when it falls an amount of 5 p.s.i. The test pump gauge and meter shall be connected to the water main at a location other than the highest point in the line, in order to allow release of air from the high point. Means shall be provided for accurately measuring the quantity of water pumped through a meter and pumped into the pipe immediately, during and after the test period in order to maintain or restore the initial test pressure. All pipe, fittings, valves, services and appurtenances shall be subjected to the hydrostatic test and irrespective of the measured quantity of leakage, all detectable leaks shall be repaired by the Contractor at the contractor's expense and no cost to Carlsbad Municipal Water district. If a tested system is damaged or a leak occurs after official test the entire system or portion of system will be retested as directed by Inspector. 8/13/09 Contract No. 3811 HYDROSTATIC TESTING OF PRESSURE PIPELINES PALOMAR AIRPORT ROAD WIDENING 15044-4 SECTION 15056 DUCTILE-IRON PIPE AND FITTINGS PART 1 - GENERAL 1.1 DESCRIPTION This section includes materials and installation of ductile-iron pipe and fittings for potable water systems. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. 3 1.3 I ANSI B16.42 ASTM A536 AWWAC104 AWWAC105 AWWAC111 AWWA C600 Ductile iron pipe flanges and flanged fittings, classes 150 and 300 Specification for ductile iron castings Cement mortar lining for ductile iron pipe and fittings for water Polyethylene encasement for ductile iron pipe systems Rubber-gasket joints for ductile iron pipe Installation of ductile iron water mains and their appurtenances RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 03000, 09900, 15000, 15044, 15061, 15064, 15108, and 15112 1.4 SERVICE APPLICATION Ductile-iron pipe shall be used only in specific areas, locations, and uses allowed by the District. 1.5 DESIGN REQUIREMENTS A. General: 1. Ductile-iron pipe and fittings shall be manufactured per AWWA C110, C111, C115, C150, C151, and C153. Gray-iron and cast-iron fittings or flanges shall not be used. 2. Ductile-iron fittings manufactured per AWWA C153 shall be installed on mains 300mm (12") and smaller only. 3. Joints for ductile-iron pipe and fittings shall be mechanical, flanged, or push-on in accordance with AWWA C110, C111, and C153. o 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 DUCTILE-IRON PIPE & FITTINGS 15056-1 4. Except as amended herein, or otherwise shown on the Approved Plans, joints for ductile-iron pipe and ductile-iron fittings shall have a pressure rating equal to or greater than the adjacent piping. 5. Joints in buried piping may be of the push-on, flanged or mechanical-joint type per AVWVA C111 except where particularly specified on the Approved Drawings. 6. Joints that are aboveground, within structures, or submerged shall be flanged unless otherwise shown on the Approved Plans. B. Unless otherwise specified, ductile-iron flanges shall be in accordance with AWWA C115, rated at a working pressure of 1,724 KPa (250 psi). Where required in order to connect to the flanges of 1,724 KPa (250 psi) butterfly valves, or as otherwise shown on the approved plans, ductile-iron flanges shall be compatible with AWWA C207, Class "F". Maximum working pressure of flanges shall be as specified in AWWA or ASME/ANSI. Flanges shall be integrally cast per AWWA C110 or shop-threaded per AWWA C115. Flanges shall be solid. Hollow-back flanges are not permitted. Gray-iron or cast-iron flanges are not permitted. Threading of flanges in the field is not permitted. Where threaded flanges are used, the pipe or spool piece to which they are connected will be hydrostatically tested in the presence of the Engineer prior to installation. The pipe section or spool piece shall be hydrostatically tested for 15 minutes at the pressure rating of the flanges. No leaks shall be permitted. C. Plain ends shall conform to the requirement of AWWA C151 and to the dimensions included within AWWA C110 to accept a mechanical joint, push-on joint, flanged coupling adaptor, flexible coupling, or grooved coupling. Refer to Section 15000 for coupling descriptions. D. The exterior surfaces of all pipe and fittings shall be factory coated with a minimum one-(1) mil thick petroleum asphaltic material per AWWA C110 and C151. E. All pipe and fittings shall be cement-mortar lined in accordance with AWWA C104, using the double thickness requirements indicated in said standard. Type II or Type V Portland cement per ASTM C 150 shall be used. 1.6 QUALITY ASSURANCE A. The manufacturer of each shipment of pipe shall be required to supply a statement certifying that each lot or load of pipe and fittings has been subjected to and met the tests specified for ductile-iron pipe and fittings per AWWA C110, C111, C115, C150, C151, and C153, as applicable. B. All pipe shall have a home mark on the spigot end to indicate proper penetration when the joint is made. C. Ductile-iron pipe shall bear indelible identification markings as required by AWWA C151. 8/13/09 Contract No. 3811 DUCTILE-IRON PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 15056-2 1.7 SUBMITTALS ^n^ N^^^HFThe following items shall be submitted and reviewed by the District prior to shipping of ductile-iron pipe and fittings: A. An affidavit of compliance with AWWA C104, C110, C111, C115, C150, C151, C153, and the requirements of this specification. B. Typical joint details. C. Typical details and description of lining and coating. D. Calculations supporting selected wall thickness. E. Calculations demonstrating that each proposed restrained joint arrangement can resist the applied forces. F. Cathodic protection materials. 1.8 DELIVERY, STORAGE, AND HANDLING Delivery, storage, and handling of ductile-iron pipe and fittings shall follow the recommendations of AWWA C600 and as specified herein: A. Handling of pipe shall be performed with lifts, cranes, or other suitable equipment and *m^ devices. Slings, hooks, or pipe tongs shall be padded and used in such a manner as to prevent damage to the pipe, linings, and coatings. The pipes shall not be dropped or "" dragged. B. During transport, the pipe shall be supported and secured against movement using padded devices in such a manner to prevent damage. C. Stored pipe shall be protected from damage and kept free from dirt and foreign materials by closing the ends of the pipe. Other pipeline materials shall be protected by appropriate packaging or wrapping. Gaskets shall be stored in a cool location out of direct sunlight. Bolts, nuts, and washers shall be handled and stored in a dry location in a manner that will ensure proper use with respect to types and sizes. D. Pipe laid out for installation shall be placed on earth berms or timber cradles adjacent to the trench in the numerical order of installation. E. Maintain plastic end caps on all pipe and fittings in good condition until the pipe is ready to be installed in the trench. Periodically open the plastic end caps and spray clean potable water inside the pipe for moisture control. F. Under no circumstances shall ropes or other devices be attached through the fitting's interior for handling. 8/13/09 Contract No. 3811 DUCTILE-IRON PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 15056-3 1.9 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be installed for buried ductile-iron pipe and fittings in accordance with Section 15000. 1.10 WARNING/IDENTIFICATION TAPE Warning/Identification tape shall be installed for ductile-iron pipe and fittings in accordance with Section 15000. PART 2 - MATERIALS 2.1 DUCTILE-IRON Ductile-iron pipe and appurtenant components and materials shall be selected from the Approved Materials List in accord with the Standard Drawings. 2.2 GASKETS A. Mechanical joint rubber gasket configuration and materials shall comply with AWWA C111, and according to the applicable joint type and pressure rating of the piping system. B. Flange gaskets shall be 3.2mm (1/8") thick acrylic or aramid fibers bound with nitrile for all sizes of pipe. Gaskets shall be full-face type with pre-punched holes. Ring gaskets extending to the inner edge of the bolt circumference may be used only upon approval of the District Engineer. C. Push-on joint rubber gaskets shall be per AWWA C111. D. If organic solvents or petroleum products are encountered during the course of the work, alternate gasket materials or joint treatment may be required by the Engineer. 2.9 BOLTS AND NUTS FOR FLANGES Bolts and nuts shall be in accordance with Section 15000 and shall be selected from the Approved Materials List. 2.10 WARNING/IDENTIFICATION TAPE Warning/Identification tape materials shall be in accordance with Section 15000 and selected from the Approved Materials List. PART 3 - EXECUTION 3.1 GENERAL At all times when the work of installing pipe is not in progress, including worker break times, 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. 8/13/09 Contract No. 3811 DUCTILE-IRON PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 15056-4 3.2 TRENCHING, BACKFILLING AND COMPACTING Trenching, backfilling and compacting shall be performed in accordance with Section 02223. 3.3 DEWATERING The Contractor shall provide and maintain at all times during construction ample means and devices to promptly remove and dispose of all water from any source entering trench excavations or other parts of the work. Any damage caused by flooding of the trench shall be the Contractor's responsibility. 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 or trench materials shall be repaired or replaced as directed by the Engineer. 3.4 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. 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. Install pipe in the trench as follows: A. Inspect each pipe and fitting before lowering the pipe or fitting into the trench. Inspect the interior and exterior protective coatings. Patch damaged areas in the field with material recommended by the protective coating manufacturer. Thoroughly clean the ends of the pipe. Remove foreign matter and dirt from inside of the pipe and keep pipe clean during and after installation. B. Install pipe according to the manufacturer's approved order of installation. Install pipes uphill if the grade exceeds 10%. Lower the pipe onto the bedding at the proper lines and grades. C. The manufacturer's printed installation guide outlining the radius of curvature that can be negotiated with pipe sections of various lengths shall be followed, except they shall not exceed the deflections allowed in AWWA C600 according to joint type. Combined deflections at rubber gasket or flexible coupling joints shall not exceed that recommended by the manufacturer. 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 381 1 DUCTILE-IRON PIPE & FITTINGS 1 5056-5 D. The pipe shall have firm bearing along its full length, and bell holes shall be provided at each joint to permit visual inspection of the joint and prevent the pipe from being supported by the bell end or coupling. E. Pipe Assembly: 1. Push-On Type: Assemble the pipe joint using a lubricant selected from the Approved Materials List. Insert the spigot end into the bell or coupling to the proper insertion mark. Check that the elastomeric ring has not left the groove during assembly by passing a feeler gauge around the completed joint. Drive spigot ends of the pipe into bell ends in accordance with the manufacturer's recommendations. Stabbing shall not be permitted. 2. Mechanical Joint Type: Assembly of mechanical joint fittings shall be in accordance with the manufacturer's recommendations regarding installation. F. During installation operations, do not place tools, clothing, or other materials in the pipe. G. When pipe installation is not in progress, including worker break times, ends of the pipe shall be closed with a vermin-proof and child-proof cap or plug. Do not permit trench water, animals, or foreign material to enter the pipe. 3.5 POLYETHYLENE ENCASEMENT Polyethylene encasement shall be used for the buried installation of ductile iron pipe and fittings and shall be installed in accordance with Section 15000. 3.6 FLANGED PIPE AND FITTINGS Flanged connections shall be installed where indicated on the Approved Drawings. 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 "star" pattern to the manufacturer's recommended torque. E. Coat the exterior of exposed flanges, bolts and nuts located aboveground or within vaults in accordance with Section 09900. 3.7 MECHANICAL JOINT CONNECTIONS A. Install mechanical joint connections per AWWA C600 and the manufacturer's recommendations. B. Prior to installation of the mechanical joint, clean the socket and plain end of the pipe. Lubricate both the gasket and plain end of the pipe with an approved lubricant per AWWA C111 immediately prior to slipping the gasket onto the plain end of the pipe. 8/13/09 Contract No. 3811 DUCTILE-IRON PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 15056-6 C. Tighten the bolts to the normal range of bolt torque per the manufacturer's recommendations and AWWA C600k, Table 3, as follows: Pipe Diameter Bolt Size Range of Torque 75 mm (3") 16 mm (5/8") 61-81 N-M (45-60 ft.-lb.) 100-600 mm (4-24") 19 mm (3/4") 102-122 N-M (75-90 ft.-lb.) 750-900 mm (30-36") 25 mm (1") 136-163 N-M (100-120 ft.-lb.) 3.8 CROSSES A. Each flanged ductile-iron cross shall be installed with flanged ductile-iron pipe spools between the cross and the valves. The spools are included to position the valves a sufficient distance from the cross to allow installation of the thrust blocks without conflicting with the valve actuators. B. The spools shall be 450mm (18") long for pipe sizes 200mm (8") through 300mm (12"), and 600mm (24") long for pipe sizes 400mm (16") and larger. C. The spools shall be equal in class to the adjacent pipe. 3.9 COUPLINGS FOR DUCTILE-IRON PIPE Mechanical type flexible joints shall be installed where shown on the Approved Drawings. Grooved couplings shall be used in vaults and above ground. Flexible couplings may be used, where indicated on the drawings, below ground, but may also be used above ground with restrained joints. Flanged coupling adapters shall be used for buried pipelines, where allowed by the District. A. Grooved joint couplings shall be installed per AWWA C606 and as indicated in Section 15000. B. Flanged coupling adapters, where allowed by the District, shall be installed per the manufacturer's recommendations. C. Flexible couplings shall be installed per Section 15000 and the manufacturer's recommendations. D. All couplings for ductile-iron pipe shall be shop-coated in accordance with Section 15000. 3.10 CONCRETE Concrete thrust or anchor blocks shall be placed as shown on the approved plans in accordance with the Carlsbad's Engineering Standards. 3.11 WARNING/IDENTIFICATION TAPE Warning/Identification tape shall be installed in accordance with Section 15000 and the Standard Drawings. 3.12 DISINFECTION AND BACTERIOLOGICAL TESTING Disinfection, bacteriological testing, and flushing shall be performed in accordance with Section 15041. 8/13/09 Contract No. 3811 DUCTILE-IRON PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 15056-7 3.13 HYDROSTATIC TESTING Field hydrostatic testing shall be performed in accordance with Section 15044. 8/13/09 Contract No. 3811 DUCTILE-IRON PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 15056-8 SECTION 15057 COPPER TUBING, BRASS AND BRONZE PIPE FITTINGS PART 1 - GENERAL 1.1 DESCRIPTION This section includes materials and installation of copper tubing, brass and bronze pipe fittings and appurtenances. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. ANSI B1.20.1 Pipe treads, general purpose ANSI B16.18 Case copper alloy solder joint pressure fittings 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 09900, 15000, 15041, 15044, 15056, 15061 and 15064 1.4 SERVICE LATERAL WET TAP CONNECTIONS Contractor shall perform all wet tap connections to existing pipelines in accordance with Section 15000. 1.5 RECYCLED WATER IDENTIFICATION Copper Tubing, Brass, and Bronze Pipe Fittings for recycled water shall be identified with purple color coating, purple polyethylene sleeve, identification labels or signs. 1.6 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be used for all copper tubing, except that which is bored or jacked, in accordance with Section 15000. PART 2 - MATERIALS 2.1 COPPER TUBING Copper tubing shall conform to the requirements of ASTM B 88 Type K or ASTM B 88 M (Metric) Type A seamless copper water tube. Copper tubing up to 25mm (1") diameter shall be soft; 50mm (2") may be soft or rigid. Components shall be selected from the Approved Materials List in accordance with the Standard Drawings. 8/13/09 Contract No. 3811 COPPER TUBING, BRASS & BRONZE PIPE FITTINGS PALOMAR AIRPORT ROAD WIDENING 15057-1 2.2 BRASS PIPE, NIPPLES, AND FITTINGS Threaded nipples, brass pipe and fittings shall conform to ASTM B 43, regular wall thickness. Threads shall conform to ANSI B1.20.1. Fittings shall be flared or silver soldered per CMWD Standard Drawings W3 and W4. 2.3 BRONZE APPURTENANCES A. Corporation stops, curb stops, meter and angle meter stops, meter flange adapters, and bronze-bodied service saddles shall be selected from the Approved Materials List in accordance with the Standard Drawings. B. Fittings shall be flared type or silver soldered. C. All items specified herein shall be manufactured of bronze conforming to ASTM B 62. D. Service saddles shall be the double strap type. Service saddles shall be used on all service and appurtenance connections on PVC piping. For piping materials other than PVC, service and appurtenance connections shall be performed in accordance with the Approved Drawings. 2.4 BOLTS AND NUTS FOR FLANGES Bolts and nuts shall be in accordance with Section 15000 and the Approved Materials List. 2.5 WARNING/IDENTIFICATION TAPE Warning/Identification Tape materials shall be in accordance with Section 15000 and shall be selected from the Approved Materials List. PART 3 - EXECUTION 3.1 COPPER TUBING AND FITTINGS A. Trenching, bedding, backfilling and compacting shall be performed in accordance with CMWD Standard Drawings. Provide a minimum cover of 760mm (30") below finished street grade. B. Cut tubing true and square and remove burrs. C. Bends in soft copper tubing shall be long sweep. Shape bends with shaping tools. Form bends without flattening, buckling, or thinning the tubing wall at any point. D. Assemble copper tubing and fittings per the manufacturer's recommendation in accordance with the Standard Drawings. E. Install warning/identification tape in accordance with Section 15000 and the Standard Drawings. 8/13/09 Contract No. 3811 COPPER TUBING, BRASS & BRONZE PIPE FITTINGS PALOMAR AIRPORT ROAD WIDENING 15057-2 F. All fittings shall be soldered or flared as shown on the Approved Plans and Standard Drawings. 3.2 SERVICE SADDLES A. Service saddles shall be located a minimum of 600mm (24") from any pipe joint or fittings. B. Service saddles for connections shall be located a minimum of 600mm (24") from other saddles. Additionally, multiple service saddles for connections that are installed on the same side of a single pipe length shall be alternately staggered between 10ft and 30ft to prevent a weak plane in the pipe. C. The surface of the pipe shall be clean and all loose material shall be removed to provide a hard, clean surface. D. The service saddle shall be tightened in accordance with the manufacturer's recommendations to ensure a tight seal, using care to prevent damage or distortion of the service saddle or corporation stop due to over-tightening. E. The tap into the pipe shall be made in accordance with the pipe manufacturer's recommendation. Tapping tools and shell cutters with internal teeth or double slots that will retain the coupon shall be used. 3.3 DISINFECTION AND BACTERIOLOGICAL TESTING Disinfection, bacteriological testing, and flushing shall be performed in accordance with Section 15041. 3.4 HYDROSTATIC TESTING Field hydrostatic testing shall be performed in accordance with Section 15044. 8/13/09 Contract No. 3811 COPPER TUBING, BRASS & BRONZE PIPE FITTINGS PALOMAR AIRPORT ROAD WIDENING 15057-3 SECTION 15064 POLYVINYL CHLORIDE (PVC) PRESSURE PIPE AND FITTINGS (AWWA C900) PART 1 - GENERAL 1.1 DESCRIPTION This section designates the requirements for the manufacture and installation of polyvinyl chloride, abbreviated PVC, pressure pipe, to be furnished and installed by the Contractor, at the location and to the lines and grades shown on the Plans as herein specified. Specifications for related Work are as follows: AWWA C900 PVC Pressure Pipe ANSI A21.10 Ductile Iron and Gray-Iron Fittings AWWA C110 Ductile Iron and Gray-Iron Fittings AWWA C153 Ductile Iron Compact Fittings AWWA Manual M23 Pipe Design and Installation 1.2 RELATED WORK DESCRIBED ELSEWHERE The Contractor shall refer to the following Specification section(s) for additional requirements: A. Disinfection of Piping: 15041 B. Hydrostatic Testing of Pressure Pipeline: 15044 1.3 SUBMITTALS The Contractor shall furnish submittals in accordance with Section 2-5.3, Submittals Shop Drawing. Submittals are required for the following: A. Submit Shop Drawings, material lists, manufacturer's literature and catalog cuts and other information. B. Submit an affidavit from the pipe manufacturer that all delivered materials comply with the requirements of AWWA C900, the Plans and Specifications. 1.4 PAYMENT A. Payment for the Work in this section shall be included as part of the lump-sum or unit-price bid amount for which such Work is appurtenant thereto. B. Payment by the linear foot shall be for each diameter and for each pipe strength designation measured horizontally over the pipe centerline. 8/13/09 Contract No. 3811 POLYVINYL CHLORIDE (PVC) PRESSURE PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 15064-1 PART 2 - MATERIALS 2.1 GENERAL Material used to produce the pipe shall be made from Class 12454-A or B rigid polyvinyl chloride compounds in accordance with AWWA C900 Section 2.1 (Basic Materials), with an established hydrostatic design basis (HDB) equal to or greater than 4000 psi for water at 73.4 degrees F (23 C). Elastomeric gaskets shall comply with the requirements of AWWA C900 Sections 2.1.5 and 2.1.5.1 (Gaskets and Lubricants). 2.2 PIPE PVC pressure pipe, 4-inch through 12-inch, shall be manufactured in accordance with AWWA C900, and shall be of the sizes and pressure classes shown on the Plans. The pipe shall have integral bell and spigot joints with elastomeric gaskets in accordance with AWWA C900 Section 2.2 (Pipe Requirements). The pipe shall conform with the outside diameter of cast-iron pipe unless otherwise specified and shall conform with the wall thickness of DR series 14, 18, or 25. The pipe shall be manufactured by J.M. Manufacturing Company, Certainteed Corporation, Pacific Western Extruded Plastics Company or approved equal. 2.3 FITTINGS All fittings for PVC pressure pipe shall be manufactured in accordance with ANSI A21.10, AWWA C110 or C153. All fittings shall be made of ductile iron and the letters "Dl" or "DUCTILE" shall be cast on them, unless otherwise specified. Bell size shall be for Class 150 and Class 200 cast-iron equivalent PVC pressure pipe, including the rubber-ring retaining groove. 2.4 SERVICES SADDLES Service saddles for PVC pressure pipe shall be made of silicone bronze or brass and shall be double banded or wide single band style. The band(s) and nuts shall be type 304 stainless steel and designed specifically for use with AWWA C900 PVC pipe. Each saddle shall accurately fit the contour of the pipe O.D. without causing distortion of the pipe. The saddle shall be securely held in place with stainless steel bolts and nuts. The service saddle shall have a published working pressure at least equal to the pressure class of the pipe on which it is installed. All saddles shall be provided with torque information and installation instructions. Saddles shall be in accordance with Carlsbad Rules and Regulations for the Construction of Potable Water Mains. 8/13/09 Contract No. 3811 POLYVINYL CHLORIDE (PVC) PRESSURE PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING .15064-2 PART 3 - EXECUTION 3.1 PIPE LENGTHS Laying lengths shall be 20-feet with the manufacturer's option to supply up to 15% random (minimum length 10-feet) sections. No deflections at bells, fittings or of the pipe will be allowed. The use of deflection collars shall be required. 3.2 MARKING Each pipe length shall be marked showing the nominal pipe size, O.D. base, the AWWA pressure class, and AWWA specification designation in accordance with AWWA C900 Section 2.6 (Marking Requirements). For potable water application, the pipe shall be white or blue in color and the seal of the testing agency that verified the suitability of the material for such service shall be included. 3.3 EARTHWORK Excavation and backfill, including the pipe bedding, shall conform to Section 02200. 3.4 GENERAL INSTALLATIONS PROCEDURES AND WORKMANSHIP PVC pressure pipe and fittings shall be installed per AWWA Manual M23 "PVC Pipe-Design and Installation", and as herein specified. Proper care shall be used to prevent damage in handling, moving, and placing the pipe. Hoist pipe with fork lift or other handling equipment to prevent major damage or shorten its service life. A cloth belt sling or a continuous fiber rope shall be used to prevent scratching the pipe. The pipe shall be lowered and not dropped from the truck. Dropped pipe will be rejected. Prior to laying the pipe, the bottom of the trench shall be graded and prepared to provide uniform bearing throughout the entire length of each joint of pipe. Bell holes of ample dimension shall be dug in the bottom of the trench at the locations of each joint to facilitate the joining. The trench shall have a flat or semi-circular bottom conforming to the grade to which the pipe is to be laid. The pipe shall be accurately placed in the trench to the lines and grades on the Plans. Fittings shall be supported independently of the pipe. 3.5 LONGITUDINAL BENDING No longitudinal bending shall be allowed in the installation of PVC pressure pipe. All deflections shall be accomplished by the use of deflection collars or couplings specifically designed for use with PVC C900 pipe and the deflections as installed shall not exceed the manufacturers written recommendations. 8/13/09 Contract No. 3811 POLYVINYL CHLORIDE (PVC) PRESSURE PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 15064-3 3.6 PIPE JOINT ASSEMBLY The spigot and bell shall slide together without displacement of the rubber gasket. The joint shall be dirt free. The best laying practice is with the bell facing in the direction of laying. Insert the rubber ring into the groove making sure the ring is completely seated. Lubrication of the spigot and instruction of use shall be supplied by the pipe manufacturer. The spigot shall be inserted into the bell and forced slowly into position by use of a large bar lever and a wood block across the pipe end. For large pipe, a come-along (with padding that will not scratch the pipe) may be used. 3.7 CONCRETE THRUST BLOCKS Concrete thrust blocks shall be placed as shown on the Plans and shall consist of Class B portland cement concrete containing not less than five sacks of portland cement per cubic yard and shall conform to SSPWC. Concrete blocks shall be placed between the undisturbed ground and the fittings to be anchored. Quantity of concrete and the bearing area of the pipe and undisturbed soil shall be as shown on the Plans, unless otherwise determined by the Owner's Representative. The concrete shall be placed, unless specifically shown otherwise on the Plans, so that the pipe joints and fittings will be accessible to repairs. 3.8 MECHANICAL THRUST RESTRAINT No mechanical thrust restraint devices which transfer forces from fittings to the PVC pipe wall shall be permitted. 3.9 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. 3.10 LEAKAGE TEST General: All pipelines shall be tested in accordance with Section 15044, Hydrostatic Testing of Pressure Pipe. 3.11 DISINFECTION Disinfection shall be in accordance with Section 15041, Testing, Flushing and Disinfection of Piping. 8/1 3/09 Contract No. 381 1 POLYVINYL CHLORIDE (PVC) PRESSURE PIPE & FITTINGS PALOMAR AIRPORT ROAD WIDENING 1 5064-4 SECTION 15092 MISCELLANEOUS COUPLINGS, PIPE AND APPURTENANCES PART 1 - GENERAL 1.1 DESCRIPTION All valves, couplings, and appurtenances shall conform to requirements of the standard dimensions and pressure classification of the immediately adjacent pipe, valve or appurtenance as specified. 1.2 RELATED WORK DESCRIBED ELSEWHERE The Contractor shall refer to the following Specification section(s) for additional requirements: A. Painting and Coating: 09900 B. Petrolatum Wax Tape Coating: 09902 1.3 SUBMITTALS Contractor shall furnish submittals in accordance with the requirements of Section 2-5.3, Shop Drawing Submittals. The following submittals are required: A. Submit Shop Drawings for all miscellaneous couplings, pipe and appurtenances. Shop Drawings shall include listing of materials of construction, with ASTM reference and grade, including lining and paint coating intended for use, with lining and coating manufacturers' and paint numbers listed. 1.4 PAYMENT Payment for the Work in this section shall be included as part of the lump-sum or unit- price bid amount for which such Work is appurtenant thereto. PART 2 - MATERIALS 2.1 GASKETS, NUTS, AND BOLTS Gaskets for flanged joints shall be "drop-in" type asbestos composition sheet packing, graphited on both sides, "drop-in" type, conforming to the requirements of ANSI B16.21 and shall be as manufactured by Crane Co., Garlock or approved equal. Bolts and studs for aboveground installations shall be cadmium plated and shall conform to ASTM A307, Grade B, "Steel Machine Bolts and Nuts and Tap Holes," when a ring gasket is used and shall conform to either ASTM A261, "Heat-Treated Carbon Steel Bolting Material" or ASTM A193, "Alloy-Steel Bolting Material for High Temperature Service," when a full-face gasket is used. Bolts and nuts shall be heavy hexagon series. Nuts shall conform to ASTM A194, "Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service" either in Grade 1, 2 or 2H. The fit shall be ANSI B1.1, "Unified Screw Threads," Class 2, except that Class 3 fit shall be used in holes tapped for studs. Threads may be made by either cutting or cold forming. 8/13/09 Contract No. 3811 MISCELLANEOUS COUPLINGS, PIPE & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15092-1 Between 1/4-inch and 3/8-inch shall project through the nut when drawn tight. Washers shall be provided for each nut and shall be the same material as each nut. All buried flanges, including bolts, nuts and washers, shall be encased in wax tape per Section 09902. All bolt threads shall be lubricated with non-oxide grease. Flanged faces shall be wire brushed and cleaned prior to joining each flange. 2.2 POLYETHYLENE ENCASEMENT Unless otherwise specified on the Plans, all couplings and appurtenances for underground installation shall be encased in wax tape per Section 09902. 2.3 PAINTING AND COATING All miscellaneous couplings, pipe and appurtenances referenced in this section shall be painted and coated, interior and exterior, in accordance with Section 09900, Painting and Coating. 2.4 FLEXIBLE COUPLINGS Joints for which flexible couplings are required, shall be made with Baker, Smith-Blair, or approved equal. Gaskets shall be plain rubber gaskets. Threads on bolts of compression collars shall be lubricated with non-oxide grease before assembling the coupling. For cast-iron, ductile-iron or asbestos cement pipe sizes 2-inches through 16-inches, use Baker Series 228, Smith-Blair Series 413, or approved equal. Transition couplings shall be Baker Series 212, Smith-Blair Series 413, or approved equal. Flanged coupling adapters for cast iron or ductile iron pipe sizes 4-inches through 12-inches shall be Baker Series 601, Smith-Blair Series 912, or approved equal. Flanged coupling adaptors for cast or ductile iron pipe greater than 12-inches shall be Baker Series 602 or Smith-Blair Series 913. 2.5 PIPE UNIONS Screw unions may be employed on pipelines 2-1/2-inches in diameter and smaller. Pipes and fittings made of non-ferrous metals shall be isolated from ferrous metals by nylon insulating pipe bushings, unions or couplings manufactured by Smith-Blair, Pipe Seal and Insulator Co. or approved equal. PART 3 - EXECUTION (Not Applicable) 8/13/09 Contract No. 3811 MISCELLANEOUS COUPLINGS, PIPE & APPURTENANCES PALOMAR AIRPORT ROAD WIDENING 15092-2 SECTION 15100 RESILIENT WEDGE GATE VALVES (RWGV's) PART 1 - GENERAL 1.1 DESCRIPTION This section includes materials, testing, and installation of manually operated resilient wedge gate valves (RWGV's). 1.2 REFERENCE STANDARDS i, The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. 1.3 RELATED WORK SPECIFIED ELSEWHERE CMWD Standard Drawings CMWD Standard Specifications 15000, 15041, 15044, 15056, 15057, 15061, 15064, 15074,15108 and 15112 1.4 SERVICE APPLICATION A. Resilient wedge gate valves (RWGVs) shall be installed on potable and recycled water mains and appurtenances in accordance with the Approved Plans and the Standard Drawings. B. Resilient wedge gate valves shall be used for open/closed operations, throttling service and frequent operation after long periods of no actuation. C. In general, resilient wedge gate valves shall be used when valves are required on pipelines and appurtenances 100m (4") through 400mm (16"). D. Valves for pipelines sized 450mm (18") and larger generally require the use of butterfly valves (BFV) in accordance with Section 15102. 1.5 SUBMITTALS The following items shall be submitted for review and approval per Section 2-5.3, prior to ordering or delivery of resilient wedge gate valves. A. An affidavit from, the valve manufacturer stating that valves have successfully passed hydrostatic tests in accordance with AWWA C509 and manufacturer's own coatings tests. B. The valve manufacturer's catalog data showing the size to be used, valve dimensions, pressure rating and materials of construction. C. Manufacturer's catalog data and proof of NSF certification for the lining materials to be used. 8/13/09 Contract No. 3811 RESILIENT WEDGE GATE VALVES PALOMAR AIRPORT ROAD WIDENING 15100-1 1.6 SIZING OF VALVES ^% Valves shall be the same size as the line in which they are installed unless otherwise noted on the Approved Plans. 1.7 VALVE ENDS Valve ends shall be compatible with the piping system in which they are being installed in accordance with the Approved Plans or directed by the District Engineer. Ductile-iron flanges shall be in accordance with Section 15056. 1.8 VALVE TESTING Resilient wedge gate valves shall be hydrostatically tested and valve coatings shall be holiday detected prior to shipment to the field in accordance with the testing procedures shown in Appendix A. Valves delivered to the site prior to successful hydrostatic testing and holiday detection shall be subject to rejection. 1.9 DELIVERY, STORAGE AND HANDLING Valves shall be delivered and stored in accordance with AWWA C550. The port openings shall be covered with plastic, cardboard or wood while in transit and during storage in the field. These covers shall remain in place until valves are ready to be installed. Valves shall not be stored in contact with bare ground. Valves shall not be s**^ stacked. ^^ 1.10 RECYCLED WATER IDENTIFICATION 1.11 POLYETHYLENE WRAP Polyethylene wrap shall be used for the buried installation of resilient wedge gate valves in accordance with Section 15000. PART 2 - MATERIALS 2.1 RESILIENT WEDGE GATE VALVES (RWGVs) A. Resilient wedge gate valves and appurtenant components and materials shall be selected from the Approved Materials List. B. RWGVs shall be ductile-iron in accordance with AWWA C509, and C515 except as modified herein. C. Each valve shall have a smooth unobstructed waterway free from any sediment pockets. D. All RWGVs shall be leak-tight at their rated pressure. E. RWGVs shall have a non-rising low-zinc bronze or stainless steel stem, opened by ^i turning left (counterclockwise). >*"*^ 8/13/09 Contract No. 3811 RESILIENT WEDGE GATE VALVES PALOMAR AIRPORT ROAD WIDENING 15100-2 F. Stem seals shall be the O-ring type incorporating a minimum of two rings as required by AWWA C509. G. Low-friction torque-reduction thrust washers or bearings shall be provided on the stem collar. H. Wedge (gate) shall be fully encapsulated with a bonded-in-place Nitrite elastomer covering. Minimum thickness of the rubber seating area shall be 6.35mm (1/4"). I. Valves for buried applications shall be provided with a 50mm (2") square operating nut, and valves located above ground or in structures shall be equipped with a hand wheel in accordance with AWWA C509 unless otherwise indicated on the Approved Plans. J. RWGV interior and exterior surfaces (except for the encapsulated disc) shall be coated as described below. K. All bolts and nuts used in the construction of RWGVs shall be Type 316 stainless steel. 2.2 EPOXY LINING AND COATING Epoxy linings and coatings for valves shall be provided in accordance with AWWA C210, C213, and C550, with the following modifications: A. Epoxy lining and coating of valve surfaces shall be performed by the manufacturer in a facility with qualified personnel, where the environment can be controlled. Epoxy lining and coating of valves in the field is prohibited. B. Repairs made to manufactures applied coatings shall be performed in a facility with qualified personnel, where the environment can be controlled. The facility shall be approved by the valve manufacturer. C. Surface preparation shall be as detailed in SSPC-SP5, White-Metal Blast Cleaning. D. Liquid epoxy lining and coating materials shall be listed in the NSF Listing for Drinking Water Additives, Standard 61, certified for use in contact with potable water. E. The minimum dry film thickness for epoxy linings shall be 0.203mm (0.008" or 8 mils). Liquid epoxy lining shall be applied in two (2) coats in accordance AWWA C210. F. Powder epoxy coating materials shall contain one hundred percent (100%) solids, in accordance with AWWA C213. 2.3 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be in accordance with Section 15000 and selected from the Approved Materials List. 8/13/09 Contract No. 3811 RESILIENT WEDGE GATE VALVES PALOMAR AIRPORT ROAD WIDENING 15100-3 2.4 CONCRETE THRUST BLOCKS ^% Concrete thrust or anchor blocks shall be placed as shown on the approved plans. 2.5 POLYETHYLENE WRAP Polyethylene wrap shall be in accordance with Section 15000 and selected from the Approved Materials List. PART 3 - EXECUTION 3.1 INSTALLATION A. Install valves with the bolt holes straddling the vertical centerline of pipe and the operating nut in the vertical position unless otherwise noted on the Approved Plans. B. Valves shall be installed in accordance with the manufacturer's recommendations and the applicable section of these specifications for the piping material and joint type being used. C. Joints shall be cleaned and installed in accordance with Section 15056. 3.2 POLYETHYLENE WRAP Installation of polyethylene wrap for buried valves shall be in accordance with \^ Section 15000. 3.3 CONCRETE Concrete thrust, anchor, and support blocks shall be installed in accordance the Standard Drawings. The concrete shall be placed so that valves and valve operators will be accessible for repairs or replacement. 3.4 GATE WELLS AND EXTENSION STEMS Gate wells and extension stems for buried valves shall be installed in accordance with Section 15000 and the Standard Drawings. 3.5 DISINFECTION OF VALVES Disinfection and flushing of valves shall be in accordance with Section 15041, as part of the process of disinfecting the main pipeline. The valves shall be operated during the disinfection period to completely disinfect all internal parts. 3.6 HYDROSTATIC TESTING Valves shall be hydrostatically tested in conjunction with the pipeline in which they are installed in accordance with Section 09900. 8/13/09 Contract No. 3811 RESILIENT WEDGE GATE VALVES PALOMAR AIRPORT ROAD WIDENING 15100-4 3.7 FIELD PAINTING AND COATING The exterior of valves installed above ground or exposed in vaults or enclosures shall be field painted in accordance with Section 09900. 8/13/09 Contract No. 3811 RESILIENT WEDGE GATE VALVES PALOMAR AIRPORT ROAD WIDENING 15100-5 SECTION 15112 BACKFLOW PREVENTERS PART 1 - GENERAL 1.1 DESCRIPTION This section includes materials, installation, and testing of reduced-pressure backflow prevention devices and check valve and double check valve assemblies. 1.2 REFERENCE STANDARDS The publications listed below form part of this specification to the extent referenced and are referred to in the text by the basic designation only. Reference shall be made to the latest edition of said standards unless otherwise called for. State of California Department of Health Services Division of Drinking Water and Environmental Management, Approved Backflow Prevention Assemblies for Service Isolation. 1 .3 RELATED WORK SPECIFIED ELSEWHERE Agencies of Jurisdiction Rules and regulations regarding "Cross Connection Control and Backflow Prevention" CMWD Standard Drawings CMWD Standard Specifications 09900, 15000, 15041, 15044, 15056, 15057, 15061, 15064 and 151 00 1 .4 SERVICE APPLICATION A. Reduced-pressure backflow prevention assemblies shall be provided on all commercial, industrial irrigation and multi-family water services. B. Reduced-pressure backflow prevention assemblies shall be provided on all irrigation services by potable and recycled water. C. Reduced-pressure backflow prevention assemblies shall be provided on potable water services where recycled water, well water or any other water supply is served to the same property. D. Reduce pressure backflow preventers assemblies shall be provided at all points of connections to District sources at construction sites. E. Double check detector assemblies shall be provided on all fire services. F. The District shall be the final authority as to the location, installation, and type of backflow prevention device required. 8/1 3/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 381 1 BACKFLOW PREVENTERS 15112-1 1.5 GENERAL DESIGN CONSIDERATIONS A. The Design and construction of the backflow prevention assembly shall meet the requirements called for in this specification except that any modifications specifically shown on the Approved Plans shall take precedence over these general standards. B. The nominal size of the backflow prevention device shall be equal to or greater than the size of the purchased meter. For example, a 25mm (1") meter shall have a 25mm (1") or larger backflow device. C. The assembly shall include same size valves located on either side of the backflow prevention assemblies. Four test cocks shall be appropriately located on the assembly for testing and certification. D. The nominal size of double check detector assemblies shall be as shown on the Approved Plans or as directed by the Fire Department. E. Enclosures and concrete slabs shall be provided only as shown on the Approved Plans. 1.6 DELIVERY, STORAGE AND HANDLING Backflow prevention assemblies shall be delivered and stored in accordance with AWWA C210, AWWA C213, and AWWA C550. The port openings shall be covered with plastic, cardboard, or wood while in transit and during storage in the field. These covers shall remain in place until the backflow assembly is ready to be installed. Backflow assemblies shall not be stored in contact with bare ground. Backflow assemblies shall not be stacked. 1.7 RECYCLED WATER IDENTIFICATION Backflow prevention assemblies and enclosures for recycled water shall be identified with purple-colored coating, identification labels, or signs. 1.8 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be installed for backflow prevention assemblies in accordance with Section 15000. PART 2 - MATERIALS 2.1 BACKFLOW PREVENTION ASSEMBLIES Backflow prevention assemblies shall be among those listed on the list of "Approved Backflow Prevention Assemblies for Service Isolation" as issued by the State of California Department of Health Services, Division of Drinking Water and Environmental Management. 8/13/09 Contract No. 3811 BACKFLOW PREVENTERS PALOMAR AIRPORT ROAD WIDENING 15112-2 2.2 CONCRETE Concrete used for pads and anchor or thrust blocks shall be as shown on the approved plans. 2.3 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be in accordance with Section 15000 and the Approved Materials List. PART 3 - EXECUTION 3.1 INSTALLATION A. Installation shall comply with the latest edition of the Uniform Plumbing Code, applicable local agency and District requirements. B. Backflow prevention assemblies shall be installed in accordance with the Standard Drawings. C. Water service and fire service shut-off valves will be secured closed during installation until an approved backflow prevention device is installed and tested in compliance with this specification. D. When static pressure exceeds 1 .OSMPa (1 50psi), or when recommended by the backflow device manufacturer, a pressure-reducing valve shall be installed as shown on the Standard Drawings. 3.2 WARNING/IDENTIFICATION TAPE Warning/Identification Tape shall be installed in accordance with Section 15000 and the Standard Drawings. 3.3 CONCRETE Concrete thrust or anchor blocks and slabs shall be installed per W20 of the Carlsbad's Engineering Standards. 3.4 ENCLOSURES Enclosures shall be installed where shown on the Approved Plans in accordance with the Standard Drawings. 3.5 DISINFECTION Disinfection and flushing shall be performed in accordance with Section 15041, as part of the process of disinfecting the main pipeline. The backflow assemblies shall be operated during the disinfection period to completely disinfect all internal parts. 3.6 HYDROSTATIC TESTING 8/1 3/09 Contract No. 381 1 BACKFLOW PREVENTERS PALOMAR AIRPORT ROAD WIDENING 151 12-3 Backflow assemblies shall be hydrostatically tested in conjunction with the pipeline to which they are connected in accordance with Section 15044. 3.7 TESTING The District will inspect and initially test each backflow prevention assembly after inspection of its proper installation is complete. Required maintenance of the backflow prevention device and appurtenances and annual testing of the device shall be the owner's responsibility. 8/13/09 Contract No. 3811 BACKFLOW PREVENTERS PALOMAR AIRPORT ROAD WIDENING 15112-4 SECTION 15140 A. RELOCATE FIRE HYDRANTS AND WATER METERS '^J PART 1 - GENERAL 1.1 SECTION INCLUDES A. Relocation of existing fire hydrants and water meters which may be necessary because of changes in grade or installation of new improvements which conflict with existing hydrant and meter locations 1.2 REFERENCES A. AWWA C203: AWWA Standard for Coal-Tar Protective Coatings and Linings for Steel Water Pipelines - Enamel and Tape - Hot-Applied. B. AWWA: AWWA Standard for Wet Barrel Fire Hydrants. 1.3 JOB CONDITIONS A. Secure utility agency permit to do relocation work and pay applicable fees. B. Secure utility agency approval of joints, connections, and pipe installations prior to commencing backfill operations. PART 2 - PRODUCTS ^••^n? 2.1 HYDRANTS A. Use existing hydrant unless Contract Documents specifies AGENCY or CONTRACTOR will provide a new unit. B. Use the same type of pipe material as used for existing hydrant piping unless indicated otherwise. C. Use mechanical and flange joint fittings unless indicated otherwise. Use only new tees, fittings, and bends. D. Coat all weld connections and damaged areas of metal piping with coal tar enamel. Follow AWWA C203 requirements. Tape wrap coatings. 2.2 WATER SERVICE METERS A. Use existing water meter and yoke unless Contract Documents specifies AGENCY or CONTRACTOR will provide a new unit. B. When relocating meters, provide Type K copper pipe per Section 15012 from main to meter yoke. 8/13/09 Contract No. 3811 RELOCATE FIRE HYDRANTS & WATER METERS PALOMAR AIRPORT ROAD WIDENING 15140-1 2.3 CONCRETE A. Class 3000 or 4000 per Section 03300. PART 3 - EXECUTION 3.1 PREPARATION A. Before commencing work, coordinate location and shutdown of utility lines with utility agency and residents. See GENERAL PROVISIONS. B. Protect existing hydrants and meters from damage. C. Control ground water, surface water, and storm water. D. Control pedestrian or vehicular traffic. E. Provide all excavation backfill, compaction, connections, testing, and surface restorations to make the installation complete. 3.2 MOVING EXISTING HYDRANTS A. Relocate to locations indicated in the drawing per CES W-12. B. . Do not disturb location of hydrant lateral tee at water main. C. The method of harnessing the hydrant (reshackling or reblocking) shall match existing conditions or approval of ENGINEER. D. Install hydrant so base flange is even with or less than 4-inches above grade of surrounding surface. 3.3 RECONNECTING EXISTING HYDRANTS A. When existing tee on water main is to be moved to new location, seal and shackle old tee. 3.4 HYDRANT BARREL EXTENSIONS A. Follow AWWA to extend barrels, operating stems and flanged adapters in design material and workmanship so hydrant base flange is even with or less than 4-inches above grade of surrounding surface. 3.5 RESETTING WATER METERS A. Follow Section 15000 to relocate water meters and service connections to locations indicated. 3.6 FIELD QUALITY CONTROL A. Hydrostatic Tests: Follow Section 15044 requirements. 8/13/09 Contract No. 3811 RELOCATE FIRE HYDRANTS & WATER METERS PALOMAR AIRPORT ROAD WIDENING 15140-2 B. Disinfection: Follow Section 15041 requirements 8/13/09 PALOMAR AIRPORT ROAD WIDENING Contract No. 3811 RELOCATE FIRE HYDRANTS & WATER METERS 15140-3 SECTION 16560-TRAFFIC SIGNALS, LIGHTING, AND TRAFFIC ELECTRICAL SYSTEMS PART 1 - GENERAL 1.1 THE REQUIREMENT A. Signals, lighting and electrical systems work shall consist of furnishing and installing, modifying or removing one or more traffic signals, traffic signal master controller assemblies and interconnection facilities, flashing beacon systems, lighting systems, sign illumination systems, traffic monitoring stations, communication systems, electrical equipment in structures, falsework lighting, provisions for future systems, or combinations thereof, all as shown on the plans, and as specified in these technical specifications. The locations of signals, beacons, standards, lighting fixtures, signs, controls, services and appurtenances shown on the plans are approximate and the exact locations will be established by the Engineer in the field. All systems shall be complete and in operating condition at the time of acceptance of the contract. 1.2 REFERENCES A. ANSI publication Y32.2, entitled "IEEE Standard and American National Standard Graphic Symbols for Electrical and Electronic Diagrams". B. The California Manual on Uniform Traffic Control Devices (FHWA's MUTCD 2003 Revision 1, as amended for California). C. National Electric Code 2004 edition. D. AWS D1.1 "Structural Welding Code". E. Standard Specifications for Public Works Construction 2006 edition. F. ASTM D 635 Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position. G. ASTM B 3 Standard Specification for Soft or Annealed Copper Wire. H. ASTM B 8 Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium- Hard, or Soft. I. ASTM A 307 Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength J. ASTM A 325 Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength K. ASTM A 449 Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use L. ASTM A 563 Standard Specification for Carbon and Alloy Steel Nuts. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-1 M ASTM F 476 Standard Test Methods for Security of Swinging Door Assemblies. N. ASTM B 117 Standard Practice for Operating Salt Spray (Fog) Apparatus. O. ANSI C82.6-1980, Methods of Measurement of High-Intensity-Discharge Lamp Ballasts. P. ANSI Standard: C 78.388, Methods of Measurement of High Pressure Sodium Lamp Characteristics. Q. NEMA Standards Publication No. TS 1, Section 11. R. State of California Standard Plans, July 2002 S. AASHTO Standard Specification for Steel Anchor Bolts AASHTO Designation: M 314-90 (2004) T. ASTM A 53 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless U. ASTM A 27 Standard Specification for Steel Castings, Carbon, for General Application V. ASTM E 94 Standard Guide for Radiographic Examination W. ASTM E 186 Standard Reference Radiographs for Heavy-Walled (2 to 4 1/2-in. (51 to 114-mm)) Steel Castings X. ASTM E 446 Standard Reference Radiographs for Steel Castings Up to 2 in. (51 mm) in Thickness Y. ASTM A 239 Standard Practice for Locating the Thinnest Spot in a Zinc (Galvanized) Coating on Iron or Steel Articles Z. ASTM D 635 Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position AA. ASTM B 286 Standard Specification for Copper Conductors for Use in Hookup Wire for Electronic Equipment. AB. ASTM D 2219 Standard Specification for Poly(Vinyl Chloride) Insulation for Wire and Cable, 60°C Operation. AC. ASTM D1351 Standard Specification for Thermoplastic Polyethylene Insulation for Electrical Wire and Cable AD. CalTrans, Transportation Electrical Equipment Specifications AE. CalTrans, Traffic Signal Control Equipment Specifications AF. ANSI C82.6-1980 Methods of Measurement of High-Intensity-Discharge Lamp Ballasts 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-2 AG. ASTM B 209 Standard Specification for Lampblack Pigment or D5052 Test Method for Permeability of Leather to Water Vapor. AH. ANSI Standard: C 78, Lamp Specifications, Physical and Electrical Characteristics of High-Intensity-Discharge Lamps Al. ANSI Standard C82.6-1980, Methods of Measurement of High-Intensity-Discharge Lamp Ballasts. AJ. AASHTO publication, Standard Specifications for Structural Supports of Highway Signs, Luminaries and Traffic Signals. 1.3 DEFINITIONS The following definitions pertain only to Section 16560, "Signals, Lighting and Traffic Electrical Systems." Actuation. — The operation of any type of detector. Burn-In Procedure. — The procedure by which each LED signal module is energized for a minimum of 24 hours at operating voltage at a 100% duty cycle, and in an ambient temperature of 60°C (140°F). Candlepower Values. — Luminous intensity expressed in candelas (cd). Channel. — A discrete information path. Chromaticity (Color). — The color of the light emitted by a signal module, specified as x-y chromaticity coordinates on the chromaticity diagram according to the 1931 Commission Internationale d'Eclairage standard observer and coordinate system. The measured chromaticity coordinates shall fall within the limits specified in VTCSH Section 8.04 "Limits of Chromaticity Coordinates." Controller Assembly. — The complete assembly for controlling the operation of a traffic signal or other system, consisting of a controller unit, and all auxiliary equipment housed in a rainproof cabinet. Controller Unit. — That part of the controller assembly which performs the basic timing and logic functions. Detector. — A device for indicating the passage or presence of vehicles or pedestrians. Duty Cycle. — The amount of illuminated on-time a signal module is energized, expressed as a percent of signal cycle time period. Electrolier. — The complete assembly of lighting standard, luminaire, ballast and lamp. Flasher. — A device used to open and close signal circuits at a repetitive rate. Flashing Beacon Control Assembly. — A complete electrical mechanism for operating a warning beacon or intersection control beacon. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-3 Inductive Loop Vehicle Detector. —A detector capable of being actuated by the change of inductance caused by a vehicle passing over or standing over the loop. Integrating Photometer. — An instrument used in measuring the intensity of light that enables total luminous flux to be determined by a single measurement. LED Light Source. — An individual light emitting diode. LED Signal Module. — A sealed circular ball or arrow that includes the lens and utilizes LED devices as the light source. An LED signal module may directly replace an existing traffic signal lamp and lens combination. Lighting Standard.— The pole and mast arm which support the luminaire. Luminaire.— The assembly which houses the light source and controls the light emitted from the light source. Magnetic Vehicle Detector.— A detector capable of being actuated by the induced voltage caused by the passage of a vehicle through the earth's magnetic field. Magnetometer Vehicle Detector.— A detector capable of being actuated by the magnetic disturbance caused by the passage or presence of a vehicle. Major Street.— The roadway approach or approaches at an intersection normally carrying the major volume of vehicular traffic. Minimum Intensity. — In accordance with the values in Table 1 of the existing "Vehicle Traffic Control Signal Heads", hereinafter VTCSH standard, the minimum intensity values below which no LED signal modules will be released from the supplier. Minor Street.— The roadway approach or approaches at an intersection normally carrying the minor volume of vehicular traffic. Pedestrian Detector.— A detector, usually of the push button type, capable of being operated by hand. Plans. — For Section 16560 plans shall include all documents listed in Section 2.5, "Plans and Specifications" of the General Provisions, et seq. as well as the "STANDARD PLANS", 2006 edition as promulgated by the State of California, Department of Transportation. Power Consumption. — The rms electrical power (watts) consumed by an LED signal module when operated at rated voltage. Pre-timed Controller Assembly.— A controller assembly for operating traffic signals in accordance with a pre-determined cycle length. Rated Initial Intensity. — The light intensity of a new LED signal module, operated at rated voltage, measured after the burn-in procedure with an integrating photometer. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-4 Rated Voltage. — The ac rms voltage at which light output performance and power consumption are specified (117 VAC at 60 Hz). Signal Face.— That part of a signal head provided for controlling traffic in a single direction and consisting of one or more signal sections. Signal Head.— An assembly containing one or more signal faces. Signal Indication.— The illumination of a signal section or other device, or of a combination of sections or other devices at the same time. Signal Section.—A complete unit for providing a signal indication consisting of a housing, lens, reflector, lamp receptacle and lamp. Sun Phantom. — The effect of an outside light source entering the signal assembly and being returned in such a manner as to present the appearance of the signal assembly being illuminated. Traffic-Actuated Controller Assembly. —A controller assembly for operating traffic signals in accordance with the varying demands of traffic as registered with the controller unit by detectors. Traffic Phase.— The right of way, change and clearance intervals assigned to a traffic movement or combination of movements. Vehicle.— Any motor vehicle normally licensed for highway use. VTCSH Standard. — The definitions and practices described in "Vehicle Traffic Control Signal Heads" published in the "Equipment and Materials Standards" of the Institute of Transportation Engineers. 1.4 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS All electrical equipment shall conform to the standards of the National Electrical Manufacturers Association (NEMA), the Underwriters' Laboratories Inc. (UL), the Electrical Testing Laboratories (ETL), the National Electrical Testing Association, Inc. (NETA), or the Electronic Industries Association (EIA), wherever applicable. In addition to the requirements of the plans, these special provisions, all materials and workmanship shall conform to the requirements of the National Electrical Code 2004 edition, hereinafter referred to as the Code; California Code of Regulations, Title 8, Chapter 4, Subchapter 5, Electrical Safety Orders; Rules for Overhead Electrical Line Construction, General Order No. 95 of the Public Utilities Commission; Standards of the American Society for Testing and Materials (ASTM); American National Standards Institute (ANSI); and any local ordinances which may apply. Wherever reference is made to any of the standards mentioned above, the reference shall be construed to mean the code, order, or standard that is in effect on the day the Notice to Contractors for the work is dated. 1.5 CONTRACTOR SUBMITTALS 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-5 A. Unless otherwise permitted in writing by the Engineer, the Contractor shall, within 15 days following award of the contract, submit to the Engineer for review a list of equipment and materials which the Contractor proposes to install as specified in Section 2-5.3, "Shop Drawings and Submittals" of the General Provisions. The list shall be complete as to name of manufacturer, size and identifying number of each item. The list shall be supplemented by such other data as may be required, including schematic wiring diagrams and scale drawings of cabinets showing location and spacing of shelves, terminal blocks and equipment, including dimensioning. All of the above data shall be submitted, install as specified in Section 2-5.3, "Shop Drawings and Submittals", for review. Where electrical equipment is constructed as detailed on the plans, the submission of detailed drawings and diagrams will not be required. B. The Contractor shall furnish 5 sets of controller cabinet schematic wiring diagrams made by (1) wet blueprint, white background process using iron-sensitized paper, (2) the offset lithograph process, or (3) the electrostatic process. The diagrams shall show the location of the installation and shall list all equipment installed in each controller cabinet. In addition, for each signal installation, the Contractor shall furnish an intersection sketch showing poles, detectors, field wire connection terminals and phasing as shown on the plans. All schematic wiring diagrams of the controller units and auxiliary equipment, all cabinet diagrams, and all operation manuals shall be submitted at the time the controller assemblies are delivered for testing. The schematic wiring diagram shall show in detail all circuits and parts. All parts shown thereon shall be identified by name or number and in such manner as to be readily interpreted. All diagrams, plans and drawings shall be prepared using graphic symbols shown in ANSI publication Y32.2, entitled "IEEE Standard and American National Standard Graphic Symbols for Electrical and Electronic Diagrams." C. Manufacturers' warranties and guaranties furnished for materials used in the work and instruction sheets and parts lists supplied with materials shall be delivered to the Engineer prior to acceptance of the project. 2.1 FOUNDATIONS Portland cement materials and construction methods shall conform to SSPWC Section 201, "Concrete, Mortar and Related concrete Materials," for Materials and SSPWC Section 303, "Concrete and Masonry Construction," for construction methods. Concrete foundations shall rest on firm ground. A. Except when located on structures, foundations for posts, standards, and pedestals, not shown on the plans to have mortar pads, shall be placed "in the solid" and monolithic except for the top 50 mm (2") which shall be placed after the post, standard or pedestal is in proper position. After each post, standard, or pedestal on structures, and each standard shown on the plans to have mortar pads, is in proper position, mortar shall be placed under the base plate as shown on the plans. The exposed portions shall be formed to present a neat appearance. Mortar shall consist of one part by volume of Portland cement and 3 parts of clean sand, shall contain only sufficient moisture to permit packing and shall be cured by keeping it damp for 3 days. B. Reinforced cast-in-drilled-hole concrete pile foundations for traffic signal and lighting standards shall conform to the provisions in SSPWC Section 205-3.3, "Cast-in-Place 8/1 3/09 Contract No. 381 1 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 1 6560-6 Concrete Piles," except that material resulting from drilling holes shall be disposed. The exposed portions of the foundation shall be formed to present a neat appearance. C. Forms shall be true to line and grade. Tops of foundations for posts and standards, except special foundations, shall be finished to curb or sidewalk grade or as directed by the Engineer. Forms shall be rigid and securely braced in place. Conduit ends and anchor bolts shall be placed in proper position and to proper height, and shall be held in place by means of a template until the concrete sets. 2.2 ANCHOR BOLTS, STUDS, AND NUTS Anchor bolts or studs and nuts, except for Type 30 and Type 31 lighting standards, shall conform to ASTM Designation: A 307. Headed anchor bolts for foundations shall conform to the specifications of ASTM Designation: A 307, Grade B with S1 supplementary requirements. At the option of the Contractor, nonheaded anchor bolts for foundations shall conform either to the specifications of ASTM Designation: A 307, Grade C or to the provisions in AASHTO Designation: M 314, Grade 36 or 55 with S1 supplementary requirements. When nonheaded anchor bolts conforming to the specifications of ASTM Designation: A 307, Grade C are furnished, the end of each fabricated anchor bolt shall be either coded by end stamping as required in ASTM Designation: A 307 or the end that projects from the concrete shall be permanently coded with a green color by the manufacturer. High strength anchor bolts, bars, or studs for Type 30 and Type 31 lighting standards shall conform to ASTM Designation: A 325, A325M or A 449 and shall comply with the mechanical requirements of ASTM Designation: A 325 or A 325M after galvanizing. Nuts and washers for high strength anchor bolts shall conform to ASTM Designations: A 563 or A 563M, and F 476 or F 476M, respectively. In addition to the requirements of ASTM Designation: A 449, studs shall be marked on either end as required for bolt heads. All steel parts shall be galvanized in accordance with the provisions in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." 2.3 STANDARDS, STEEL PEDESTALS, AND POSTS A. Standards for traffic signals and lighting, and steel pedestals for cabinets and other similar equipment shall be located as shown on the plans. Workmanship and finish shall be equal to the best general practice of metal fabrication shops. All welding shall conform to AWS D1.1, "Structural Welding Code". All welds joining the shafts of the standards and mast arms to their base plates shall be as shown on the plans, however, alternative weld joint details may be approved by the Engineer. Approval of alternative weld joint details will be contingent upon the proposed weld joint passing both weld procedure and nondestructive testing as deemed necessary by the Engineer. All costs of the supplemental testing shall be borne by the Contractor. B. All standards except Type 1, and all signal mast arms, shall have an aluminum identification plate, as noted on the plans, attached with stainless steel rivets or screws. Type 1 standards and steel pedestals for controller cabinets shall be constructed of 3 mm (.125") or thicker galvanized steel; or 100 mm (4") standard weight galvanized, steel pipe or Size 103, Type 1 conduit, with the top designed for post-top slip-fitter. Standard weight galvanized, steel pipe shall conform to the specifications of ASTM Designation: A 53. Materials and construction methods for all ferrous metal parts of standards, with 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-7 shaft length of 4.6 m (15') and longer, shall conform to the details shown on the plans, the requirements of Sections 206, "Miscellaneous Metal Items," for Materials and Section 304, "Metals Fabrication and Construction," for construction methods except as otherwise noted, and the following requirements: C. Except as otherwise specified, standards shall be fabricated from sheet steel of weldable grade having a minimum yield strength, after fabrication, of 276 Mpa (40,000 psi). Certified test reports which verify conformance to the minimum yield strength requirements shall be submitted to the Engineer. The test reports may be the mill test reports for the as-received steel or, when the as-received steel has a lower yield strength than required, the Contractor shall provide supportive test data which provides assurance that the Contractor's method of cold forming will consistently increase the tensile properties of the steel to meet the specified minimum yield strength. The supportive test data shall include tensile properties of the steel both before and after cold forming for specific heats and thicknesses. D. When a single-ply 8 mm (0.3125") thick pole is specified, a 2-ply pole with equivalent section modulus may be substituted. Standards may be fabricated of full-length sheets or shorter sections. Each section shall be fabricated from not more than 2 pieces of sheet steel. Where 2 pieces are used, the longitudinal welded seams shall be directly opposite one another. When the sections are butt-welded together, the longitudinal welded seams on adjacent sections shall be placed to form continuous straight seams from base to top of standard. E. Butt-welded transverse joints shall be strengthened by inserting a metal sleeve at each joint. The sleeve shall be 3 mm (0.120") nominal thickness, or thicker, steel having the same chemical composition as the steel in the standard. When the sections to be joined have different specified minimum yield strengths, the steel in the sleeve shall have the same chemical composition as the higher minimum yield strength steel to be joined. The metal sleeve shall have a minimum length of 25 mm. The sleeve shall be centered at the joint and have the same taper as the standard with the outside of the sleeve in full contact with the inside of the standard throughout the sleeve length and circumference. All welds shall be continuous. The weld metal at the transverse joint shall extend to the sleeve, making the sleeve an integral part of the joint. Longitudinal welds in steel tubular sections will be tested in accordance with California Test 664. The sampling frequency shall be as determined by the Engineer. The welds may be made by the electric resistance welding process. All exposed welds, except fillet and fatigue resistant welds and welds on top of mast arms, shall be ground flush with the base metal. F. All exposed edges of the plates which make up the base assembly shall be finished smooth and all exposed corners of the plates shall be neatly rounded unless otherwise shown on the plans. Shafts shall be provided with slip-fitter shaft caps. Standards shall be straight, with a permissive variation not to exceed 25 mm (1") measured at the midpoint of a 9 m (301) or 11 m (36') standard and not to exceed 20 mm (3/4") measured at the midpoint of a 5 m (17') through 6 m (20') standard. Variation shall not exceed 25 mm (1") at a point 4.5 m (15') above the base plate for Type 35 and Type 36 standards. G. All galvanized nuts, used on assemblies with a specified preload or torque, shall be lubricated in accordance with the requirements specified for galvanized Grade DH nuts in ASTM Designation: A 563 "Standard Specification for Carbon and Alloy Steel Nuts". 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-8 H. Standards with an outside diameter of 300 mm (12") or less shall be round. Standards with an outside diameter greater than 300 mm (12") shall be round or multisided. Multisided standards shall have a minimum of 10 sides which shall be convex and shall have a minimum bend radius of 100 mm (4"). I. Mast arms for standards, shall be fabricated from material as specified for standards and shall conform to the dimensions shown on the plans. J. The cast steel option for slip bases shall be fabricated from material conforming to the requirements of ASTM Designation: A 27 "Standard Specification for Steel Castings, Carbon, for General Application", Grade 70-40. Other comparable material may be used if written permission is given by the Engineer. The casting tolerances shall be in accordance with the Steel Founder's Society of America recommendations (green sand molding). One casting from each lot of 50 castings or less shall be subject to radiographic inspection, in accordance with the provisions in ASTM Designation: E 94 "Standard Guide for Radiographic Examination". The castings shall comply with the acceptance criteria severity level 3 or better for all types and categories of discontinuities as specified in ASTM Designations: E 186 "Standard Reference Radiographs for Heavy-Walled (2 to 4 1/2-in. (51 to 114-mm)) Steel Castings", and E446 "Standard Reference Radiographs for Steel Castings Up to 2 in. (51 mm) in Thickness". If the one casting fails to pass the inspection, 2 additional castings shall be radiographed. Both of these castings shall pass the inspection or the entire lot of 50 will be rejected. Material certifications consisting of physical and chemical properties, and radiographic films of the castings shall be filed at the manufacturer's office. These certifications and films shall be available for inspection upon request. K. High-strength bolts, nuts and flat washers used to connect slip base plates shall conform to ASTM Designation: A 325 or A 325M "Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength" and shall be galvanized as specified in SSPWC Section 210-3.6, "Galvanizing for Traffic Signal Facilities." L. Plate washers shall be fabricated by saw cutting and drilling steel plate conforming to AISI Designation: 1018, and be galvanized as specified in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." M. Prior to galvanizing, all burrs and sharp edges shall be removed and holes shall be chamfered sufficiently on each side to allow the bolt head to make full contact with the washer without tension on the bolt. N. High-strength cap screws shown on the plans for attaching mast arms to standards shall conform to ASTM Designation: A 325, A325M or ASTM Designation: A 449 "Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use" and shall comply with the mechanical requirements of ASTM Designation: A 325 or A 325M after galvanizing. The cap screws shall be galvanized as specified. The threads of the cap screws shall be coated with a lubricant which is clean and dry to the touch. O. The galvanized faying surfaces of the connections between signal or lighting mast arms and poles shall be free of surface imperfections, such as lumps, runs, and scum, which would prevent intimate, uniform contact between the faying surfaces. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-9 P. Handholes in the base of standards shall conform to the details shown on the plans. All handholes shall be provided with covers. Q. Changes in configuration of mast arms will be permitted, provided the mounting height and stability are maintained. Fabricators electing to use larger than minimum arm diameters shall adjust the details as required to permit solid seating of the cap screws. All arms shall be bent to the approximate configuration shown on the plans. A smooth curving arm is required. R. Pedestrian push button posts shall be constructed of 65 mm (2 1/2") standard pipe conforming to the dimensions shown on the plans. Guard posts shall be constructed of 100 mm (4") nominal dimension galvanized standard pipe 1.7 m (66") long. Posts shall be set 900 mm (3') in a block of portland cement concrete, as shown on the plans, and the pipe shall be filled with portland cement concrete. Push button posts and guard posts shall be pipe conforming to the specifications of ASTM Designation: A 53 "Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless". S. Slip bases shall be assembled and tightened when the pole is on the ground prior to erection. The threads of the heavy hex nuts for the slip base bolts shall be coated with an additional lubricant which is clean and dry to the touch. Each high strength slip base bolt shall be tightened to within 10N-m (10 foot-pounds), plus or minus, of values in Table 2.3 (A): TABLE 2.3 (A) HIGH STRENGTH SLIP BASE BOLT TORQUE VALUES Standard Type 15-SB 30 31 36-20A Torque (Newton-meters) 200 200 275 225 Torque Foot- Pounds 150 150 200 165 T. Holes left in the shafts of existing standards, due to removal of equipment or mast arms, shall be repaired by welding in a suitable disk, grinding smooth, and painting as provided for repairing damaged galvanized surfaces. When directed by the Engineer, existing standards to be relocated or reused in place shall be repaired. Large dents shall be removed, shafts shall be straightened, and portions which are in poor condition due to corrosion or damage, shall be replaced. Extent of repairs or replacements will be determined by the Engineer and the repairs or replacements ordered by the Engineer will be paid for as extra work as provided in General Provisions Section 3-2, "Changes Initiated By The Agency." U. Anchor bolts or bars and nuts required for relocating existing standards shall be furnished by the Contractor. When a standard or mast arm is relocated, or when a used standard or mast arm is Agency-furnished, new nuts, bolts, cap screws and washers shall be provided and, if the standard has a slip base, a new keeper plate shall be provided. New hardware shall conform to the requirements for hardware used with new 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-10 standards. New standards, mast arms, posts and other ferrous materials shall be galvanized as provided in SSPWC. 2.4 CONDUIT A. All conductors shall be run in conduit, except overhead and temporary installations, and where conductors are run inside poles. Conduit shall be of the sizes shown on the plans and as specified in this Section 16560-2.4. In addition, the Contractor may, as an option at the Contractor's expense, use conduit of a larger size than that shown or specified, provided the larger size is used for the entire length of the run from outlet to outlet. Reducing couplings will not be permitted. New conduit shall not pass through foundations for standards. B. Conduit and conduit fittings shall be UL or ETL listed and shall conform to the following: Type 1. Hot-dip galvanized rigid steel conduit conforming to the requirements in UL Publication UL 6 for Rigid Metallic Conduit. The zinc coating will be tested in accordance with ASTM Designation: A 239 "Standard Practice for Locating the Thinnest Spot in a Zinc (Galvanized) Coating on Iron or Steel Articles". C. Type 2. Hot-dip galvanized rigid steel conduit conforming to Type 1 above and coated with polyvinyl chloride or polyethylene. The exterior thermoplastic coating shall have a minimum thickness of 0.9 mm (35 mils). D. Type 3. Rigid non-metallic conduit conforming to the requirements in the UL Standard for Rigid Non-Metallic Conduit (Publication UL 651). Type 3 conduit shall be installed at all underground locations. E. Type 4. Liquid tight flexible metal conduit shall consist of conduit with a liquid tight, non- metallic, sunlight-resistant jacket over an inner flexible metal core. Type 4 conduit shall be UL listed for use as the grounding conductor. F. Type 5. Intermediate steel conduit (IMC) conforming to the requirements in UL Publication 1242 for Intermediate Metallic Conduit. Type 5 conduit shall only be used when specified. G. Bonding bushings to be installed on metal conduit shall be insulated and shall be the galvanized or zinc alloy type. All conduit installed underground shall be Type 3, rigid non-metallic conduit. Type 3 conduit shall be installed at underground locations only. H. Exposed conduit installed on a painted structure shall be painted the same color as the structure. Unless otherwise indicated, the minimum metric trade size of conduit shall be: Size 78 (3°). 2.5 EXPANSION FITTINGS Expansion fittings shall be installed where the conduit crosses any expansion joint in the structure. Each expansion fitting for metal conduit shall be provided with a copper bonding jumper having the ampacity required by the Code. Each expansion-deflection fitting for expansion joints of 38 mm (11/2") movement rating shall be watertight and shall consist of a molded neoprene sleeve, a bonding jumper and 2 silicon bronze or zinc- plated iron hubs. Each fitting shall permit a minimum of 19 mm (3/4") expansion and 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-11 contraction and a minimum of 19 mm (%") lateral deflection. Details of expansion- deflection fittings for joints of movement rating of more than 38 mm (11/2 U) shall be as shown on the plans and specified in these special provisions. 2.6 PULL BOXES A. Pull boxes shall be installed at the locations shown on the plans or as specified. The Contractor may, as an option, at the Contractor's expense, use pull boxes of a larger standard size than that shown or specified. B. Pull boxes, covers and extensions for installation in the ground or in sidewalk areas shall be of the sizes and details shown on the plans and shall be precast of reinforced Portland cement concrete (PCC) or of non-PCC material. Non-PCC material shall be fire resistant and shall not burn at a rate greater than 8 mm (0.3") per minute per 2.5 mm (0.1") of thickness when tested in accordance with ASTM Designation: D 635 ". The non-PCC material shall show no appreciable change in physical properties with exposure to the weather. Non-PCC material shall be dense and free of voids or porosity, and shall be a gray or brown color. Top dimensions of non-PCC pull boxes shall not exceed the bottom dimensions by more than 25 mm (1"). Extensions for non- PCC pull boxes shall be of the same material as the pull boxes, and shall be attached to the pull boxes in a manner that will maintain the minimum combined depths shown on the plans. Non-PCC pull boxes shall be of sufficient rigidity that when a designated concentrated force is applied perpendicularly to the midpoint of one of the long sides at the top while the opposite long side is supported by a rigid surface, it shall be possible to remove the cover without the use of tools. The designated concentrated force shall be 650 N (150 Ibs.) for a No. 31/2 pull box and shall be 450 N (100 Ibs.) for a No. 5 or No. 6 pull box. When a vertical force of 6500 N (1,500 Ibs.) is applied, through a 13 mm (1//2U) x 75 mm (3") x 150 mm (6") steel plate, to a non-PCC cover in place on a pull box, the cover shall not fail and shall not deflect more than 6 mm (V4"). The steel plate shall be centered on the cover with its longitudinal axis coinciding with the longitudinal axis of the cover. Where a ballast or transformer or other device is to be placed in a non-metallic pull box, the box shall be provided with recesses for a hanger. Pull boxes and covers for installation in structures shall be of the sizes and details shown on the plans. Each No. 7 ceiling pull box located near a flush soffit fixture and to be used to house the ballast for the fixture shall be provided with mounting brackets for the ballast and any required capacitors. C. Covers, except covers for ceiling pull boxes, shall be secured with 9 mm (%") bolts, cap screws, or studs, and nuts which shall be of brass, stainless steel or other non-corroding metal material. Stainless steel holddown bolts, cap screws or studs, and nuts and washers shall have a chromium content of not less than 18 percent and a nickel content of not less than 8 percent. All ferrous metal parts shall be galvanized in accordance with the provisions in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." D. Covers for pull boxes, except covers for ceiling pull boxes, shall be marked as shown on the plans. Marking shall be clearly defined and uniform in depth and may be placed parallel to either the long or short sides of the cover. Marking letters shall be between 25 mm (1") and 75 mm (3") high. Marking shall be applied to each steel or cast iron cover prior to galvanizing by one of the following methods: 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-12 (a) Cast iron strips, at least 6 mm (V4") thick, with the letters raised a minimum of 1.5 mm (1/ie°). Strips shall be fastened to covers with 6 mm (V4") flathead stainless steel machine bolts and nuts. Bolts shall be peened after tightening. (b) Sheet steel strips at least 0.7 mm (22 ga.) with the letters raised a minimum of 1.5 mm (Vie") above the surrounding surface of the strips. Strips shall be fastened to covers by spot welding, tack welding or brazing, with 6 mm (1/4") stainless steel rivets, or with 6 mm (V4 U) roundhead stainless steel machine bolts and nuts. Bolts shall be peened after tightening. (c) Bead welding the letters on the covers. The letters shall be raised at least 2 mm (V). 2.7 CONDUCTORS A. Conductors shall be copper of the gage shown on the plans, unless specified otherwise. Copper wire shall conform to the specifications of ASTM Designations: B 3 and B 8. B. Wire sizes, other than conductors used in loop detector lead-in cable, shall be based on American Wire Gage (AWG), except that conductor diameter shall be not less than 98 percent of the specified AWG diameter. Conductors for branch circuits shall be sized to prevent a voltage drop exceeding 3 percent at the furthest connected load, while drawing the combination of all connected loads capable of simultaneous operation. The maximum voltage drop for both feeders and branch circuits shall not exceed 5 percent at the furthest connected load, while drawing the combination of all connected loads capable of simultaneous operation. Conductors used in loop detector lead-in cable shall conform to the specifications of ASTM Designation: B 286. A Certificate of Compliance conforming to the provisions in Section 4-1.5, "Certification," shall be submitted by the manufacturer with each type of cable to be used on a project. C. Conductor Identification. All single conductors in cables, except detector lead-in cables, shall have clear, distinctive and permanent markings on the outer surface throughout the entire length showing the manufacturer's name or trademark, insulation type letter designation, conductor size, voltage rating and the number of conductors if a cable. Conductor insulation shall be of a solid color or of basic colors with a permanent colored stripe as detailed in the following table unless otherwise specified. Solid or basic colors shall be homogeneous through the full depth of insulation. Identification stripes shall be continuous over the entire length of the conductor. For conductor sizes No. 2 and larger, the insulation may be black and the ends of the conductors shall be taped with electrical insulating tape of the required color for a minimum of 500 mm (20"). All single conductors in cables shall be marked as shown in Table 2.7 (A): 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-13 TABLE 2.7 (A) CONDUCTORS Circuit Vehicle Signals (Note 4) Pedestrian Signals (Note 4) Pedestrian Push Buttons (Note 4) Traffic Signal Controller Cabinet Highway Lighting Pull Box to Luminaire (Note 9) Multiple Highway Lighting Lighting Control Multiple Service Sign Lighting (Note 8) Flashing Beacons (Note 7) Grounded & Common Interconnect Railroad Pre-Emption.... Spares Signal Phase or Function >,6 18 1,5 3,7 >p,6p to 80 lo5D JP.7P >D,6D lp 80 |p,5p 5P.7P Jngrounded between Service switch & Cabinet Jngrounded-Line 1 Jngrounded-Line 2 Grounded Jnqrounded-Line 1 Jngrounded-Line 2 Jngrounded to Photoelectric Unit (PEU) Switching leg from PEU unit or SM transformer Jngrounded-Line 1 (Signals) Jngrounded-Line 2 (Lighting) Jngrounded-Line 1 Jngrounded-Line 2 Jngrounded between Flasher and Beacons3edestrian Push Buttons.. Signals & Multiple Lighting Hashing Beacons & Sign Lighting ighting Control Multiple Service :lash )ia!2 )ial 3 )ffset Identification Insulation Colors Base Red, Yellow, Brown Red, Yellow, Brown Red, Yellow, Brown Red, Yellow, Brown Red, Brown Red, Brown Red, Brown Red, Brown Blue Blue Blue Blue Black Red Black Red White Black Red Black Red Black Red (Note 10) Black Red Red or Yellow White White White White White White Orange Orange Orange Orange Black Black Stripe (Note 1) Black Orange None Purple Black Orange None Purple Black Orange None Purple None None None None None None None None None None None None None None Black None None None None None None None None None None None Band Symbols (Note 6) 26 48 1 5 37 . 2o 60 4n ftp 1o 5o 3p,7p P-2 P-6 P-4P-8 P-1 P-5 P-3.P-7 CON-1 CON-2 No band requirec No band requirec No band requirec MM ML2 P1 C2 No band require Except per Note SL-1 SL-2 F-Location No. (See Note 3) .. No band requirec No band requirec No band requirec C-3 No band requirecI I-F I-D2 I-D3 I-O R No band requirec Minimum Size (Note 11) 14 14 14 14 14 14 14 14 14 14 14 14 6 6 14 14 14 10 10 14 14 6 8 10 10 14 14 10 12 14 14 14 14 14 14 14 14 14 o Notes: 1. On overlaps, insulation is striped for first phase in designation, for example, a phase (2+3) conductor is striped as for phase 2. 2. Band for overlap and special phases as required. 3. Flashing beacons having separate service do not require banding. 4. These requirements do not apply to signal cable. 5. "S" if circuit is switched on line side of service equipment by utility. 6. Band conductors in each pull box and near ends of termination points. On signal light circuits, a single band may be placed around 2 or 3 ungrounded conductors comprising a phase. 7. Ungrounded conductors between service switch and flasher mechanism shall be black and banded as indicated in this column. 8. Conductors between ballasts and sign lighting lamps shall be No. 16 and color shall correspond to that of the ballast leads. 9. Both conductors between external H.I.D. ballast and lamp socket shall be black. 10. Black acceptable for size No. 2 and larger. Tape ends for 500 mm (20") with indicated color. 11. Wire sizes listed are minimums. Ampacity requirements of specific circuits or voltage drop may necessitate larger conductors. 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-14 D. Multiple Circuit Conductors. Conductors for multiple circuits shall be UL or ETL listed and rated for 600-volt operation. The insulation for No. 14 through No. 4 conductors shall be one of the following: 1. Type TW polyvinyl chloride conforming to the requirements of ASTM Designation: D2219. 2. Type THW polyvinyl chloride. 3. Type USE, Type RHH or Type RHW cross-linked polyethylene. At any point, the minimum thickness of any Type TW, THW, USE, RHH or RHW insulation shall be 1.0 mm (40 mils) for conductor sizes No. 14 to No. 10, inclusive, and 1.3 mm (54 mils) for No. 8 to No. 2, inclusive. The insulation for No. 2 and larger conductors shall be one of the types listed above or shall be Type THWN. Conductors for wiring wall luminaires shall be stranded copper, with insulation rated for use at temperatures up to 125°C. Overhead lighting conductors shall be No. 8, or larger, medium hard drawn copper with weatherproof covering. E. Series Circuit Conductors. Conductors for series circuits shall be No. 8, shall be rated for 5000-volt operation and shall be insulated with 3.7 mm (150 mils) minimum thickness polyvinyl chloride compound conforming to the specifications of ASTM Designation: D2219, or polyethylene conforming to the specifications of ASTM Designation: D 1351. F. Signal Cable. Signal cable shall be installed. Individual conductors are not allowed. Signal cable shall conform to the following: The cable jacket shall be black polyethylene with an inner polyester binder sheath, and shall be rated for 600- volt and 75°C. All cables shall have clear, distinctive, and permanent markings on the outer surface throughout the entire length of the cable showing the manufacturer's name or trademark, insulation designation, number of conductors, conductor sizes, and the voltage rating of the jacket. Filler material, if used, shall be polyethylene material. Individual conductors in the cable shall be solid copper with Type THWN insulation, and shall conform to the requirements in Section 2.7, "Conductors," and ASTM Designation: B 286. The minimum thickness of Type THWN insulation, at any point, shall be 0.3 mm (13 mils) for conductor sizes No. 14 and No. 12, and 0.4 mm (18 mils) for conductor size No. 10. The minimum thickness of the nylon jacket shall be 0.1 mrn (4 mils) at any point. G. Three-Conductor Cable (3CSC). The 3-conductor signal cable shall consist of three No. 14 conductors. The cable jacket shall have a minimum average thickness of 1.1 mm (45 mils) and a minimum thickness at any point of 0.9 mm (36 mils). The nominal outside diameter of the cable shall not exceed 10 mm (0.10"). The color code of the conductors shall be blue/black stripe, blue/orange stripe, and white/black stripe. The 3 conductor cable shall be used for pedestrian push buttons and a spare. H. Five-Conductor Cable (5CSC). The 5-conductor signal cable shall consist of five No. 14 conductors. The cable jacket shall have a minimum average thickness of 1.1 mm (45 mils) and shall have a minimum thickness at any point of 0.9 mm (36 mils). The nominal outside diameter of the cable shall not exceed 13 mm (0.50"). The color code of the conductors shall be red, yellow, brown, black, and white. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-15 J. K. Nine-Conductor Cable (9CSC). The 9-conductor cable shall consist of eight No. 14 conductors and one No. 12 conductor. The cable jacket shall have a minimum average thickness of .5 mm (60 mils) and shall have a minimum thickness at any point of 1.2 mm (48 mils). The nominal outside diameter of the cable shall not exceed 17 mm (0.70"). The color code for the No. 12 conductor shall be white. The color code for the No. 14 conductors shall be as Table 2.3 (B): TABLE 2.3 (B) NINE-CONDUCTOR CABLE SIGNAL CABLE Insulation Colors red yellow brown red/black stripe yellow/black stripe brown/black stripe black white/black stripe Twelve-Conductor Cable (12CSC). The 12-conductor signal cable shall consist of eleven No. 14 conductors and one No. 12 conductor. The cable jacket shall have a minimum average thickness of 1.5 mm (60 mils) and shall have a minimum thickness at any point of 1.2 mm (48 mils). The nominal outside diameter of the cable shall not exceed 17 mm (0.70"). The color code for the No. 12 conductor shall be white. The color code and functional connections for the No. 14 conductors shall be as Table 2.3 (C), unless otherwise approved by the Engineer: TABLE 2.3 (C) TWELVE -CONDUCTOR CABLE SIGNAL CABLE Color Code red yellow brown red/black stripe yellow/black stripe brown/black stripe black/red stripe black/white stripe black red/white stripe brown/white stripe Termination vehicle signal red vehicle signal yellow vehicle signal green vehicle signal red vehicle signal yellow vehicle signal green spare, or use as required for red or Don't Walk spare, or use as required for yellow spare, or use as required for green or Walk ped signal Don't Walk ped signal Walk Phase 2, 4, 6 or 8 2, 4, 6 or 8 2, 4, 6 or 8 1,3, 5 or 7 1,3, 5 or 7 1,3, 5 or 7 The 12-conductor cable shall be used for vehicle signals, pedestrian signals, spares and the signal common. Twenty Eight-Conductor Cable (28CSC). The 28-conductor signal cable shall consist of 27 No. 14 conductors and one No. 10 conductor. The cable jacket shall have a minimum average thickness of 2 mm (80 mils) and shall have a minimum thickness at any point of 1.6 mm (64 mils). The nominal outside diameter of the cable shall not exceed 23mm (0.90"). The color code for the No. 10 conductor shall be white. The color code and functional connections for the No. 14 conductors shall be as Table 2.3 (D): o 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-16 TABLE 2.3 (D) TWENTY EIGHT - CONDUCTOR CABLE SIGNAL CABLE Color Code red/black stripe yellow/black stripe brown/black stripe red/orange stripe yellow/orange stripe brown/orange stripe red/silver stripe yellow/silver stripe brown/silver stripe red/purple stripe yellow/purple stripe brown/purple stripe red/2 black stripes brown/2 black stripes red/2 orange stripes brown/2 orange stripes red/2 silver stripes brown/2 silver stripes red/2 purple stripes brown/2 purple stripes blue/black stripe blue/orange stripe blue/silver stripe blue/purple stripe white/black stripe black/red stripe black Termination vehicle signal red vehicle signal yellow vehicle signal green vehicle signal red vehicle signal yellow vehicle signal green vehicle signal red vehicle signal yellow vehicle signal green vehicle signal red vehicle signal yellow vehicle signal green ped signal Don't Walk ped signal Walk ped signal Don't Walk ped signal Walk overlap A, C red overlap A, C green overlap B, D red overlap B, D green ped push button ped push button overlap A, C yellow overlap B, D yellow ped push button common railroad pre-emption spare Phase 2 or 6 2 or6 2 or6 4 or 8 4 or 8 4 or 8 1 or 5 1 or 5 1 or 5 3 or 7 3 or 7 3 or 7 2 or 6 2 or 6 4 or 8 4 or 8 OLA, OLC OLA, OLC OLB, OLD OLB, OLD 2 or 6 4 or 8 OLA(y), OLC(y) OLB(y), OLD(y) 1) The signal commons in each 28-conductor cable shall be kept separate except at the signal controller. 2) Each 28-conductor cable shall be labeled in each pull box "C1" or "C2",. 3) The cable identified "CT shall be used for signal Phases 1, 2, 3 and 4. The cable identified "C2" shall be used for signal Phases 5, 6, 7 and 8. 4) Each signal cable, except 28-conductor, shall be marked, in each pull box, showing the signal standard to which it is connected. L. Signal Interconnect Cable (SIC). Signal Interconnect Cable shall consist of six or twelve No. 20, minimum, stranded tinned copper conductors as shown on the plans or required herein. Each conductor shall be insulated with 0.33 mm (0.013"), minimum nominal thickness, color coded, polypropylene material. Conductors shall be in twisted pairs. Color coding shall distinguish each pair. Each pair shall be wrapped with an aluminum polyester shield and shall have a No. 22 or larger, stranded, tinned copper drain wire inside the shielded pair. The cable jacket shall be black, high density polyethylene, rated for a minimum of 300- volts and 60°C, and shall have a nominal wall thickness of 1.0 mm (40 mils), minimum. The cable jacket or the moisture-resistant tape directly under the outer jacket shall be marked with the manufacturer's name, 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-17 insulation type designation, number of conductors and conductor size, and voltage and temperature ratings. Splices shall be made only where shown on the plans or in con- trailer cabinets. A minimum of one meter (3') of slack shall be provided at each splice and 2 m (6') at each controller cabinet. Splices of conductors shall be insulated with heat-shrink tubing of the appropriate size and shall overlap the conductor insulation at least 15mm (0.5"). The overall cable splice shall be covered with heat-shrink tubing, with at least 40 mm (1V) of overlap of the cable jacket. M. Wiring. All conductors shall be run in conduit, except overhead and temporary installations and where conductors are run inside poles. Wiring shall be done in conformance with the regulations and code listed in Section 1.4, "Reference Specifications, Codes, and Standards," and the following additional requirements: N. Circuitry. Sufficient traffic signal light conductors shall be provided to perform the functional operation of the signal and, in addition thereto, 3 spare conductors shall be provided in all conduits containing traffic signal light conductors, unless shown otherwise on the plans. Traffic signal light conductors shall not run to a terminal block on a standard unless they are to be connected to a signal head that is mounted thereon. Connection to each terminal of a pedestrian push button shall be by a single conductor. The common for pedestrian push button circuits shall be separate from the traffic signal light circuit grounded conductors. Where ballasts or transformers are used, series conductors shall be run from ballast to ballast, transformer to transformer, and from bal- last or transformer to service. 2.8 WOOD POLES Wood poles for service or temporary installations shall be ANSI Class 5, or larger. Poles shall not have more than 180 degrees twist in grain over the full length. Sweep shall be no more than 100 mm (4"). Tops of poles shall be beveled. Poles shall be placed in the ground to a depth of at least 1.8 m (6'). The lengths of poles shall be 7.6 m (25') for service poles and 10.7 m (35') for other poles, unless otherwise specified. 2.9 SIGN CONTROL Each sign illumination installation shall be provided with a disconnect circuit breaker mounted on the sign standard or structure, as shown on the plans. Where the sign lighting is served from a series lighting circuit through a series-multiple transformer, the circuit breaker shall be installed in the secondary circuit. Where the sign lighting is served through a multiple-multiple transformer, the circuit breaker shall be installed in the primary circuit. Circuit breakers shall meet the requirements for circuit breakers in Section 3.10 K, "Service." Enclosure for the circuit breaker shall be NEMA Type 3R, shall be galvanized or shall be cadmium plated, and shall be provided with dead front panel and a hasp with a 11 mm (7/16") diameter hole for a padlock. Padlocks will be furnished by others. When the sign structure is to be painted, the circuit breaker or sign switch enclosure shall be painted the same color as the sign structure on which it is mounted. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-18 2.10 GALVANIZING Galvanizing shall be in accordance with the provisions in SSPWC Section 210-3.6, "Galvanizing for Traffic Control Facilities," except that cabinets may be constructed of material galvanized prior to fabrication in conformance with the specifications of ASTM Designation: A 525 or A 525M, Coating Designation G 90, in which case all cut or damaged edges shall be painted with at least 2 applications of approved unthinned zinc- rich primer (organic vehicle type) conforming to the requirements in SSPWC Section 210-3.5, "Repair of Damaged Zinc Coating." Aerosol cans shall not be used. Other types of protective coating shall be approved by the Engineer prior to installation. Iron or steel pipe standards and pipe mast arms shall be hot-dip galvanized after fabrication in conformance with the specifications of ASTM Designation: A 53. Galvanized surfaces shall have spurs removed. Tie-rods, bolts, nuts, washers, clamps and other miscellaneous ferrous parts shall be hot-dip galvanized after fabrication in accordance with the provisions in SSPWC Section 210-3.6, "Galvanizing for Traffic Control Facilities." Not less than 250 mm (10") of the upper end of the anchor bolts, anchor bars, or studs, and all nuts and washers shall be galvanized in accordance with the provisions in SSPWC Section 210-3.6, "Galvanizing for Traffic Control Facilities." After galvanizing, the bolt threads shall accept galvanized standard nuts without requiring tools or causing removal of protective coatings. Galvanizing of existing materials in an electrical installation will not be required. 2.11 PAINT MATERIAL Paint materials for electrical installations, unless otherwise specified, shall conform to the provisions in Section 210, "Paint and Protective Coatings." Factory or shop cleaning methods for metals will be acceptable if equal to the methods specified herein. In lieu of the temperature and seasonal restrictions for painting as provided in Section 3.12, "Painting," paint may be applied to equipment and materials for electrical installations at any time permitted by the Engineer. 2.12 CONTROLLER ASSEMBLIES A. Controller Assembly. A controller assembly shall consist of a complete mechanism for controlling the operation of traffic signals or other systems, including the controller unit and all necessary auxiliary equipment, mounted in a cabinet. All equipment required to provide the operation shown on the plans and as specified shall be provided. All field conductors No. 12 and smaller shall terminate with spade type terminals. All field conductors No. 10 and larger shall terminate in spade type or ring type terminals. B. Model 170 and Model 2070 Controller Assemblies. Model 170 and Model 2070 (Model 170/2070) controller assemblies shall consist of a Model 170, 170E or 2070 controller unit, a wired cabinet and all auxiliary equipment required to control the system as shown on the plans, and as specified in these special provisions. Model 170/2070 controller assemblies shall conform to the requirements in "Transportation Electrical Equipment Specifications," (TEES) and "Traffic Signal Control Equipment Specifications" (TSCES), issued by the State of California, Department of Transportation, and to all ad- dendums thereto current at the time of project advertising. Unless otherwise specified or shown on the plans, controller assembly cabinets (housing) shall be Type 1 as shown in the TSCES. In addition to the requirements found 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-19 in TEES and TSCES, Model 170/2070 controller assemblies shall conform to the ^^ following: ^^ C. Controller Cabinets. Unless otherwise specified, controller cabinets for Model 170/2070 controllers shall conform to the following: 1) Controller cabinets shall be fabricated from aluminum sheet per the TSCES. 2) Controller cabinets shall have a single front door equipped with a Best Company lock core and lock. No other manufacturers shall be accepted. D. Cabinet Accessories. The following accessories shall be furnish with each cabinet assembly for Model 170/2070 controllers: 1) Controller cabinets shall have a pull-out type document tray. 2) Each cabinet shall be provided with a fluorescent lighting fixture mounted on the inside top of the cabinet near the front edge. Fixture shall be provided with an F15T8, cool white lamp operated from a normal power factor UL or ETL listed ballast. The "on-off switch for the lighting fixture shall be a door-actuated switch that turns the light on when either door is open and off when either door is closed. 3) An uninterruptible power system (UPS) shall be installed in each cabinet. The UPS shall be Clary SP 1000 series or approved equal and shall provide a minimum of eight (8) hours of continuous red flash operation at intersections using red LED ^^ signal indications and provide power conditioning to the controller. Batteries for the ^1 UPS shall be housed in a NEMA 3R rated cabinet mounted to the side of the Model ""*"**' 332 cabinet per Caltrans specifications. 2.13 TRAFFIC SIGNAL FACES AND FITTINGS A. Vehicle Signal Faces. Each vehicle signal face shall be of the adjustable type conforming to the provisions in Institute of Traffic Engineers (ITE) Publication: ST-008B, "Vehicle Traffic Control Signal Heads." Plastic signal sections shall meet the requirements of California Test 605. Any fracture within the housing assembly, or a deflection of more than 10 degrees in either the vertical or horizontal plane after the wind load has been removed from the front of the signal face, or a deflection of more than 6 degrees in either the vertical or horizontal plane after the wind load has been removed from the back of the signal face will be considered structural failure. Vehicle signal faces, except arrow and "X° faces, shall meet the requirements of California Test 604. Adjustment shall permit rotation of 360 degrees about a vertical axis. The number and type of sections shall be as specified herein or as shown on the plans. Each vehicle signal face shall be installed at the location and mounted in the manner shown on the plans. Unless otherwise shown on the plans, all vehicle signal faces shall contain 3 sections arranged vertically; red-top, yellow-center, green-bottom. All new vehicle signal faces, except programmed visibility type, installed at any one intersection shall be of the same manufacture and of the same material. B. Optical Units. Each optical unit for green, yellow and red sections, circular ball or arrow, —«-' 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-20 shall conform to the provisions in Section 2.14, "Light Emitting Diode Signal Module". C. Signal Sections. Each signal section housing shall be structural plastic. Signal sections shall conform to the following: 1. Maximum height of a signal section shall be 375 mm (143/4") for each 300 mm (12") section. 2. The housing of each signal section shall be provided with a one-piece, hinged, square-shaped door designed to permit access to the section for relamping without the use of tools. 3. The door shall be secured by a method that will hold the door closed during the loading tests specified in this Section. 4. The lens shall be mounted in the door in a watertight manner. 5. All exposed hardware, such as hinge pins and door latching devices, shall be Type 304 or 305 stainless steel. 6. All interior screws and fittings shall be stainless steel. 7. An opening shall be provided in the top and bottom of each signal section to receive 40 mm (11/2") pipe. 8. The 300 mm (12") signal sections of an individual manufacturer shall be capable of joining to form a signal face in any combination. This interchangeability is not required between metal and plastic signal sections. 9. All gaskets, including those for the door, lens, reflector and lamp holder, shall be made of a material that is not affected when installed in a signal section with a metal or plastic housing that is operated continuously for 336 hours. D. Plastic Signal Sections. Housings shall be either molded in one piece or shall be fabricated from 2 or more pieces joined into a single piece. The plastic shall have ultraviolet stability, shall be unaffected by the heat of the lamp used and shall be self-extinguishing. Housings and doors shall be colored throughout and shall be black matching Color No. 17038, 27038 or 37038 of Federal Standard 595B. Each section in a face shall be joined to the adjacent section by one of the following methods: 1. A minimum of 4 machine screws for 300 mm (12") sections, installed through holes near the front and rear of the housings. Machine screws shall be No. 10 and each shall be provided with a nut, flat washer and lock washer. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-21 2. Two machine screws (each with a nut, flat washer and lock washer) installed through holes near the front of the housings, plus a fastening through the 40 mm (11/2") pipe openings. The fastening shall consist of two large flat washers to distribute the load around the pipe opening and three carriage bolts, each with a nut and lock washer. Minimum size of machine screws shall be No. 10. Minimum size of carriage bolt shall be 6 mm (V-20). The supporting section of each signal face supported solely at the top or bottom shall be provided with reinforcement. Reinforcement plates shall be either sheet aluminum, galvanized steel, or cast aluminum. Each plate shall be not less than 2.7 mm (0.110") thick and shall have a hole concentric with the 40 mm (11/2 U) pipe mounting hole in the housing. Sheet aluminum reinforcement plates shall be placed both inside and outside the housing; galvanized steel reinforcement plates shall be placed inside only; and cast aluminum reinforcement plates shall be placed outside only. Reinforcement plates placed outside of the housing shall be finished to match the color of the signal housing and shall be designed to permit the proper serrated coupling between signal face and mounting hardware. A minimum of three No. 10 machine screws shall be installed through holes in the plates and matching holes in the housing. Each screw shall have a round or binder head and shall be provided with a nut and lock washer. Where a signal face is to be supported by a Type MAS side attachment slip-fitter inserted between 2 sections, a spacer or spacers shall be placed between the 2 sections. The vertical dimension of spacers shall permit proper seating of the serrations between the slip-fitter and the 2 sections. Holes in spacers shall align with the front holes in the section housings. In addition to the fastening through the large openings in the housings, the 2 sections shall be joined with at least 2 machine screws through holes near the front of the housings and the spacers, and through matching holes in a reinforcing plate installed in each housing. Machine screws shall be No. 10 minimum size. Spacers shall be made of the same material as the signal housings. Reinforcing plates and machine screws shall be as specified above. Reinforcing plates will not be required where the housing is provided with reinforcing webs connecting the rear of the housing with the top, bottom and sides. Holes for machine screws shall be either cast or drilled during fabrication of the signal section. Each hole shall be surrounded by a 3 mm (1/8") minimum width boss to permit contact between signal sections about the axis of the hole. Each plastic signal face shall be provided with plastic or metal visors. Plastic signal faces which require backplates shall be provided with plastic backplates. A serrated nylon washer shall be inserted between each plastic signal section and a metal mounting assembly. Each washer shall be not less than 4 mm (3/ie") nor more than 6 mm (1/4") thick. Serrations shall match those on the signal section and the mounting assembly. E. Electrical Components. Lamp receptacles and wiring shall conform to ITE Publications: ST-008B. The metal portion of the medium base lamp socket shall be brass, copper or phosphor bronze. Each lamp receptacle shall be wired with a conductor, connected to the shell of the receptacle, with black insulation or with insulation color-coded. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-22 These conductors shall, in turn, be connected to a terminal block mounted inside at the back of the housing. The terminal block shall have sufficient screw type terminals or NEMA type tab connectors to terminate all field conductors and lamp conductors independently. The terminals to which field conductors are attached shall be permanently identified or conductors shall be color coded to facilitate field wiring. Lamp receptacle conductors shall be No. 18 or larger, 600-V, appliance wiring material (AWM), with 0.75 mm (30 mil) thickness insulation rated 105°C or with insulation that conforms to the requirements in Military Specification MIL-W-16878D, Type B, with vinyl nylon jacket rated 115°C. The manufacturer's name or trademark, conductor size, insulation type letter designation and temperature rating shall be marked on the insulation or a Certificate of Compliance conforming to the provisions in Section 6-1.07, "Certification of Compliance", shall be submitted by the manufacturer with each shipment of traffic signal faces. F. Visors. Each signal section shall be provided with a removable visor conforming to ITE Publication: ST-008B. Visors are classified, on the basis of lens enclosure, as full circle, tunnel (bottom open), or cap (bottom and lower sides open). Unless otherwise specified, visors shall be the full circle type. The visor shall be a minimum of 240 mm (91/2 U) in length for nominal 300 mm (12") round lenses, with a downward tilt between 3 degrees and 7 degrees. Plastic visors shall conform to the following: 1. Visors shall be either formed from sheet plastic or assembled from one or more injection, rotational or blow molded plastic sections. 2. Sections shall be joined using thermal, chemical or ultrasonic bonding or with aluminum rivets and washers permanently colored to match the visor. 3. Visors shall be of black homogeneous colored material with a lusterless finish. 4. Each visor shall be secured to its door in a manner that will prevent its removal or permanent deformation when the wind load specified in California Test 605 for plastic visors is applied to the side of the visor for 24 hours. 2.14 Light Emitting Diode Signal Modules. Each light emitting diode (LED) signal module shall be Type 2 and consist of an assembly that utilizes light emitting diodes as the light source in lieu of an incandescent lamp for use in traffic signal sections and conform to the following: 1. Each Type 2 LED signal module shall be designed to mount in the standard lamp socket normally used with an incandescent lamp. When a Type 2 LED signal module is used, a standard traffic signal lens in the doorframe shall be used or, at the option of the Contractor, the standard lens may be replaced with a translucent or clear lens to seal the signal section from weather. The installation of a Type 2 LED signal module shall not require any modification to the standard lamp socket or reflector. 2. LED signal modules shall be from the same manufacturer, and each size shall be the same model. 3. Type 2 LED signal modules shall be a sealed unit containing all components necessary for operation except, at the option of the Contractor, use of a corresponding lens mounted in the doorframe will be allowed. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-23 4. Type 2 LED signal modules shall not require a specific mounting orientation or have a variance in light output, pattern or visibility for any mounting orientation. 5. The LEDs utilized in the modules shall be Aluminum Indium Gallium Phosphide (AllnGaP) technology for red indications and Gallium Nitride (GaN) technology for green indications, and shall be the ultra bright type rated for 100,000 hours of continuous operation from -40°C to +74°C. 6. The individual LEDs shall be wired such that a catastrophic failure of one LED will result in the loss of not more than 5 percent of the signal module light output. The failure of an individual LED in a string shall only result in the loss of that LED, not the entire string or indication. A. Physical and Mechanical Requirements. LED traffic signal modules shall be designed as retrofit replacements for existing optical units of signal lamps and shall not require special tools for installation. LED signal modules shall fit into existing traffic signal section housings without any modification to the housing. B. LED Signal Module Lens. The LED signal module shall be capable of replacing the optical unit. The lens may be tinted or may use transparent film or materials with similar characteristics to enhance ON/OFF contrasts. The use of tinting or other materials to enhance ON/OFF contrasts shall not affect chromaticity and shall be uniform across the face of the lens. If a polymeric lens is used, a surface coating or chemical surface treatment shall be used to provide front surface abrasion resistance. C. Environmental Requirements. The LED signal module shall be rated for use in the operating temperature range of -40°C (-40°F) to +74°C (+165°F). The LED signal module shall be protected against dust and moisture intrusion per the requirements of NEMA Standard 250-1991 for Type 4 enclosures to protect all internal components. The LED signal module lens shall be UV stabilized and shall be capable of withstanding ultraviolet (direct sunlight) exposure for a minimum period of 60 months without exhibiting evidence of deterioration. D. Construction. The LED signal module shall be a single, self-contained device, not requiring on-site assembly for installation into an existing traffic signal housing. The power supply for the LED signal module shall be integral to the unit. The assembly and manufacturing process for the LED signal assembly shall be designed to assure all internal components are adequately supported to withstand mechanical shock and vibration from high winds and other sources. E. Materials. Material used for the lens and signal module construction shall conform to ASTM specifications for the materials where applicable. Enclosures containing either the power supply or electronic components of the signal module shall be made of UL94VO flame retardant materials. The lens of the signal module is excluded from this requirement. F. Module Identification. Each LED signal module shall have the manufacturer's name, trademark, and other necessary identification permanently marked on the back of the module. Each individual LED signal module shall be identified with serial number for warranty purposes. The following operating characteristics shall be identified: rated voltage, power consumption, and volt-ampere. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-24 G. Photometric Requirements. The minimum initial luminous intensity values for the modules shall be as stated in Table 2.14 (A) and Table 2.14 (B) at 25°C. The modules shall meet or exceed the illumination values as shown in Table 2.14 (B) and Table 2.14 (D), throughout the useful life based on normal use in a traffic signal operation over the operating temperature range. The measured chromaticity coordinates of the modules shall conform to the chromaticity requirements of Table 2.14 (E), throughout the useful life over the operating temperature range. The LED signal modules tested or submitted for testing shall be representative of typical average production units. Circular modules shall be tested according to California Test No. 604. All optical testing shall be performed with the module mounted in a standard traffic signal section but without a visor or hood attached to the signal section. The LEDs shall be spread evenly across the illuminated portion of the arrow area. Arrow modules shall be tested according to California Test No. 3001. All optical testing shall be performed with the module mounted in a standard traffic signal section but without a visor or hood attached to the signal section. Each LED arrow signal section indication shall provide a minimum average luminous intensity as listed in Table 2.14 (C). All measurements shall be performed at rated operating voltage of 120 VAC. Table 2.14 (A) Minimum Initial Intensities for Circular Indications (in cd) ir^:;:;«i^trigle|v;h)'- • .-- .. 2.5, ±2.5 2.5, ±7.5 2.5, ±12.5 2.5, ±17.5 7.5, ±2.5 7.5, ±7.5 7.5, ±12.5 7.5, ±17.5 7.5, ±22.5 7.5, ±27.5 12.5, ±2.5 12.5, ±7.5 12.5, ±12.5 12.5, ±17.5 12.5, ±22.5 12.5, ±27.5 17.5, ±2.5 17.5, ±7.5 17.5, ±12.5 17.5, ±17.5 17.5, ±22.5 17.5, ±27.5 - MO mrr 399 295 166 90 266 238 171 105 45 19 59 57 52 40 26 19 26 26 26 26 24 19 i(12"|;-,-..,v^-%^fc^-^ • |i^Wellcw&<3reen v«;>; *; 798 589 333 181 532 475 342 209 90 38 119 114 105 81 52 38 52 52 52 52 48 38 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-25 Table 2.14 (B) Maintained Minimum Intensities for Circular Indications (in cd) • -*^iigte:(Vih)^4>: 2.5, ±2.5 2.5, ±7.5 2.5, ±12.5 2.5, ±17.5 7.5, ±2.5 7.5, ±7.5 7.5, ±12.5 7.5, ±17.5 7.5, ±22.5 7.5, ±27.5 12.5, ±2.5 12.5, ±7.5 12.5, ±12.5 12.5, ±17.5 12.5, ±22.5 12.5, ±27.5 17.5, ±2.5 17.5, ±7.5 17.5, ±12.5 17.5, ±17.5 17.5, ±22.5 17.5, ±27.5 :vf£__^2 300mm (12") * -*>,-• -,,••.,, rvr-",-y :-:*<, : ••-. Red-'A^ =•; •£ 339 251 141 77 226 202 145 89 38 16 50 48 44 34 22 16 22 22 22 22 20 16 ^Yellow &Green 678 501 283 154 452 404 291 178 877 32 101 97 89 69 44 32 44 44 44 44 41 32 o Table 2.14 (C) Minimum Initial Intensities for Arrow Indications (in cd/m2) Arrow Indication Red 5,500 Yellow & Green 11,000 Table 2.14(D) Minimum Maintained Intensities for Arrow Indications (in cd/m2) Arrow Indication Red 5,500 Yellow & Green 11,000 Table 2.14 (E) Chromaticity Standards (CIE Chart) Red Yellow Green Y: not greater than 0.308, or less than 0.998-x Y: not less than 0.411, nor less than 0.995-x, nor than 0.452 . Y: not less than 0.506-0.51 9x, nor less 0.1 50+1. 068x, nor more than 0.730-x less than 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-26 H.Electrical. Maximum power consumption requirements for LED signal modules shall be as listed in Table 2.14 (F). Table 2.14 (F) Maximum Power Consumption (in Watts) Temperature 300 mm circular 300 mm arrow Red 25°C 11 9 74°C 17 12 Yeltow 25°C 22 10 74°C 25 12 Green 25°C 12 13 74°C 12 13 LED signal modules shall operate from a 60 Hz ±3 Hz AC line over a voltage ranging from 80 volts to 135 volts. The LED circuitry shall prevent perceptible flicker over the voltage range specified above. The fluctuations of line voltage shall have no visible effect on the luminous intensity of the indications. Rated voltage for all measurements shall be 120 volts. The signal module on-board circuitry shall include voltage surge protection to withstand high-repetition noise transients as stated in Section 2.1.6 of NEMA Standard TS-2, 1992. LED signal modules shall be operationally compatible with currently used controller assemblies (solid state load switches, flashers, and conflict monitors). When a current of 20 ma AC (or less) is applied to the unit, the voltage read across the two leads shall be 15 VAC or less. LED signal modules and associated on-board circuitry must meet Federal Communications Commission (FCC) Title 47, SubPart B, Section 15 regulations concerning the emission of electronic noise. The LED signal module shall provide a power factor of 0.90 or greater. Total harmonic distortion (current and voltage) induced into an AC power line by an LED signal module shall not exceed 20 percent. Quality Assurance. LED signal modules shall be manufactured in accordance with a vendor quality assurance (QA) program. The QA program shall include two types of quality assurance: (1) design quality assurance and (2) production quality assurance. The production quality assurance shall include statistically controlled routine tests to ensure minimum performance levels of LED signal modules built to meet this specification. QA process and test results documentation shall be kept on file for a minimum period of seven years. LED signal module designs not satisfying design qualification testing and the production quality assurance testing performance requirements described below shall not be labeled, advertised, or sold as conforming to this specification. Manufacturer's Serial Numbers. Identification of the component and sub-assembly level may be required if the reliability and performance of the module must be traceable to the original item manufacturers of the module components and subassemblies. 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-27 K. Production Quality Assurance Testing. The following Production Quality Assurance tests shall be performed on each new LED signal module prior to shipment. Failure to meet requirements of any of these tests shall be cause for rejection. The manufacturer for warranty purposes shall retain test results for seven years. Each LED signal module shall be tested for rated initial intensity after burn-in. Burn-in period shall consist of each signal module being energized at rated voltage for a 30 minutes stabilization period before the measurement is made. A single point measurement with a correlation to the intensity requirements of Table 2.14 (A) for circular modules may be used. The ambient temperature for this measurement shall be +25°C (+77°F). Each LED signal module not meeting minimum luminous intensity requirements per Table 2.14 (A) or Table 2.14 (C) shall be a cause for rejection. Each LED signal module shall be tested for required power factor after burn-in. Each LED signal module shall be measured for current flow in amperes after burn-in. The measured current values shall be compared against current values resulting from design qualification measurements under "Design Qualification Testing". The current flow shall not exceed the rated value. The measured ampere values with rated voltage shall be recorded as volt-ampere (VA) on the product labels. Each LED signal modules shall be visually inspected for any exterior physical damage or assembly anomalies. Careful attention shall be paid to the surface of the lens to ensure there are no scratches (abrasions), cracks, chips, discoloration, or other defects. Any such defects shall be cause for rejection. L. Design Qualification Testing. Design Qualification testing shall be performed on new LED signal module designs, and when a major design change has been implemented on an existing design. The minimum sample quantity of LED signal modules shall be as stated for each test. Failure to meet requirements for any of these tests shall be cause for rejection. A random sample of six LED signal modules shall be energized for a minimum of 24 hours, at 100 percent on-time duty cycle, in a temperature of 74°C (+165°F) before performing any design qualification testing. Any failure within an LED signal module after burn-in shall be cause for rejection. M. Rated Initial Luminous Intensity. After burn-in, a sample of six LED signal modules shall be tested for rate initial intensity per the requirements of "Photometric Requirements". Before measurement, each LED signal module shall be energized at rated voltage, with 100 percent on-time duty cycle, for a time period of 30 minutes. The ambient temperature for this measurement shall be 25°C (77°F). The test results for this test shall have recorded the current voltage, total harmonic distortion (THD), and power factor (PF) associated with each measurement. N. Chromaticity (Color). A sample of two LED signal modules shall be measured for chromaticity (color) per the requirements of "Chromaticity requirements under "Photometric Requirements." A spectra radiometer shall be used for this measurement. The ambient temperature for this measurement shall be 25°C (77°F). 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-28 O. Electrical. A sample of six LED signal modules shall be measured for current flow in amperes. The measured current values shall be used for quality comparison of Production Quality Assurance current measurement on production modules. A sample of six LED signal modules shall be measured for power factor. A commercially available power factor meter may be used to perform this measurement. A sample of six LED modules shall be measured for total harmonic distortion. A commercially available total harmonic distortion meter may be used to perform this measurement. A sample of six LED signal modules shall be tested per the requirements of "Electrical", with reference to Class A emission limits referenced in Federal Communications Commission (FCC) Title 47, SubPart B, Section 15. A sample of six LED signal modules shall be tested for compatibility with the controller unit, conflict monitor, and load switch. Each signal module shall be connected to any AC voltage supply between the values of 80 and 135 VAC. The AC voltage developed across each LED signal module so connected shall not exceed 10 volts rms as the input AC voltage is varied from 80 volts to 135 volts rms. A sample of six LED modules shall be tested for transient immunity per "Electrical" using the procedure described in NEMA Standard TS-1992. Mechanical vibration testing shall be performed on a sample of three LED signal modules per MIL-STD-883, Test Method 2007, using three 4 minute cycles along each x, y, and z axis, at a force of 2.5 Gs, with a frequency sweep from 2 Hz to 120 Hz. The loosening of the lens, of any internal components, or other physical damage shall be cause for rejection. Temperature cycling shall be performed on a sample of three LED signal modules per MIL-STD-883, Test method 1010. The temperature range shall be per "Environmental Requirements". A minimum of 20 cycles shall be performed with a 30 minute transfer time between temperature extremes and a 30 minute dwell time at each temperature. Signal under test shall be non-operating. Failure of a module to function properly or any evidence of cracking of the module lens or housing after temperature cycling shall be cause for rejection. Moisture resistance testing shall be performed on a sample of three LED signal modules per NEMA Standard 250-1991 for Type 4 enclosures. Any evidence of internal moisture after testing shall be cause for rejection. P. Certificate of Compliance. The Contractor shall provide the Engineer a Certificate of Compliance from the manufacturer in accordance with the provisions of Section 6-1.07, "Certificates of Compliance," of the Caltrans Standard Specifications. The certificate shall certify that the LED signal modules comply with the requirements of these specifications. The certificate shall also include a copy of all applicable test reports on the LED signal modules. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-29 LED signal modules shall be guaranteed by the Contractor for a period of one year starting on the day after the project is accepted by the Engineer. Modules that fail during this period shall be replaced at no cost to the City, except that City forces will change out the modules in the field. The replacement modules shall be delivered to the Public Works Department at 405 Oak Avenue within five working days after notification. The failed modules will be made available to the Contractor at the above address at the same time as the replacement is delivered. The manufacturer shall provide a written warranty against defects in materials and workmanship for the LED signal modules for a period of 36 months after installation of the modules. Replacement modules shall be provided promptly after receipt of modules that have failed at no cost to the State except cost of shipping of the failed modules. All warranty documentation shall be given to the Engineer prior to installation. The replacement modules shall be delivered to the Public Works Department at 405 Oak Avenue. 2.15 DIRECTIONAL LOUVERS Where shown on the plans, directional louvers shall be furnished and installed in signal visors. Directional louvers shall be so constructed as to have a snug fit in the signal visors. The outside cylinder shall be constructed of 0.75 mm (0.030") nominal thickness, or thicker, sheet steel and the vanes shall be constructed of 0.4 mm (0.016") nominal thickness, or thicker, sheet steel or the cylinder and vanes shall be constructed of 5052- H32 aluminum alloy of equivalent thickness. Dimensions of louvers and arrangements of vanes shall be as shown on the plans. 2.16 BACKPLATES Where shown on the plans, backplates shall be furnished and installed on signal faces. Dimensions, materials and installation details shall be as shown on the plans. No background light shall show between the backplate and the signal face or between sections. Plastic backplates shall be supplied and either formed from sheet plastic or assembled from extruded, molded or cast sections. Sections shall be factory joined using. (1) an appropriate solvent cement, (2) aluminum rivets and washers painted or permanently colored to match the backplate, or (3) No. 10 machine screws with washer, lock washer and nut, painted to match the backplate. Backplates shall be of black homogeneous colored material with a lusterless finish. Each plastic backplate shall be secured to the plastic signal face in a manner that will prevent its removal or permanent deformation when the wind-load test is applied to either the front or the rear of the signal face. The permanent deformation of any portion of the backplate shall not exceed 5 degrees forward or backward after the wind loading has been applied for 24 hours. When a plastic backplate requires field assembly, it shall be joined with at least four No. 10 machine screws at each field assembled joint. Each machine screw shall be provided with an integral or captive flat washer, a hexagonal head slotted for a standard screwdriver, and either (1) a locking nut with an integral or captive flat washer, or (2) a nut, flat washer and lockwasher. Machine screws, nuts and washers shall be stainless steel. Where a metal backplate consists of 2 or more sections, the sections shall be fastened with rivets or with aluminum bolts peened after assembly to prevent loosening. In lieu of the screws shown on the plans, plastic backplates may be fastened to the plastic signal face using self-threading No. 10 stainless steel screws. The screws shall have an integral or captive flat washer and a hexagon head slotted for a standard screwdriver, and shall be stainless steel. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-30 2.17 PROGRAMMED VISIBILITY VEHICLE SIGNAL FACES Each programmed visibility signal face and the installation thereof shall conform to the provisions in Section 2.13, "Vehicle Signal Faces," 2.16, "Backplates," and 2.15, "Signal Mounting Assemblies," except that the provisions in Section 2.13B, "Optical Units," shall not apply. Each programmed visibility signal section shall provide a nominal 300 mm (12") diameter circular or arrow indication. Color and arrow configuration shall conform to ITE Publication: ST-008B. Each section shall be provided with a cap visor. Each signal section shall be provided with an adjustable connection that permits incremental tilting from 0 to 10 degrees above or below the horizontal while maintaining a common vertical axis through couplers and mountings. Terminal connection shall permit external adjustment about the mounting axis in 5 degree increments. The signal shall be mountable with ordinary tools and capable of being serviced without tools. Adjustment shall be preset at 4 degrees below the horizontal, unless otherwise specified. The visibility of each programmed visibility signal face shall be capable of adjustment or programming within the face. When programmed, each signal face's indication shall be visible only in those areas or lanes to be controlled, except that during dusk and darkness a faint glow to each side will be permissible. Prior to programming, each signal section with a yellow indication shall provide a minimum luminous intensity of 2500 cd on the optical axis, and a maximum intensity of 100cd at 15 degrees horizontal from the axis. Each signal section with a yellow indication shall be capable of having its visibility programmed to achieve the following luminous intensities: a minimum of 2500 cd on the optical axis, a maximum of 100 cd at from 0.5 to 2 degrees horizontal from the axis and a maximum of 10 cd at from 2 to 15 degrees horizontal from the axis. Under the same conditions, the intensities of the red indication and the green indication shall be at least 19 and 38 percent, respectively, of the yellow indication. Each signal face or each signal section shall include integral means for regulating its luminous intensity between limits in proportion to the individual background luminance. Lamp intensity shall not be less than 97 percent of uncontrolled intensity at 10 000 Ix, and shall reduce to 15 ±2 percent of maximum intensity at less than 10 Ix. The dimming device shall operate over an applied voltage range of 95 to 130V, 60 Hz and a temperature range of -40°C to 74°C. The Contractor shall program the head as recommended by the manufacturer and as directed by the Engineer. 2.18 PEDESTRIAN SIGNAL FACES Message symbols for pedestrian signal faces shall be white WALKING PERSON and Portland orange UPRAISED HAND conforming to the requirements of the Institute of Transportation Engineers Standards: "Pedestrian Traffic Control Signal Indications" and the "Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement". The height of each symbol shall be not less than 250 mm (10") and the width of each symbol shall be not less than 165 mm (61/2"). The luminance of the UPRAISED HAND symbol shall be 3750 cd/m2 (1,100 foot- lamberts), minimum, and the luminance of the WALKING PERSON symbol shall be 5300 cd/m2 (1,550 foot-lamberts), minimum, when tested in accordance with California Test 606. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-31 The uniformity ratio of an illuminated symbol shall not exceed 4 to 1 between the highest luminance area and the lowest luminance area. The luminance difference between a nonilluminated symbol and the background around the symbol shall be less than 30 percent when viewed with the front screen in place and at a low sun angle. Brightness measurements for signals designed for an incandescent lamp will be made when the signal is equipped with an A-21 traffic signal lamp operated at a voltage to produce 665 lumens. Each housing, including the front screen, shall have maximum overall dimensions of 470 mm (18r/2 B) width, 483 mm (19") height and 292 mm (111/2") depth. All new pedestrian signal faces installed at any one intersection shall be the same make and type. Each pedestrian signal face shall be installed at the location and mounted in the manner shown on the plans. A. Types. Pedestrian signal faces shall be Type A and shall conform to the following: Each Type A signal shall consist of a housing, two-color message plate, a reflector assembly, two light emitting diode modules conforming to the provisions in Section 209- 4.07, "Light Emitting Diode Pedestrian Signal Modules", with sockets and a front screen. Each message plate shall be one piece and shall be made 4.7 mm (3/16") tempered glass. The symbols shall be applied to the inside smooth surface of the message plate. Each reflector assembly shall consist of a double reflector or 2 single reflectors. Each reflector shall be made of either aluminum or plastic. All reflectors shall conform to the provisions in Institute of Traffic Engineers Publication: ST-008B, "Vehicle Traffic Control Signal Heads." Plastic reflectors shall consist of molded or vacuum-formed plastic with a vacuum-deposited aluminum reflecting surface. The plastic material shall not distort when the reflector is used with the lamp of the wattage normally furnished with the signal. In addition, the UL nonmechanical loading temperature of the material shall exceed, by at least 10°C, the maximum temperature in the signal section with the lamp "ON" and measured in an ambient air temperature of 25°C in accordance with UL Publication UL 746B. Each completed reflector shall, when operated with the appropriate lamp and lens, provide the message brightness specified. B. Front Screen. The front screen provided on each Type A signal shall have a 38 mm (11/2"> deep eggcrate or Z-crate type screen of 0.8 mm (0.03") nominal thickness polycarbonate. The screening shall be mounted in a frame constructed of 1.0 mm (0.04") minimum thickness polycarbonate. The screen shall be installed parallel to the face of the message plate and shall be held in place by the use of stainless steel screws. The front screen shall not fracture, separate at the welds, or compress more than 3 mm (1/8") when a 75 mm (3") diameter, 1.8-kg (4lb.) steel ball is dropped onto the screen from a height of 1.2 m (4') above the screen. The screen will be lying in a horizontal position and supported on its edges for this test. The message plate will be removed from the pedestrian signal housing, when the pedestrian housing is used to support the front screen during the test, so there will be no back support for the screen. The screen and frame shall be fabricated from aluminum anodized flat black, or finished with lusterless black exterior grade latex paint formulated for application to properly prepared metal surfaces, or shall be fabricated from flat black plastic. Alternate methods of screening may be substituted for the above screens provided that the results are at least equal to those obtained with the above specified screens as determined by the Engineer. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-32 C. Housing. Pedestrian signal housings shall conform to the provisions in Section 2.13C, "Signal Sections." D. Finish. The exterior of each housing and visor and the interior of visors shall be painted in accordance with the provisions in Section 3.12, "Painting." E. Controls. All pedestrian signals shall be capable of being controlled by the solid-state switching devices specified for traffic signal controller assemblies. F Terminal Blocks. Each pedestrian signal face shall be provided with a light duty terminal block conforming to the provisions in SSPWC Section 2.13E, "Electrical Components." All field wiring shall connect to this terminal block. 2.19. LIGHT EMITTING DIODE PEDESTRIAN SIGNAL MODULES For Type A pedestrian signal faces, the pedestrian signal face "Upraised Hand" & "Walking Person" module shall utilize light emitting diode. Each light emitting diode (LED) pedestrian signal face "Upraised Hand" & "Walking Person" module shall consist of an assembly that utilizes light emitting diodes as the light source in lieu of an incandescent lamp for use in pedestrian signal faces and shall conform to the following: 1. LED Pedestrian signal face "Upraised Hand" & "Walking Person" module shall be designed to mount in the standard existing Type "A" Housing. Pedestrian signal face modules shall be designed to mount behind or replace the existing face plate of existing Type "A" housing as specified by the requirements of the ITE Standards: "Pedestrian Traffic Control Signal Indications" and the "Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement". The design of the modules shall require a specific mounting orientation. 2. LED pedestrian signal module used on this project shall be from the same manufacturer. 3. The circuit board and power supply shall be contained inside the module. Circuit boards shall conform to Chapter 1, Section 6 of the 'Transportation Electrical Equipment Specifications". 4. LED pedestrian signal modules shall fit into the existing type "A" housing and shall not require a specific mounting orientation or have a variance in light output, pattern or visibility for any mounting orientation. 5. The LEDs for "Upraised Hand" symbol shall utilize AllnGaP technology and shall be the ultra bright type rated for 100,000 hours of continuous operation from - 40°C to 74°C. 6. The individual LEDs shall be wired such that a catastrophic failure of one LED will result in the loss of not more then 5 percent of the signal module light output. The failure of an individual LED in a string shall only result in the loss of that LED, not the entire string or indication. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-33 7. The LED ped modules tested or submitted for testing shall be representative of typical average production units. LED ped modules shall be tested according to California Test No. 610 and as described herein. All optical testing shall be performed with the module mounted in a standard Type "A" Pedestrian Housing but without a visor or hood attached to the housing. 8. The luminance of the UPRAISED HAND symbol shall be 3750 cd/m2 minimum. The color of UPRAISED HAND should be Portland orange conforming to the requirements of the institute of Transportation Engineers Standards: "Pedestrian Traffic Control Signal Indications" and the "Manual on Uniform Traffic Control Devices." The height of each symbol shall be not less than 250 mm and the width of each symbol shall not be less than 165 mm. 9. The luminance of the WALKING PERSON symbol shall be 5300 cd/m2 minimum. The color of WALKING PERSON should be White conforming to the requirements of the Institute of Transportation Engineers Standards: "Pedestrian Traffic Control Signal Indications" and the "Manual on Uniform Traffic Control Devices (MUTCD) 2003 Edition as amended by the MUTCD 2003 California Supplement". The height of each symbol shall be not less than 250 mm and the width of each symbol shall not be less than 165 mm. 10. The uniformity ratio of an illuminated symbol shall not exceed 4 to 1 between the highest luminance area and the lowest luminance area. 11. LED ped module shall be rated for a minimum useful life of 48 months and shall maintain not less than 85 percent of 3750 cd/m2 for UPRAISED HAND & 5300 cd/m2 for WALKING PERSON after 48 months of continuous use in a traffic signal operation over the temperature range of -40°C to +74°C. A. Physical And Mechanical Requirements. LED ped module traffic signal modules shall be designed as retrofit replacements for existing optical units of signal lamps and shall not require special tools for installation. LED ped module shall fit into existing traffic signal section housings built to the VTCSH without modification to the housing. Installation of an LED ped module shall require the removal of the lens, reflector and lamps. B. Environmental Requirements. LED ped modules shall be rated for use in the operating temperature range of -40°C (-40°F) to +74°C (+165°F). C. Construction. LED ped modules shall be a single, self-contained device, not requiring » on-site assembly for installation into an existing Type "A" housing. The power supply for the LED ped module shall be integral to the unit. The assembly and manufacturing process for the LED ped module assembly shall be designed to assure all internal components are adequately supported to withstand mechanical shock and vibration from high winds and other sources. D. Materials. Material used for the LED ped module construction shall conform to ASTM specifications for the materials where applicable. Enclosures containing either the power supply or electronic components of the LED ped module shall be made of UL94VO flame retardant materials. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-34 Module Identification. Each LED ped module shall have the manufacturer's name, trademark, and other necessary identification permanently marked on the back of the module. Each individual LED ped module shall be identified for warranty purposes. The following operating characteristics shall be identified: rated voltage, power consumption, and volt-ampere. If a specific mounting orientation is required, each module shall have prominent and permanent marking(s) for correct indexing and orientation within a signal housing. The marking shall consist of an up arrow, or the word "UP" or "TOP". Type A Pedestrian Signal Face (Combination Raised Hand/Walking Person section) housing without the reflector shall be utilized for LED combo modules. Photometric Requirements.An LED ped module shall meet at least 85 percent of the minimum 3750 cd/m2 for UPRAISED HAND & 5300 cd/m2 for WALKING PERSON while operating throughout the operating temperature range of -40°C to 74°C. The minimum initial luminous intensity values for UPRAISED HAND LED ped modules shall be 3750 cd/m2 at 25°C. The minimum initial luminous intensity values for WALKING PERSON LED ped modules shall be 5300 cd/m2 at 25°C. The measured chromaticity coordinates of LED ped modules shall conform to the chromaticity requirements of Section 5.3.2.1 and Figure C of the VTCSH standards. Electrical. Maximum power consumption requirements for LED signal modules shall be as follows: NSUMPTKWER CONSUMPTIO WALKING PERSON LED pedestrian signal modules shall operate from a 60 ±3 Hz AC line over a voltage ranging from 95 V to 135 V. The LED ped module circuitry shall prevent perceptible flicker over the voltage range specified above. The fluctuations of line voltage shall have no visible effect on the luminous intensity of the indications. Rated voltage for all measurements shall be 120 V. The LED ped module on-board circuitry shall include voltage surge protection to withstand high-repetition noise transients as stated in Section 2.1.6 of NEMA Standard TS-2, 1992. The LED circuitry shall prevent perceptible flicker to the unaided eye over the voltage range specified above. All wiring and terminal blocks shall meet the requirements of Section 13.02 of ITE Publication: Equipment and Material Standards, Chapter 2 (Vehicle Traffic Control Signal Heads). LED ped modules shall be operationally compatible with currently used controller assemblies (solid state load switches, flashers, and conflict monitors). When a current of 20 ma AC (or less) is applied to the unit, the voltage read across the two leads shall be 15 VAC or less. LED ped modules and associated on-board circuitry must meet Federal Communications Commission (FCC) Title 47, SubPart B, Section 15 regulations concerning the emission of electronic noise. The LED ped module shall provide a power factor of 0.90 or greater. Total harmonic distortion (current and voltage) induced into an AC power line by an LED ped module shall not exceed 20 percent. 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-35 G. Quality Assurance. LED ped modules shall be manufactured in accordance with a vendor quality assurance (QA) program. The QA program shall include two types of quality assurance: (1) design quality assurance and (2) production quality assurance. The production quality assurance shall include statistically controlled routine tests to ensure minimum performance levels of LED ped modules built to meet this specification. QA process and test results documentation shall be kept on file for a minimum period of seven years. LED ped module designs not satisfying design qualification testing and the production quality assurance testing performance requirements described below shall not be labeled, advertised, or sold as conforming to this specification. H. Manufacturer's Serial Numbers. Identification of the component and sub-assembly level may be required if the reliability and performance of the module must be traceable to the original item manufacturers of the module components and subassemblies. I. Production Quality Assurance Testing. The following Production Quality Assurance tests shall be performed on each new LED ped module prior to shipment. Failure to meet requirements of any of these tests shall be cause for rejection. The manufacturer for warranty purposes shall retain test results for seven years. Each LED ped module shall be tested for rated initial intensity after burn-in. Burn-in period shall consist of each signal module being energized at a rated voltage for a 30 minute stabilization period before the measurement is made. Each LED ped module not meeting 3750 cd/m2 for UPRAISED HAND & 5300 cd/m2 for WALKING PERSON luminous intensity requirements shall be cause for rejection. Each ped module shall be tested for required power factor after bum-in. Each LED ped module shall be measured for current flow in amperes after burn-in. The measured current values shall be compared against current values resulting from design qualification measurements under "Design Qualification Testing". The current flow shall not exceed the rated value. The measured ampere values with rated voltage shall be recorded as volt-ampere (VA) on the product labels. Each LED ped module shall be visually inspected for any exterior physical damage or assembly anomalies. Careful attention shall be paid to the surface of the lens to ensure there are no scratches (abrasions), cracks, chips, discoloration, or other defects. Any such defects shall be cause for rejection. J. Design Qualification Testing. Design qualification testing shall be performed on new LED ped module designs, and when a major design change has been implemented on an existing design. The minimum sample quantity of LED ped modules shall be as stated for each test. Failure to meet requirements for any of these tests shall be cause for rejection. A random sample of six LED ped modules shall be energized for a minimum of 24 hours, at 100 percent on-time duty cycle, in a temperature of 74°C (+165°F) before performing any design qualification testing. Any failure within an LED ped module after burn-in shall be cause for rejection. K. Rated Initial Luminous Intensity. After burn-in, a sample of six LED ped modules shall be tested for rated initial intensity per the requirements of "Photometric Requirements". Before measurement, each LED ped module shall be energized at rated voltage, with 100 percent on-time duty cycle, for a time period of 30 minutes. The ambient temperature for this measurement shall be 25°C (77°F). The test results for this test shall have recorded the current voltage, total harmonic distortion (THD), and power factor (PF) associated with each measurement. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-36 L. Chromaticity (Color). A sample of two LED ped modules shall be measured for chromaticity (color) per the requirements of "Chromaticity requirements under "Photometric Requirements." A spectraradiometer shall be used for this measurement. The ambient temperature for this measurement shall be 25°C (77°F). M. Electrical. A sample of six LED ped modules shall be measured for current flow in amperes. The measured current values shall be used for quality comparison of Production Quality Assurance current measurement on production modules. A sample of six LED ped modules shall be measured for power factor. A commercially available power factor meter may be used to perform this measurement. A sample of six LED ped modules be measured for total harmonic distortion. A commercially available total harmonic distortion meter may be used to perform this measurement. A sample of six LED ped modules shall be tested per the requirements of "Electrical", with reference to Class A emission limits referenced in Federal Communications Commission (FCC) Title 47, SubPart B, Section 15. A sample of six LED ped modules shall be tested for compatibility with the controller unit, conflict monitor, and load switch. Each signal module shall be connected to any AC voltage supply between the values of 80 and 135 VAC. The AC voltage developed across each LED ped module so connected shall not exceed 10 volts rms as the input AC voltage is varied from 80 V rms to 135 V rms. A sample of six LED ped modules shall be tested for transient immunity per "Electrical" using the procedure described in NEMA Standard TS-1992. Mechanical vibration testing shall be performed on a sample of three LED ped modules per MIL-STD-883, Test Method 2007, using three 4 minute cycles along each x, y, and z axis, at a force of 2.5 g, with a frequency sweep from 2 Hz to 120 Hz. The loosening of the lens, of any internal components, or other physical damage shall be cause for rejection. Temperature cycling shall be performed on a sample of three LED ped modules per MIL- STD-883, Test method 1010. The temperature range shall be per "Environmental Requirements". A minimum of 20 cycles shall be performed with a 30 minute transfer time between temperature extremes and a 30 minute dwell time at each temperature. Signal under test shall be non-operating. Failure of a module to function properly or any evidence of cracking of the module lens or housing after temperature cycling shall be cause for rejection. Moisture resistance testing shall be performed on a sample of three LED ped modules per NEMA Standard 250-1991 for Type 4 enclosures. Any evidence of internal moisture after testing shall be cause for rejection. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-37 N. Certificate of Compliance. The Contractor shall provide the Engineer a Certificate of Compliance from the manufacturer in accordance with the provisions of Section 6-1.07, "Certificates of Compliance," of the Standard Specifications. The certificate shall certify that the LED ped modules comply with the requirements of these specifications. The certificate shall also include a copy of all applicable test reports on the LED ped modules. O. 1. Guarantee. The Contractor shall guarantee LED ped modules for a period of one year starting on the day after the Engineer accepts the project. Modules that fail during this period shall be replaced at no cost to the State, except that State forces will change out the modules in the field. The replacement modules shall be delivered to the Engineer, or to the Public Works Department at 405 Oak Avenue, within five working days after notification. The failed modules will be made available to the Contractor at the above address at the same time as the replacement is delivered. 2. Warranty. The manufacturer shall provide a written warranty against defects in materials and workmanship for the LED ped modules for a period of 36 months after installation of the modules. Replacement modules shall be provided promptly after receipt of modules that have failed at no cost to the State except cost of shipping of the failed modules. All warranty documentation shall be given to the Engineer prior to installation. 2.20 SIGNAL MOUNTING ASSEMBLIES Signal mounting assemblies shall consist of 40 mm (11/2") standard weight steel galvanized pipe conforming to the specifications of ASTM Designation: A 53, necessary fittings, slip-fitters and terminal compartments. Pipe fittings shall be ductile iron, galvanized steel, aluminum alloy Type AC-84B No. 380, or bronze. Mast arm slip-fitters shall be cast bronze or hot-dip galvanized ductile iron. 2.21 FLASHING BEACONS A. Each beacon shall consist of a single section traffic signal face, conforming to the provisions in Section 2.13A, "Vehicle Signal Faces," with yellow or red lens as shown on the plans. The beacon flasher unit shall be independent of the intersection flasher unit. Reflective sheeting for W41 "Signal Ahead" signs, mounted on flashing beacons, shall be prismatic lens reflective sheeting (Diamond Grade or equal). B. Backplates. Each beacon shall be provided with a backplate conforming to the requirements in Section 2.16, "Backplates." C. Visors. Each beacon shall be provided with a full circle type visor conforming to the requirements in Section 2.13F, "Visors." D. Flashing Beacon Control Assembly. Each flashing beacon control assembly shall consist of switches, circuit breakers, terminal blocks, flasher, dimming relay, wiring and electrical components necessary to provide proper operation of the beacons, all housed in a single enclosure. E. Enclosure. The enclosure shall be NEMA Type 3R, and shall be provided with dead front panel and a hasp to permit padlocking of the cover. The padlock will be furnished by others. The enclosure shall be hot-dip galvanized or, at the option of the Contractor, shall be provided with a factory applied rust resistant prime coat and finish coat. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-38 wHfea ;-^..^~-*wSfr1^ir«i)sS3»«)fci,* F. Circuit Breakers and Switches. A 15-A circuit breaker shall be installed to control each ungrounded conductor entering the enclosure. A switch to permit manual operation of the sign lighting circuit shall be provided. Switches shall be of the single- hole-mounting toggle type, single-pole, single-throw, rated at 12 A, 120V. Switches shall be furnished with an indicating nameplate reading "Auto - Test" and shall be connected in parallel with the load contacts of the photoelectric control circuit. A 15-A circuit breaker may be used in place of the toggle switch. G. 209-4.090(3) Flasher. The flasher shall meet the requirements of Section 8, "Solid- State Flashers," of NEMA Standards Publication No. TS 1. The flasher shall be a solid- state device with no contact points or moving parts. The flasher shall provide 2 output circuits to permit alternate flashing of signal faces and shall be capable of carrying a minimum of 10 A per circuit at 120 V. H. Wiring. Conductors and wiring in the enclosure shall conform to the requirements in Section 2.12C, "Controller Cabinets." I. Terminal Blocks. Terminal blocks shall be rated at 25 A, 600 V, shall be molded from phenolic or nylon material and shall be the barrier type with plated brass screw terminals and integral type marking strips. J. Dimming Relay. A heavy duty dimming relay shall be provided to reduce the voltage to the lamps at night. Heavy duty relays shall be designed for continuous duty. Relays shall operate during ambient temperatures from -18°C to 71°C (0° to 160°F). Each relay shall operate in the 8-pin Jones-type socket shown on the plans. Relays shall be provided with double-pole, double-throw contacts. Contact points shall be of fine silver, silver-alloy, or superior alternative material. Contact points and contact arms shall be capable of operation for 250,000 cycles with 20 A of tungsten load per contact at 120 V, 60 Hz AC. Coils shall have a power consumption of 10V-A or less and shall be designed for continuous duty on 120 volts AC. Heavy duty relays shall be enclosed with a removable, clear plastic cover. 2.22 DETECTORS A. Vehicle Detectors. Vehicle detectors shall be the type or types shown on the plans. All sensor units, control units, and amplifiers shall meet the requirements of California Test 675. The units shall not be affected by transient voltages when tested in accordance with California Test 667. After a power interruption the units shall return to normal operation within one minute. Each unit shall be provided with a light or meter, for each output circuit, to indicate when the detector is detecting a vehicle. Each detector shall operate over the range of voltages from 100 volts to 135 volts at 60 Hz. Circuitry shall be solid-state except relays with normally closed contacts may be used for the output circuit. Units shall be designed to provide ease of maintenance with easily ac- cessible electronic components. Each detector shall provide vehicle detection without readjustment from -18°C to 71 °C (0° to 160°F). Units shall use printed circuit boards designed to facilitate identification of components. This shall be done by either part identification markings or by providing a pictorial diagram showing physical location and identification of each component. Each printed circuit board shall have the following minimum quality requirements: NEMA FR-4 glass cloth base epoxy resin board, 1.5 mm (1/16") minimum thickness, organic solder masking and gold plated contacts. Intercomponent wiring shall be copper track with a minimum mass of 600 g/m2 (2 oz/ft2). Printed circuit design shall be such that components may be removed and replaced without permanent damage to boards or tracks. Splices shall conform to the provisions in Section 2.25F, "Wiring." 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-39 B. Inductive Loop Detectors. Inductive loop detectors shall conform to the following: C. General. The term "inductive loop detector" applies to a complete installation consisting of a loop or group of loops installed in the roadway, as shown on the plans, lead-in cable and a sensor unit with power supply installed in a controller cabinet. D. Sensor Unit Construction. "Card" type sensor units shall conform to the requirements in "Traffic Signal Control Equipment Specifications," issued by the State of California, Department of Transportation, and to all addendums thereto current at the time of project advertising. Shelf mounted sensor units shall conform to the requirements in Section 11 of the NEMA Standards Publication No. TS 1. Capacitors or inductors necessary for loop tuning shall not be mounted external to the sensor unit. E. Construction Materials. Conductor for each inductive loop detector shall be continuous and unspliced and shall conform to one of the following: Type 1 loop wire shall be Type RHW-USE neoprene-jacketed or Type USE cross-linked polyethylene insulated, No. 12, stranded copper wire. The minimum insulation thickness at any point shall be 1.0 mm (40 mils). Type 2 loop wire shall consist of a conductor inside of plastic tubing. The conductor shall be Type THWN or Type XHHW, No. 14, stranded copper wire. The tubing shall be polyethylene or vinyl, rated for use at 105°C, and shall be resistant to oil and gasoline. The tubing shall have a maximum outside diameter of 7 mm (0.27") and a minimum wall thickness of 0.71 mm (0.028"). The conductors shall not be spliced inside the tubing. Conductors for loop detector lead-in cable shall be 2 No. 16 (19 x 29) stranded tinned copper. Loop detector lead-in cable shall conform to the calculated cross sectional area of ASTM Designation: B 286, Table 1. The lead-in cable shall conform to one of the fol- lowing: Type B lead-in cable shall be insulated with 0.5 mm (20 mils) of high-density polyethylene. The conductors shall be twisted together with at least 6 turns per meter and the twisted pair shall be protected with a copper or aluminum polyester shield. A No. 20, minimum, copper drain wire shall be provided and connected to the equipment ground within the cabinet. The cable shall be provided with a high-density polyethylene or high-density polypropylene outer jacket with a nominal thickness of 0.8 mm (35 mils). An amorphous interior moisture penetration barrier of nonhydroscopic polyethylene or polypropylene fillers shall be provided. Type C lead-in cable shall conform to International Municipal Signal Association (IMSA) Specification No. 50-2. A No. 20, minimum, copper drain wire shall be provided and connected to the equipment ground within the cabinet. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-40 2.23 LIGHTING A. High Pressure Sodium Luminaires. High pressure sodium luminaires shall be the enclosed type with a horizontal burning lamp. Luminaires shall be the cutoff type. Each luminaire shall consist of a housing, a reflector, a refractor or a lens, a lamp socket, an integral ballast, a terminal strip and a lamp. Housings shall be fabricated from aluminum. Housings that are painted shall withstand a 1000-hour salt spray test as specified in ASTM Designation: B 117. All other metal parts of the housing shall be fabricated from metal at least equal in corrosion resistance and finish to the metal in the housing. Each housing shall be provided with a slip-fitter capable of mounting on a 50 mm (2") pipe tenon and of being adjusted 5 degrees from the axis of the tenon. The clamping brackets of the slip-fitter shall not bottom out on the housing bosses when adjusted within the ±5 degree range. No part of the slip-fitter mounting brackets on the luminaires shall develop a permanent set in excess of 0.5 mm (0.020") when the four 10 mm (3/8u) diameter cap screws used for mounting are tightened to 13 N-m (10 ft/lbs.). All luminaires to be mounted on horizontal mast arms, when tested in accordance with California Test 611, shall be capable of withstanding cyclic loading in (G = Acceleration of Gravity): 1. a vertical plane at a minimum peak acceleration level of 3.0 G peak-to-peak sinusoidal loading (same as 1.5 G peak) with the internal ballast removed, for a minimum of 2 million cycles without failure of any luminaire parts. 2. a horizontal plane perpendicular to the direction of the mast arm at a minimum peak acceleration level of 1.5 G peak-to-peak sinusoidal loading (same as 0.75- G peak) with the internal ballast installed, for a minimum of 2 million cycles without failure of any luminaire parts. 3. a vertical plane at a minimum peak acceleration level of LOG peak-to-peak sinusoidal loading (same as 0.5-G peak) with the internal ballast installed, for a minimum of 2 million cycles without failure of any luminaire parts. Each mast arm mounted luminaire shall be furnished with a photoelectric unit receptacle. If a photoelectric unit receptacle is included and the plans call for the omission of a photoelectric unit, a raintight shorting cap shall be installed. The surface of each reflector shall be specular and shall be protected by either an anodized finish or a silicate film. The reflector shall be shaped so that a minimum of light is reflected through the arc tube of the lamp. Each refractor or lens shall be mounted in a frame that is hinged to the housing and secured with a spring-loaded latch. Each refractor shall be made of glass or polycarbonate plastic. Each lens shall be made of heat and impact resistant glass. The optical system, consisting of the reflector, refractor or lens, lamp socket and lamp, shall be in a sealed chamber. Sealing shall be provided by a gasket between the reflector and refractor or lens and a gasket between the reflector and lamp socket. The chamber shall have provision for filtered flow of air in and out of the chamber due to lamp heat. Filtering shall be accomplished by either a separate filter or a filtering gasket. Each lamp socket shall be a porcelain enclosed mogul-multiple type. The shell shall contain integral lamp grips to assure electrical contact under conditions of normal vibration. The socket shall be mounted in the luminaire in a manner to permit pre-setting a variety of specified light distribution patterns. The socket shall be rated for 1500 W and 600 V, and shall be rated for a 4-kV pulse. When the components are mounted on a down-opening door, the door shall be hinged and secured to the luminaire housing 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-41 separately from the refractor or flat lens frame. The door shall be easily removable and replaceable. The door shall be secured to the housing in a manner to prevent its accidental opening when the refractor or flat lens frame is opened. Field wires connected to the luminaire shall terminate on a barrier type terminal block secured to the housing. The terminal screws shall be captive and equipped with wire grips for conductors up to No. 6. Each terminal position shall be clearly identified. The minimum light distribution for each luminaire shall be as shown on the isolux diagrams on the plans. The maximum brightness of each cutoff luminaire, with the lamp indicated, shall be as Table 2.23(A): TABLE 2.23(A) CUTOFF TYPE LUMINAIRE Lamp ANSI Code No. S55 S66 S50 S67 S51 Lamp Wattage 150 200 250 310 400 Maximum Brightness (cd/m2) 140 140 175 210 260 Brightness readings will be taken using a brightness meter with an acceptance angle of 1.5 degrees. When measured on the 90-degree and 270-degree lateral angle line, the maximum brightness shall not exceed the above specified brightness when the meter is located at a horizontal distance of 37 m (120') and a vertical distance of 2.3 m (7.5') between the luminaire and the meter, or at an angle of 3 degrees 35 minutes from the horizontal to the line between the luminaire and the meter. Measurements shall be made from both the 90-degree line and the 270-degree line and averaged. The lamp used for each test shall be operated at the wattage necessary to produce a light output as shown in Table 2.23(B): TABLE 2.23 (B) LAMP WATTAGE VERSUS LIGHT OUTPUT Lumens 16000 22000 27000 37 000 50000 Lamp Wattage 150 200 250 310 400 o 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-42 B. High Pressure Sodium Lamp Ballasts. Each ballast shall be designed for the type, characteristics and wattage of the lamp it is to operate and it shall provide the proper starting and operating waveforms, voltage and current. Ballasts shall provide reliable lamp starting and operation at ambient temperature down to -30°C for the rated life of the lamp. Ballasts shall be designed for continuous operation at ambient air temperatures from -20°C to 25°C without reduction in ballast life. Ballasts shall have a design life of not less than 100,000 hours. Ballasts shall be designed to operate for at least 180 cycles of 12 hours on and 12 hours off, with the lamp circuit in an open or short-circuited condition and without measurable reduction in the operating re- quirements. Ballasts shall be tested in accordance with the requirements of ANSI C82.6-1980, "Methods of Measurement of High-Intensity-Discharge Lamp Ballasts." Starting aids for ballasts of a given lamp wattage shall be interchangeable between ballasts of the same wattage and manufacturer without adjustment. A Certificate of Compliance conforming to the provisions in Section 4-1.5, "Certification," shall be submitted by the manufacturer with each lot of integral ballast luminaires and with each lot of ballasts designed for use outside of luminaires. The certificate shall state that the lot of ballasts meets, in every respect, the above requirements and the lamp-ballast specifications of the lamp manufacturer. The input voltage for ballasts shall be as shown on the plans or as specified in these special provisions. Each integral ballast shall consist of separate components, each of which shall be capable of being easily replaced. A starting aid which is encapsulated will be considered as a single component. Each component shall be provided with screw terminals, NEMA tab connectors or a single multi-circuit connector. All conductor terminals shall be identified as to the component terminal to which they connect. Heat-generating components shall be mounted so as to use the portion of the luminaire upon which they are mounted as a heat sink. Capacitors shall be located as far as practicable from heat-generating components or shall be thermally shielded to limit the case temperature to 75°C. Transformers and inductors shall be resin-impregnated for protection against moisture. Capacitors, except those in starting aids, shall be metal cased and hermetically sealed. Ballasts to be located remote from the luminaire shall be the submersible type and shall conform to the requirements in Section 2.26C, "Submersible Type Transformers." All components, including starting aid, shall be enclosed in a single housing. Ballast leads shall extend a minimum of 300 mm (12") from the case. Steel housings shall be galvanized or painted. Ballast housings shall be clearly labeled to indicate lamp type, lamp wattage and input voltage. Ballasts for high-pressure sodium lamps shall have a ballast characteristic curve which will intersect both of the lamp-voltage limit lines between the wattage limit lines and remain between the wattage limit lines throughout the full range of lamp voltage. This requirement shall be met not only at the rated input voltage of the ballast, but also at the lowest and highest input voltage for which the ballast is rated. Throughout the lifetime of the lamp, the ballast curve shall fall within the specified limits of lamp voltage and wattage. Ballasts for luminaires to be mounted on mast arms, brackets or lowering assemblies shall be located within the luminaire housing. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-43 C. Regulator Type Ballasts. Regulator type ballasts shall conform to the following: For nominal input voltage and lamp voltage, the ballast design center shall not vary more than 7.5 percent from rated lamp watts. The ballast shall be designed so that a capacitance variance of ±6 percent will not cause more than a ±8 percent variation in lamp wattage regulation throughout rated lamp life for nominal input voltage. The lamp current crest factor shall not exceed 1.8 for input voltage variation of ±10 percent at any lamp voltage from initial through life. Regulator type ballasts shall be lag-type or lead-type conforming to the following: Lag-Type Regulator Ballasts.— Each lag-type regulator ballast shall have the primary and secondary windings electrically isolated and, when operated with the appropriate lamp, shall have the following characteristics and shall maintain the following lamp operation: The power factor shall be not less than 90 percent throughout the life of the lamp at nominal line voltage with a nominally rated reference lamp. Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 18 percent for ±10 percent input voltage variation. Lead-Type Regulator Ballasts.— Each lead-type regulator ballast (CWA-constant wattage auto-regulator) shall, when operated with the appropriate lamp, have the following characteristics and shall maintain the following lamp operation: The power factor shall be not less than 90 percent when the ballast is operated at nominal line voltage with a nominally rated reference lamp. Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 30 percent for ±10 percent input voltage variation. D. Autotransformer or Reactor Type Ballasts. Each nonregulating reactor, autotransformer, or high reactance ballast shall, when operated with the appropriate lamp, have the following characteristics and shall maintain the following lamp operations: The power factor shall be not less than 90 percent when the ballast is operated at nominal line voltage with a nominally rated reference lamp. Lamp wattage regulation spread at any lamp voltage from nominal through life shall not vary by more than 25 percent for ±5 percent input voltage variation. For nominal input voltage and lamp voltage, the ballast design center shall not vary more than 7.5 percent from rated lamp watts. The lamp current crest factor shall not exceed 1.8 for input voltage variation of ±5 percent at any lamp voltage from initial through life. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-44 High Pressure Sodium Lamps. High pressure sodium lamps shall conform to the ANSI Standard: C 78, "Lamp Specifications, Physical and Electrical Characteristics of High-Intensity-Discharge Lamps," when tested in accordance with ANSI Standard: C 78.388, "Methods of Measurement of High Pressure Sodium Lamp Characteristics." High-pressure sodium lamps shall have a minimum average rated life of 24 000 hours. Mission Bell Luminaires. The contractor shall be responsible for furnishing and installing all components of the Mission Bell fixture and light standard in accordance to manufacturer's specifications and these special provisions. The Contractor's responsibility shall include, but is not limited to, mounting adaptor to mast arm, mounting bracket for use with photoelectric control and suspension method for conductors. Dissimilar metals shall not be used for mounting the Mission Bell to the fixture adapter (plumberizer). The 50 mm (2") diameter close aluminum nipples used between the plumberizer and Mission Bell casting shall be fabricated from bar stock aluminum conforming to ASTM designation 6061-T6 or 6063-T1 and shall be bored through along their central axis with a 25 mm (1") diameter hole to accommodate the lighting conductors. All aluminum incorporated in the fixture shall be clear anodized in accordance with Aluminum Association designation AA- M12C22A41. The minimum anodic coating thickness shall be not less than 0.03 mm (1.0 mil). Mission Bell Luminaires shall conform to the requirements of section 209-6.01 of these special provisions except as noted in this section (209-6.02) and shall be Sierra Lighting catalog number MB-200-HPS-240-DBZ, General Electric catalog number BELL20S3AGMN3DB or approved equal. All Mission Bell Luminaires from any source shall be modified as specified herein. The Contractor shall submit shop drawings for the mounting design for approval by the Engineer prior to fabrication in accordance with Section 2-5.3 Shop Drawings. Soffit and Wall Luminaires, and Lamps. Soffit and wall luminaires shall be of the type or types specified. Soffit and wall luminaires shall be weatherproof and corrosion resis- tant. Installation details and minimum light distribution shall be as shown on the plans. Each flush-mounted soffit luminaire shall consist of a metal body, a prismatic refractor mounted in a door frame, a prismatic glass or specular anodized aluminum reflector, a ballast, and a lamp socket. The body shall have provisions for anchoring in concrete and shall be provided with two Size 27, minimum, conduit hubs. The refractor shall be glass and shall be clearly identified as to "street side." The door frame assembly shall be hinged, gasketed and secured to the body by at least 3 machine screws. The ballast shall be located either within the housing or in a ceiling pull box as shown on the plans. Each pendant soffit luminaire shall be enclosed and gasketed, and shall be furnished with aluminum finish. The reflector shall have a specular anodized aluminum finish. The refractor shall be made of heat-resistant polycarbonate or glass. The optical assembly shall be hinged and latched for lamp access and shall be provided with a device to prevent dropping. Each pendant soffit luminaire shall be furnished with a ballast and with a galvanized metal box for mounting the luminaire. The ballast shall be designed for operation in a raintight enclosure. The box shall be provided with a gasketed cover with 2 captive screws and 2 chains to prevent dropping. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 1656(M5 Each wall-mounted luminaire shall consist of a cast metal body, a prismatic refractor mounted in a door frame, an aluminum reflector with a specular anodized finish, an integral ballast and a lamp socket. The refractor shall be glass. A gasket shall be provided between the refractor and the body of the fixture. Each luminaire shall be provided with at least two 8 mm (5/16") minimum diameter mounting bolts. Cast aluminum bodies, which are to be cast into or mounted against concrete, shall be given a thick application of alkali-resistant bituminous paint on all surfaces to be in contact with concrete. Unless otherwise specified, each soffit luminaire and each wall luminaire shall be furnished with a 70-W high-pressure sodium lamp, with a minimum average rated life of 24 000 hours. Each lamp socket shall be positioned to locate the light center of the lamp within 13 mm (1/2") qf the light center location for which the luminaire is designed. Ballasts for soffit and wall luminaires shall be the autotransformer, reactor or regulator type conforming to the provisions in Section 2.23B, "High Pressure Sodium Lamp Ballasts." Ballasts for wall luminaires shall be located in the luminaire housing or, when shown on the plans, in a pull box adjacent to the luminaire. H. Pedestrian Crossing Fixtures. Pedestrian crossing fixtures shall consist of fluorescent lighting fixtures for pedestrian undercrossings and for pedestrian overcrossings as shown on the plans. I. Sign Lighting Fixtures—Mercury. Each mercury sign lighting fixture shall be designed for mounting near the bottom of the sign panel on an overhead sign structure. The fixture shall be of an enclosed design and shall be raintight and corrosion resistant. Each fixture shall consist of a housing with door, a reflector, refractor or a flat lens, a lamp, a socket assembly, a ballast and a fuse block, and shall conform to the following: 1. Housing.— The housing shall have a door designed to hold a refractor or flat lens. Housings and doors shall be fabricated of sheet or cast aluminum. Sheet aluminum shall conform to the requirements of ASTM Designation: B 209 or B 209M for 5052-H32 aluminum sheet. Painting is not required. All external bolts, screws, hinges, hinge pins and door closure devices shall be of material which will not corrode in normal use.The housing shall be provided with holes to permit condensed water to drain. The door shall be hinged to the housing on the side of the fixture away from the sign panel and shall be provided with two captive latch bolts or other latching device. The door shall be provided with means to allow the door to be locked in the open position (50 degrees, minimum from the plane of the door opening) with a wind of 110 km/h (70 mph) striking the door from either side. The juncture of the door and the housing shall be gasketed to provide a raintight and dusttight joint. The thickness of the gasket shall be 6 mm (0.25"), minimum. The maximum height of the fixture shall be 300 mm (12") above the top of the mounting rails. When the fixture is mounted on the mounting channels without a mounting plate, 4 holes of 11 mm (7/16 u) diameter shall be provided. The distance between the front and back holes shall be 165 mm (61/2"). 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-46 2. Reflector.— The reflector shall be one piece and shall be made from specularly finished aluminum protected with an electrochemically applied anodized finish or a chemically applied silicate film. The reflector shall be designed so that water deposited on it due to condensation will drain away. The reflector shall be secured to the housing with a minimum of two screws and shall be removable without removing any fixture parts. No reflectors shall be attached to the outside of the housing. 3. Refractor.— Refractors shall be made from borosilicate heat resistant glass. When a flat lens is used, the lens shall be made from heat resistant glass. The refractor shall be so designed or shielded that no fixture luminance is visible when the fixture is approached directly from the rear and the viewing level is the bottom of the fixture. When a shield is used it shall be an integral part of the door casting. 4. Lamp.— Each fixture shall be furnished with a 175-W mercury lamp conforming to ANSI C78.386-1989, Code: H39KC-175/DX. Lamps shall have a minimum average rated life of 16 000 hours. 5. Lamp Socket.— The lamp socket shall be a porcelain enclosed mogul type. The shell shall contain integral lamp grips to assure electrical contact under conditions of normal vibration. The center contact shall be spring-loaded. Shell and center contact shall be nickel plated brass. The socket shall be rated for 1500 Wand 600V. 6. Ballast. — The ballast for each mercury sign fixture shall be designed for the characteristics and wattage of the lamp and it shall provide the proper starting voltage and operating waveforms, voltage and current. Ballasts shall provide reliable lamp starting and operation at ambient temperatures down to -25°C for the rated life of the lamp. Ballasts shall be designed for continuous operation at ambient air temperatures from -20°C to 25°C without reduction in ballast life. Ballasts shall have a design life of not less than 100 000 hours. Ballasts shall be tested in accordance with the requirement of ANSI Standard C82.6-1980, "Methods of Measurement of High-Intensity-Discharge Lamp Ballasts." A Certificate of Compliance conforming to the provisions in Section 4-1.5, "Certification," shall be submitted by the manufacturer with each lot of sign lighting fixtures. The certificate shall state that the ballasts meet, in every respect, the above requirements and the lamp ballast specifications of the lamp manufacturer. Ballasts consisting of separate components shall conform to the following: 1. Each component shall be capable of being easily replaced. Each component shall be provided with screw terminals, NEMA tab connect or a single multi-circuit connector. All conductor terminals shall be identified as to the component terminal to which they connect. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-47 2. Heat-generating components shall be mounted so as to use the portion of the sign lighting fixture upon which they are mounted as a heat sink. Capacitors shall be located as far as practicable from heat-generating components or shall be thermally shielded to limit the case temperature to 75°C. 3. Transformers and inductors shall be resin-impregnated for protection against moisture. Capacitors shall be metal cased and hermetically sealed. 4. Ballasts for mercury sign lighting fixtures shall be normal power factor reactor type or autotransformer regulator type (CWA-constant wattage autotransformer). 5. Reactor Type Ballasts.— Each reactor type ballast shall, when operated with the mercury lamp, have the following characteristics and shall maintain the following lamp operation: a) The power factor shall be not less than 50 percent. b) The lamp wattage shall not vary by more than a ±10 percent for a ±5 percent input voltage variation. c) The lamp current crest factor shall not exceed 1.5 at rated input voltage. d) Ballast losses shall not exceed 25 W. 6. Autotransformer Regulator Ballasts.— Each autotransformer regulator type ballast shall, when operated with the mercury lamp, have the following characteristics and shall maintain the following lamp operation: a) The power factor shall be not less than 90 percent. b) The lamp wattage shall not vary by more than a ±7 percent for a ±10 percent input voltage variation. c) The lamp current crest factor shall not exceed 1.7 at rated input voltage. d) Ballast losses shall not exceed 40 W. 7. Fuse Block.— Each fixture shall be provided with a barrier type fuse block for terminating field connections. The block shall be secured to the housing and shall be accessible without removal of any fixture parts. The block shall be mounted to leave a minimum of 13 mm (0.5") air space from the sidewalls of the housing. The block shall be designed for easy removal of fuses with fuse puller, shall be rated at 600 volts and shall have box terminals. Fuses shall be 10 mm (13/32U) diameter, 38 mm (11/2") long ferrule type and shall be UL or ETL listed. For 120-volt input fixtures, only the ungrounded conductor shall be fused and a solid link shall be provided between the neutral and the ballasts. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-48 8. Wire Guard.— When shown on the plans, each sign lighting fixture shall be provided with a wire guard to prevent damage to the refractor or lens. The guard shall be constructed of 6.5 mm (0.2625") (minimum) diameter steel wire and shall be either hot-dip galvanized or provided with an electroplated zinc coating conforming to ASTM Designation: B 633, Service Condition SC4 with a clear chromate dip treatment. Guard elements shall be spaced so as to prevent rocks in excess of 40 mm (11/2") in diameter from passing through. When the fixture is located so that the light center of the lamp is 1.4 m (56") in front of, 300 mm (12") below, and centered on a 3 m (10') high by 6 m (20') wide sign panel, the ratio of the maximum to minimum illuminance level on the panel shall not exceed 12 to 1 in 95 percent of the points measured. In addition, the illuminance gradient shall not exceed 2 to 1. Illuminance gradient is defined as the ratio of the minimum illuminance on any 300 mm (12") square of panel to that on any adjacent 300 mm (12") square of panel. The minimum horizontal lux requirements shall conform to the "Isolux Diagrams" shown on the plans. Each fixture shall be furnished with a mounting assembly that will permit the fixture to be mounted on the continuous slot channels shown on the plans. The mounting assembly shall be either cast aluminum, hot-dip galvanized steel plate or steel plate that has been galvanized and finished with a polymeric coating system. J. Sign Lighting Fixtures— Incandescent. Each sign lighting fixture for an incandescent lamp shall be of the type shown on the plans or as specified in these special provisions. Sign lighting fixtures shall be UL or ETL listed for outdoor installation. The fixture shall consist of a hood with side outlet tapped for conduit and a symmetrical 250 mm (10") steel reflector. Fixture shall be rated at 150W minimum. The reflector shall have a white porcelain enamel finish. The fixture shall have a medium base socket. 2.24. INTERNALLY ILLUMINATED STREET NAME SIGNS A. Internally illuminated street name signs shall conform to the details shown on the plans. The general design of signs shall be as shown on the plans. Minor details of construction shown are typical and may be modified subject to approval by the Engineer. The sign fixture shall be designed and constructed to prevent deformation or failure when subjected to 113 km/h (TOmph) wind loads as set forth in the AASHTO publication, "Standard Specifications for Structural Supports of Highway Signs, Luminaires and Traffic Signals," and amendments thereto. The sign panels shall not deform or warp under a 113 km/h (70 mph) wind loading. A Certificate of Compliance conforming to the provisions in Section 4-1.5, "Certification," shall be submitted by the manufacturer with each lot of internally illuminated street name signs. The certificate shall state that the internally illuminated street name signs meets the wind load requirements as described above. All material used in fabrication shall be new. If not covered herein, both the material and workmanship shall be of the best quality consistent with the intended purpose. All ferrous parts shall be galvanized or cadmium plated, unless otherwise specified herein or shown otherwise on the plans. Signs shall be Type B. Additionally all Internally Illuminated Street Name Signs shall conform to the following requirements: 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-49 1. Housing.— The top and bottom shall be formed or extruded aluminum and shall s*^ be attached to formed or cast aluminum end fittings. The design shall provide continuous sealing between top and bottom assemblies and the end fittings. The "*"""" housing shall be rigidly constructed to resist torsional twist and warp. Provisions shall be made for ease of maintenance of all components. The opening or removal of one panel shall permit access to the interior of the sign and allow for . replacement of lamps, ballasts and fuses. Type IV photoelectric unit sockets shall be provided. On Type A signs, both sides shall be hinged at the top to permit installation or removal of the sign panels, and to permit access to the interior of the sign. On Type B signs, the sign panels shall be slide-mounted into the housing. 2. Reflectors.— At the option of the Contractor, reflectors may be used to provide the required sign brightness. Reflectors, if used, shall be formed aluminum with acrylic baked white enamel surface having a minimum reflectance of 0.85. 3. Sign Panels.— The sign panels shall be slide-mounted or rigid mounted in a frame, with white legend, symbols, arrows, and border on each face, as shown on the plans. The background shall be green. The entire surface of the sign panel shall fabricated with prismatic, cube corner reflective sheeting (Diamond Grade or equal) and shall be evenly illuminated. The average of brightness readings for the letters shall be 500 cd/m2 (150 foot-lamberts), minimum. The light transmission factor of the sign panel shall provide a letter to background brightness ratio of between 10 to 1 and 20 tol The luminance of the background shall not vary by more than 40 percent from the average of background brightness reading. The luminance of the letters, symbols and arrows shall not vary by more than 20 percent from the average brightness reading of letters, symbols and arrows. The sign panels shall be translucent .**\ panels of high impact resistant plastic of one of the following types: ^^ a) Glass fiber reinforced acrylated resin. b) Polycarbonate resin. c) Cellulose acetate butyrate plastic. d) Paint on the outside of the plastic shall be protected by a plastic film which shall seal the front surface of the panel and filter out ultraviolet radiation. Paint shall be acrylic plastic type. e) All surfaces shall be free of blemishes in the plastic or coating that may impair the serviceability or detract from the general appearance and color matching of the sign. f) The white or green color shall not fade or darken when the sign is exposed to an accelerated test of ultraviolet light which is equivalent to 2 years of outdoor exposure. The green color of the sign, when not illuminated, shall conform to Color No. 14109 of Federal Standard 595B. g) The sign panels shall not crack or shatter when a 25.4 mm (1") diameter, steel ball with a mass of 67 grams (4 oz.) is dropped from a height of 2.6 m (8.5') above the sign panel to any point of the sign panel. The panels shall be lying in a horizontal position and supported within their frame for this test. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-50 4. Gaskets.— On Type A signs, gaskets shall be installed between the sign panel frame and the fixture housing to prevent the entrance of water between the frame and the fixture housing. Gaskets shall be uniform and even textured and shall be the closed cell, sponge neoprene type, designed for use at temperatures between -20°C(-4°F) and +70°C (158°F). Gaskets shall be neatly applied to thoroughly degreased, clean surfaces with a suitable heat-resistant adhesive which will not allow the gaskets to slip at temperatures between -20°C and +70°C. 5. Ballasts.— Ballasts shall be of the high power factor type and shall be capable of starting the lamps at -20°C (-4°F) and above. Ballasts for Type A signs shall be rated at 200 mA. Ballasts for Type B signs shall be rated at 430 mA. Ballasts shall be listed by UL or ETL for operation on 110 to 125 V, 60 Hz circuits, and shall conform to the requirements of ANSI Standard: C 82.1 and ANSI Standard: C 82.2. A separate ballast shall be provided for each lamp. 6. Lamp holders.— Lamp holders shall be listed by UL or ETL for outdoor use, shall be provided with silver coated contacts and waterproofed entrance leads for use with a rapid-start fluorescent lamp. Removal of the lamp from the socket shall de-energize the primary of the ballast. Each lamp holder shall be provided with a heat-resistant, circular cross section, partially recessed neoprene ring to seal against the lamp ends and protect electrical contacts from moisture and dirt or other injurious elements. One lamp holder for each lamp shall be of the spring- loaded type. The distance between the face of the lamp holders for each lamp shall provide a compression of at least 2.5 mm (0.10") on the spring-type lamp holder when the lamp is in place. The lamp shall have positive mechanical and electrical contact when the lamp is in place. The socket on the spring-type lamp holder shall have sufficient travel to permit installation of the lamp. Springs for lamp holders shall not be part of the current carrying circuit. Lamp holders shall match lamp requirements and shall not increase cathode filament circuit resistance by more than 0.10 Q. 7. Lamps.— Lamps shall be of the types shown on the plans and shall meet the requirements of ANSI Standard: C 78. 8. Terminal Blocks.— All wiring connections in the fixture shall be terminated on molded, phenolic, barrier type, terminal blocks rated at 15 A, 1000V, and shall have integral type, white, waterproof marking strips. All current carrying parts of the terminal block shall be insulated from the fixture with integral plugs or strips to provide an insulating value in excess of the line-to-ground flashover voltage. If the Contractor elects to use sectionalized terminal blocks, each section shall be provided with an integral barrier on each side and shall be capable of rigid mounting and alignment. Terminal screws shall be size No. 10, minimum. 9. Fuses.— Fuses shall be Type SAG, miniature, slow blowing type with appropriate current and voltage ratings. Fuseholder shall be a panel-mounting type with threaded or bayonet type knob which grips the fuse tightly for extraction. A separate fuse shall be provided for each ballast. 10. Weep Holes.— Screened weep holes shall be provided at strategic locations in all members subject to the collection of moisture. Weep holes shall be shielded to prevent light leakage from the fixture. 11. Fasteners.— All fasteners, screws, and hardware shall be of passive stainless steel (Type 302 or 304) or aluminum Type 6060-T6. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-51 12. Mounting Assemblies.— The top of the fixture housing shall have 2 free-swinging mounting brackets. Each of the brackets shall be adjustable vertically for leveling the sign to either a straight or curved mast arm. The bracket assembly shall permit the fixture to swing perpendicular to the sign panel. Hinge pins for the free-swinging brackets shall have a minimum diameter of 6 mm (0.25"). At least 4.6 m (15') clearance shall be provided between the bottom of the fixture and the roadway. 13. Message.— The message, as shown on the plans, shall be displayed on both sign panels. If not shown on the plans, the message, and the size of symbols or arrows will be furnished by the Engineer at the request of the Contractor. Unless shown otherwise, letters shall be 200 mm (8U) upper case and 150 mm (6") lower case, Series E. 14. Mass.— The total mass of the complete sign assembly, including lamps, ballasts, mounting brackets and appurtenances shall not exceed 30 kg. 15. Conductors.— All fixture conductors shall be UL or ETL listed appliance wiring material (AWM) stranded copper wire with 0.7 mm (28 mils), minimum, thermoplastic insulation, rated at 1000 volts and rated for use at 90°C. Conductors shall be No. 16, minimum, and shall match the color coding of the ballast leads. The size of conductors from the sign disconnect to the fuse block shall be as shown on the plans. All conductors within the fixture shall be secured with easily removable spring cross straps (not clamped) in the chassis or fixture. Straps shall be installed not more than 300 mm (12") apart. Stranded copper conductors connected to screw type terminals shall terminate in approved crimp type ring connectors. Splices will not be permitted within the fixture unless approved in writing by the Engineer. 16. Equipment List and Drawings.—Within 15 days following approval of contract, the Contractor shall submit 3 sets of shop drawings and a list of equipment and materials he proposes to install, as specified in Section 2-5, "Plans and Specifications." The shop drawings shall show the message for each sign and shall include the size of letters, symbols or arrows, as shown on the plans or as furnished by the Engineer. The list of equipment shall include the name of the manufacturer of all materials and sufficient detail to identify the materials. If re- quested, the Contractor shall supply, without cost to the Agency, sufficient samples of materials to be used in the fabrication of the sign, or a complete sign assembly, to permit adequate testing and evaluation of conformance to the specified requirements. 2.25. PHOTOELECTRIC CONTROLS A. Photoelectric controls, as specified in these special provisions or as shown on the plans, shall be capable of switching multiple lighting systems directly. Type IV photoelectric control shall be used unless otherwise shown on the plans or required by these special provisions and shall be installed in a receptacle integral with the luminaire. 1. Type I photoelectric control shall consist of a remote photoelectric unit and a test switch housed in an enclosure. 2. Type II photoelectric control shall consist of a remote photoelectric unit, a separate contactor located in a service equipment enclosure, and a test switch located in the service equipment enclosure unless shown otherwise. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-52 3. Type III photoelectric control shall consist of a remote photoelectric unit, and a separate contactor and a test switch housed in an enclosure. 4. Type IV photoelectric control shall consist of a photoelectric unit which plugs into an EEI-NEMA twist lock. B. Types. The types of photoelectric controls shall be as follows: 1. Receptacle integral with the luminaire. 2. Type V photoelectric control shall consist of a photoelectric unit, contactor and test switch located in a service equipment enclosure. 3. A switch to permit manual operation of the lighting circuit shall be provided for each Type I, Type II, Type III, and Type V photoelectric control. Switches shall be of the single-hole mounting toggle type, single-pole, single-throw, rated at 12 A and a voltage rating to match the circuit. Switches shall be furnished with an indicating nameplate reading "Auto-Test" and shall be connected in parallel with the load contacts of the photoelectric unit. Test switch shall not have an "OFF" position. 4. Photoelectric units for Types I, II and III photoelectric controls, shall be pole-top mounted unless otherwise specified. C. Equipment Details. Equipment details shall conform to the following: Photoelectric Unit. The photoelectric unit shall provide an output in response to changing light levels. Components of the unit shall not require periodic replacement. Units shall have a "turn-on" between 10 and 50 lux (one and 5 footcandles) and a "turn- off at between 1.5 and 5 times "turn-on." Measurements shall be by the procedures set forth in EEI-NEMA Standards for Physical and Electrical Interchangeability of Light- Sensitive Control Devices Used in the Control of Roadway Lighting. Photoelectric controls, except Type IV and Type V, shall be furnished with a 100 mm (4") minimum inside diameter pole-top mounting adaptor containing a terminal block and with cable supports or clamps to support pole wires. The photoelectric unit receptacle shall be the EEI-NEMA type. Mounting brackets shall be used where pole-top mounting is not possible. Photoelectric controls shall be installed at the locations shown on the plans and oriented as directed by the Engineer. For switching 480V, 60 Hz circuits, a 100 V'A, minimum, 480/120-volt transformer shall be installed in the contactor enclosure to provide 120 volts for the photoelectric control unit. Where more than one photoelectric unit is to be installed at the same location, a single transformer, with a volt- ampere rating capable of handling the total controlled load, may be used. Photoelectric units shall be screened to prevent artificial light from causing cycling. The photoelectric unit shall also conform to the following: 1. The supply voltage rating shall be 60 Hz, 105-130 V, 210-240 V, or 105-240 V, as specified. 2. The load rating shall be 800 W minimum, incandescent, mercury or fluorescent. 3. The operating temperature range shall be from -29°C (-20T) to 65°C (150°F). 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-53 4. The power consumption shall be less than 10 W. 5. The unit shall be housed in a weatherproof enclosure. 6. The base of the unit shall be provided with a 3-prong, EEI-NEMA standard, twist- lock plug mounting. 7. Units shall be provided with a "fail-on" feature. D. Contactor. The contactor shall have contacts rated to switch the specified lighting load and shall be normally open, unless otherwise specified. The contactor shall be either the mechanical armature type or the mercury displacement type. The contacts of the mechanical armature type contactor shall be either fine silver, silver alloy, or superior alternative material. The contactor shall have a minimum rating of 30 A, per contact, inductive load. E. Contactor and Test Switch Housing. The enclosure for Type I and Type III photoelectric controls shall be NEMA Type 3R. The enclosure shall be provided with a factory applied rust resistant prime coat and finish coat. Two applications of paint to match the color of the standard shall be applied as specified in Section 3.12, "Painting." The enclosure may be hot-dip galvanized in lieu of painting. A minimum of 65 mm (21/2") shall be provided between contactor terminals and end of enclosure for wiring connections. The enclosure shall be mounted on the same standard as the photoelectric unit at a height of approximately 1.8 m (6') above the base. F. Wiring. Conductors between the photoelectric unit and an external contactor shall be No. 14 and shall be run inside the lighting standard, or in conduit, unless otherwise shown on the plans. G. Terminal Blocks. Terminal blocks shall be rated at 25 A, 600 V, shall be molded from phenolic or nylon material and shall be the barrier type with plated brass screw terminals and integral type marking strips. 2.26. TRANSFORMERS A. Multiple to multiple and series to multiple transformers shall be of the single-phase, dry type designed for operation on a 60 Hz supply. B. Electrical Requirements. Transformer ratings shall be 120/480 volts, 240/480 volts or 480/120 volts for multiple to multiple units and 6.6 A/120 volts or 6.6 A/480 volts for series to multiple units or other ratings as shown on the plans. Secondary 480-volt windings shall be center tapped. Volt-ampere ratings shall be as shown on the plans. Transformer efficiency shall exceed 95 percent for multiple to multiple units and 80 percent for series to multiple units. Secondary voltage regulation and tolerance shall be ±3 percent from half load to full load for multiple to multiple units and +10 percent (maximum) at no load to ±3 percent at full load for series to multiple units. Transformers shall have a decal showing a connection diagram. The diagram shall show either color coding or tagging of wires with primary (H1, H2) or secondary (X1, X2) markers, and shall also show the primary and secondary voltage and volt-ampere rating. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-54 C. Physical Requirements. External leads for multiple to multiple and series to multiple secondary connections shall be Type USE, No. 10, rated 600 volts AC. Primary conductors for series to multiple transformers shall be rated for use on 5000-volt AC circuits. Transformer leads shall extend a minimum of 300 mm (12") from the case. Transformer insulation shall be NEMA 185°C or better. Series to multiple transformers shall withstand the application of 12 000 volts AC from core to primary coil and from coil to coil for a one minute period. Series to multiple transformer secondaries and multiple to multiple transformers shall withstand the application of 2200 volts AC from core to coils and, for multiple units only, from coil to coil for a one minute period. The above tests shall be made immediately after operation of the transformer at full load for 24 hours. Non-submersible transformers shall be provided with metal half-shell coil protection, shall have moisture resistant, synthetic varnish impregnated windings and shall be suitable for outdoor operation in a raintight enclosure. Each transformer to be installed in a pull box shall be the submersible type and shall be provided with a handle and a hanger. D. Submersible Type Transformers. Submersible type transformers shall be securely encased in a rugged corrosion resistant, watertight case and shall withstand a 5-day test submerged in 600 mm (2') of salt water (2 percent salt by mass) with 12-hour on and off periods. The operating periods shall be at full load. Leads of submersible transformers shall be brought out through one or more sealed hubs and shall be secured in a manner which will withstand a 450-N (100 Ib) static pull without loosening or leaking. E. Falsework Lighting. Falsework lighting shall consist of lighting to illuminate the pavement, portals and pedestrian walkways at or under openings in the falsework required for traffic. 2.27 TESTING Attention is directed to Section 4-1.4, "Testing Materials". Testing shall conform to the following: A. Materials Testing. Material and equipment to be tested shall be delivered to a testing location designated by the Engineer. Testing will be performed by the Agency. Testing and quality control procedures for Elite gate operator, or approved equal, assemblies shall conform to the requirements in "Transportation Electrical Equipment Specifications," and "Traffic Signal .Control Equipment Specifications," issued by the State of California, Department of Transportation, and to all addendums thereto current at the time of project advertising. Testing and quality control procedures for all other traffic signal controller assemblies shall conform to the requirements in the NEMA TS Standards for Traffic Control Systems. In the event equipment submitted for testing does not comply with specifications, the Contractor shall remove the equipment for repair within 5 working days after notification that the equipment is rejected. In the event the equipment is not removed within that period, it may be shipped to the Contractor at the Contractor's expense. The Contractor shall allow 30 days for Agency testing from the time the material or equipment is delivered to the Agency test site. When equipment being tested has been rejected for failure to comply with the specifications, the Contractor shall allow 30 days for Agency retesting. The retesting period shall begin when the corrected equipment is made available at the test site. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-55 All testing subsequent to rejection of the equipment for failure to comply with specification requirements will be at the expense of the Contractor. Deductions to cover the cost of that testing will be made from any moneys due or which may become due the Contractor under the contract. The Contractor will be notified when testing of the equipment has been completed and it shall be the Contractor's responsibility to deliver the equipment to the site of the work or, at the Contractor's request and the Agency's convenience, the Agency will pack and ship the equipment to the Contractor or to the site of work. The sum of $100 or the actual cost of packing and shipping, whichever amount is greater, will be deducted, for each unit of equipment shipped by the Agency, from any moneys due to the Contractor under the contract. B. Field Testing. Prior to start of functional testing, the Contractor shall perform the following tests on all circuits, in the presence of the Engineer. 1. Continuity. Each circuit shall be tested for continuity. 2. Ground. Each circuit shall be tested for grounds. 3. Insulation Resistance. An insulation resistance test at 500 volts DC shall be made on each circuit between the circuit and a ground. The insulation resistance shall not be less than 10 MO on all circuits, except for inductive loop detector circuits which shall have an insulation resistance value of not less than 100 MQ. C. Functional Testing. Attention is directed to Section 3.2, "Scheduling of Work," regarding requirements for test periods. A functional test shall be made in which it is demonstrated that each and every part of the system functions as specified. The functional test for each new or modified system shall consist of not less than 5 days of continuous, satisfactory operation. If unsatisfactory performance of the system develops, the condition shall be corrected and the test shall be repeated until the 5 days of continuous, satisfactory operation is obtained. Turn-on of new or modified traffic signals shall be made only after all traffic signal circuits have been thoroughly tested as specified above. Except for new or modified portions of existing lighting circuits and sign illumination systems, the Agency will maintain the system or systems during the test period and will pay the cost of electrical energy for the operation of all of the facilities that are undergoing testing. The cost of any necessary maintenance performed by the Agency on new circuits or on the portions of existing circuits modified under the contract, except electrical energy, shall be at the Contractor's expense and will be deducted from any moneys due, or to become due, the Contractor. A shutdown of the electrical system resulting from damage caused by public traffic, from a power interruption or from unsatisfactory performance of Agency-furnished materials shall not constitute discontinuity of the functional test. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-56 PART 3 - EXECUTION 3.1 MAINTAINING EXISTING AND TEMPORARY ELECTRICAL SYSTEMS A. Existing electrical systems (traffic signal, street lighting, flashing beacon, traffic monitoring, sign illumination and other facilities), or approved temporary replacements thereof, shall be kept in effective operation for the benefit of the traveling public during the progress of the work, except when shutdown is permitted, to allow for alterations or final removal of the systems. The traffic signal shutdowns shall be limited to normal working hours. Lighting system shutdowns shall not interfere with the regular lighting schedule, unless otherwise permitted by the Engineer. The Contractor shall notify the local traffic enforcement agency prior to any operational shutdown of a traffic signal. B. Where an existing system or temporary system is being modified, work not shown on the plans or specified in these special provisions and which is considered by the Engineer as necessary to keep all or any part of the system in effective operation will be paid for as extra work as provided in General Provisions Section 3-3 "Extra Work.". The Agency will: 1. Continue the operation and maintenance of existing electrical facilities. 2. Continue to provide for electrical energy for the operation of existing electrical facilities. 3. Repair or replace existing facilities damaged by public traffic. 4. Pay the cost of electrical energy for the operation of existing or new facilities that are undergoing the functional tests described in Section 2.27C, "Functional Testing." C. The Contractor shall ascertain the exact location and depth of existing detectors, conduits, pull boxes and other electrical facilities before using any tools or equipment that may damage those facilities or interfere with any electrical system. Where damage is caused by the Contractor's operations, the Contractor shall, at the Contractor's expense, repair or replace damaged facilities promptly in accordance with these specifications. If any existing loop conductor, including the portion leading to the detector hand hole or termination pull box, is damaged by the Contractor's operations, the Contractor shall immediately notify the Engineer. The affected detectors shall be replaced at the Contractor's expense and as directed by the Engineer within 24 hours. If the Contractor fails to complete the repairs within this period, the repairs will be made by Agency forces at the Contractor's expense. Should the Contractor fail to perform the required repairs or replacements, the cost of performing the repairs or replacements will be deducted from any moneys due or to become due the Contractor. D. Where roadways are to remain open to traffic and existing lighting systems are to be modified, the lighting systems shall remain in operation and the final connection to the modified circuit shall be made so that the modified circuit will be in operation by nightfall of the same day. Temporary electrical installations shall be kept in effective operation 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-57 until the temporary installations are no longer required for the traveling public. Removal of temporary installations shall conform to the provisions in Section 3.18, "Removing, Reinstalling or Salvaging Electrical Equipment." These provisions will not relieve the Contractor in any manner of the Contractor's responsibilities as provided in Sections 4-1.1, "General" and 4-1.2, "Protection of Work and Materials." E. During traffic signal system shutdown the Contractor shall place "STOP AHEAD" and "STOP" signs to direct vehicle and pedestrian traffic through the intersection. All signal faces shall be covered when the system is shut down overnight. Temporary "STOP AHEAD" and "STOP" signs shall be either covered or removed when the system is turned on. "STOP AHEAD" and "STOP" signs shall be furnished by the Contractor and shall conform to the provisions in SSPWC Section 7-10.3, "Street Closures, Detours, Barricades." Minimum size of "STOP" signs shall be 750 mm (30"). One "STOP AHEAD" sign and one "STOP" sign shall be placed for each direction of traffic. For two, or more, lane approaches, two "STOP" signs shall be placed for each direction of traffic. Location of the signs shall be as directed by the Engineer. 3.2 SCHEDULING OF WORK A. Scheduling of Work. No above ground work, except service equipment, shall be performed until the Contractor has all materials on hand to complete that particular signal location or lighting circuit. Work shall be so scheduled that each traffic signal, lighting and sign illumination system shall be completed and ready for operation prior to opening the corresponding section of the roadway to traffic. B. Traffic signals shall not be placed in operation for use by public traffic without the written approval of the Engineer. The Contractor shall obtain the written approval of the Engineer no less than three days prior to placing any traffic signal in operation. Traffic signals shall not be placed in operation for use by public traffic without the energizing of street lighting at the intersection to be controlled if street lighting exists or is being installed in conjunction with the traffic signals. Traffic signals shall not be placed in operation until the roadways to be controlled are open to public traffic, unless otherwise directed by the Engineer. Lighting and traffic signals shall not be placed in operation, including flashing operation, prior to commencement of the functional test period specified in Section 2.27, "Testing," unless ordered otherwise by the Engineer. C. Conductors shall not be pulled into conduit until pull boxes are set to grade, crushed rock sumps installed and metallic conduit bonded. In vehicular undercrossings, soffit lights shall be placed in operation as soon as practicable after falsework has been removed from the structure. Lighting for pedestrian structures shall be placed in operation prior to opening the structure to pedestrian traffic. If the Engineer orders soffit lights or lighting for pedestrian structures placed in operation before permanent power service is available, the cost of installing and removing temporary power service will be paid for as extra work as provided in Section 3-3, "Extra Work." D. The initial turn-on shall be made only between the hours of 9:00 a.m. and 2:00 p.m. and Tuesday through Thursday unless otherwise approved, in writing, by the Engineer. Prior to turn-on, all equipment as shown on the plans shall be installed and operable including pedestrian signals, pedestrian push buttons, vehicle detectors, lighting, signs and pavement delineation. All louvers, visors, and signal faces shall be directed to 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-58 provide maximum visibility. Functional tests shall start on any working day except Friday, or the day preceding a legal holiday. 3.3 SAFETY PRECAUTIONS A. Safety Precautions. Attention is directed to Section 7-10.4.1, "Safety Orders." Before starting work on existing series street lighting circuits, the Contractor shall obtain daily a safety circuit clearance from the serving utility. By-pass switch plugs shall be pulled and "Men at Work" signs posted at switch boxes before any work is done. 3.4 EXCAVATING AND BACKFILLING A. The excavations required for the installation of conduit, foundations, and other appurtenances shall be performed in such a manner as to avoid any unnecessary dam- age to streets, sidewalks, landscaping, and other improvements. The trenches shall not be excavated wider than necessary for the proper installation of the electrical appurtenances and foundations. Excavation shall not be performed until immediately before installation of conduit and other appurtenances. The material from the excavation shall be placed in a position that will not cause damage or obstruction to vehicular and pedestrian traffic nor interfere with surface drainage. B. Unless otherwise permitted in writing by the Engineer, all surplus excavated material shall be removed and disposed of, within 48 hours, outside the public right of way in accordance with the provisions in SSPWC Sections 7-8.1, "Cleanup and Dust Control", 300-1.3, "Removal and Disposal of Materials" and 300-2.6, "Surplus Material", depending on the origin and nature of the materials to be removed and disposed. C. The excavations shall be backfilled in conformance with the provisions in SSPWC Sections 300-3.5, "Structure Backfill" or 306-1.3, "Backfill and Densification," depending on the nature of the structure or conduit that the excavation being backfilled accommodates. Excavations after backfilling shall be kept well filled and maintained in a smooth and well-drained condition until permanent repairs are made. All excavations shall be filled, and sidewalks, pavement, and landscaping restored at each intersection prior to excavating at any other intersection, unless otherwise permitted by the Engineer. Excavations in the street or highway shall be performed in such a manner that not more than one traffic lane is restricted at any time, unless otherwise approved by the Engineer. 3.5 REMOVING AND REPLACING IMPROVEMENTS A. In addition to the requirements of SSPWC sections 7-9, "Protection and Restoration of Existing Improvements" and 306-1.5, "Trench Resurfacing" Improvements such as sidewalks, curbs, gutters, Portland cement concrete and asphalt concrete pavement, underlying material, lawns and plants, and any other improvements removed, broken or damaged by the Contractor's operations, shall be replaced or reconstructed with the same kind of material as found on the work or with materials of equal quality. The new work shall be left in a serviceable condition. B. Whenever a part of a square or slab of existing concrete sidewalk, curb, gutter, or driveway is broken or damaged, the entire square, section or slab shall be removed and the concrete reconstructed as above specified. The outline of all areas to be removed in 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-59 Portland cement concrete sidewalks and driveways and in pavements shall be cut to a minimum depth of 50 mm (2") with an abrasive type saw prior to removing the sidewalk, driveways and pavement material. Cuts shall be neat and true along score lines, with no shatter outside the removal area. 3.6 FOUNDATIONS A. Concrete foundations shall rest on firm ground. Except when located on structures, foundations for posts, standards, and pedestals, not shown on the plans to have mortar pads, shall be placed "in the solid" and monolithic except for the top 50 mm (2") which shall be placed after the post, standard or pedestal is in proper position. After each post, standard, or pedestal on structures, and each standard shown on the plans to have mortar pads, is in proper position, mortar shall be placed under the base plate as shown on the plans. The exposed portions shall be formed to present a neat appearance. Mortar shall consist of one part by volume of portland cement and 3 parts of clean sand, shall contain only sufficient moisture to permit packing and shall be cured by keeping it damp for 3 days. B. Reinforced cast-in-drilled-hole concrete pile foundations for traffic signal and lighting standards shall conform to the provisions in SSPWC Section 205-3.3, "Cast-in-Place Concrete Piles", except that material resulting from drilling holes shall be disposed of as provided in Section 3.4, "Excavating and Backfilling." The exposed portions of the foundation shall be formed to present a neat appearance. C. Forms shall be true to line and grade. Tops of foundations for posts and standards, except special foundations, shall be finished to curb or sidewalk grade or as directed by the Engineer. Forms shall be rigid and securely braced in place. Conduit ends and anchor bolts shall be placed in proper position and to proper height, and shall be held in place by means of a template until the concrete sets. 3.7 WOOD POLES After each wood pole is set in the ground, the space around the pole shall be backfilled with selected earth or sand, free of rocks and other deleterious material, placed in layers approximately 100 mm (4") thick. Each layer shall be moistened and thoroughly compacted. Mast arms for wood pole installations shall be fabricated from standard pipe, free from burrs. Each mast arm shall be provided with an insulated wire inlet and wood pole mounting brackets for mast arm and tie-rod cross arm. Tie rods shall be of structural steel and pipe. Mast arms for luminaries shall be mounted to provide a mounting height of 9.1 m (30'). Mast arms for traffic signals and flashing beacons shall provide a minimum vertical clearance of 5.2 m (17') from bottom of equipment to the pavement. Wood poles, not to be painted, shall be pressure treated after fabrication with creosote, pentachlorophenol (oil borne) or copper naphthenate as provided in Section 204-2, "Treatment with Preservatives." All wood poles shall be pressure treated after fabrication with ammoniacal copper arsenate, chromated copper arsenate or ammoniacal copper zinc arsenate as provided in Section 204-2 "Treatment with Preservatives." The minimum retention for water borne preservatives shall be that specified for posts. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-60 3.8 ANCHOR BOLTS A. The upper threaded portion of all anchor bolts shall be provided with 2 nuts and 2 washers each. Anchor bars or studs shall be provided with 3 nuts and washers each. Welding shall not be performed on any portion of the body of high-strength anchor bolts, anchor bars, or studs. Plumbing of the standards shall be accomplished by adjusting the leveling nuts before placing mortar or before the foundation is finished to final grade. Shims, or other similar devices shall not be used for plumbing or raking of posts, standards or pedestals. B. Both forms and ground which will be in contact with the concrete shall be thoroughly moistened before placing concrete. Forms shall not be removed until the concrete has thoroughly set. Ordinary surface finish, as specified in SSPWC Section 303-1.9.2, "Ordinary Surface Finish," shall be applied to exposed surfaces of concrete. Where obstructions prevent the construction of a planned foundation, the Contractor shall construct an effective foundation as directed by the Engineer. The foundations shown on the plans shall be extended if conditions require additional depth, and the additional work, if ordered by the Engineer, will be paid for as extra work as provided in General Provisions Section 3-2, "Changes Initiated By The Agency." C. Unless otherwise specified or shown on the plans, foundations not to be reused shall be removed. When a foundation is shown on the plans to be abandoned, the top of foundation, anchor bolts, and conduits shall be removed to a depth of not less than 1.0 m (3') below surface of sidewalk or unimproved ground. The resulting hole shall be backfilled with material equivalent to the surrounding material. Unless otherwise shown on the plans, all standards to be relocated shall be provided with new foundations and anchor bolts of the proper type and size. Posts, poles, standards, pedestals, and cabinets shall not be erected until the foundation has set at least 7 days, and shall be plumbed or raked, as directed by the Engineer. In unpaved areas, a 1.0 m (3') square, 100 mm (4") thick or of the size shown on the plans, whichever is the larger, raised pad of portland cement concrete shall be placed in front of each controller cabinet. 3.9 CONDUIT A. Conduit shall be installed in conformance with the codes and regulations listed in Section 1.4, "Reference Specifications, Codes, and Standards." Conduit runs shown on the plans may be changed to avoid underground obstructions with written approval by the Engineer. The ends of all conduits, whether shop or field cut, shall be reamed to remove burrs and rough edges. Cuts shall be made square and true. Slip joints or running threads will not be permitted for coupling conduit. When a standard coupling cannot be used for coupling metal type conduit, a UL or ETL listed threaded union coupling shall be used. All couplings for metal type conduit shall be tightened to provide a good electrical connection throughout the entire length of the conduit run. Conduit shall be tightened into couplings or fittings using strap wrenches or approved groove joint pliers. Conduit threads and damaged surfaces on metal conduit shall be painted with 2 applications of approved unthinned zinc-rich primer (organic vehicle type) conforming to the requirements in Section 210-3.6, "Galvanizing for Traffic Signal Facilities." Aerosol cans shall not be used. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-61 B. The ends of conduit shall be threaded and shall be capped with standard pipe caps or "pennies" to protect the raceway against dirt and concrete until wiring is started. When caps or "pennies" are removed, the ends of conduit and conduit fittings shall be provided with conduit bushings. Conduit terminating in pull boxes or foundations shall be provided with insulated bonding bushings C. Conduit bends, except factory bends, shall have a radius of not less than 6 times the inside diameter of the conduit. Where factory bends are not used, conduit shall be bent, without crimping or flattening, using the longest radius practicable. D. A No. 12 copper pull wire or a pull rope shall be installed in all conduits which are to receive future conductors. The pull rope shall be nylon or polypropylene with a minimum tensile strength of 2225 N (500 pounds). At least 0.6 m (2') of pull wire or rope shall be doubled back into the conduit at each termination. Existing underground conduit to be incorporated into a new system shall be cleaned with a mandrel or cylindrical wire brush and blown out with compressed air. E. Conduit shall be laid to a depth of not less than 460 mm (18") below grade in portland cement concrete sidewalk areas and curbed paved median areas, and not less than 750 mm (30") below finished grade in all other areas. Conduit may be laid on top of the existing pavement within new curbed medians being constructed on top of the existing pavement. Conduit couplings shall be located at least 150 mm (6") from face of foundation. Unless "Trenching In Pavement Method" is specifically allowed or required on the plans or in these special provisions, conduit shall be placed under existing pavement by jacking or drilling methods. Pavement shall not be disturbed without permission from the Engineer. In the event obstructions are encountered, upon approval of the Engineer, small holes may be cut in the pavement to locate or remove obstructions. Jacking or drilling pits shall be kept 0.6 m (2') clear of the edge of any type of pavement wherever possible. Excessive use of water, such that pavement might be undermined or subgrade softened, will not be permitted. Conduit to be placed as part of the completed work shall not be used for drilling or jacking. When "Trenching in Pavement Method" is specifically allowed or required on the plans or in these special provisions, installation of conduit under pavement shall conform to the following: Conduit shall be placed under existing pavement in a trench approximately 50 mm (2") wider than the outside diameter of the conduit to be installed. Trench shall not exceed 150 mm (6") in width. Trench depth shall not exceed 300 mm (12") or conduit metric trade size plus 250 mm (10"), whichever is greater, except that at pull boxes the trench may be hand dug to required depth. The top of the installed conduit shall be a minimum of 230 mm (9") below finished grade. In areas where additional pavement is to be placed, trenching installation shall be completed prior to placing the final pavement layer. The outline of all areas of pavement to be removed shall be cut to a minimum depth of 75 mm (3") with a rock cutting excavator specifically designed for this purpose. Cuts shall be neat and true with no shatter outside the removal area. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-62 The conduit shall be placed in the bottom of the trench and the trench shall be backfilled with trench backfill slurry concrete. Concrete backfill shall be placed to the pavement surface except, when the trench is in asphalt concrete pavement and additional pavement is not being placed, the top 30 mm (0.10') of the trench shall be backfilled with asphalt concrete produced from commercial quality paving asphalt and aggregates. Prior to spreading asphalt concrete, paint binder (tack coat) shall be applied as specified in Section 302-5.4, Tack Coat." Spreading and compacting of asphalt concrete shall be performed by any method which will produce an asphalt concrete surfacing of uniform smoothness, texture, and density. All excavated areas in the pavement shall be backfilled, except for the top 30 mm (0.10'), by the end of each work period. The top 30 mm (0.10') shall be placed within 3 calendar days after trenching. Conduit to be placed beneath railroad tracks shall comply with the following: The conduit shall be Size 41 (1V dia.) minimum, and shall be placed to a minimum depth of 900 mm (3') below bottom of tie. The near side of each conduit jacking pit shall be constructed not less than 4 m (12') from the centerline of track. When the jacking pit is to be left overnight, it shall be covered with substantial planking. Conduit terminating in standards or pedestals shall extend not more than 50 mm (2U) vertically above the foundation and shall be sloped towards the handhole opening. Conduit entering through the side of non-metallic pull boxes shall terminate not more than 50 mm (2") inside the box wall and not less than 50 mm (2") above the bottom, and shall be sloped toward top of box to facilitate pulling of conductors. Conduit entering through the bottom of a pull box shall terminate 50 mm (2") above the bottom and shall be located near the end walls to leave the major portion of the box clear. At all outlets, conduits shall enter from the direction of the run. Conduit runs from underground, including under sidewalks, which are adjacent to gasoline service stations or other installations of underground gasoline or diesel storage, piping, or pumps, and which lead to a controller cabinet, circuit breaker panel, service, or any enclosure where an arc may occur during normal operations, shall be sealed if the conduit is within the limits specified in the National Electrical Code for Class 1, Division 1, Hazardous Locations. Type 1 or Type 2 conduit shall be used for these runs. Conduit for future use in structures shall be threaded and capped. Conduit leading to soffit, wall or other lights or fixtures below the grade of the pull box shall be sealed by means of a sealing fitting and sealing compound, except that sealing fitting and sealing compound will not be required where conduit terminates in a No. 9 or No. 9A pull box. Conduits in or on walls or bridge superstructures shall be supported as shown on the plans, in conformance with the following: Steel hangers, steel brackets, and other fittings shall conform to the materials and construction methods provisions in Sections 206-1, "Structural Steel, Rivets, Bolts, pins and Anchor Bolts", for materials and 304-1, "Structural Steel" for construction methods. Cast-in-place metal inserts for hangers or brackets shall be capable of developing 135Mpa (20,000 pounds per square inch) in tension on the net section of the bolt or threaded rod. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-63 Precast concrete conduit cradles shall conform to the dimensions shown on the plans and shall be constructed of commercial quality concrete containing not less than 350 kg of portland cement per cubic meter (564 Ibs. per cubic yard) and commercial quality welded wire fabric. The cradles shall be moist cured for not less than 3 days. Precast concrete cradles shall be bonded to the structure with epoxy adhesive conforming to the provisions in Section 214-6.2.2, "Standard Set Epoxy Adhesive for Pavement Markers," or Section 214-6.2.1, "Rapid Set Epoxy Adhesive for Pavement Markers" or conforming to State of California specification 8040-21 M-08, Type I when cure temperatures are above IS^C (59^F) or to State of California specification 8040-21 M-08, Type I when cure temperatures are below Openings for conduits through bridge superstructure concrete shall be formed or may consist of pipe sleeves. Where conduits pass through the abutment concrete, the conduits shall be wrapped with 2 layers of asphalt-felt building paper, securely taped or wired in place. The space around conduits through bridge abutment walls shall be filled with portland cement mortar conforming to the provisions in SSPWC Section 201-5, "Cement Mortar," except that the proportion of cement to sand shall be one to 3. When the bridge superstructure is to be prestressed, the space around conduits through abutments shall not be filled until the prestressing has been completed. Conduit which is surface mounted shall be run straight and true, horizontal or vertical on the walls and parallel to walls on ceilings or other similar surfaces. Conduit shall be supported at intervals of not more than 1.5m (5'), and closer where necessary to prevent vibration or unsightly deflection. The supports shall consist of galvanized malleable iron conduit clamps and clamp backs secured with expansion anchorage devices conforming to the requirements for concrete anchorage devices in SSPWC Sections 206-1, "Structural Steel, Rivets, Bolts, pins and Anchor Bolts", for materials and 304-1, "Structural Steel" for construction methods. Threaded studs shall be galvanized and shall be of the largest diameter that will pass through the mounting hole in conduit clamp. Attention is directed to Section 3.10J, "Bonding and Grounding." Where pull boxes are placed in conduit runs, the conduit shall be fitted with threaded bushings and bonded. The location of ends of all conduits in structures, or terminating at curbs, shall be marked by a "Y" at least 75 mm (3") high cut into the face of curb, gutter, or wall, directly above the conduit and above grade line. 3.10 PULL BOXES A. Pull boxes shall be installed at the locations shown on the plans and, in conduit runs exceeding 60 m(200'), shall be spaced at not over 60 m (200') intervals. The Contractor may, at the Contractor's expense, install additional pull boxes to facilitate the work. The bottoms of pull boxes installed in the ground or in sidewalk areas, shall be bedded in crushed rock as shown on the plans. 3.11 CONDUCTOR INSTALLATION A. A UL or ETL listed inert lubricant shall be used in placing conductors in conduit. Conductors shall be pulled into conduit by hand and the use of winches or other power actuated pulling equipment will not be permitted. All conductors shall be pulled directly 8/1 3/09 Contract No. 381 1 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 1 6560-64 from the spool into the conduit and shall not be dragged on the ground as to cause damage to the conductors. When new conductors are to be added to existing conductors in a conduit, all conductors shall be removed; the conduit shall be cleaned as provided in Section 3.9, "Conduit"; and both old and new conductors shall be pulled into the conduit as a unit. Where traffic signal light conductors are run in lighting standards containing street lighting conductors from a different service point, either the traffic signal light conductors or the lighting conductors shall be encased in flexible or rigid metal conduit, to a point where the 2 types of conductors are no longer in the same raceway. Temporary conductors less than 3 m (10') above grade shall be enclosed in flexible or rigid metal conduit. B. At least 0.3 m (1 ') of slack shall be left for each conductor at each signal or lighting standard, or combined standard, and at least one meter (31) of slack at each pull box. At least one meter (3') of slack shall be left for each conductor at each splice. Ends of spare conductors or conductors terminated in pull boxes shall be taped to provide a watertight seal. C. Conductors within fixtures or service cabinets shall be neatly arranged and shall be cabled together with self-clinching nylon cable ties, or other method approved by the Engineer. Traffic signal light conductors, interconnect conductors, service conductors, detector conductors and cables in controller cabinets and flashing beacon cabinets shall be neatly arranged, and shall be cabled together with self-clinching nylon cable ties, or enclosed in plastic tubing or raceway. D. Conductor identification shall be provided under the following conditions: Where signal phase or circuit are not clearly indicated by conductor insulation color and stripe as detailed in the conductor table in Section 2.7, "Conductors," or when identi- fication stripes are not available, marking shall be as detailed in the conductor table for special and overlap phases. Where metered and unmetered conductors occupy the same pull box, the unmetered circuit conductors shall be identified, "UNMETERED-STREET LTG," "UNMETERED- COUNT STATION," or as appropriate to describe the unmetered circuit. E. Conductors shall be permanently identified as to function. Identification shall be placed on each conductor, or each group of conductors comprising a signal phase, in each pull box and near the end of terminated conductors. Identification shall be by direct labeling, tags or bands fastened to the conductors in such a manner that they will not move along the conductors. Labeling shall be by mechanical methods. F. Connectors and Terminals. Conductors shall be joined by the use of UL or ETL listed crimp type connectors as shown on the plans. Connectors and terminals shall be applied with the proper type tool as recommended by the manufacturer of the connector or terminal being used. Finished connections and terminals shall comply with the requirements of Military Specification MIL-T-7928. All stranded conductors smaller than No. 14 shall be terminated in crimp style terminal lugs. All connectors and terminal lugs for conductor sizes No. 8 and smaller shall be soldered by the hot iron, pouring or dipping method. Open flame soldering will not be permitted. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-65 G. Splicing and Terminations. Unless specified otherwise or permitted by the Engineer, splices shall conform to the details shown on the plans and will be permitted only in the following types of circuits at the following locations: 1. Grounded conductors in pull boxes. 2. Pedestrian push button conductors in pull boxes. 3. Multiple or series lighting conductors in the pull box adjacent to each electrolier or luminaire location or in the bases of Type 21 standards. Where electroliers are more than 120 m (400') apart, splices will be permitted in pull boxes at 120 m (400'), or greater, intervals. 4. When traffic signals are being modified, ungrounded traffic signal light conductors may be spliced in pull boxes at locations shown on the plans. 5. Ungrounded traffic signal light conductors to a terminal compartment or signal head on a standard may be spliced to through conductors of the same phase in the pull box adjacent to the standard. 6. All splices and terminal lugs for conductor sizes No. 8 and smaller shall be soldered by the hot iron, pouring or dipping method. Open flame soldering will not be permitted. H. Splice Insulation. All splices shall be capable of satisfactory operation under continuous submersion in water. Multi-conductor cables shall be spliced and insulated to provide a watertight joint and to prevent absorption of moisture by the cable. Where more than one conductor enters the sleeve of a ballast installed in a pull box, the insulation and taping shall be applied between the conductors in such a manner as to provide a watertight joint. 1. Splice insulation shall conform to the details shown on the plans. 2. Low-voltage tape shall be UL or ETL listed and shall be the following types: Self- fusing, oil and flame-resistant, synthetic rubber. 3. Pressure-sensitive, adhesive, polyvinyl chloride, 0.15 mm (0.007") minimum thickness. Tape for insulating splices in high-voltage (over 600 V) circuits shall be designed for use on 5-kvolt circuits and shall be resistant to ozone, corona and water. Insulating pad shall be composed of a laminate of 2 mm (0.085") thickness of electrical grade polyvinyl chloride and a 3 mm (0.125") thickness of butyl splicing compound with removable liner. Heat-shrink tubing shall be medium or heavy wall thickness, irradiated polyolefin tubing containing an adhesive mastic inner wall. Minimum wall thickness prior to contraction shall be one millimeter (39 mils). When heated, the inner wall shall melt and fill all crevices and interstices of the object being covered while the outer wall shrinks to form a waterproof insulation. Each end of the heat shrink tube or the open end of the end cap of heat-shrink tubing shall, after contraction, overlap the conductor insulation at least 38 mm (IVz"). Heat-shrink tubing 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-66 shall conform to the requirements of UL Standard 468D and ANSI C119.1, for extruded insulated tubing at 600-V. All heat-shrink tubing shall also meet the requirements of Table3.10(A): TABLE 3.10(A) HEAT-SHRINK TUBING Property Shrinkage Ratio Dielectric Strength Resistivity Tensile Strength Operating Temperature Water Absorption Requirement 33 percent, maximum, of supplied diameter when to 125°C and allowed to cool to 25°C. heated 140 kV per 10 mm, minimum. 10^3 4 • mm, minimum. 14 MPa, minimum. -40°C to 90°C (135°C Emergency). 0.5 percent, maximum. When three or more conductors are to be enclosed within a single splice using heat- shrink tubing, mastic shall be placed around each conductor, prior to being placed inside the heat-shrink tubing. The mastic shall be the type recommended by the manufacturer of the heat-shrink tubing. After contraction, the ends and seams of heat-shrink tubing shall be painted with electrical insulating coating. Heat-shrink tubing shall not be heated with an open flame. A heating device designed for the purpose is required. The Contractor may, at the Contractor's option, use either of the following splice insulation methods: 1 . "Method B" as shown on the plans. A minimum of 2 thicknesses of electrical insulating pad shall be used. Pads shall be applied to the splice in accordance with the manufacturer's recommendations. 2. Heat-shrink tubing as provided above. Fused Splice Connectors. In the pull box adjacent to each luminaire a fused disconnect splice connector shall be installed in each ungrounded conductor between the line and the ballast. The connector shall be readily accessible in the pull box regardless of whether the ballast is remote or is integral with the luminaire. For 240-volt and 480-volt circuits, each connector shall be designed so that both ungrounded conductors are disconnected simultaneously. The connector shall have no exposed metal parts, except the head of a stainless steel assembly screw may be exposed. The head of the metal assembly screw shall be recessed a minimum of 0.8 mm (1/32") below the top of a plastic boss which surrounds the head. The splice connector shall completely enclose the fuse and shall protect the fuse against damage from water and weather. The contact between the fuse and fuse holder shall be by spring pressure. The terminals of the splice connector shall be rigidly crimped, using a tool of the type recommended by the manufacturer of the fused splice connector, onto the line conductors and the conductors to the ballasts and shall be insulated and made waterproof in accordance with the splice connector manufacturer's recommendations. Fused splice connectors shall not be used in series circuits. Fuses shall be standard midget, ferrule type, with "Non-Time-Delay" feature, and shall be 10 mm (13/32") x 38 mm 8/1 3/09 Contract No. 381 1 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-67 J. Bonding and Grounding. Metallic cable sheaths, metal pull box covers, metal conduit, equipment grounding conductors, ballast and transformer cases, service equipment, sign switches, and metal poles and pedestals shall be made mechanically and electrically secure to form a continuous system, and shall be effectively grounded. Bonding jumpers shall be copper wire or copper braid of the same cross sectional area as No. 6 for series lighting systems and No. 8 or larger for all other systems. The jumper size shall be increased to match the load or the circuit breaker size, or shall be as shown on the plans. Equipment grounding conductors shall be color coded to Code requirements or shall be bare. The bonding jumper in standards with handholes shall be attached by a 4.5 mm (3/ieu) or larger brass bolt and shall be run to the conduit or bonding wire in the adjacent pull box. Standards without handholes shall be bonded by a jumper attached to all anchor bolts, and shall be run to the conduit or bonding wire in the adjacent pull box. Grounding jumper shall be visible after cap has been placed on foundation. Where slip base standards or slip base inserts are installed, the bonding jumper shall not intrude into the slip plane. Bonding shall be accomplished by a bonding strap to all anchor bolts or a 4.5 mm (3/16") or larger brass bolt installed in the bottom slip base plate. One side of the secondary circuit of series-multiple and step-down transformers shall be grounded. Grounding of metal conduit, service equipment and the grounded conductor at service point shall be accomplished as required by the Code and the serving utility, except that grounding electrode conductor shall be No. 6, or larger. For equipment grounding purposes in Type 3 conduit, a No. 6 copper wire shall be run continuously in circuits used for series lighting, and a No. 8, minimum, copper wire shall be run continuously in all other circuits. The bonding wire size shall be increased to match the circuit breaker size, or shall be as shown on the plans. Where Type 3 conduit is to be installed for future conductors, the copper wire may be omitted. Equipment bonding and grounding conductors are not required in conduits which contain only loop lead-in cable or signal interconnect cable or both. At each multiple service disconnect location, a ground electrode shall be furnished and installed. Ground electrodes shall be one-piece lengths of galvanized steel rod or pipe not less than 19 mm (3/4") in diameter, or of copper clad steel rod not less than 15 mm (5/8 u) in diameter. Ground electrodes shall be installed in accordance with the provisions of the Code. The service equipment shall be bonded to the ground electrode by use of a ground clamp or exothermic weld and No. 6 or larger copper wire, enclosed in a size 16 or larger diameter conduit. Ground clamp for service grounding and for grounding of equipment on wood poles shall be Size 16 galvanized, malleable iron conduit hub with swivel feature. On wood poles, all metallic equipment mounted less than 2.4 m (8') above ground surface shall be grounded. Bonding of metallic conduit in non-metallic pull boxes shall be by means of bonding bushings and bonding jumpers. Bonding of metallic conduit in metal pull boxes shall be by means of locknuts, one inside and one outside of the box. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-68 K. Service. Electrical service installation and materials shall conform to the requirements of the serving utility. When the service equipment is to be installed on a utility-owned pole, the Contractor shall furnish and install conduit, conductors and all other necessary material to complete the installation of the service. The position of the riser and equipment will be determined by the utility. Service conduit shall conform to the requirements of the serving utility and shall be not less than Size 41 (1V2" dia.). Where a kilowatt-hour meter is required, a meter socket with sealing ring, as approved by the serving utility, shall be furnished and installed. Where a meter socket is installed, the meter enclosure shall be provided with factory installed test bypass facilities as required by the serving utility. Service equipment shall be installed as soon as possible to enable the utility to schedule its work well in advance of the completion of the project. Each service shall be provided with a circuit breaker which shall simultaneously disconnect all ungrounded service entrance conductors. All circuit breakers shall be quick-break on either automatic or manual operation. The operating mechanism shall be enclosed and shall be trip-free from the operating handle on overload. Circuit breakers shall be trip-indicating, shall have frame size plainly marked and shall have trip rating clearly indicated on the operating handle. Overload tripping of breakers shall not be influenced by an ambient temperature range of from -18°C to 50°C. Multiple-pole breakers shall be the internal trip type. All circuit breakers shall be listed by UL or ETL. Current rating of breakers shall be as shown on the plans. Circuit breakers used as service disconnect equipment shall have a minimum interrupting capacity of 10 000 A, rms. Circuit breakers shall be enclosed in a NEMA rain tight enclosure with dead-front panel and hasp with a 11 mm (7/16") hole for a padlock. The padlock will be furnished by others. Service equipment enclosures, except Types II and III, shall be galvanized. Types II and III service equipment enclosures shall be fabricated from galvanized sheet steel or fabricated from sheet steel and zinc or cadmium plated after fabrication, or shall be fabricated from aluminum. Fabrication of service equipment enclosures shall conform to the requirements of Section 2.12C, "Controller Cabinets." Steel enclosures shall be painted in accordance with the provisions in Section 3.12, "Painting." All overlapping exterior seams and doors shall meet the requirements for Type 3R enclosures specified in the NEMA Enclosure Standards. Except for falsework lighting and power for the Contractor's operations, upon written request by the Contractor, the Engineer will arrange with the serving utility to complete service connections for both temporary and permanent installations and the Agency will pay all costs and fees required by the utility. The request shall be submitted not less than 15 days before service connections are required. Except for falsework lighting and power for the Contractor's operations, upon written request by the Contractor, the Engineer will arrange for furnishing electrical energy. Energy used prior to completion of the contract will be charged to the Contractor, except that the cost of energy used for public benefit, when an operation is ordered by the Engineer, will be at the expense of the Agency. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-69 Full compensation for furnishing and installing Agency-owned or permanent service poles, service equipment, conduit, conductors and pull boxes (including equipment, conduit, and conductors placed on utility-owned poles) shall be considered as included in the contract item of electrical work involved and no additional compensation will be allowed therefore. Where the service point is indeterminate and is shown on the plans as an "approximate location" or "service point not yet established", the labor and materials required for making the connection between the service point, when established, and the nearest pull box shown on the plans will be paid for as extra work as provided in Section 3-3, "Extra Work." 3.12 PAINTING A. All ungalvanized ferrous surfaces to be painted shall be cleaned prior to applying the prime coat. Blast cleaning will not be required. If an approved prime coat has been applied by the manufacturer, and it is in good condition, the first primer application by the Contractor will not be required. B. Existing equipment to be painted in the field, including Agency-furnished equipment, shall be washed with a stiff bristle brush using a solution of water containing 7.5 ml. of heavy duty detergent powder per liter (2 tablespoons per gallon). After rinsing, all surfaces shall be wire brushed with a coarse, cup shaped, power-driven brush to remove all poorly bonded paint, rust, scale, corrosion, grease or dirt. Any dust or residue remaining after wire brushing shall also be removed prior to priming. Immediately after cleaning, all galvanized surfaces and all non-ferrous metal surfaces shall be coated with one application of Primer (Wash) Pre-Treatment, Section 210-1.5 or wash primer conforming to the requirements of Military Specification MIL-P-15328D. The wash primer shall be applied by spraying or brushing to produce a uniform wet film on the surface. Galvanized equipment and wood poles for traffic signal or flashing beacon installations shall not be painted. C. New galvanized metal surfaces to be painted in the field shall be cleaned as specified for existing equipment before applying the prime coats specified. Wire brushing of new galvanized surfaces will not be required. After erection, all exterior surfaces shall be examined for damaged primer and the damaged surfaces shall be cleaned and spot coated with primer. Galvanized metal guard posts shall not be painted. Painting of Agency-furnished controller cabinets will not be required. D. Types II and III steel service equipment enclosures shall be painted with a polymeric or an enamel coating system conforming to Color No. 14672 (light green) of Federal Standard 595B. All coatings shall be commercially smooth, substantially free of flow lines, paint washout, streaks, blisters, and other defects that would impair serviceability or detract from general appearance. The coatings shall comply with the following requirements: 1. Coating Hardness - The finish shall have a pencil lead hardness of HB minimum using an Eagle Turquoise pencil. 2. Salt Spray Resistance - The undercutting of the film of the coating system shall not exceed 3 mm (V8") average, from lines scored diagonally and deep enough to expose the base metal, after 250 hours exposure in a salt spray cabinet in accordance with ASTM Designation: B 117. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-70 3. Adherence - There shall be no coating loss when tested by California Test 645. Compliance of the coating system to the above requirements may be determined by the application of the coating, to 100 mm (4") x 200 mm (8") x 0.6 mm (0.0236") test specimens of the same material as the cabinets, in the same manner as applied to the cabinets. E. A Certificate of Compliance shall be furnished in accordance with the provisions of Section 4-1.5, "Certification," certifying that the coating system furnished complies in all respects with these requirements. Interior of metal signal visors, louvers and front faces of back plates shall be finished with 2 applications of lusterless black exterior grade latex paint formulated for application to properly prepared metal surfaces, except that factory finish in good condition will be acceptable. F. Metal signal sections, signal head mountings, brackets and fittings, outside of visors, pedestrian push button housings, pedestrian signal sections and visors, and back faces of back plates, shall be finished with 2 applications of lusterless black or dark olive green exterior grade latex paint formulated for application to properly prepared metal surfaces. Dark olive green color shall match Color Chip No. 68 on file at the CALTRANS Transportation Laboratory. G. Conduit and conduit fittings above ground shall be prepared and finished in the same manner as the adjacent standard or post. Relocated, reset or modified equipment previously finished as specified in this Section 3.12, "Painting", except for galvanized standards previously finished with traffic signal yellow enamel, shall be given a spot finishing application on newly primed areas, followed by one finishing application over the entire surface. If any signal faces or mounting brackets are required to be painted under this Section, all signal faces and mounting brackets on the same mounting shall be repainted. H. Small rusted or repaired areas of relocated or reset galvanized equipment shall be cleaned and painted as provided in Section 210-3.6, "Galvanizing for Traffic Control Facilities,"for repairing damaged galvanized surfaces. Equipment number shall be neatly stenciled on the standard or adjacent structure. The number designation will be determined by the Engineer. All paint shall be applied either by hand brushing or by spraying machines in the hands of skilled operators. The work shall be done in a neat and workmanlike manner. The Engineer reserves the right to require the use of brushes for the application of paint, should the work done by the paint spraying machine prove unsatisfactory or objectionable, as determined by the Engineer. 3.13 LED SIGNAL INSTALLATION Installation of a LED signal module shall only require the removal of the optical unit components, i.e., lens, lamp module, gaskets, and reflector, shall be weather tight and fit securely in the housing; and shall connect directly to electrical wiring. The arrow modules shall meet or exceed specifications stated in Section 9.01 of the ITE Publication: Equipment and Materials Standards, Chapter 2 (Vehicle Traffic Control Signal Heads) for arrow indications. The LEDs shall be spread evenly across the illuminated portion of the arrow area. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-71 3.14 SIGNAL MOUNTING ASSEMBLY INSTALLATION A. After installation, any exposed threads of galvanized pipe brackets and all areas of the brackets damaged by wrench or vise jaws shall be cleaned with a wire brush and painted with 2 applications of approved unthinned zinc-rich primer (organic vehicle type) conforming to the requirements in Section 210, "Paint and Protective Coatings." Aerosol cans shall not be used. B. Each terminal compartment shall be fitted with a terminal block containing a minimum of 12 poles, each with 2 screw type terminals. Each terminal shall be designed to accommodate at least 5 No. 14 conductors. A cover shall be provided on the compartment to give ready access to the terminal block. Where used to bracket mount signals, the terminal compartment shall be designed to bolt securely to a pole or standard. The horizontal dimension of mounting assembly members between the vertical centerline of the terminal compartment or slip-fitter and the vertical centerline of each signal face, shall not exceed 280mm (11"), except where required to provide proper signal face alignment or permit programming of programmed visibility signal faces or when otherwise directed by the Engineer. Each mounting assembly shall be oriented to provide maximum horizontal clearance to the adjacent roadway. All mounting assembly members shall be either plumb or level, symmetrically arranged and securely assembled. Construction shall be such as to permit all conductors to be concealed. Mounting assemblies shall be watertight and free of sharp edges or protrusions which might damage conductor insulation. C. For post-top mounting of signals, a slip-fitter shall be used. Slip-fitter shall fit over a 115 mm (41/2U) outside diameter pipe or tapered standard end. Each slip-fitter shall be provided with cadmium-plated steel set screws, arranged as shown on the plans. Each slip-fitter used to post-top mount signals with brackets shall be provided with an integral terminal compartment. Each mounting assembly shall be provided with positive locking, serrated fittings, which when mated with similar fittings on the signal faces shall prevent faces from rotating. Fittings shall permit fastening at increments of not more than 7 degrees. D. Signal faces shall not be installed at any intersection until all other signal equipment, including the complete controller assembly, is in place and ready for operation at that intersection, except that the signal faces may be mounted if they are not directed toward traffic or if they are covered. 3.15 DETECTOR A. Installation Details. Installation and tests shall conform to the details and notes shown on the plans. Unless shown otherwise each loop shall consist of 3 turns of conductor as specified in Section 2.22E, "Construction Materials." Slots cut in the pavement shall be washed clean, blown out and thoroughly dried before installing conductors. Residue resulting from slot cutting operations shall not be permitted to flow across shoulders or lanes occupied by public traffic and shall be removed from the pavement surface before any residue flows off of the pavement surface. Residue from slot cutting operations shall be disposed of outside the highway right of way in accordance with Section 7-8.1, "Cleanup and Dust Control." After conductors are installed in the slots cut in the pavement, the slots shall be filled with sealant to within 3 mm (V) of the pavement 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-72 surface. The sealant shall be at least 25 mm (1") thick above the top conductor in the saw cut. B. Before setting, surplus sealant shall be removed from the adjacent road surfaces without the use of solvents. The sealant for filling slots shall conform to the following: 1. Hot-Melt Rubberized Asphalt Sealant.— Hot-melt rubberized asphalt shall be in solid form at room temperature and fluid at an application temperature of 190°C (375T) to 205°C (400°F). Fumes from the material shall be non-toxic. Sealant shall be suitable for use in both asphalt concrete and portland cement concrete. Performance characteristics of the cured hot-melt rubberized asphalt shall be as per Table 3.14(B). TABLE 3.14(B) CURED HOT-MELT RUBBERIZED ASPHALT Property Cone Penetration Flow. 60°C Resilience Softening Point, Ductility, Flash Point, COC, °C Viscosity, Brookfield Thermosel, Measuring Standard (ASTM Designation) ASTM D 3407, Sec. 5 ASTM D 3407, Sec. 6 .ASTM D 3407, Sec. 8 ASTM D 36 ASTM D 113 ASTM D 92 ASTM D 4402 Results 3.5 mm, max. 5 mm, max. 25%, min. 82 °C, min. 300 mm, min. 288 °C, min. 2.5-3.5 Pa-s Conditions 25°C,150g, 5s 25°C 25°C, 50 mm/min No. 27 Spindle, 20rpm, 190°C, The hot-melt rubberized asphalt shall be melted in a jacketed, double boiler type melting unit. Temperature of the heat transfer medium shall not exceed 245°C (475°F). Application of the hot-melt sealant shall be made with a pressure feed applicator or pour pot. Sealant shall be applied when the pavement surface temperature is greater than 4°C (40°F). Hot-melt sealant shall be packaged in containers clearly marked "Detector Loop Sealant" and specifying the batch and lot number of the manufacturer. Loop conductors shall be installed without splices and shall terminate in the nearest pull box. The loops shall be joined in the pull box in combination of series and parallel so that optimum sensitivity is obtained at the sensor unit. Final splices between loops and lead-in cable shall not be made until the operation of the loops under actual traffic conditions is approved by the Engineer. All loop conductors for each direction of travel for the same phase of a traffic signal system, in the same pull box, shall be spliced to a detector lead-in cable which shall be run from the pull box adjacent to the loop detector to a sensor unit mounted in the controller cabinet. All loop conductors for traffic monitoring shall terminate in a pull box or terminal strip in the traffic monitor station cabinet when a cabinet of that type is installed. Conductors for inductive loop traffic signal and traffic monitoring installations shall be identified and banded, in pairs, by lane, in the pull box adjacent to the loops and near the termination of the conductors in the controller or traffic monitoring station cabinet. Bands shall conform to the provisions in Section 209-2.09, "Wiring." If asphalt concrete surfacing is to be placed, the loop conductors shall be installed prior to placing the uppermost layer of asphalt concrete. The conductors shall be installed, as shown on the plans, in the compacted layer of asphalt concrete immediately below the uppermost layer. Installation details shall be as shown on the plans, except the sealant shall fill the slot flush to the surface. 8/13/09 Contract No. 3811 PALOMAR AIRPORT ROAD WIDENING TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS 16560-73 C. Emergency Vehicle Pre-Emption Detector System. Each emergency vehicle pre- emption detector system shall conform to the details shown on the plans and these special provisions and shall consist of an optical emitter assembly or assemblies located on the appropriate vehicle and an optical detector/discriminator assembly or assemblies located at the traffic signal. Each system shall permit detection of Class II emergency vehicles. Class II emergency vehicles shall be capable of being detected at any range up to 2,500 feet from the optical detector. D. 209-5.016(1) Optical Emitter Assembly. Each optical emitter assembly shall consist of an emitter unit, an emitter control unit and connecting cables and shall conform to the following: Each optical emitter assembly, including lamp, shall be designed to operate over an ambient temperature range of -34° C to 74° C at both modulation frequencies and to operate continuously at the higher frequency for a minimum of 3,000 hours at 25 °C ambient before failure of lamp or any other component. Each emitter unit shall be controlled by a single, maintained-contact switch on the respective emitter control unit. The switch shall be capable of being positioned in a readily accessible location to the vehicle driver. The control unit shall contain a pilot light to indicate that the emitter power circuit is energized and shall be capable of generating only Class II modulating code. E. Functional Requirements. Each emitter unit shall transmit optical energy in one direction only. The signal from each emitter unit shall be capable of being detected at a distance of 2,500 feet when used with a standard optical detection/discriminator assembly. The modulation frequency for Class II signal emitters shall be 14.035 Hz ± 0.003 Hz. The standard optical detection/discriminator assembly to be used in conducting the range tests shall be available from the manufacturer of the system. A certified performance report shall be furnished by the contractor with each assembly. The emitter unit shall be configured with a grating to provide precise directionality control. F. Electrical Requirements. Each optical emitter assembly shall be capable of providing full light output with input voltages between 10 and 16 volts DC. An optical emitter assembly shall not be damaged by input voltages up to 7.5 volts DC about the supply voltage. The optical emitter assembly shall not generate voltage transient, on the input supply, which exceeds the supply voltage by more than 4 volts. Each optical emitter assembly shall not consume more than 100 watts at 17.5 volts DC and shall have a power input circuit breaker rated at 10 to 12 amperes, 12 volts DC. The design and circuitry of each emitter unit shall permit its use on vehicles with either negative or positive ground without disassembly or rewiring of the unit. G. Mechanical Requirements. Each emitter unit shall be housed in a weatherproof, corrosion-resistant housing. The housing shall be provided with facilities to permit mounting on various types of vehicles and shall have provision for proper alignment of the emitter unit and for locking of the emitter unit into proper alignment. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-74 Each emitter control unit shall be provided with appurtenant hardware to permit its mounting in or on an emergency vehicle or mass transit vehicle. Where required for certain emergency vehicles, the emitter control unit and all exposed controls shall be weatherproof. Each emitter shall include a multi-purpose port compliant with the SAE J1708 communication standard to enable unit configuration to be set into the emitter and read from the emitter. H. Optical Detection/Discriminator Assembly. Optical detection/discriminator assembly shall consist of one or more optical detectors, connecting cable and a discriminator module and conform to the following: Each such assembly, when used with standard emitters, shall have a range of up to 2,500 feet for Class II signals. Standard emitters for Class II signals shall be available from the manufacturer of the system. Range measurements shall be taken with all range adjustments on the discriminator module set to "maximum". I. Optical Detector. Each optical detector shall be a waterproof unit capable of receiving optical energy from one or two separately aimable directions. The horizontal angle between the two directions shall be variable from 5 degrees to 180 degrees. The reception angle for each photocell assembly shall be a maximum of 8 degrees in all directions about the aiming axis of the assembly. Measurements of reception angle will be taken at a range of 2,500 feet for a Class II emitter. All internal circuitry shall be solid state and electrical power shall be provided by the associated discriminator module. Each optical detector shall be contained in a housing, which shall include one or two rotatable photocell assemblies, an electronic assembly and a base. The base shall have an opening to permit its mounting on a mast arm. Each optical detector shall weigh no more than 2.5 pounds and shall present a maximum wind load area of 36 square inches. The housing shall be provided with weep holes to permit drainage of condensed moisture. Each optical detector shall be installed, wired and aimed as specified by the manufacturer. J. Optical Detector Cable. Optical detector cable shall meet the requirements of IPCEA- S-61-402/NEMA WC 5, Section 7.4, 600 volt control cable, 75°C, Type B and the following: The cable shall contain three conductors, each of which shall be AWG #20 (7x28) stranded, tinned copper with low-density polyethylene insulation. Minimum average insulation thickness shall be 25 mils. The insulation of individual conductors shall be color coded as follows: Yellow - Detector Signal #1 Blue - Detector Signal #2 Orange - Power (+) Bare (Drain) - Common or Ground The shield shall be either tinned copper braid or aluminized polyester film with a nominal 20 percent overlap. Where the film is used, a AWG #20 (7x28) standard, tinned, bare 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-75 drain wire shall be place between the insulated conductors and the shield and in contact with the conductive surface of the shield The jacket shall be black polyvinyl chloride with a minimum rating of 600 volts and 80°C and a minimum average thickness of 45 mils. The jacket shall be marked as required by IPCEA/NEMA. The finished outside diameter of the cable shall not exceed 0.3 inches. The capacitance of the optical detector cable, as measured between any conductor and the other conductors and the shield, shall not exceed 14.3 microfarads per 1000 feet. The characteristic impedance of the optical detector cable shall be 0.6 ohms per 1000 feet. K. Discriminator Module. Each discriminator module shall be designed to be compatible and usable with Model 170 controller unit and to be mounted in the input file of a Model 332 controller cabinet, and shall conform to the requirements of Chapter 1 of the State of California, Department of Transportation, "Traffic Signal Control Equipment Specifications", dated January 1989, and to all addenda thereto current at the time of project advertisement. Each discriminator module shall be capable of operating one or two channels and shall be capable of: 1. Receiving Class II signals at a range of up to 2,500 feet. 2. Decoding the signal on the basis of frequency at 14.035 Hz ± 0.003 Hz for Class II signals. 3. Establishing the validity of received signals on the basis of frequency and length of time received. A signal shall be considered valid only when received for more than 0.50 seconds. No combination of Class I signals shall be recognized as a Class II signal regardless of the number of signals being received, up to a maximum of ten signals. Once a valid signal has been recognized, its effect shall be held by the module in the event of temporary loss of the signal for a period adjustable from 4.5 seconds to 11 seconds in at least 2 steps at 5 + 0.5 seconds and 10 ±0.5 seconds. 4. Providing an output for each channel that will result in "low" or grounded condition of the appropriate input of a Model 170 controller unit. For Class II signals the output shall be steady. Each discriminator module shall be powered from 115 volt (95 volts AC to 135 volts AC), 60 Hz mains and will contain an internal, regulated power supply that supports up to twelve optical detectors. Electric power, one detector input for each channel and one output for each channel, shall terminate at the printed circuit board edge connector pins listed below. Board edge connector pin assignments shall be as follows: 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-76 Pins Function Pins Function A Ground P Not used D Channel A primary detector input R Detector 24 VDC power output E Detector 24 VDC power output S Not used F Channel A output, collector (+) T Not used H Channel A output, emitter (-) U Not used J Channel B primary detector input V Detector ground K Detector ground W Channel B output collector (+) L Earth ground X Channel B output emitter (-) M AC-(in) Y Not used N AC + (in) Z Not used Two auxiliary inputs for each channel shall enter each module through the front panel connector. Pin assignment for the connector shall be as follows: Pins Function 13 Auxiliary detector 2 input, Channel A 14 Auxiliary detector 1 input, Channel B 15 Auxiliary detector 2 input, Channel B 28 Auxiliary detector 1 input, Channel A Each channel output shall be an optically isolated NPN open collector transistor capable of sinking 50 milliamperes at 30 volts and shall be compatible with Model 170 controller unit inputs. Each discriminator module shall be provided with means of preventing transients received by the detector from affecting the Model 170 controller assembly. Each discriminator module shall have a single connector board, shall be capable of being inserted into the input file of a Model 332 cabinet and shall occupy one slot width of the input file. The front panel of each module shall have a handle to facilitate withdrawal and the following controls and indicators for each channel: 1. A Command (High) and Advantage (Low) solid-state LED indicator for each channel to display active calls. 2. A test switch for each channel to test proper operation of Command or Advantage priority. 3. A single confirmation light control output for each channel. These outputs shall be user configurable through software for a variety of confirmation light sequences. The front panel shall be provided with a single circular, bayonet-captured, multi-pin connector for two auxiliary detector inputs for each channel. Connector shall be a mechanical configuration equivalent to a D-Shell 44-Pin front panel. Wiring for a Model 332 cabinet shall conform to the following: Slots 12 and 13 of the input file "J" shall be wired to accept a two-channel module. Field wiring for the primary detectors, except 24-volt DC power, shall terminate on either 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-77 terminal board TB-9 in the controller cabinet or on the rear of input file "J", depending on cabinet configuration. Where TB-9 is used, position assignments shall be as follows: Position Assignment 4 Channel A detector input, 1st module (Slot J-12) 5 Channels detector input, 1st module (Slot J-12) 7 Channel A detector input, 2no module (Slot J-13) 8 Channel B detector input, 2na module (Slot J-13) The 24 volt cabinet DC power shall be available at Position 1 of terminal board TB-1 in the controller cabinet. All field wiring for the auxiliary detectors shall terminate on terminal board TB-0 in the controller cabinet. Position assignments are as follows: Position Assignment 7 +24VDC from (J-13E) 8 Detector ground from (J-13K) 9 Channel A auxiliary detector input 1 10 Channel A auxiliary detector input 2 11 Channel B auxiliary detector input 1 12 Channel B auxiliary detector input 2 The contractor shall demonstrate that all of the components of the system will perform satisfactorily as a system. Satisfactory performance shall be determined using the following test procedure: 1. Each system to be used for testing shall consist of an optical emitter assembly, an optical detector, at least 200 feet of optical detector cable and a discriminator module. 2. The discriminator modules shall be installed in the proper input file slot of Model 332 controller cabinet. The controller cabinet, together with a Model 170 controller unit with the appropriate operating program, a Model 210 monitor unit and 120 volt AC power, will be available as shown on the plans and as indicated elsewhere in these special provisions. 3. One test shall be conducted using a Class II signal emitter and a distance of 2,500 feet between the emitter and the detector. All range adjustments on the module shall be set to "Maximum" for each test. 4. Each test shall be conducted for a period of one hour, during which the emitter shall be operated for 30 cycles, each consisting of a one minute "on" interval and a one minute "off" interval. During the total test period: (A) the emitter signal shall cause the proper response from the Model 170 controller unit during each "on" interval and (B) there shall be no improper operation of either the Model 170 controller unit or the monitor during each "off interval. L. Video Detection System. The video detection system shall consist of one (1) video camera and one (1) video detection processor (VDP) for each vehicle approach. A video monitor and a pointing device shall be housed in the controller cabinet. The system shall include software that detects vehicles in multiple lanes using only the video image. Detection zones shall be defined using only a video menu and a pointing device to place zones on a video image. A minimum of 24 detection zones per camera shall be available. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-78 M. Functional Requirements. The VDP shall process video from a single source. The source can be a video camera or a video tape player. The video shall be input to the VDP in RS170 format and shall be digitized and analyzed in real time. The VDP shall detect the presence of vehicles in up to 24 detection zones per camera. A detection zone shall be approximately the width and length of one car. Detection zones shall be programmed via a menu displayed on a video monitor and a pointing device connected to the VDP. The menu shall facilitate placement of the detection zones and setting of zone parameters. A separate computer shall not be required for programming detection zones or to view system operations. The VDP shall store up to three different detection zone patterns. The VDP shall be able to switch to any one of the three different detection zone patterns within one second of user request via menu selection with the pointing device. The VDP shall detect vehicles in real time as they travel across each detection zone. The VDP shall have an RS-232 port for communications with an external computer. The VDP shall accept new detector patterns from an external computer through the RS-232 port when that computer uses the appropriate communications protocol for downloading detector patterns. The VDP shall send its detector patterns to an external computer through the RS-232 port when requested when that computer uses the appropriate communications protocol for uploading detector patterns. A Windows-based software program designed for local or remote connection and providing video capture, real-time detection indication and detection zone modification capability shall be provided with the system. The camera system shall be able to transmit an NTSC video signal, with minimal signal degradation, up to 300m (1000 ft). The VDP shall default to a safe condition, such as a constant call to each active detection channel, in the event of unacceptable interference in the video signal. The system shall be capable of automatically detecting a low visibility condition such as fog and respond by placing all defined detection zones in a constant call mode. A user- selected output shall be active during the low visibility condition that can be used to modify the controller operation if connected to the appropriate controller input modifier(s). The system shall automatically revert to normal detection mode when the low visibility condition no longer exists. N. Operational Requirements. A minimum of 24 detection zones per camera shall be supported and each detection zone can be sized to suit the conditions and the desired vehicle detection region. A single detection zone shall be capable of replacing multiple loops and the detection zone may be AND'ed or OR'ed together to indicate vehicle presence on a single phase of traffic movement. Placement of detection zones shall be done by using a pointing device and a graphical interface built into the VDP and displayed on a video monitor. No separate computer shall be required to program the detection zones. Up to three detection zone patterns shall be saved within the VDP memory and this memory shall be preserved during power outages. The selection of the detection zone pattern for current use shall be done through a menu system. It shall be possible to activate a detection zone pattern for a camera from VDP memory and have the detection zone pattern displayed within one second of activation. When a vehicle is detected crossing a detection zone, the detection zone will flash a symbol on the screen to confirm the detection of the vehicle. Detection shall be at least 98% accurate in good weather conditions and at least 96% accurate under adverse weather conditions (rain, snow or fog). Detector placement shall not be more distant from the camera than a distance of fifteen times the mounting height of the camera. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-79 The VDP shall provide up to eight channels of vehicle presence detection through a NEMA TS1 port. The VDP shall provide dynamic zone reconfiguration (DZR) to enable normal detector operation of existing zones except the one being added or modified during the setup process. The VDP shall output a constant call on any detection channel when the corresponding zone is being modified. Detection zone outputs shall be configurable to allow the selection of presence, pulse, extend and delay outputs. Timing parameters of pulse, extend, and delay outputs shall be user definable between 0.1 and 25.0 seconds. Up to six detection zones shall be capable of counting the number of vehicles detected. The count value shall be internally stored for later retrieval through the RS-232 port. The data collection interval shall be user definable in periods of five, fifteen, thirty or sixty minutes. O. Hardware Requirements. The VDP shall be housed in a durable metal enclosure suitable for shelf mounting in the side rails of the controller cabinet. The VDP enclosure shall not exceed 180mm (7.1 in) in length and 157mm (6.2 in) in depth. The VDP shall operate satisfactorily in a temperature range of-34°C to +74°C (-29°F to +165°F) and a humidity range of 0%RH to 95% RH, non-condensing. The VDP shall be powered by 24 volts DC. VDP power consumption shall not exceed 10 watts. The VDP shall include an RS-232 port for serial communications with a remote computer. This port shall be a 9- pin "D" subminiature connector on the front of the VDP. The front of the VDP shall include one BNC video input connection suitable for RS170 video inputs. The video input shall include a switch-selectable 75-ohm or high impedance termination to allow camera video to be routed to other devices, as well as input to the VDP for vehicle detection. The front of the VDP shall include one BNC video output providing real time video output that can be routed to other devices. P. Video Detection Camera. The video camera shall be furnished by the VDP supplier and shall be qualified by the supplier to ensure proper system operation. The camera shall produce useable video image of the bodies of vehicles under all roadway lighting conditions, regardless of time of day. The minimum range of scene luminance over which the camera shall produce a useable video image shall be the minimum range of night time to day time but not less than the range of 0.1 lux to 10,000 lux. The camera shall use a CCD sensing element and shall output monochrome video with resolution of not less than 380 lines vertical and 380 lines horizontal. The camera shall include an electronic shutter control based upon average scene luminance and shall be equipped with a factory adjusted manual iris. The camera shall include a variable focal length lens with variable focus that can be adjusted, without opening the camera housing, to suit the site geometry by means of a portable interface device designed for that purpose and manufactured by the detection system supplier. The horizontal field of view shall be adjustable from 8.1° to 45.9°. A single camera configuration shall be used for all approaches in order to minimize setup time and spares required by the user. The camera electronics shall include AGC to produce a satisfactory image at night. The camera shall be housed in a weather-tight sealed enclosure. The camera enclosure shall be able to rotate to allow proper alignment between the camera and the traveled road surface. The camera enclosure shall be equipped with a sun shield. The sun shield shall include a provision for water diversion to prevent water from flowing in the camera's field of view. The camera enclosure with sun shield shall be less than 170mm (6 in) in diameter, less than 380mm (15 in) long, and shall weigh less than 13.3kg (6 pounds) when the camera and lens are mounted inside the enclosure. The camera enclosure shall include a thermostatically controlled heater to assure proper operation of 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-80 the lens at low temperatures and to prevent moisture condensation on the optical faceplate of the enclosure. When mounted outdoors in the enclosure, the camera shall operate satisfactorily in a temperature range of-34°C to +60°C (-29°F to +140°F) and a humidity range of 0% RH to 100% RH. The camera shall be powered by 120/240 VAC, 50/60 Hz. Power consumption shall be 15 watts or less under all conditions. Recommended camera placement height shall be 10m (33 ft) above the roadway, and over the traveled way on which vehicles are to be detected. For optimum detection, the camera should be centered above the traveled roadway. The camera shall view approaching vehicles at a distance not to exceed 100m (350 ft) for reliable detection (heightdistance ration of 10:100). Camera placement and field of view shall be unobstructed and as noted in the installation documentation provided by the supplier. The camera enclosure shall be equipped with separate, weather-tight connections for power and video cables at the rear of the enclosure. These connections may also allow diagnostic testing and viewing of the video signal at the camera while the camera is installed, using a lens adjustment module supplied by the VDP supplier. Video and power shall not be connected within the same connector. The video signal output by the camera shall be black and white in RS170 or CCIR format. The video signal shall be fully isolated from the camera enclosure and power cabling. Q. Installation Requirements. The coaxial cable to be used between the camera and the VDP in the controller cabinet shall be Belden 8281 or a 75 ohm, precision video cable with 20 gauge solid bare copper conductor (9.9 ohms/M), solid polyethylene insulating dielectric, 98% (min) tinned copper double-braided shield and black polyethylene outer covering. The signal attenuation shall not exceed 0.78 dB per 30m (100 ft) at 10 MHz. Nominal outside diameter shall be 8mm (0.304 in). The coaxial cable shall be a continuous, unbroken run from the camera to the VDP. This cable shall be suitable for installation in conduit or overhead with appropriate span wire. 75 ohm BNC plug connectors shall be used at both the camera and controller. The coaxial cable, BNC connector and crimping tool shall be approved by the supplier of the video detection system, and the manufacturer's instructions must be followed to ensure proper connection. The power cabling shall be 16 AWG three conductor cable. The cabling shall comply with the National Electric Code, as well as local electrical codes. Cameras may acquire power from the luminaire if necessary. The video detection system shall be installed by supplier factory certified installers and as recommended by the supplier and documented in the installation materials provided by the supplier. Proof of factory certification shall be provided. R. Warranty. The supplier shall provide a limited two year warrant on the video detection system. See supplier's standard warranty included in the Terms and Conditions of Sale documentation. During the warranty period, technical support shall be available from the supplier via telephone within four hours of the time a call is made by the user. This support shall be made available from factory certified personnel or factory certified installers. During the warranty period, updates to the VDP software shall be made available from the supplier without charge. S. Maintenance and Support. The supplier shall maintain an adequate inventory of parts to support maintenance and repair of the video detection system. These parts shall be made available for delivery within 30 days of placement of an acceptable order at the supplier's current pricing and terms of sale for said parts. The supplier shall maintain an ongoing program of technical support for the video detection system. This technical support shall be available via telephone, or via personnel sent to the installation site 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-81 upon placement of an acceptable order at the supplier's current pricing and terms of sale for on site technical support services. Installation or training support shall be provided by a factory authorized representative. All product documentation shall be written in the English language. The contractor shall ensure the presence of a factory authorized representative at the time of traffic signal turn-on. T. Pedestrian Push Button Assemblies. Where shown on the plans, pedestrian push button assemblies of substantial tamper-proof construction and signs shall be furnished and installed. The housing shall be either die-cast or permanent mold cast aluminum, or when specified shall be ultraviolet stabilized, self-extinguishing structural plastic. Plastic housings shall be black matching Color No. 17038, 27038 or 37038 of Federal Standard No. 595B, and shall be colored throughout. The assembly shall be rainproof and shall be shockproof in any weather condition. The pedestrian push button switch shall be a phenolic enclosed precision snap-acting type, single-pole, double-throw, switching unit, with screw type terminals, rated 15 A at 125 volts AC, and shall have the following characteristics: 1. Switching unit shall have a stainless steel plunger actuator and shall be provided with U-frame to permit recessed mounting in push button housing. 2. Switch shall have an operating force of 2.5 N (9 oz.) to 3.6 N (13 oz.) and a minimum release force of one newton (4 oz.). 3. Pretravel shall be 0.4 mm (VeV) maximum. 4. Over travel shallbe 6 mm (7/32") minimum. 5. Differential travel shall be 0.01 mm (0.0004") to 0.05 mm (0.002"). 6. Actuator shall have a minimum diameter of 50 mm (2"). Where a pedestrian push button is attached to a pole, the housing shall be shaped to fit the curvature of the pole and secured to provide a rigid installation. Saddles shall be provided to make a neat fit when required. Where a pedestrian push button is to be mounted on top of a Size 65 (21/2") diameter post, the housing shall be provided with a slip-fitter fitting and screws for securing rigidly to the post. Pedestrian push button signs shall be porcelain enameled metal or structural plastic. Push button and sign shall be installed on the crosswalk side of the pole. Arrows on push button signs shall point in the same direction as the corresponding crosswalk. Where Type A push buttons are specified, each push button assembly shall be equipped with red and green indicator lamps. Lamps shall be so connected that, when the push button has been activated, the red lamp shall be energized and continue so until the next pedestrian walk interval, at which time the green lamp shall be energized in lieu of the red lamp. At the termination of the pedestrian walk interval, the lamps shall be de-energized until the next actuation of the push button. Lenses for the lamps shall have a visible diameter of approximately 32 mm (11/4") and a length of approximately 22 mm (7/8")- On the Type A or Type B push button assembly, the sign shall attach to and be securely supported by the framework. With Type C pedestrian push buttons, the instruction sign shall be mounted, using 2 straps and saddle brackets, on the same standard as the push button assembly. Straps and saddle brackets shall be as shown on the plans and shall be corrosion-resisting chromium nickel steel conforming to the specifications of ASTM Designation: A 167, Type 302. Bolts shall be stainless steel with a chromium content of at least 17 percent and a nickel content of at least 8 percent. Bolts shall NOT be theft-proof. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-82 3.17 LIGHTING INSTALLATION A. General. The Contractor shall submit a plan of the proposed lighting installations and shall not commence falsework opening construction until those plans have been reviewed and approved by the Engineer. Approval will be made in accordance with Section 2-5, "Plans and Specifications." The Contractor shall design falsework lighting so that required maintenance can be performed with a minimum of inconvenience to public traffic. Closing of traffic lanes for routine maintenance will not be permitted on roadways with posted speed limits in excess of 25 miles per hour. Illumination of pavement under falsework with portals less than 45 m (150') apart and illumination of falsework portals shall be provided only during the hours of darkness as defined in Division 1, Section 280, of the California Vehicle Code. Photoelectric switches shall be used to control those falsework lighting systems. Illumination of pavement under falsework with portals 45 m (150') or more apart and illumination of all pedestrian openings through falsework shall be provided 24 hours per day. All lighting fixtures shall be aimed in such a manner as to preclude glare to oncoming motorists. Type NMC cable with No. 12 minimum, conductors with ground wire shall be used. The cable shall be fastened to the supporting structure at sufficient intervals to adequately support the cable and within 300 mm (12") from every box or fitting. All conductors within 2.4 m (8') of ground shall be enclosed in a Size 16, or larger metal conduit. Each illumination system shall be on a minimum of one separate branch circuit at each bridge location. Each branch circuit shall be fused, not to exceed 20 A. For falsework lighting, the Contractor shall arrange with the serving utility to complete service connections. Energy, line extension, service, and service hookup costs shall be paid by the Contractor. Upon completion of the project or when directed by the Engineer, falsework lighting equipment shall become the property of the Contractor and shall be removed from the site of the work. The Contractor may propose a lighting plan which will provide light intensities equivalent to the systems specified herein. The Contractor shall supply sufficient data to permit evaluation of alternative methods. B. Pavement Illumination. For illumination of pavement at vehicular openings through falsework the following shall apply: 1. Lighting fixtures shall be provided with R/FL commercial type flood lamp holder with protective covers. 2. Fixtures shall be fully adjustable with brackets and locking screws and shall permit mounting directly to a standard metal junction box. 3. Lamps shall be medium-base R-40 flood lamps and shall be 150 W minimum. 4. A continuous row of the type of fixtures required shall be installed at the location and spacing as shown on the plans or as specified in these special provisions. The fixtures shall be installed beneath the falsework structure, with the end fixtures not further than 3 m (10') inside the portal faces. Fixtures shall be installed and energized as a first order of work after the members supporting them have been erected. 5. Fixtures along the sides of the opening shall be placed no more than 1.2m (41) behind or 600 mm (2') in front of the roadway face of the temporary railing. Mounting heights of these fixtures shall be between 3.6 m (12') and 5 m (16') above the roadway surface and shall present an unobstructed light pattern on the pavement. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-83 C. Portal Illumination. For illumination of falsework portals the following shall apply: 1. On each side of each entrance portal, clearance guides consisting of plywood sheets, 1.2 m (4') wide by 2.4 m (8') high, shall be fastened vertically facing traffic with the bottom of the panel 1.0 m (31) to 1.2 m (4') above the roadway. The center of the panel shall be located approximately one meter (3') horizontally behind the roadway face of the railing. The panels shall be freshly painted for each installation with not less than 2 applications of flat white paint, furnished and applied by the Contractor. Testing of paint will not be required. 2. When ordered by the Engineer, in order to improve the general appearance of the painted surfaces herein described, the Contractor shall repaint designated areas and that painting will be paid for as extra work as provided in Section 3-3, "Extra Work." 3. Falsework portals shall be illuminated on the side facing traffic with 150-W, minimum, PAR reflector flood lamps mounted on the structure directly over each vertical support adjacent to the traveled way, as needed to uniformly illuminate the exterior falsework beam, the clearance guides and the overhead clearance sign. Each lamp shall be supported approximately 5 m (16') above the pavement and approximately 1.8m (6') in front of the portal face, the exact position to be as directed by the Engineer. 4. The above specified portal lighting and clearance guides shall be installed on the day that vertical members are erected. D. Pedestrian Walkway illumination. For illumination of pedestrian openings through or under falsework, the following shall apply: 1. Fixtures shall be flush mounted in the overhead protection shield, and shall be equipped with a clear polycarbonate diffuser lens, which is damage resistant. 2. Lamps shall be standard incandescent 100 W, 120 V. 3. Fixtures shall be centered over the passageway at intervals of not more than 4.5 m (15') with the end fixtures not more than 2 m (7') inside the end of the pedestrian openings. 4. Pedestrian passageway light systems shall be installed as a first order of work after the overhead protection shield is erected. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-84 3.18 REMOVING, REINSTALLING OR SALVAGING ELECTRICAL EQUIPMENT A. Removing Electrical Equipment. Attention is directed to Section 7-9, "Protection and Restoration of Existing Improvements" of the General Provisions. Existing electrical equipment shown on the plans or specified in these special provisions to be removed and not reused or salvaged, and pull boxes, conduit and detector frames not reused, shall become the property of the Contractor and shall be removed from the street right of way in accordance with the provisions in SSPWC Section 300-1, "Clearing and Grubbing" except, if not interfering with other construction, underground conduit may be abandoned in place after all conductors have been removed. Care shall be exercised in salvaging equipment so that it will not be damaged or destroyed and will remain in its existing condition whenever possible. Mast arms shall be removed from standards. Luminaires, signal heads, and signal mounting assemblies shall be removed from stan- dards and mast arms. Attention is directed to the provisions in Section 7-9, "Protection and Restoration of Existing Improvements" in the General Provisions. The Contractor will be required to repair or replace, at the Contractor's expense, any electrical equipment to be salvaged which, as determined by the Engineer, has been damaged or destroyed by reason of the Contractor's operations. Attention is directed to the provisions in Section 2.1, "Foundations," of the SSPWC regarding foundations to be abandoned or removed. Holes resulting from removing pull boxes and detector frames shall be filled with material equivalent to the surrounding material. B. Reinstalling Removed Electrical Equipment When removed electrical equipment is to be reinstalled, the Contractor shall furnish and install all necessary materials and equipment, including signal mounting assemblies, anchor bolts, nuts, washers and concrete as required to complete the new installation. All traffic signal and flashing beacon faces to be reinstalled or to be part of a modified system shall be cleaned and relamped. All luminaires and sign lighting fixtures to be reinstalled shall be cleaned and relamped. Existing materials required to be relocated and found to be unsatisfactory by the Engineer shall be replaced by new material and the cost therefore will be paid for as extra work as provided in Section 3-3, "Extra Work" of the General Provisions. 3.19 GALVANIZING 210-3 GALVANIZING. Add the following section: 210-3.6 Galvanizing for Traffic Signal Facilities. The requirements of this section shall pertain only to the preparation and galvanizing of traffic signal facilities. Galvanizing of products fabricated from rolled, pressed and forged steel shapes, plates, bars and strip 3.2 mm (1/8") thick or thicker, shall conform to the specifications of ASTM Designation: A 123, except that complete seal welding of tightly contacting surfaces of these products prior to galvanizing is required only where seal welding is shown on the plans or specified in these special provisions. Except for pre-galvanized standard pipe, galvanizing of material 3.2 mm (1/8") thick or thicker shall be performed after fabrication into the largest practical sections. At the option of the Contractor, material thinner than 3.2 mm (1/8") shall be galvanized either before fabrication in conformance with the requirements of ASTM Designation: A 525M, Coating Designation Z600, or after fabrication in conformance with the requirements of ASTM Designation: A 123, except that the weight of zinc coating shall average not less than 365 g per square meter (1.2 oz. per ft2) of actual surface area with no individual specimen having a coating weight of less than 305 g per square meter (1.0 oz. per ft2). 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-85 Galvanizing of standard pipe shall conform to the requirements of ASTM Designation: A 53. Galvanizing will not be required for stainless steel, monel metal and similar corrosion resistant parts. Fabrication shall include all operations such as shearing, cutting, punching, forming, drilling, milling, bending, welding and riveting. All welded areas shall be thoroughly cleaned prior to galvanizing to remove all slab or other material that would interfere with the adherence of the zinc. When it is necessary to straighten any sections after galvanizing, the work shall be performed without damage to the zinc coating. Galvanizing of iron and steel hardware and nuts and bolts, when specified or shown on the plans, shall conform to the specifications of ASTM Designation: A 153, except whenever threaded studs, bolts, nuts, and washers are specified to conform to ASTM Designation: A 307, A 325, A 325M, A 449, A 563, A 563M, or F 436 and zinc coating is required, they shall be hot- dip zinc coated or mechanically zinc coated in accordance with the requirements of the ASTM Designations. Unless otherwise specified, galvanizing shall be performed after fabrication. Components of bolted assemblies shall be galvanized separately before assembly. Tapping of nuts or other internally threaded parts to be used with zinc coated bolts, anchor bars or studs shall be done after galvanizing and shall conform to the requirements for thread dimensions and overlapping allowances in ASTM Designation: A 563 or A 563M. When specified, painting of zinc coated surfaces shall be in accordance with the procedures in Section 210.1 "Paint". Galvanized surfaces that are abraded or damaged at any time after the application of the zinc coating shall be repaired by thoroughly wire brushing the damaged areas and removing all loose and cracked coating, after which the cleaned areas shall be painted with two applications of unthinned zinc-rich primer (organic vehicle type) conforming to the provisions in Section 210- 3.5, "Repair of Damaged Zinc Coating." Aerosol cans shall not be used. 3.20 PAYMENT A. The contract lump sum price or prices paid for signal, flashing beacon, lighting, sign illumination, traffic monitoring station, closed circuit television systems, or combinations thereof; for modifying or removing those systems; for temporary systems; or the lump sum or unit prices paid for various units of those systems; or the lump sum or per meter price paid for conduit of the various sizes, types and installation methods listed in the Engineer's Estimate shall include full compensation for furnishing all labor, materials, tools, equipment and incidentals, and for doing all the work involved in furnishing and installing, modifying, or removing the systems, combinations or units thereof, as shown on the plans, as specified in these special provisions, and as directed by the Engineer, including any necessary pull boxes (except when the type required is shown as a separate contract item); excavation and backfill; concrete foundations (except when shown as a separate contract item); pedestrian barricades; furnishing and installing illuminated street name signs; installing Agency-furnished sign panels on pedestrian ' barricades, on flashing beacon standards, and on traffic signal mast arms; restoring sidewalk, pavement and appurtenances damaged or destroyed during construction; salvaging existing materials; and making all required tests. Full compensation for all additional materials and labor, not shown on the plans or specified, which are necessary to complete the installation of the various systems, shall be considered as included in the prices paid for the systems, or units thereof, and no additional compensation will be allowed therefore, except as provided in Section 209- 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-86 1.05, "Maintaining Existing and Temporary Electrical Systems" of the General Provisions. When shown as a contract item, the contract price paid per meter for cast-in-drilled-hole concrete pile (signal foundation) shall include full compensation for furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in constructing reinforced concrete pile foundations of the size shown on the Engineer's Estimate, including drilling holes, disposing of the material resulting from drilling holes, furnishing and placing anchor bolt assemblies and reinforcing steel, complete in place, as shown on the plans, and as specified in these special provisions and as directed by the Engineer. When shown as a contract item, non-reinforced portland cement concrete foundations will be measured and paid for in the manner as provided in SSPWC Section 303-1.11, "Payment" of the General Provisions. When shown as a separate contract item by the lump sum or per bid item linear measurement, interconnection conduit and conductor shall include all interconnection conductors, but shall only include conduit and pull boxes containing interconnection conductors and no other conductors. The quantity of interconnection conduit and conductor to be paid for by the lump sum bid or the bid item linear measurement shall be the length of that conduit. Compensation for conduit containing interconnection conductors and other conductors shall be considered as included in the contract price paid for the item requiring the other conductors. Full compensation for furnishing, installing, maintaining and removing falsework lighting equipment shall be considered as included in the contract prices paid for the items of work involved in the structure which requires the falsework lighting and no additional compensation will be allowed therefore. 8/13/09 Contract No. 3811 TRAFFIC SIGNALS, LIGHTING & TRAFFIC ELECTIRCAL SYSTEMS PALOMAR AIRPORT ROAD WIDENING 16560-87